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Komatsu Hydraulic Crane 150A / 150FA Repair Service Manuals

Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Cranes 150A, 150FA, with all the technical information to maintain, diagnose, repair, service like professional mechanics.

Komatsu Hydraulic Cranes 150A, 150FA workshop service & repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

CEBD001400 – Hydraulic Crane 150A, 150FA Shop Manual (SN 10828 & up).pdf
SMC-150FA – Hydraulic Crane 150A, 150FA Shop Manual (SN ~09695 – 10827).pdf

PRODUCT DETAILS:
Total Pages: 756 + 974 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English

MAIN SECTIONS
00 INTRODUCTION . . 00-1
01 GENERAL . . 01-1
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD . . 10-1
20 TESTING, ADJUSTING AND TROUBLESHOOTING . . 20-1
30 DISASSEMBLY AND ASSEMBLY. . 30-1
90 OTHER . . 90-1

CEBD001400 – Hydraulic Crane 150A, 150FA Shop Manual (SN 10828 & up)….2
COVER….2
CONTENTS….3
00 INTRODUCTION….2
    SAFETY….6
      SAFETY NOTICE….6
        IMPORTANT SAFETY NOTICE….6
        GENERAL PRECAUTIONS….6
        PREPARATIONS FOR WORK….6
        PRECAUTIONS DURING WORK….7
        ASBESTOS AND NON-ASBESTOS FIBERS….8
    GENERAL….11
    HOW TO READ THE SHOP MANUAL….12
      VOLUMES….12
      DISTRIBUTION AND UPDATING….12
      FILING METHOD….12
      REVISED EDITION MARK….12
      REVISIONS….12
      SYMBOLS….12
    GENERAL MACHINE HOISTING INSTRUCTIONS….13
      GENERAL MACHINE HOISTING….13
      GENERAL MACHINE WIRE ROPES….13
    COATING MATERIALS….14
    STANDARD TIGHTENING TORQUE FOR METRIC….16
      STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS….16
      TIGHTENING TORQUE OF HOSE NUTS….17
      TIGHTENING TORQUE OF SPLIT FLANGE BOLTS….17
      TIGHTENING TORQUE FOR FLARED NUTS….17
    STANDARD TIGHTENING TORQUE FOR STANDARD ENGLISH….18
      BOLT IDENTIFICATION CHART….18
      TYPE 1, 5 AND 8 NON-PHOSPHATE COATED HARDWARE….18
      TYPE 8 PHOSPHATE COATED HARDWARE….20
      TORQUE VALUES FOR HOSE CLAMPS….20
      TORQUE VALUES FOR SPLIT FLANGE CONNECTIONS….21
      TORQUE VALUES FOR HYDRAULIC TUBES AND FITTINGS….21
    ELECTRIC WIRE CODE….22
      CLASSIFICATION BY THICKNESS….22
      CLASSIFICATION BY COLOR AND CODE….22
    CONVERSION TABLES….23
      METHOD OF USING THE CONVERSION TABLE….23
01 GENERAL….30
    GENERAL ASSEMBLY DRAWING….31
    FUEL, COOLANT, AND LUBRICANTS….34
      ACCORDING TO AMBIENT TEMPERATURE….34
      PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS….34
      ENGINE OIL SPECIFICATIONS….36
        NORMAL OPERATION….36
        ARCTIC OPERATION….36
      TRANSMISSION, TORQUE CONVERTER AND OIL COOLER, AND HYDRAULIC SYSTEM OIL SPECIFICATIONS….37
      REAR-DRIVE AXLE AND CIRCLE DRIVE BRAKE HOUSING OIL SPECIFICATIONS….37
      DIESEL FUEL SPECIFICATIONS….37
      COOLANT SPECIFICATIONS….38
        GENERAL….38
        WATER….38
        ANTIFREEZE….38
        SUPPLEMENTAL COOLANT ADDITIVES….40
        MAINTENANCE OF SUPPLEMENTAL COOLANT ADDITIVES….40
        COOLANT TESTING FOR CONDITIONER CONCENTRATION….40
        REPLENISHING COOLANT CONDITIONER….40
        SUPPLEMENTAL COOLANT ADDITIVE MAINTENANCE GUIDE….41
        COOLING SYSTEM TEST KIT….43
10 STRUCTURE AND FUNCTION….44
    WIRE ROPE….46
      WIRE ROPE SPECIFICATIONS….46
      MAINTENANCE RECOMMENDATIONS….46
    TRANSMISSION – T20000….47
      SPECIFICATIONS….48
      OPERATION….51
      POWERFLOWS….56
      GEAR AND CLUTCH LAY-OUT….62
      SECTIONAL VIEWS….63
        CONVERTER HOUSING….63
        TRANSMISSION CASE AND REAR COVER….65
        TURBINE SHAFT….67
        DRIVE PLATE….69
        TORQUE CONVERTER….71
        AUXLIARY PUMP DRIVE….73
        PUMP DRIVE….75
        FORWARD SHAFT….77
        REVERSE AND 2ND SHAFT….79
        REVERSE IDLER….81
        LOW SPEED SHAFT….83
        3RD SHAFT….85
        IDLER SHAFT….87
        OUTPUT SHAFT….89
        HI & LOW RANGE SHIFT CONTROL….91
        CHARGING PUMP & FILTER….93
        TRANSMISSION CONTROL VALVE (MANUAL)….95
    TRANSMISSION – HR18000….97
      SPECIFICATIONS….99
      HR18000 CONVERTER….101
      HR18000 LONG DROP CONVERTER AND TRANSMISSION CASE….103
      CONTROL VALVE….105
      6 SPEED CLUTCH AND GEAR….107
      REAR VIEW….110
      POWER FLOW….111
        LOW RANGE….111
        HIGH RANGE….112
      CLUTCH AND GEAR ARRANGEMENT….114
    STEERING CONTROL VALVE….115
      TYPICAL OIL FLOW….117
      OPERATION….118
        DESIGN AND FUNCTION….119
        CONTROL VALVE….120
        METERING SECTION….120
        ROTOR OPERATION IN THE ROTOR SET….120
        POWER STEERING OPERATION….121
        MANUAL STEERING OPERATION….121
    BRAKE VALVE – MASTER….122
      MASTER CYLINDER SECTION….122
      POWER ASSIST SECTION….122
      BRAKE VALVE – EXPLODED VIEW….123
    HYDRAULIC PUMP….125
      DUAL TANDEM….125
        EXPLODED VIEW….125
        DUAL TANDEM PUMP CUTAWAY VIEW….126
      SWING DRIVE MOTOR….127
        EXPLODED VIEW….127
      HOIST/WINCH MOTOR….128
        EXPLODED VIEW….128
      AUXILIARY HOIST MOTOR….129
        EXPLODED VIEW….129
    PARKING BRAKE….131
    SERVICE BRAKE….132
    AXLES….133
      DIFFERENTIAL….133
      PLANETARY AXLE WHEEL ENDS….137
    SENSORS….140
      BACKUP ALARM PRESSURE SWITCH….140
      FUEL LEVEL SENDER….140
      TORQUE CONVERTER OIL TEMPERATURE SENDER….141
      ENGINE WATER TEMPERATURE SENDER….141
      ENGINE OIL PRESSURE SENDER….141
      NEUTRAL START SWITCH….142
      BRAKE LIGHT OIL PRESSURE SWITCH….142
      ENGINE HIGH WATER TEMPERATURE SWITCH (OPTION)….143
      ENGINE LOW OIL PRESSURE SWITCH (OPTION)….143
      REAR STEERING INDICATOR LIGHT SWITCH….144
    TOWING THE CRANE….145
      FRONT DRIVELINE….145
      REAR DRIVELINE….145
20 TESTING, ADJUSTING AND TROUBLESHOOTING….146
    TANDEM PUMP….148
      WEAR CONSIDERATIONS IN CS & S PUMPS….148
      TEST PROCEDURE FOR REBUILT PUMP….148
    WINCH MOTOR….150
      INSPECTION & REPLACEMENT….150
      CLEANING….151
    WINCH SPOOLING ADJUSTMENT….151
      PROCEDURE FOR CORRECTING WINCH SPOOLING BY ROTATING AND SHIMMING….152
        ROTATING PROCEDURE:….152
        SHIMMING PROCEDURE:….153
    HOIST AND SWING BRAKE CHECKS AND ADJUSTMENTS….154
      HOIST BRAKE CHECKS AND ADJUSTMENTS….154
    PRIMARY MANIFOLD….156
      CLEANING AND INSPECTION….156
    SECONDARY MANIFOLD….156
      CLEANING AND INSPECTION….156
      TESTING AND TROUBLESHOOTING….156
    SWING DRIVE BEARING & GEAR ASSEMBLY WEAR TOLERANCE….157
      PERMISSIBLE BEARING CLEARANCES….157
      PROCEDURE FOR CLEARANCE MEASUREMENT….158
    STEERING CONTROL VALVE….161
      INSPECTION AND REPLACEMENT….162
      FILLING AND AIR BLEEDING THE SYSTEM WHEN DRAINED OF OIL….164
      HYDRAULIC FLUID….164
      TIPS FOR MAINTAINING THE HYDROSTATIC STEERING SYSTEM….165
    BRAKE VALVE….166
      PRESSURE BLEEDING INSTRUCTIONS….166
      BENCH BLEEDING INSTRUCTIONS….167
    SPRING MOTORS….168
      ADJUSTMENT….168
    HEAD & HOOK BLOCK INSPECTION….169
      HEAD….169
        SHEAVES AND DRUM….169
      HOOK BLOCK INSPECTION….169
        DAILY/10 HOUR INSPECTION….169
        ANNUAL/500 HOUR INSPECTION….170
    WIRE ROPE….171
      RESTING HOOK BLOCK….171
      IMPORTANCE OF LUBRICATION….171
        RECONNECTED LUBRICANTS FOR WIRE ROPE….172
        METHODS OF LUBRICATION….172
        LUBRICATION IN STORAGE….173
      IDLE ROPES….173
      INSPECTION OF WIRE ROPE, SHEAVES AND DRUM….174
      BREAKING IN WIRE ROPE….175
    RESETTABLE CIRCUIT BREAKERS….176
    TROUBLESHOOTING….178
      ALTERNATORS….180
        PRELIMINARY CHECKS….180
        LUBRICATION….183
      CRANKING MOTOR….184
        PRELIMINARY CHECKS….184
        LUBRICATION….186
      WIRE ROPE….187
      HR18000 TRANSMISSION….188
        PRESSURE CHECK POINTS….189
        3 SPEED CLUTCH AND GEAR ARRANGEMENT….190
      T20000 TRANSMISSION….191
        STALL TEST….191
        PRESSURE CHECKS….191
        MECHANICAL AND ELECTRICAL CHECKS….192
        HYDRAULIC CHECKS….192
        GUIDE….193
        CHECK POINTS….194
      HYDRAULIC….197
        HYDRAULIC PEDESTAL CRANE….197
        INTRODUCTION TO THE HYDRAULIC SYSTEM….197
        50 GPM CIRCUIT….199
          50 GPM CONTROLS SLOW OR LACKING IN POWER WHEN 30 GPM AND FRONT STEERING CIRCUITS ARE NORMAL….199
        30 GPM CIRCUIT….200
          30 GPM CONTROLS SLOW OR LACKING IN POWER WHEN 50 GPM AND FRONT STEERING CIRCUITS ARE NORMAL….201
          FRONT STEERING – SLOW, HARD OR STOPPED WHEN 30 AND 50 GPM SYSTEMS ARE FUNCTIONING PROPERLY….202
        RAPID WARMUP OF HYDRAULIC SYSTEM….202
        SWING DRIVE CIRCUIT….203
          SWING DRIFTS AFTER CONTROL VALVE HAS BEEN RETURNED TO NEUTRAL….203
          SWING RUNS AWAY WHILE SWINGING DOWN HILL WITH LOAD….204
          SWING REFUSES TO ROTATE, WHEN OTHER 30 GPM CONTROLS FUNCTION NORMALLY….204
          SWING ERRATIC AND JERKY IN OPERATION….205
        BOOM LIFT CYLINDER….206
          BOOM LIFT CYLINDER DRIFTS WITH HYDRAULIC CONTROL VALVE IN THE NEUTRAL POSITION….206
          BOOM DROPS MOMENTARILY WHEN CONTROL IS MOVED FROM NEUTRAL TO RAISE….207
          BOOM LIFT CYLINDER REFUSES TO LOWER….207
        CROWD CYLINDER(S)….208
          CROWD CYLINDER DRIFTS IN WITH OR WITHOUT LOAD….209
          CROWD SECTION(S) CHATTERS OR REFUSES TO EXTEND UNDER HEAVY LOAD CONDITIONS….209
          INSIDE CROWD CYLINDER CANNOT BE RETRACTED, CAUSED BY BROKEN OIL SUPPLY LINE ON A THREE SECTION POWER BOOM….210
          INSIDE CROWD CYLINDER CANNOT BE RETRACTED, CAUSED BY BROKEN OIL SUPPLY LINE ON A FOUR SECTION POWER BOOM….211
          REMOVAL OF THE INSIDE CROWD CYLINDER ON A THREE SECTION POWER BOOM….212
        HOIST WINCH CIRCUIT….213
          HOIST WINCH CIRCUIT OPERATION….215
          HOIST WINCH DRIFTS WITH LOAD….215
          HOIST WINCH CANNOT BE FEATHERED WHEN LOWERING A LOAD….218
          HOIST WINCH WON'T LOWER OR HESITATES BEFORE LOWERING….218
          HOIST WINCH LOWERS IN AN UNEVEN OR JERKY MANNER….219
          HOIST WINCH WILL NOT LIFT LOAD….219
        REAR STEERING….220
          REAR STEERING CYLINDERS DRIFT….220
        OUTRIGGERS….221
          OUTRIGGER CYLINDER DRIFT….221
          OUTRIGGERS CHATTER WHEN RAISING….222
      SERVICE BRAKES….223
        ADJUST BRAKE….223
        WHEEL CYLINDER MAINTENANCE….223
          WHEEL CYLINDER DIAGNOSTICS….224
        BLEED HYDRAULIC SYSTEM….224
        MAINTENANCE SCHEDULES….225
          MINOR INSPECTION: HYDRAULIC BRAKES….225
          MAJOR INSPECTION: HYDRAULIC BRAKES….226
      PARKING BRAKE….227
        ADJUST BRAKE….227
        MAINTENANCE SCHEDULES….227
          MINOR INSPECTION: MECHANICAL BRAKES….227
          MAJOR INSPECTION: MECHANICAL BRAKES….227
    PRE-DELIVERY PROCEDURE….228
      PRE-UNLOADING CHECKS….230
      EXAMPLE OF SERVICE REPORT ON DELIVERY….231
      RECORD SERIAL NUMBERS….232
      LUBRICATION….234
      TORQUES….240
        SPECIFIC BOLT TORQUES….241
      ENGINE CHECKS….242
      HYDRAULIC PRESSURE TEST….244
      TRANSMISSION CHECKS….246
      ADJUSTMENTS….248
        ROTARY DRIVE SCREWS CLEARANCE….248
        RETRACT REEL – SPRING MOTOR….248
        BOOM ROLLERS….248
        BOOM WEAR PLATES….248
        SWING AND HOIST BRAKE ROD AND SPRING….249
        CRANE OPERATION….250
        TIRE INFLATION….250
        REAR STEERING INDICATOR….250
      TESTING….251
        YARD TEST CRANE….251
        ROAD TEST CRANE….251
        ELECTRICAL SYSTEM CHECKS….251
30 DISASSEMBLY AND ASSEMBLY….252
    METHOD OF USING MANUAL….258
    PRECAUTIONS DURING OPERATION….259
      PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK….259
      PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK….260
      PRECAUTIONS WHEN COMPLETING THE OPERATIONS….261
      OTHER PRECAUTIONS….261
    SKETCHES OF SPECIAL TOOLS….263
      REVERSE IDLER SHAFT NUT SOCKET (TG 1304 – 54)….263
      HYDRAULIC MOTOR….264
        STEEL SLEEVE….264
        SEAL RETAINER TOOL….264
        CHECK VALVE TOOL….265
        SEAL RETAINER TOOL….265
      DIFFERENTIAL CARRIER….266
        REPAIR STAND….266
    TRANSMISSION T20000 POWERSHIFT 6 SPEED….268
      SERVICING MACHINE AFTER COMPONENTS OVERHAUL….268
      TRANSMISSION TO ENGINE INSTALLATION PROCEDURE….269
      CLEANING AND INSPECTION….270
        CLEANING….270
        INSPECTION….270
      DISASSEMBLY….272
        LOW (1ST) CLUTCH….286
        REVERSE CLUTCH….294
        2ND CLUTCH….302
        3RD CLUTCH….306
        FORWARD CLUTCH….311
        CONVERTER HOUSING….319
        IDLER SHAFT….330
        OUTPUT SHAFT….334
      ASSEMBLY….338
      CONVERTER DRIVE COUPLING INSTALLATION DETAILS….361
      HYDRAULIC ACTUATED AXLE DISCONNECT….363
        SECTIONAL VIEWS AND PARTS IDENTICATION….363
        OUTPUT SHAFT WITH AXLE DISCONNECT….366
        AXLE DISCONNECT….371
      TOWING OR PUSHING….379
    TRANSMISSION 18000 SERIES 6 SPEED….380
      DISASSEMBLY….380
        FREEWHEEL DISASSEMBLY….384
        TRANSMISSION CASE DISASSEMBLY….389
        LOW CLUTCH….395
        REVERSE AND 2nd CLUTCH….401
        3RD CLUTCH….408
        FORWARD CLUTCH….413
        LOCK NUT TYPE IDLER SHAFT….420
        TURBINE HUB ASSEMBLY WITH BACKING RING AND SPECIAL SELF LOCKING SCREWS….425
        CONVERTER HOUSING….426
      ASSEMBLY….429
        FREEWHEEL ASSEMBLY….429
        CONVERTER HOUSING….435
      18000 SERIES TRANSMISSION CONVERTER DRIVE PLATE KIT….442
      CLUTCH SHAFT OIL SEALING RING (PISTON RING)….443
        INSTALLATION….443
      TRANSMISSION TO ENGINE INSTALLATION PROCEDURE….445
      SERVICING MACHINE AFTER TRANSMISSION OVERHAUL….446
      TOWING OR PUSH STARTING….446
    PEDESTAL, ROTEK BEARING & SWING DRIVE SYSTEM….447
      REMOVAL….447
      DRIVE MOTOR AND BRAKE….448
        DISASSEMBLY….448
        ASSEMBLY….454
      INSTALLATION….463
    SWING DRIVE MOTOR….465
      REMOVAL….465
      DISASSEMBLY….465
      CLEANING….466
      INSPECTION….467
      ASSEMBLY….468
      INSTALLATION….470
      START-UP PROCEDURE….470
    WINCH MOTOR….471
      DISASSEMBLY….471
      ASSEMBLY….475
    BOOM WINCH….478
      REMOVAL OF WINCH ASSEMBLY FROM CRANE….478
      DISASSEMBLY….479
      INSPECTION & CLEANING….484
      ASSEMBLY….485
      INSTALLING WINCH ASSEMBLY ON CRANE….490
    JIB AND GANTRY….491
      JIB EXTENSION PROCEDURE….491
      JIB STOWAGE PROCEDURE….499
    HEAD & HOOK BLOCK….500
      DISASSEMBLY….500
      ASSEMBLY….503
      CARE OF WIRE ROPE….505
      WIRE ROPE REPLACEMENT….505
      HOOK & HEAD BLOCK REEVING….507
      METHODS OF LUBRICATION….508
        LUBRICATION IN STORAGE….508
    SPRING MOTORS….509
      UNLOADING RETRACT MECHANISM….509
      DISASSEMBLY….511
      SHAFT BEARINGS AND CABLE DRUM….515
      ASSEMBLY….519
      LOADING RETRACT MECHANISM….522
        SETTING SPRING TENSION….522
      LUBRICATION….523
    BRAKE VALVE….524
      MASTER CYLINDER SECTION….524
        REMOVE AND SEPARATE INTO SECTIONS….524
        DISASSEMBLY….525
        ASSEMBLY….526
        CONNECTING SECTIONS AND MOUNTING BRAKE VALVE ON VEHICLE….526
      POWER ASSIST SECTION….528
        REMOVE AND SEPARATE INTO SECTIONS….528
        DISASSEMBLY….529
        ASSEMBLY….530
        CONNECTING SECTIONS AND MOUNTING BRAKE VALVE ON VEHICLE….531
    STEERING CONTROL VALVE….533
      SERVICING….534
      DISASSEMBLY….534
      ASSEMBLY….537
    TANDEM PUMP….543
      REMOVAL….543
      DISASSEMBLY….545
      ASSEMBLY….553
      INSTALLATION….560
    PRIMARY MANIFOLD & CONTROLS….561
      REMOVAL….561
      DISASSEMBLY….561
        OPERATING CABLES….564
      ASSEMBLY….567
        OPERATING CABLES….567
      INSTALLATION….572
    PRIMARY MANIFOLD….573
      REMOVAL….573
      DISASSEMBLY….575
      ASSEMBLY….577
      INSTALLATION….579
    SECOND MANIFOLD….581
      REMOVAL….581
        REMOVAL OF INDIVIDUAL VALVES….583
      DISASSEMBLY….585
      ASSEMBLY….587
        INSTALLATION OF INDIVIDUAL VALVES….588
      INSTALLATION….590
    HYDRAULIC CYLINDERS….592
      BOOM LIFT CYLINDER….592
        DISASSEMBLY….592
        ASSEMBLY….595
      BOOM CROWD CYLINDER ROD SEAL….603
      DUAL CROWD CYLINDER FOUR SECTION POWER BOOM….607
        REMOVEAL….607
        DISASSEMBLY….614
        ASSEMBLY….618
        INSTALLATION….626
      STEERING CYLINDER….633
        DISASSEMBLY….634
        ASSEMBLY….634
      OUTRIGGER CYLINDER….635
        DISASSEMBLY….636
        ASSEMBLY….636
      LOWER CROWD CYLINDER….637
        DISASSEMBLY….638
        ASSEMBLY….638
      SWING & HOIST BRAKE CYLINDER….639
        DISASSEMBLY….640
        ASSEMBLY….640
    PARKING BRAKE….641
      DISASSEMBLY….641
      ASSEMBLY….642
    SERVICE BRAKE….643
      DISASSEMBLY….643
      ASSEMBLY….644
      WHEEL CYLINDER….646
        DISASSEMBLY….646
        ASSEMBLY….647
    AXLES….648
      DIFFERENTIAL….648
        DISASSEMBLY….648
        PREPARING PARTS FOR ASSEMBLY….660
        ASSEMBLY….675
        LUBRICANT….707
        FASTENER TORQUE INFORMATION….709
        ADJUSTMENTS AND SPECIFICATIONS….713
      PLANETARY AXLE WHEEL ENDS….715
        REMOVAL….715
        PREPARE PARTS FOR ASSEMBLY….723
        ASSEMBLY….723
90 OTHERS….734
    HYDRAULIC….736
      150A – SHEET 1 OF 2, PART 1 OF 2….736
      150A – SHEET 1 0F 2, PART 2 OF 2….738
      150A – SHEET 2 OF 2, PART 1 OF 2….740
      150A – SHEET 2 OF 2, PART 2 OF 2….742
      150FA – SHEET 1 OF 2, PART 1 OF 2….744
      150FA – SHEET 1 OF 2, PART 2 OF 2….746
      150FA – SHEET 2 OF 2, PART 1 OF 2….748
      150FA – SHEET 2 OF 2, PART 2 OF 2….750
    ELECTRICAL….752
      150A/FA – SHEET 1 OF 1, PART 1 OF 2….752
      150A/FA – SHEET 1 OF 1, PART 2 OF 2….754
SMC-150FA – Hydraulic Crane 150A, 150FA Shop Manual (SN ~09695 – 10827)….758
COVER….758
TABLE OF CONTENTS….759
1 A-1.20 ROSS POWER STEERING GEAR (G-R-C)….760
    CONTENTS….760
    TORQUE SHEET….761
    DISASSEMBLY….762
    SERVICE TO CAM AND ACTUATOR ASSEMBLY….770
    SERVICE TO LEVER SHAFT AND STUD ASSEMBLY….771
    SERVICE TO VALVE ASSEMBLY….772
    REASSEMBLY….775
    INSTALLATION AND ADJUSTMENT OF VALVE ASSEMBLY….783
    LUBRICANT SPECIFICATIONS ….786
    TROUBLESHOOTING….786
2 B-2.10 TORQUE CONVERTER (MODELS C272 & C273) (G-C)….790
    CONTENTS….790
    TORQUE SHEETS….791
    SPECIAL TOOLS….826
    DISASSEMBLY….792
    REASSEMBLY….806
    INSTALLATION….821
3 C-07.00 TRANSMISSION (MODEL 2420) (G-C)….828
    CONTENTS….828
    TORQUE SHEET….829
    SPECIAL TOOLS….830
    TRANSMISSION DISASSEMBLY….832
    CLUTCH DISASSEMBLY….844
    CLUTCH REASSEMBLY….849
    CONTROL VALVE & OIL CIRCUIT PLATE DISASSEMBLY & ASSEMBLY….855
    TRANSMISSION REASSEMBLY….857
    PRESSURE CHECKS….871
4 C-10.00 ALLISION MODEL TT-2421-1 TRANSMISSION (C)….874
    CONTENTS….874
    GENERAL TORQUE VALUES….875
    SCOPE OF MANUAL….876
    SPECIFICATION, WEAR LIMITS, AND SPRING DATA….877
    DESCRIPTION….881
    OPERATION….883
    TROUBLESHOOTING ….886
    SPECIAL TOOLS….889
    REMOVAL FROM CRANE….890
    DISASSEMBLY OF TRANSMISSION….892
    INSPECTION AND CLEANING….902
    REBUILD OF SUB-ASSEMBLIES….905
    INSTALLATION IN CRANE….931
    SERVICING TRANSMISSION….935
5 E-2.03 PRIMARY MANIFOLD & CONTROLS (C)….936
    CONTENTS….936
    TORQUE SHEET….937
    DISASSEMBLY….938
    REASSEMBLY….945
6 E-02.04 PRIMARY MANIFOLD (C)….952
    CONTENTS….952
    GENERAL TORQUE VALUES….953
    SYSTEM APPLICATION….954
    REMOVAL….956
    DISASSEMBLY….959
    CLEANING AND INSPECTION….963
    REASSEMBLY….964
    INSTALLATION….967
7 E-2.40 SECOND MANIFOLD (C)….970
    CONTENTS….970
    TORQUE SHEET….971
    REMOVAL OF MANIFOLD….972
    REMOVAL OF INDIVIDUAL VALVES….975
    DISASSEMBLY OF VALVE COMPONENTS….977
    CLEANING AND INSPECTION….980
    REASSEMBLY OF VALVE COMPONENTS….981
    INSTALLATION OF INDIVIDUAL VALVES….983
    INSTALLATION OF MANIFOLD….985
    TESTING AND TROUBLESHOOTING….987
8 E-3.10 HYDRAULIC CRANE CYLINDERS (C)….988
    CONTENTS….988
    TORQUE SHEET….989
    PRECAUTIONS & SERVICE NOTES….990
    SERIAL NUMBER RANGES BY CYLINDER….990
    STEERING CYLINDERS ….992
    OUTRIGGER CYLINDERS….998
    BOOM CROWD CYLINDERS….1002
    SWING & HOIST BRAKE CYLINDERS….1008
    SWING & HOIST BRAKE CHECKS AND ADJUSTMENTS….1011
9 E-3.11 POLYURETHATNE ONE PEICE ROD SEAL USED ON BOOM CYLINDERS (C)….1014
10 E-3.12 HYDRAULIC CRANE BOOM LIFT CYLINDER (C)….1022
    CONTENTS….1022
    TORQUE SHEET ….1023
    DISASSEMBLY….1028
    REASSEMBLY….1032
11 E-3.13 DUEL CROWD CYLINDER FOUR SECTION POWER BOOM (C)….1042
    CONTENTS….1042
    TORQUE SHEET….1043
    REMOVAL OF DUAL CROWD CYLINDER FROM CRANE….1044
    DISASSEMBLY OF DUAL CROWD CYLINDER….1053
    REASSEMBLY OF DUAL CROWD CYLINDER….1058
    INSTALLATION OF DUAL CROWD CYLINDER IN CRANE….1068
12 E-10.10 HYDRAULIC WINCH MOTOR (COMMERCIAL SHEARING) (C)….1078
    CONTENTS….1078
    TORQUE SHEET….1079
    DESCRIPTION & IDENTIFICATION….1080
    TROUBLESHOOTING ….1081
    DIASSEMBLY….1082
    INSPECTION & REPLACEMENT….1085
    CLEANING….1087
    SPECIAL TOOLS….1088
    REASSEMBLY….1089
13 E-11.30 SWING DRIVE HYDRAULIC MOTOR (COMMERCIAL SHEARING)….1094
    CONTENTS….1094
    TORQUE SHEET….1095
    SWING DRIVE HYDRAULIC MOTOR REMOVAL….1096
    SWING DRIVE HYDRAULIC MOTOR DISASSEMBLY….1097
    CLEANING ….1100
    INSPECTION….1101
    SWING DRIVE HYDRAULIC MOTOR REASSEMBLY….1102
    SWING DRIVE HYDRAULIC MOTOR INSTALLATION….1106
    START-UP PROCEDURE….1107
    SPECIAL TOOLS….1108
14 E-12.01 TANDEM PUMP (COMMERCIAL SHEARING MODEL 25X) (C)….1110
    CONTENTS….1110
    END COVER REMOVAL….1114
    GEAR HOUSING REMOVAL….1117
    DRIVE & DRIVEN GEAR REMOVAL….1118
    DISASSEMBLY OF SHAFT END COVER….1119
    DISASSEMBLY OF SHAFT ASSEMBLY….1121
    DISASSEMBLY OF BEARING CARRIER….1123
    REASSEMBLY….1124
    TEST PROCEDURE FOR REBUILT PUMP….1134
    TORQUE SHEET….1135
15 E-14.00 SWING COUNTERBALANCE VALVE (C)….1136
    CONTENTS….1136
    TORQUE SHEET….1137
    INTRODUCTION….1138
    REMOVAL….1141
    DISASSEMBLY….1142
    CLEANING AND INSPECTION….1145
    REASSEMBLY….1146
    INSTALLATION….1149
16 E-15.00 HYDRAULIC CRANE TROUBLESHOOTING (C)….1150
    CONTENTS….1150
    TORQUE SHEET….1151
    SECTION I – HYDRAULIC PRESSURE & ENGINE SPEED CHARTS….1156
    SECTION II – HYDRAULIC SYSTEM INTRODUCTION….1158
      50 GPM CIRCUIT….1163
        TROUBLESHOOTING 50 GALLON PER MINUTE SYSTEM….1163
          50 GPM CONTROLS SLOW OR LACKING IN POWER WHEN 30 GPM AND FRONT STEERING CIRCUITS ARE NORMAL….1164
      30 GPM CIRCUIT….1165
        TROUBLESHOOTING 30 GALLON PER MINUT SYSTEM….1165
          30 GPM CONTROLS SLOW OR LACKING IN POWER WHEN 50 GPM AND FRONT STEERING CIRCUITS ARE NORMAL….1166
          FRONT STEERING – SLOW, HARD OR STOPPED WHEN 30 AND 50 GPM SYSTEMS ARE FUNCTIONING PROPERLY….1167
      RAPID WARMUP OF HYDRAULIC SYSTEM….1169
    SECTION III – TROUBLESHOOTING THE SWING DRIVE CIRCUIT….1170
      SWING DRIFTS AFTER CONTROL VALVE HAS BEEN RETURNED TO NEUTRAL….1173
      SWING RUNS AWAY WHILE SWINGING DOWN HILL WITH LOAD….1174
      SWING REFUSES TO ROTATE WHEN OTHER 30 GPM CONTROLS FUNCTION NORMALLY….1174
      SWING ERRATIC AND JERKY IN OPERATION….1174
    SECTION IV – TROUBLESHOOTING THE BOOM LIFT CYLINDER CIRCUIT….1176
      BOOM LIFT CYLINDER DRIFTS WITH HYDRAULIC CONTROL VALVE IN THE NEUTRAL POSITION….1180
      BOOM DROPS MOMENTARILY WHEN CONTROL IS MOVED FROM NEUTRAL TO RAISE….1180
      BOOM LIFT CYLINDER REFUSES TO LOWER….1181
    SECTION V – TROUBLESHOOTING THE CROWD CYLINDER(S) CIRCUIT….1182
      CROWD CYLINDER DRIFTS IN WITH OR WITHOUT LOAD….1187
      CROWD SECTION(S) CHATTERS OR REFUSES TO EXTEND UNDER HEAVY LOAD CONDITIONS….1187
      CROWD CYLINDERS OUT OF PHASE .(3 AND 4 SECTION POWER BOOMS ONLY)….1187
      INSIDE CROWD CYLINDER CANNOT BE RETRACTED DUE TO BROKEN OIL SUPPLY LINE ON A THREE SECTION POWER BOOM….1188
      INSIDE CROWD CYLINDER CANNOT BE RETRACTED DUE TO BROKEN OIL SUPPLY LINE ON A FOUR SECTION POWER BOOM….1189
      REMOVAL OF THE INSIDE CROWD CYLINDER ON A THREE SECTION POWER BOOM….1190
      REMOVAL OF THE INSIDE DUAL CROWD CYLINDER ON A FOUR SECTION POWER BOOM….1042
    SECTION VI – TROUBLESHOOTING THE WINCH CIRCUIT….1192
      GALION HOIST WINCH OPERATION….1197
      HOIST WINCH DRIFTS WITH LOAD….1197
      HOIST WINCH CANNOT BE FEATHERED WHEN LOWERING A LOAD….1201
      HOST WINCH WON'T LOWER OR HESITATES BEFORE LOWERING….1202
      HOIST WINCH LOWERS IN A JERKY MANNER….1203
      HOIST WINCH WON'T LIFT LOAD….1203
    SECTION VII – TROUBLESHOOTING THE REAR STERRING CYLINDERS….1206
      REAR STEERING CYLINDER DRIFT….1208
    SECTION VIII – TROUBLESHOOTING THE OUTRIGGER CIRCUIT….1210
      OUTRIGGER CYLINDER DRIFT….1213
      OUTRIGGER CHATTER WHEN RAISING….1214
17 F-6.20 BOOM WINCH ASSEMBLY (C)….1216
    CONTENTS….1216
    CONFIGURATION CHANGES….1217
    REMOVAL OF WINCH ASSEMBLY FROM CRANE….1218
    DISASSEMBLY….1219
    INSPECTION & CLEANING….1226
    REASSEMBLY….1227
    INSTALLING WINCH ASSEMBLY ON CRANE….1233
    TESTING….1234
    GENERAL TORQUE VALUES….1235
18 F-10 SPRING MOTORS (C)….1236
    CONTENTS….1236
    TORQUE SHEET….1237
    DESCRIPTION….1238
    UNLOADING RETRACT MECHANISM….1239
    SERVICE TO OLD TYPE SPRING MOTOR….1241
    DISASSEMBLY….1241
    ASSEMBLY….1249
    SERVICE TO NEW TYPE SPRING MOTOR….1260
    SPRING CARTRIDGES….1260
    DISASSEMBLY….1260
    SHAFT BEARING S AND CABLE DRUM….1265
    ASSEMBLY….1270
    RELOADING RETRACT MECHANISM….1274
    ADJUSTMENT ….1275
    LUBRICATION OF GLEASON REEL….1277
19 G-06.00 PLANETARY DRIVE AXLE (CLARK SERIES DS-12152) (C)….1278
    CONTENTS….1278
    GENERAL TORQUE VALUES….1279
    SPECIAL TOOLS….1280
    DESCRIPTION….1281
    REMOVAL OF AXLE FROM CRANE….1282
    DISASSEMBLY….1287
    CLEANING AND INSPECTION….1301
    REASSEMBLY….1303
    INSTALLATION OF AXLE TO CRANE….1317
    TOOTH CONTACT SHEET….1323
20 G-7 ROCKWELL AXLE ASSEMBLY (C)….1324
    CONTENTS….1324
    TORQUE SHEET….1325
    SPECIAL TOOLS….1326
    REMOVAL OF AXLES FROM CRANE….1329
    DISASSEMBLY….1335
    CLEANING AND INSPECTION….1348
    REASSEMBLY….1350
    INSTALLATION….1364
    BRAKE ADJUSTMENT, BLEEDING & BURNISHING….1369
21 G-07.10 CLARK AXLE ASSEMBLIES (MODELS DS-13311 OR D1280736, AND DS-13550 OR D12S0840) (C)….1374
    TABLE OF CONTENTS….1376
    SPECIAL TOOLS….1378
      ADAPTOR BAR….1378
      DIFFERENTAL CARRIER SUPPORT PLATE….1379
      DIFFERENTIAL CARRIER SUPPORT PLATE LEGS….1380
      SPINDLE NUT WRENCH (FOR HUB RETAINING NUT P/N 1259 944 H1)….1381
      SPINDLE NUT WRENCH (FOR HUB RETAINING NUTS P/N 134701. 134758. 75491)….1382
      SPREADER BAR AND CHAINS….1383
      PLUG TOOL (FOR P/N 134705. 1257 751 H91 AND 1260 021 H91)….1384
      MASTER CYLINDER BLEEDING ADAPTOR TOOL….1385
      AXLE HOUSING BUSHING AND OIL SEAL DRIVER….1387
      AXLE TRUNNION BUSHING DRIVER….1388
      SPINDLE BUSHING DRIVER….1389
      SPINDLE OIL SEAL DRIVER….1390
    INTRODUCTION….1391
    TROUBLESHOOTING ….1394
      NOSPIN (FRONT AXLE ONLY)….1395
    SERVICING ….1396
      REMOVAL….1396
        FRONT AXLE REMOVAL….1398
        REAR AXLE REMOVAL….1400
      GENERAL DISASSEMBLY….1402
        PLANETARY DISASSEMBLY….1402
        DIFFERENTAL DISASSEMBLY….1407
      CLEANING AND INSPECTION….1408
      GENERAL REASSEMBLY….1410
        DIFFERENTAL REASSEMBLY….1411
        PLANETARY REASSEMBLY….1411
      PLANETARY CARRIER ASSEMBLY (P/N 134705. 1257 751 H91 AND 1260 021 H91)….1420
        DISASSEMBLY….1420
        REASSEMBLY….1421
      PLANETARY CARRIER BRAKE ASSEMBLY (P/N 81803. 81804. 81771 AND 81772)….1422
        DISASSEMBLY….1422
        REASSEMBLY….1423
      PLANETARY CARRIER BRAKE ASSEMBLY (P/N 1228 948 H91, 1228 949 H91, 1228 944 H91 AND 1228 943 H91)….1424
        DISASSEMBLY….1424
        REASSEMBLY….1425
      REAR AXLE DIFFERENTAL & CARRIER ASSEMBLY (P/N 134762 AND 1260 034 H91)….1427
        DISASSEMBLY….1427
        REASSEMBLY….1430
          PINION GEAR ROLLING TORQUE….1430
          PINION GEAR INSTALLATION….1431
          REASSEMBLY OF RING GEAR AND DIFFERENTIAL ASSEMBLY….1433
          RING GEAR PRELOAD AND BACKLASH ADJUSTMENT….1433
          CHECK ROLLING PATTERN OF RING GEAR AND PINION….1434
          FINAL INSTALLATION OF DIFFERETIAL & CARRIER….1435
      FRONT AXLE DIFFERENTIAL & CARRIER ASSEMBLY (WITH PARKING BRAKE ASSEMBLY) (P/N 134728 AND 1260 025 H91)….1436
        DISASSEMLBY….1436
        REASSEMBLY….1441
          PINION GEAR ROLLING TORQUE….1441
          PINION GEAR INSTALLATION….1442
          REASSEMBLY OF RING GEAR AND DIFFERENTAL ASSEMBLY….1445
          RING GEAR PRELOAD AND BACKLASH ADJUSTMENT….1446
          CHECK ROLLING PATTERN OF RING GEAR AND PINION ….1447
          FINAL INSTALLATION OF DIFFERENTAL & CARRIER….1447
      INSTALLATION….1448
        FRONT AXLE INSTALLATION….1448
        REAR AXLE INSTALLATION….1450
    TOOTH CONTACT CHARTS….1452
    STEERING ADJUSTMENT PROCEDURE (FRONT AND REAR AXLES)….1454
    BRAKE SHOE ADJUSTMENT PROCEDURE (FRONT AND REAR AXLES)….1454
    PARKING BRAKE ADJUSTMENT PROCEDURE (FRONT AXLE)….1455
    BRAKE BLEEDING PROCEDURE (FRONT AND REAR AXLES)….1456
    BURNISHING PROCEDURE (FRONT AND REAR AXLES)….1458
    REAR STEERING INDICATOR ADJUSTMENT PROCEDURE (REAR AXLE)….1459
22 J-02.00 LUBRICATION SPECIFICATIONS (G-R-P-C-M)….1462
    CONTENTS….1463
    A ATF TRANSMISSION FLUID….1470
    B E050 SAE 50 HD ENGINE OIL….1471
    C EP80 EXTREME PRESSURE SAE 80 GEAR OIL….1471
    D EP90 EXTREME PRESSURE SAE 90 GEAR OIL….1472
    E WBL WORM GEAR LUBRICANT….1472
    F OGL OPEN GEAR LUBRICANT (SPECIAL PURPOSE)….1473
    G SAE80 STRAIGHT MINERAL SAE 80 GEAR OIL….1474
    H SAE90 STRAIGHT MINERAL SAE90 GEAR OIL….1474
    I SHC HIGH TEMPERATURE GEAR LUBRICANT (SYNTHESIZED HYDROCARBON BASE FLUID)….1475
    J C-2 TRANSMISSION FLUID….1475
    K C-3 TRANSMISSION FLUID….1476
    L HO HYDRAULIC OIL….1476
    M HO HYDRAULIC OIL….1477
    N MPG MULTI-PURPOSE LITHIUM BASE GREASE….1478
    0 BF HYDRAULIC BRAKE FLUID….1478
    P 10W30 SAE 10W30 ENGINE OIL….1479
    Q HO HYDRAULIC OIL – LOW TEMPERATURE….1479
    R 80W140 SAE 80W-140….1480
    S SAE40 SAE 40 ENGINE OIL….1480
    T 68 HYDRAULIC OIL – PETROLEUM BASE – ANTI-WEAR ADDITIVES….1481
    U SAE1OW SAE 10W ENGINE OIL….1481
23 K-2 WAGNER POWER MASTER CYLINDER USED WITH FOUR WHEEL SERVICE BRAKES (G-C)….1484
    CONTENTS….1484
    POWER FUNCTION….1488
    MANUAL FUNCTION….1488
    DISASSEMBLY OF POWER UNIT….1489
    REASSEMBLY OF POWER UNIT….1493
    DISASSEMBLY OF OLD STYLE MASTER CYLINDER….1496
    REASSEMBLY OF OLD STYLE MASTER CYLINDER….1498
    DISASSEMBLY OF NEW STYLE MASTER CYLINDER….1501
    REASSEMBLY OF NEW STYLE MASTER CYLINDER….1502
    SPECIAL TOOLS….1504
24 K-6 DELCO MORAINE HYDRAULIC MASTER BRAKE CYLINDER (C)….1508
    CONTENTS….1508
    TORQUE SHEET….1509
    SPECIAL TOOLS….1510
    REMOVAL….1512
    DISASSEMBLY….1514
    CLEANING AND INSPECTION….1517
    REASSEMBLY….1518
    INSTALLATION….1521
    BRAKE ADJUSTMENT AND BLEEDING….1523
    BURNISHING….1528
25 K-06.5 BENDIX MASTER CYLINDER & POWER BOOSTER (C)….1530
    CONTENTS….1530
    SPECIAL TOOLS….1532
    REMOVAL….1534
      REMOVAL FROM 150A AND 150F ….1534
      REMOVAL FROM 180S AND 220S….1536
    DISASSEMBLY….1538
    CLEANING AND INSPECTION….1541
    REASSEMBLY….1542
    INSTALLATION….1545
      INSTALLATION ON 150A AND 150FA….1545
      INSTALLATION ON 180S AND 220S….1547
    BLEEDING PROCEDURE – 180S AND 220S….1548
    BRAKE ADJUSTMENT -180S AND 220S….1551
    BURNISHING – 180S AND 220S….1552
    BRAKE ADJUSTMENT AND BLEEDING FOR 150 AND 150FA….1553
    BURNISHING – 150 AND 150FA….1556
26 K-07.00 MINNESOTA BRAKE VALVE (G-P-C)….1558
    CONTENTS….1559
    GENERAL TORQUE VALUES….1560
    REMOVAL FROM MACHINE….1562
    DISASSEMBLY OF RESERVOIR….1565
    REASSEMBLY OF RESERVOIR SECTION….1566
    DISASSEMBLY OF POWER ASSIST SECTION….1567
    REASSEMBLY OF POWER ASSIST SECTION….1568
    INSTALLATION OF BRAKE VALVE ON MACHINE….1571
    BRAKE BLEEDING PROCEDURE….1573
27 K-10.30 DELCO MORAINE POWER BOOSTER (C)….1574
    CONTENTS….1574
    TORQUE SHEET….1575
    INTRODUCTION….1576
    TROUBLESHOOTING ….1577
    IDENTIFICATION….1580
    SERVICE CHART….1582
    SPECIAL TOOLS….1583
      PISTION ROD GAUGE….1583
      150A AND 150FA….1584
      180S AND 220S….1586
    SERVICING ….1588
      REMOVAL….1589
        REMOVAL 150A AND 150FA….1589
        REMOVAL 180S AND 220S….1591
      DISASSEMBLY….1593
        GENERAL ….1593
          DISASSEMBLY OF 124287….1593
          DISASSEMBLY OF 126448….1599
          DISASSEMBLY OF 138622….1604
          DISASSEMBLY OF 148399….1608
      CLEANING AND INSPECTION….1612
      REASSEMBLY….1613
        REASSEMBLY OF 124287….1613
        REASSEMLBY OF 126448….1619
        REASSEMBLY OF 138622….1624
        REASSEMBLY OF 148399….1628
      INSTALLATION….1633
        INSTALLATION 150A AND 150FA….1633
        INSTALLATION 180S AND 220S….1635
      BRAKE ADJUSTMENT AND BLEEDING 150A AND 150FA….1636
      BURNISHING 150A AND 150FA….1641
      BLEEDING PROCEDURE 180S AND 220S….1642
      BRAKE ADJUSTMENT 180S AND 220S….1644
      BURNINSHING 180S AND 220S….1645
28 L-03.00 WIRING DIAGRAMS – CRANES (C)….1646
    CRANE MODEL 80….1646
      ENGINE DD 3-53N S/N 01710 THRU 03131 WIRING DIAGRAM NUMBER 111379….1656
      ENGINE DD 3-53N S/N 04001 AND UP WIRING DIAGRAM NUMBER 111379….1656
      ENGINE IH UB-264 S/N 01710 THRU 03131 WIRING DIAGRAM NUMBER 96962….1648
      ENGINE IH UB-264 S/N 04001 THRU 04638 WIRING DIAGRAM NUMBER 96962….1648
      ENGINE IH UB-264 S/N 04639 THRU 05644 WIRING DIAGRAM 109795….1652
      ENGINE IH UC-263 S/N 01710 THRU 03131 WIRING DIAGRAM 109795….1652
      ENGINE IH UC-263 S/N 05645 AND UP WIRING DIAGRAM 109795….1652
      ENGINE IH UD-282 S/N 01710 THRU 03131 WIRING DIAGRAM 92695….1649
      ENGINE IH UD-282 S/N 04001 AND UP WIRING DIAGRAM 109796….1653
    CRANE MODEL 90, 100, 110 & 125….1646
      ENGINE DD 3-53N S/N 05410 AND UP WIRING DIAGRAM 111379….1656
      ENGINE IH UB-264 S/N 01001-04677 EXCEPT 04655-04657 WIRING DIAGRAM 96962….1648
      ENGINE IH UB-264 S/N 04655 THRU 04657, 04678 AND UP WIRING DIAGRAM 109795….1652
      ENGINE IH UC-263 S/N 05563 AND UP WIRING DIAGRAM 109795….1652
      ENGINE IH UD-282 S/N 01001 THRU 04677 WIRING DIAGRAM 92695….1649
      ENGINE IH UD-282 S/N 04678 AND UP WIRING DIAGRAM 109796….1653
    CRANE MODEL 125F….1646
      ENGINE MODEL DD4-53N S/N 02965 AND UP WIRING DIAGRAM 109797….1654
    CRANE MODEL 90A, 100A, 110A & 125A….1646
      ENGINE MODEL CUM UV-352C S/N 02006 AND UP WIRING DIAGRAM 97869….1651
      ENGINE MODEL DD4-53N S/N 02006 AND UP WIRING DIAGRAM 109797….1654
      ENGINE MODEL IH UV-345 S/N 02006 THRU 04677 WIRING DIAGRAM 96704….1650
      ENGINE MODEL UV-345 S/N 04678 AND UP WIRING DIAGRAM 109798….1655
    CRANE MODEL 125FA….1646
      ENGINE MODEL IH UV-345 S/N 07990 AND UP WIRING DIAGRAM 109798….1655
      ENGINE MODEL DD 4-53N S/N 07990 AND UP WIRING DIAGRAM 109797….1654
    CRANE MODEL 140F….1646
      ENGINE MODEL DD 3-53N S/N 07571 AND UP WIRING DIAGRAM 111379….1656
    CRANE MODEL 150 & 150FA….1646
      ENGINE MODEL CUM UV-352C S/N 02832 THRU 04246 WIRING DIAGRAM 97869….1651
      ENGINE MODEL DD 4-53N S/N 02832 AND UP WIRING DIAGRAM 109797….1654
      ENGINE MODEL DEUTZ F6L-912 S/N 2832 AND UP WIRING DIAGRAM 122748….1657
      ENGINE MODEL IH UV-345 S/N 02832 THRU 04677 WIRING DIAGRAM 96704….1650
      ENGINE MODEL IH UV-345 S/N 04678 AND UP WIRING DIAGRAM 109798….1655
    CRANE MODEL 180S….1646
      ENGINE MODEL DD 6V-53N S/N 08502 AND UP WIRING DIAGRAM 138253….1658
    CRANE MODEL 200FA ….1647
      ENGINE MODEL DD 4-53N S/N 09401 AND UP WIRING DIAGRAM 109797….1654
    CRANE MODEL 220A ….1647
      ENGINE MODEL DD 4-53N S/N 07107 AND UP WIRING DIAGRAM 109797….1654
    CRANE MODEL 220S ….1647
      ENGINE MODEL DD6V-53N S/N 07724 ABD UP WIRING DIAGRAM 138253….1658
    CRANE MODEL 125P….1647
      ENGINE MODEL ALL S/N 01001 AND UP….1659
      ENGINE MODEL ELECTRIC MOTOR S/N 01001 AND UP….1660
    CRANE MODEL 150P & 150T….1647
      ENGINE MODEL ALL S/N 01011 AND UP….1661
      ENGINE MODEL ELECTRIC MOTOR S/N 01011 AND UP….1662
29 L-10.00 TROUBLESHOOTING & REMOVAL OF CRANKING MOTORS (M-P-G-R-C)….1664
    CONTENTS….1664
    TORQUE SHEETS….1665
    PRELIMINARY CHECKS….1666
    REMOVAL ….1670
    BENCH TESTING ….1671
    INSTALLATION….1674
    LUBRICATION….1675
30 L-11.00 TROUBLESHOOTING & REMOVAL OF ALTERNATORS (M-G-P-R-C)….1676
    CONTENTS….1676
    TORQUES SHEET….1677
    PRELIMINARY CHECKS ….1678
    REMOVAL ….1683
    INSTALLATION….1684
    LUBRICATION….1685
31 N-03.40 PREDELIVERY PROCEDURES (C) (NOT INCLUDED – LISTED FOR REFERENCE ONLY)….1685
32 O-01.00 HEAD AND HOOK BLOCK (C)….1686
    CONTENTS….1686
    TORQUE SHEET….1687
    DISASSEMBLY….1688
    INSPECTION….1691
    REASSEMBLY….1694
    CARE OF WIRE ROPE….1697
    WIRE ROPE REPLACEMENT….1698
    METHODS OF LUBRICATION….1699
33 O-03.00 DRESSER HYDRAULIC CRANE – WIRE ROPE SPECIFICATION (C)….1702
    MODEL BREAKDOWN….1704
      MODEL 80….1704
      MODEL 90, 100, 110 AND 125….1704
      MODEL 125F….1705
      MODEL 90A, 100A, 110A AND 125A….1705
      MODEL 125FA….1706
      MODEL 140F….1706
      MODEL 150A….1706
      MODEL 150FA….1707
      MODEL 180S….1707
      MODEL 220A….1707
      MODEL 200FA….1709
      MODEL 220S….1708
      MODEL 400S….1708
      MODEL 125P….1708
      MODEL 150P AND 150T….1709
      FRONT END WINCH (ALL MODELS….1709
    MANUFACTURERS DESCRIPTION….1710
    WIRE ROPE….1712
      WIRE ROPE SPECIFICATIONS….1712
      MAINTENANCE RECOMMENDATIONS….1712
    SERVICE AND INSPECTION OF WIRE ROPE….1713
      RESTING HOOK BLOCK….1713
      IMPORTANCE OF LUBRICATION….1713
      RECOMMENDED LUBRICANTS FOR WIRE ROPE….1714
      METHODS OF LUBRICATIONS….1715
      LUBRICATION IN STORAGE….1716
      IDLE ROPES….1716
      COMPONENT PARTS OF WIRE ROPE….1717
      INSPECTION OF WIRE ROPE SHEAVES & DRUM….1717
        WIRE ROPE….1717
        SHEAVES AND DRUM….1719
      WIRE ROPE REPLACEMENT ….1719
      INSTALLATION OF WIRE ROPE….1720
      BREAKING IN WIRE ROPE….1721
      HOOK AND HEAD BLOCK REEVING….1721
34 Y-01.00 GENERAL TORQUE VALUES (G-R-P-C-M)….1722
    CONTENTS….1722
    INTRODUCTION….1724
    TORQUES….1725
      TORQUE VALUES FOR STANDARD ENGLISH FASTENERS….1725
        BOLT IDENTIFICATION CHART….1725
        TYPE 1, 5 AND 8 NON-PHOSPHATE COATED HARDWARE….1725
        TYPE 8 PHOSPHATE COATED HARDWARE….1727
    TORQUE VALUES FOR STANDARD METRIC FASTENERS….1728
    TORQUE VALUES FOR HOSE CLAMPS….1729
    TORQUE VALUES FOR SPLIT FLANG CONNECTIONS….1730
    TORQUE VALUES FOR HYDRAULIC TUBES AND FITTINGS….1731

Komatsu Hydraulic Crane 150A / 150FA Repair Service Manuals

INSTANT DOWNLOAD

Posted on June 5, 2025 by admin

Komatsu Model 100, 125 series C and E Loaders & TD-7, TD-8 Series C and E Dozers Chassis Repair Service Manual

INSTANT DOWNLOAD

Complete service repair manual for Komatsu Model 100, 125 series C and E Loaders & TD-7, TD-8 Series C and E Dozers Chassis, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Komatsu Model 100, 125 series C and E Loaders & TD-7, TD-8 Series C and E Dozers workshop service & repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

ISS-1543 – Komatsu International Model 100, 125 series C and E Loaders & TD-7, TD-8 Series C and E Dozers (Chassis) (replace GSS-1426 & supplement).pdf

PRODUCT DETAILS:
Total Pages: 412 pages
File Format: PDF
Language: English

TABLE OF CONTENTS
1 – SPECIFICATIONS
2 – ELECTRICAL SYSTEM
3 – COOLING SYSTEM
4 – ENGINE
5 – HYDRAULIC TORQUE CONVERTER
6 – TRANSMISSION (GEAR DRIVE)
7 – TRANSMISSION (POWER SHIFT)
8 – STEERING SYSTEM
9 – SPROCKET DRIVE
10 – TRACK AND TRACK FRAME ASSEMBLY
11 – EQUIPMENT HYDRAULIC SYSTEM
12 – ADJUSTMENTS
13 – GEARMATIC WINCH ADAPTER

Komatsu Model 100, 125 series C and E Loaders & TD-7, TD-8 Series C and E Dozers Chassis Repair Service Manual

INSTANT DOWNLOAD

Posted on June 5, 2025 by admin

Hyster G019 (H300HD, H330HD, H360HD, H360HD-12EC & H13.00XM, H14.00XM, H16.00XM-6, H10.00XM-12EC, H12.00XM-12EC Europe) Repair Service Manual

INSTANT DOWNLOAD

Complete service repair manual for Hyster G019 (H300HD, H330HD, H360HD, H360HD-12EC & H13.00XM, H14.00XM, H16.00XM-6, H10.00XM-12EC, H12.00XM-12EC Europe), with all the shop information to maintain, diagnose, repair, and rebuild like professional mechanics.

Hyster G019 (H300HD, H330HD, H360HD, H360HD-12EC & H13.00XM, H14.00XM, H16.00XM-6, H10.00XM-12EC, H12.00XM-12EC Europe) workshop service & repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

Hyster G019 (H300HD, H330HD, H360HD, H360HD-12EC & H13.00XM, H14.00XM, H16.00XM-6, H10.00XM-12EC, H12.00XM-12EC Europe) Service Manual.pdf

Total Pages: 2,021 pages
File Format: PDF
Language: English

G019 (H13.00XM, H14.00XM, H16.00XM-6, H10.00XM-12EC, H12.00XM-12EC Europe)….2
1494140-1600SRM0936-(03-2007)-UK-EN….3
toc….3
Steering System….3
Safety Precautions Maintenance and Repair….4
General….7
Description….7
Steering Wheel and Column Assembly….9
General….9
Steering Wheel and Horn….9
Remove….9
Install….9
Steering Control Unit Repair….11
General….11
Description….11
Operation….11
Remove….12
Disassemble….12
Clean….15
Assemble and Install….15
Steering System Air Removal….21
Steering Relief Pressure Check….22
Troubleshooting….22
1494141-1800SRM0937-(03-2007)-UK-EN….27
toc….27
Dry Brake System….27
Safety Precautions Maintenance and Repair….28
General….31
Description….31
Operation….32
Service Brakes….32
Parking Brake….34
Air Tank Repair….35
Relief Valve….35
Drain Valve….35
Brake Pedal Valve Repair….36
Remove….36
Disassemble, Inspect, and Assemble….36
Install….36
Air Chambers Repair….37
Remove….37
Disassemble….37
Inspect….38
Assemble….39
Install….39
Actuator Arms Repair….39
Remove….39
Inspect….40
Install….40
Brake Assemblies Repair….41
Brake Shoe, Remove….41
Camshaft, Remove….43
Clean….43
Inspect….44
Camshaft, Install….44
Brake Shoe, Install….45
Air Dryer….46
Description….46
Cartridge….46
Remove….46
Install….46
Filter….46
Remove….46
Install….46
Quick-Release Valve….48
Governor Check and Adjustment for Air Compressor….48
Brake Shoes Adjustment….49
Specifications….50
Troubleshooting….50
Service Brakes….50
Service Brakes, Park Function ….53
tables….27
Table 1. Air Chambers Operation….34
1494142-1900SRM0938-(03-2007)-UK-EN….57
toc….57
Hydraulic System….57
Safety Precautions Maintenance and Repair….58
General….61
Description and Operation….61
Hydraulic Tank….61
Hydraulic Pump….62
Steering Priority Flow Valve….62
Pilot Valve….63
Main Control Valve….65
Unloader Valve….66
Hydraulic Operation….67
Checks and Adjustments….70
Quick Disconnect Fittings….70
Steering Priority Flow Valve….70
Steering Relief Pressure….70
Modulator Valve….71
Pilot Valve and Pressure Reducing Valve….71
Accumulator….72
Filter….72
Main Control Valve….72
Relief Pressure Check….72
Check Valves….73
Unloader Valve….73
Hydraulic Pump Repair….74
Remove….74
Disassemble….74
Clean and Inspect….74
Assemble….75
Install….76
Pilot Accumulator Replacement ….76
Remove….76
Install….76
Pilot Valve Repair….77
Remove….77
Disassemble….78
Clean and Inspect….78
Assemble….78
Install….78
Control Levers and Joystick Repair….79
Remove….79
Install….79
Calibration and Diagnostics….80
General….80
Description….80
Lever and Joystick Calibration….80
Flow Adjustment….80
Dead Band Value Setting….81
Lowering Delay….82
PWM and I/O Module Readouts….82
Function Disable….83
General Startup….83
Minimum system requirements….83
Install the Hydraulic Controls Program….83
DelayTimeFile (Reset)….83
Select the Processor Speed….84
Hydraulic Controls Program….84
Calibration….86
Joystick/Lever Calibration….86
Levers….86
Joystick….86
Valve Flow Adjustment….87
Diagnostics….87
Calibration System Shutdown….87
LED Diagnostics….88
Electrical Connections….91
Specifications….95
tables….57
Table 1. Main Control Valve Port Settings….63
Table 2. Processor Speed Settings….83
Table 3. PWM Board LED Error Codes….88
Table 4. Altering PT FLT I/O Board LED's (Old Logic)….89
Table 5. Altering PT FLT I/O Board LED's (New Logic)….89
Table 6. Fixed PT Logic I/O Boards LED's….90
Table 7. ECH….90
Table 8. PWM Driver Module….91
Table 9. Input/Output Module 1….92
Table 10. Input/Output Module 2….93
Table 11. Altering PT FLT….94
Table 12. Fixed PT FLT….94
Table 13. ECH….95
1494953-1400SRM0944-(03-2007)-UK-EN….99
toc….99
Planetary Drive Axle….99
Safety Precautions Maintenance and Repair….100
General….103
Description….103
Operation….105
Identification….105
Removal….106
Disassembly….106
Planetary Spider and Gearing Assembly H8.00-12.00XM (H170-280HD)….106
Planetary Spider and Gearing Assembly H13.00-14.00XM (H300-330HD….108
Wheel End….110
Spindle and Piston Housing….111
Cleaning….112
Clean Ground or Polished Parts….112
Clean Parts With Rough Finish….112
Clean Axle Assemblies….112
Drying Cleaned Parts….112
Corrosion Prevention….112
Parts Inspection….113
Tapered Roller Bearings….113
Bevel Pinion and Ring Gear Sets….114
Main Differential Assembly….114
Axle Shafts….114
Yoke….114
Brakes….114
Repair or Replace Parts….114
Repair Welding….114
Apply Silicone Gasket Material….115
Assembly….115
Spindle and Piston Housing to Axle Housing….115
Wet Disc Brakes….116
Adjust Wheel Bearing Preload….117
Planetary Spider and Gearing Assembly H8.00-12.00XM (H170-280HD)….118
Planetary Spider and Gearing Assembly H13.00-14.00XM (H300-330HD….119
Planetary Spider Assembly….119
Installation….120
Fill Wet Disc Brakes With Hydraulic Fluid….120
Torque Specifications….121
Lubrication Specification….122
1494955-2000SRM0943-(03-2007)-UK-EN….125
toc….125
Main Control Valve….125
Safety Precautions Maintenance and Repair….126
General….129
Description….129
Operation….132
Lift Section….132
Tilt/Auxiliary Section….132
Relief Valves….132
Unloader Valve….132
Main Control Valve Repair….135
Remove….135
Disassemble….135
Auxiliary Side….135
Lift Side….135
Clean and Inspect….138
Assemble….138
Auxiliary Side….138
Lift Side….138
Install….138
Pressure Relief Valve Check and Adjustment….139
Check and Adjust….139
Replace….139
Specifications….140
Troubleshooting….140
1498445-1400SRM0945-(03-2007)-UK-EN….145
toc….145
Planetary Drive Axle….145
Safety Precautions Maintenance and Repair….146
General….149
Description….149
Operation….151
Identification….151
Removal….152
Disassembly….152
Brake Drum….152
Planetary Spider and Gearing Assembly H8.00-12.00XM (H170-280HD)….153
Dry Brakes….155
Planetary Spider and Gearing Assembly H13.00-14.00XM (H300-330HD….155
Spindle and Brake Spider….157
Cleaning….158
Ground or Polished Parts….158
Parts With Rough Finish….158
Axle Assemblies….158
Drying Cleaned Parts….158
Corrosion Prevention….158
Parts Inspection….159
Tapered Roller Bearings….159
Bevel Pinion and Ring Gear Sets….160
Main Differential Assembly….160
Axle Shafts….160
Yoke….160
Brakes….160
Repair or Replace Parts….160
Repair Welding….160
Apply Silicone Gasket Material….161
Assembly….161
Spindle, Brake Spider, and Brake….161
Wheel End….162
Adjust Wheel Bearing Preload….163
Planetary Spider and Gearing Assembly H8.00-12.00XM (H170-280HD)….164
Planetary Spider and Gearing Assembly H13.00-14.00XM (H300-330HD….165
Planetary Spider Assembly….165
Installation….166
Torque Specifications….167
Lubrication Specification….168
1498450-1800SRM0951-(03-2007)-UK-EN….171
toc….171
Wet Brake System….171
Safety Precautions Maintenance and Repair….172
General….175
Description and Operation….175
Service Brakes….175
Parking Brake….175
Oil Cooler Circuit….175
Pressure Switch Replacement….179
Accumulators Replacement….179
Brake Treadle Valve Repair….179
Remove and Disassemble….179
Clean and Inspect….180
Assemble and Install….180
Parking Brake Valve Repair….180
Remove….180
Clean and Inspect….180
Repair….180
Install….180
Parking Brake Caliper Repair….181
Remove….181
Disassemble….183
Inspect….183
Install….183
Adjust….183
Brake Pad Repair….184
Inspect….184
Remove….184
Install….184
Seals Repair….184
Remove….184
Install….185
Service Brake Repair….185
Remove and Disassemble….185
Drain Lubricating Oil….185
Drain Coolant Oil….192
Disconnect Brake Lines….192
Wheel End With Outer Bearing on Ring Gear Hub Journal H13.00-14….192
Wheel End With Outer Bearing on Spindle Journal H8.00-12.00XM (H….193
Brake Disc Housing Assembly Wheel End….194
Brake Piston Housing….195
Brake Piston Housing and Wheel Spindle….196
Inspect….196
Clean….198
Assemble….199
Wheel Spindle….199
Brake Piston Housing….199
Piston Assembly….201
Brake Disc Housing….201
Duo-Cone Face Seal Into Brake Disc Housing and Into Hub….203
Check for Correct Installation of Duo-Cone Seal….204
Wheel Hub to Brake Disc Housing….205
Adjust….206
Fill Brake System With Coolant Oil….206
System Air Removal….207
Adjust Brake With New Disc Pack….207
Coolant Change Intervals….208
Coolant Draining and Filling….208
Specifications….210
Minimum Brake Disc Thickness….213
Hydraulic Fluid for Brake Actuation….213
Brake Coolant Specifications….213
Coolant Change Intervals….213
Hydraulic Fluid Specifications….213
Troubleshooting….213
Brake Does Not Apply….213
Brake Does Not Release….214
Brake Performance….214
Brake Leaks Actuation Fluid….215
Brake Cooling Fluid Leakage….216
Brake Noise and Vibration….216
Brake Overheats….216
tables….171
Table 1. Brake Pad Adjustment….183
Table 2. Minimum Brake Disc Thickness….197
Table 3. Formed Seal Wear Chart….197
1503241-5000SRM0969-(03-2007)-UK-EN….221
toc….221
Empty Container Handling Attachment….221
Safety Precautions Maintenance and Repair….222
General….225
Description….225
Operation….230
General….230
Selector Valves….230
Sideshift Circuit….230
Extend and Retract Circuit….230
Twist Lock Circuit and Control….231
Model 553 – Horizontally Mounted….231
Model 558 – Vertically Mounted….231
Lifting Hooks….231
Model 555….231
Indicator Lights and LEDs….231
Lift Interrupt and Override….232
Overlowering Interrupt and Override….232
Carriage and Attachment Repair….232
Remove….232
Attachment Without Carriage Repair….233
Remove….233
Sideshift Cylinders Repair….234
Remove….234
Disassemble….234
Assemble….234
Extension Cylinders Repair….235
Remove….235
Disassemble….235
Clean and Inspect….235
Assemble….235
Install….235
Vertical End Beams Repair….237
Remove….237
Install….237
Hose Replacement in End Beams….237
Twist Locks Repair for Model 553….238
Remove….238
Disassemble….238
Clean and Inspect….238
Assemble….238
Hooks Replacement for Model 555….239
Inspect….239
Remove….239
Install….239
Twist Locks Repair for Model 558….240
Disassemble….240
Clean and Inspect….240
Assemble….240
Bleed the System….241
Valve Assembly….241
Slide Pad Replacement….242
Adjustments….242
Twist Lock Angle Adjustment….242
Model 558 Only….242
LOCKED/NOT LOCKED Sensors Adjustment….243
Model 553….243
Model 558….243
Seated Sensor Adjustment….243
Model 553….243
Model 558….243
Overlowering Protection Sensor Adjustment (Models 553 and 558)….243
Torque Chart….244
Maintenance….244
Additional Attachment Maintenance….246
Interface Boxes….247
Model 555….247
Models 553 and 558….247
Troubleshooting….249
tables….221
Table 1. Torque Chart….244
Table 2. Inspect and Adjust (See Figure 14 )….245
Table 3. Lubricate (See Figure 14 )….246
Table 4. Replace (See Figure 14 )….246
1553599-4000SRM1062-(03-2007)-UK-EN….267
toc….267
Masts and Carriages….267
Safety Precautions Maintenance and Repair….268
General….271
Description….271
Operation….272
Two-Stage Mast….272
Three-Stage Mast….273
Safety Procedures When Working Near Mast….274
Forks Repair….277
Remove….277
Inspect and Adjust….277
Install….277
Carriage Repair….278
Description….278
Three Function….278
Four to Six Function….278
Remove….278
Disassemble….279
Clean and Inspect….281
Assemble….281
Install….281
Sideshift Cylinder Repair….282
Remove….282
Disassemble….282
Clean and Inspect….282
Assemble….282
Install….282
Fork Positioner Cylinders Repair….286
Remove….286
Disassemble….286
Clean and Inspect….286
Assemble….286
Install….286
Directional Control Valve Repair….293
Remove….293
Disassemble….293
Clean and Inspect….293
Assemble….294
Install….294
Mast Repair….294
Two- and Three-Stage Mast….294
Remove….294
Disassemble….299
Clean and Inspect….301
Assemble….302
Install….303
Three-Stage Mast (Four Cylinders)….303
Remove….303
Disassemble….305
Clean and Inspect….307
Assemble….307
Install….307
Fork Carriage Chains….309
Adjust….309
Bearing Rollers….311
Description….311
Lubrication….311
Clearance….311
Remove and Disassemble….311
Assemble….312
Mast Profile….312
Lift Cylinders Description….312
Piston-Type Cylinders….312
Displacement-Type Cylinders….312
Lift Cylinders Repair….313
Remove….313
Disassemble….315
Clean and Inspect….315
Assemble….315
Install….316
Mast Operation Check….316
Lift and Tilt System Leak Checks….317
Lift System….317
Tilt System….317
Tilt Cylinder Stroke and Backward Tilt Angle Adjustment….318
Lift Chain Adjustments….318
Mast Adjustments….319
Bearing Blocks, Two-Stage Masts….319
Wear Plates….319
Carriage Adjustment….319
Troubleshooting….321
tables….267
Table 1. Allowable Mast Movement from Internal Leakage….317
1556871-2200SRM1105-(03-2007)-UK-EN….325
toc….325
Instrument Panel Indicators and Senders….325
Safety Precautions Maintenance and Repair….326
General….329
Description….329
General….329
Instrument Panel Meters, Indicators, and LCD Display….329
Connector….335
Seat Switch Logic….336
Central Warning Light Output….336
Buzzer Output….336
Instrument Panel….338
Remove….338
Sender Replacement….339
Fuel Level Sender (Diesel Engine Only)….339
Engine Oil Pressure Sender….340
Brake Pressure Sender….340
Low Coolant Sender….340
Vacuum Switch….340
Specifications….341
Troubleshooting….342
tables….325
Table 1. Instrument Panel and Indicators….330
Table 2. Pin Description….335
Table 3. Sender Description….336
1564053-0600SRM1101-(11-2007)-UK-EN….347
toc….347
Cummins Diesel/LPG Engine Fault Code Guide….347
Safety Precautions Maintenance and Repair….348
General….351
Fault Codes….351
Normal Mode….351
Fault Log Mode….351
Access….351
Exit….352
Clear….352
Electronic Throttle Calibration….352
Electronic Throttle Calibration Procedure….352
tables….347
Table 1. Error Code Descriptions….353
1586990-8000SRM1181-(03-2007)-UK-EN….369
toc….369
Assembly Guide….369
Safety Precautions Maintenance and Repair….370
List of All Special Tools and Equipment Needed for the Assembly….373
General Considerations Before Starting the Job….373
Preparation of the Components Before Assembly….374
Liquefied Petroleum Gas (LPG Engines Only)….374
Remove….374
Install….375
Checking of the Wheels….375
Air Pressure….375
Drive Wheels….376
Steer Wheels….380
Wheel Nut Torque….383
Mast Label Placement….384
Safety Procedures When Working Near Mast….385
Mast Installation….387
Mast….387
Tilt Cylinder Pin Installation….390
Lift Cylinder Hose Connection….391
Truck Header Hoses and Electrical Cable Connections….392
Mast Light Connection….394
Carriage Installation….395
Carriage Header Hoses and Electrical Cable Connection….396
Fork Installation….399
Exhaust Extension Tube Installation….400
Lights Installation – Operator Compartment….402
Hydraulic Oil Check….403
Lubrication Points….404
Check Points….405
Checkpoint 1….405
Checkpoint 2….405
Checkpoint 3….405
Checkpoint 4….405
Checkpoint 5….405
General Truck Install Procedures….405
tables….369
Table 1. Mast Hanger Pins Capscrew Torques….390
1663926-8000SRM1346-(05-2007)-UK-EN….409
toc….409
Diagrams….409
Safety Precautions Maintenance and Repair….410
1663927-8000SRM1347-(12-2007)-UK-EN….463
toc….463
Periodic Maintenance….463
Safety Precautions Maintenance and Repair….464
General….469
Serial Number Data….469
How to Move a Disabled Lift Truck….470
How to Tow the Lift Truck….470
How to Put a Lift Truck on Blocks….470
How to Raise the Drive Tires….471
How to Raise the Steer Tires….471
Maintenance Schedule….472
Empty Container Attachment Maintenance….479
Maintenance Procedures Every 8 Hours or Daily….481
How to Make Checks With the Engine Stopped….481
Safety Labels….481
Tires and Wheels….481
Inspection of Forks, Mast, and Lift Chains….482
Header Hose Assembly….483
Forks, Adjust….483
Forks, Remove….483
Forks, Install….483
Precleaner for Air Filter….484
Check for Fuel, Oil, or Coolant Leaks….484
Coolant Hoses….484
Engine Air Intake Piping….484
Drive Belts….484
Radiator Sections for Engine Coolant, Charge Air Cooler, and Hyd….485
Engine Compartment….485
Operator Restraint System (Seat Belt and Seat Rails)….485
Steering Column Latch….485
Hydraulic System Oil….485
Windshield Washer Fluid….486
Engine Oil….486
How to Add Fuel to the Lift Truck….488
Diesel Fuel….488
Liquefied Petroleum Gas (LPG)….489
Remove….489
Fill….489
Install….490
How to Make Checks With the Engine Running….490
Gauges, Lights, Horn, Fuses, and Relays….490
Engine and Transmission Fault Codes….493
Cooling System….493
Diesel Fuel Filter/Water Separator….494
Electrical System….494
Engine Oil Pressure….494
Fuel System….494
Engine Air Filter….494
Control Levers and Pedals….494
Steering System….494
Parking Brake….494
Service Brakes….495
Lift System Operation….495
Transmission….495
Transmission Oil….495
First Inspection After First 100 Hours of Operation….496
Lift Chains….496
Hydraulic System Oil Filter….496
Engine Oil Filter….496
Transmission Oil Filter….497
Hydraulic Pilot Valve Oil Screen….497
Wet Brake System Filter….497
First Inspection After First 500 Hours of Operation….497
Cab Mounting Bolts….497
Maintenance Procedures Every 250 Hours or Monthly….498
Twist Locks….498
Lifting Hooks (Model 555)….498
Empty Container Attachment….498
Maintenance Procedures Every 250 Hours or 3 Months….498
Lift Chains….498
Wheel Nuts….499
Forks….499
LPG Crankcase Breather….499
Mast Bearing Block Surfaces and Strip Bearings….499
Sideshift Carriage Sliding Surfaces….500
Fork Pins and Guides….500
Maintenance Procedures Every 500 Hours or 3 Months….500
Rod Ends at Sideshift Cylinder….500
Mast Pivot Pins….500
Tilt Cylinder Pivot Pins….500
Steering Axle Tie Rod Pins….500
King Pins….500
Shafts for Air Brake Actuator Arms….500
Drive Shaft….500
Maintenance Procedures Every 500 Hours or 6 Months….501
Cab Air Filter….501
Planetary Drive Axle and Differential….501
Header Hose Assembly….501
Hydraulic Tank Breather….501
Air Compressor (Air Brakes Only)….501
Spark Plug Wire (LPG Engine Only)….501
Cooling Fan….501
Drive Belts….501
Coolant….501
Fuel Pump….501
Engine Oil….502
Engine Oil Filter….502
Diesel Fuel Filter….502
Maintenance Procedures Every 1000 Hours or 6 Months….502
Extension Cylinder Support Wear Pads (ECH Only)….502
Brake Accumulator (Wet Brake Only)….502
Coolant Fan Belt Tensioner….502
Fan Hub….504
Pilot Valve Accumulator….504
LPG Tank Hinges….505
Cab Door Hinges….505
LPG Vapor Fuel Filter….505
Wet Brake System Filter….505
Maintenance Procedures Every 1000 Hours or 1 Year….506
Engine Valve Adjustment….506
Diesel Fuel Filter/Water Separator….506
Transmission Oil….506
Transmission Oil Filter….506
Transmission Breather….506
Maintenance Procedures Every 1500 Hours or 6 Months….506
Drive Axle and Differential….506
Maintenance Procedures Every 2000 Hours or 1 Year….506
Transmission Calibration….506
Inching Pedal Sensor Calibration….506
Parking and Service Brakes….506
Vibration Damper….507
Engine and Transmission Isolators….507
Engine Air Intake Piping….507
Brake Air Pressure Lines….507
Spark Plug (LPG Engines Only)….508
LPG Liquid Fuel Filter….508
Maintenance Procedures Every 3000 Hours or 1 Year….509
Pedals, Levers, Seat Rails, and Hinges….509
Air Dryer Cartridge….509
Hydraulic System Oil and Filter….509
Maintenance Procedures Every 3000 Hours or 2 Years….510
Hydraulic Pilot Valve Oil Screen….510
Maintenance Procedures Every 4000 Hours or 2 Years….510
Spark Plug Wire (LPG Engines Only)….510
Steer Wheels Hub Bearings….510
Maintenance Procedures Every 5000 Hours….511
Twist Locks or Hooks….511
Maintenance Procedures Every 5000 Hours or 3 Years….511
Air Conditioning….511
Maintenance Procedures Every 6000 Hours or 2 Years….511
Turbocharger….511
Maintenance Procedures Every 12,000 Hours or 5 Years….512
Cooling System….512
Safety Procedures When Working Near Mast….513
Lift and Tilt System Leak Check….514
Lift System….514
Tilt System….514
Wheel and Tire Replacement….515
Remove Wheels From Lift Truck….515
Pneumatic Tires….516
Remove Tire From Wheel….516
Remove Tire From Two- and Four-Piece Wheel….516
Install Tire on Wheel….517
Install Tire on Two- and Four-Piece Wheel….518
Add Air to Tires….519
Solid Rubber Tires….519
Remove Tire From Wheel….519
Install Tire on Wheel….521
Wheels, Install….522
tables….463
Table 1. Daily Inspections − Condition Check….473
Table 2. Daily Inspections − Fluid Level Check….474
Table 3. Daily Inspections − Checks With the Engine Running….474
Table 4. Initial 100-Hour Check or Change….475
Table 5. Initial 500-Hour Check or Change….475
Table 6. Periodic Maintenance Schedule − Inspect and Adjust….476
Table 7. Periodic Maintenance Schedule − Lubricate….477
Table 8. Periodic Maintenance Schedule − Change….478
Table 9. Empty Container Attachment Maintenance − Inspect and ….480
Table 10. Empty Container Attachment Maintenance − Lubricate….480
Table 11. Empty Container Attachment Maintenance − Replace….480
Table 12. Approved LPG Engine Oil Types….488
Table 13. Valve Adjustment Specifications….506
Table 14. Allowable Mast Movement from Internal Leakage….515
1663928-8000SRM1348-(03-2008)-UK-EN….525
toc….525
Capacities and Specifications….525
Safety Precautions Maintenance and Repair….526
Counterweight Weights….529
Lift Truck Weights….529
Capacities….530
Engine Specifications….531
Hydraulic System….532
Electrical System….532
Tire Sizes….532
Mast Speeds….533
Torque Specifications, Cummins Diesel….533
Lubrication System….533
Torque Specifications, General….534
Transmission….534
Driveline and Axle….534
Counterweight….534
Differential….534
Brakes – Wet….534
Brakes – Dry….534
Steering….534
Wheel Nuts….534
Hydraulic System….535
Mast….535
Carriage….535
Tilt Cylinders….535
Wiper Arms, Front….535
1665777-0100SRM1349-(01-2008)-UK-EN….539
toc….539
Frame….539
Safety Precautions Maintenance and Repair….540
General….543
Description….543
Air Cleaner….544
Remove….544
Install….544
Exhaust System….545
Remove….545
Install….545
Hood Assembly….546
Remove….546
Install….547
Hydraulic Tank….547
Remove….547
Inspect….549
Clean….549
Additional Preparations for Repair….550
Repair….550
Small Leaks….550
Large Leaks….550
Preparations for use After Repair….550
Install….551
Fuel Tank….552
Remove….552
Repair….556
Install….556
Engine….557
Remove….557
Install….562
Counterweight….563
General….563
Remove….564
Install….565
Label Replacement….565
tables….539
Table 1. Counterweight Weights….563
1665778-0700SRM1350-(03-2007)-UK-EN….569
toc….569
Multiple Aligned Cooling System….569
Safety Precautions Maintenance and Repair….570
General….573
Description….574
Radiator….574
Radiator Cap….574
Thermostat….574
Water Pump….575
Fan and Fan Shroud….575
Cooling System Checks….575
Radiator….575
Thermostat….575
Water Pump….576
Exhaust Leaks….576
Fan and Fan Shroud….576
Cooling System Repair….577
Remove….577
Install….578
Core Repair….579
Remove….579
Install….579
Radiator Cleaning….579
Drain….579
Clean….579
Fill….580
Troubleshooting….580
1665779-2200SRM1351-(04-2007)-UK-EN….585
toc….585
Electrical System….585
Safety Precautions Maintenance and Repair….586
Description….589
Warning Devices….594
General….594
Description….595
Operator-Controlled Horn….595
Reverse Warning Horns/Lights….595
Warning Lights….595
Strobe Light….595
Brake Lights….597
Hazard Lights….597
Replace….597
General….597
Horns….597
Horn Relay….597
Light Assemblies….597
Flashing Unit….598
Meters, Senders, and Switches….598
General….598
1670739-1300SRM1356-(07-2008)-UK-EN….611
toc….611
Transmission….611
Safety Precautions Maintenance and Repair….612
General….615
Transmission Repair….615
Remove….615
Disassemble….619
Transmission Case, Disassemble….620
Torque Converter Housing, Disassemble….637
Forward Clutch, Disassemble….642
First-Speed Clutch, Disassemble….644
Reverse and Second-Speed Clutch….649
Reverse Clutch, Disassemble….649
Second-Speed Clutch, Disassemble….654
Third-Speed Clutch, Disassemble….656
Third Clutch Shaft, Disassemble….658
Turbine Shaft, Disassemble….659
Output Shaft, Disassemble….660
Impeller, Disassemble….661
Turbine, Disassemble….663
Clean and Inspect….665
Housings….665
Oil Seals and Gaskets….665
Bearings….666
Gears and Shafts….666
Assemble….666
Turbine, Assemble….666
Impeller, Assemble….668
Output Shaft, Assemble….670
Turbine Shaft, Assemble….672
Third Clutch Shaft, Assemble….673
Third-Speed Clutch, Assemble….674
Reverse and Second-Speed Clutch….677
Second-Speed Clutch, Assemble….677
Reverse Clutch, Assemble….680
First-Speed Clutch, Assemble….684
Forward Clutch, Assemble….689
Torque Converter Housing, Assemble….692
Transmission Case, Assemble….697
Install….718
Control Valve Removal and Installation….720
Remove….720
Install….720
Control Valve Disassemble and Assemble….722
Remove….722
Transmission Frame Bracket….722
Control Valve Cover….722
Control Valve Components….722
Install….724
Control Valve Components….724
Control Valve Cover….724
Transmission Frame Bracket….724
Torque Specifications….725
Torque Specifications for Lubricated or Plated Screw Threads….725
Troubleshooting….727
tables….611
Table 1. Grade 5….725
Table 2. Grade 8….725
Table 3. Grades 8.8, 10.9, and 12.9….726
Table 4. O-ring Port Plug Torque Chart….727
Table 5. Pipe Plug Torque Chart….727
1671895-1300SRM1358-(07-2008)-UK-EN….731
toc….731
Transmission….731
Safety Precautions Maintenance and Repair….732
General….737
Description….737
General….737
Operation….740
Hydraulic Operation….740
1st/3rd Selector Valve….742
Cooling and Lubrication….742
Control System….744
General….744
APC200 Controller….744
Self Test….744
Protection Modes….744
Limp Home Mode….744
Shut Down Mode….744
Transmission Exceed Codes….744
Fault Codes….745
Description….745
Fault Log Mode….745
Access….745
Exit….745
Clear….746
Fault Rectification….746
Hydraulic Control Valve….747
Hydraulic Control Valve Repair….748
Solenoid Replacement….748
Pressure Check….749
Pressure Specifications….749
Pressure, Speed, and Temperature Sensors….750
Pressure Switch….754
Test….754
Speed Sensor….754
Test….755
Temperature Sensors….756
Test….756
Transmission Test and Calibration….756
Precautions….756
Stall Test….756
Description….756
Stall Test Procedure….756
Clutch Calibration….757
Description….757
Procedure….758
Inching Calibration….758
Description….758
Brake and Inching Pedal Adjustment….759
Inching Sensor Adjustment….759
Inching Sensor Calibration….760
Electrical Specifications….760
APC200 Operation….761
General….761
General Information Group….761
Fault Codes….762
Indication of Protection Modes….762
Test Function Group….763
Digital Input Test….764
Analog Input Test….765
Speed Sensor Test….765
Output Test….766
Voltage Test….767
Calibration Group….767
Calibration Mode….767
Clutch Filling Calibration….768
Heat Up Mode….768
Inching Sensor Calibration….769
Inching Pedal Sensor Adjustment….769
Inching Sensor Calibration….769
TE-Userlink….770
Description….770
Connection….770
Table 12. Transmission Exceed Codes….803
Table 13. APC200 Fault Codes….803
Table 14. Common Calibration Condition Messages….814
Table 15. Fault Codes During Clutch Calibration….815
tables….731
Table 1. Activated Solenoids and Gear Selection….742
Table 2. Control Valve Pressure Check Ports….747
Table 3. Transmission Housing Check Ports….753
Table 4. Sensors and Switches….754
Table 5. Speed Sensor Check Values….755
Table 6. Temperature Sensor (In Speed Sensor) Resistance Versus ….760
Table 7. General Information Group….762
Table 8. Digital Input Test….764
Table 9. Analog Input Test….765
Table 10. Speed Sensor Test….766
Table 11. Output Test….766
1689543-0100SRM1383-(09-2008)-UK-EN….819
toc….819
Operator's Cab….819
Safety Precautions Maintenance and Repair….820
General….827
Description of Operation….828
Cab Structure….828
Cab Supporting Frame….828
Cab Tilt Cylinder….830
Extending the Cab Tilt Cylinder….830
Retracting the Cab Tilt Cylinder….831
Heater System….831
Air Conditioning….833
General….833
Dryer….834
Control Systems, Sensors, and Switches….834
Oil Filling for Cab Tilt System….835
Raising and Lowering Cab….836
Raise Cab….836
Lower Cab….837
Cab….837
Remove….837
Install….839
Cab Door Assembly….840
Cab Door….840
Remove….840
Install….840
Door Hinge….840
Remove….840
Install….840
Door Latch….840
Remove….840
Install….841
Door Handle….842
Remove….842
Install….842
Door Release….842
Remove….842
Install….842
Door Pushbutton….842
Remove….842
Install….842
Cab Tilt System….842
Electric Tilt Pump….842
Remove….842
Install….843
Hand Pump….843
Remove….843
Install….843
Cab Tilt Cylinder….843
Remove….843
Disassemble….843
Clean….845
Inspect….845
Assemble….845
Install….846
Latch….846
Remove….846
Install….846
Brake and Inching Pedals….847
Brake and Inching Pedals….847
Remove….847
Install….847
Brake Pedal Adjustment….847
Dry Brake….847
Wet Brake….847
Inching Pedal Adjustment….848
Dry Brake….848
Wet Brake….848
Inching Pedal Sensor Adjustment Using Userlink® Program….848
Inching Pedal Sensor Calibration Procedure Using Userlink® Progr….849
Inching Pedal Sensor Adjustment Using the APC200….849
Inching Pedal Sensor Calibration Procedure Using the APC200….850
Accelerator Pedal Sensor….851
Check….851
Adjust….851
Seat Assembly….852
Seat….852
Remove….852
Install….852
Seat Cushion….852
Remove….852
Install….852
Back Cushion….853
Remove….853
Install….853
Seat Suspension….853
Remove….853
Install….853
Boot….853
Remove….853
Install….853
Shock Absorber….853
Remove….853
Install….853
Compressor….854
Remove….854
Install….858
Power Assist Armrest….864
Release Cable….864
Remove….864
Install….864
Gas Spring….864
Remove….864
Install….864
Armrest Assembly….865
Adjust….865
Joystick….865
Remove….865
Install….865
Levers….866
Remove….866
Install….866
Rocker Switches….866
Remove….866
Install….866
Cover….866
Remove….866
Install….866
Instrument Panel….867
Key Switch….867
Remove….867
Install….867
12V Power Socket….867
Remove….867
Install….867
Electric-Operated Heater Control and Fan Control….868
Remove….868
Install….868
Cable-Operated Heater Control and Air Control….869
Remove….869
Install….869
Air Conditioning Switch….869
Remove….869
Install….869
Rocker Switches….869
Remove….869
Install….869
Parking Brake Switch….870
Remove….870
Install….870
Indicator Display….870
Remove….870
Install….870
Instrument Panel Top Console….871
Remove….871
Install….871
Steering Wheel and Column Assembly….871
Steering Wheel and Horn….871
Remove….871
Install….871
Steering Column Assembly….873
Remove….873
Install….874
Adjustment Mechanism….874
Remove….874
Install….874
Main Warning Lights….874
Remove….874
Install….874
Shift Lever….875
Remove….875
Install….875
Turn Signal Lever….875
Remove….875
Install….875
Window Wipers Replacement….876
Window Wiper Assembly, Replace….876
Remove….876
Install….876
Window Wiper Motor Replacement….877
Front Window Wiper Motor Assembly….877
Remove….877
Install….877
Rear Window Wiper Motor Assembly….877
Remove….877
Install….877
Top Window Wiper Motor Assembly….878
Remove….878
Install….878
Window Washer System….878
Window Washer Reservoir….878
Remove….878
Install….878
Window Washer Motors and Pumps….878
Remove….878
Install….879
Window Washer Hoses….879
Top/Rear….879
Remove….879
Install….880
Front….880
Remove….880
Install….881
Window Washer Nozzles….881
Front….881
Remove….881
Install….881
Rear….881
Remove….881
Install….882
Top….882
Remove….882
Install….882
Window Replacement….882
Front Window….884
Remove….884
Install….884
Rear Window….884
Remove….884
Install….884
Top Window….885
Remove….885
Install….885
Door Window….885
Upper/Lower Window….885
Remove….885
Install….885
Sliding Window….885
Front Sliding Window….885
Remove….885
Install….887
Rear Sliding Window….887
Remove….887
Install….887
Weather Strip, Replace….888
Window Stopper, Replace….888
Sliding Tracks, Replace….888
Window Seals, Replace….888
Sliding Window Frame….888
Remove….888
Install….888
Heater System Repair….889
Heater Assembly….889
Access….889
Remove….889
Install….890
Heater Assembly Parts, Replace….890
Heater Core….890
Remove….890
Install….891
Evaporator Core….891
Remove….891
Install….891
Blower….892
Remove….892
Install….892
Water Valve….892
Remove….892
Install….893
Vent Door….893
Remove….893
Install….893
Push/Pull Cable, Replace….894
Water Valve Cable….894
Remove….894
Install….894
Vent Door Cable….895
Remove….895
Install….895
Floor Mat….896
Front….896
Remove….896
Install….897
Rear….897
Remove….897
Install….897
Radio Console….898
Remove….898
Install….898
Air Duct….898
Front….898
Remove….898
Install….898
Rear….899
Remove….899
Install….899
Accessories….900
Mirror….900
Remove….900
Install….900
Sunshade….900
Top….900
Remove….900
Install….900
Rear….900
Remove….900
Install….901
Map Light….901
Remove….901
Install….901
Interior Fan….901
Remove….901
Install….901
Training Seat….901
Install….901
Remove….901
Air Conditioning Technical Detail….902
Technical Detail….902
Label Replacement….903
tables….819
Table 1. Air Conditioning Specifications….902
897108-1600SRM0326-(03-2007)-UK-EN….907
toc….907
Steering Axle….907
Safety Precautions Maintenance and Repair….908
General….911
Description….911
Steering Axle Assembly Repair….916
Steering Axle H3.50-5.00XL (H70-110XL) (G005), S3.50-5.50XL (S70….916
Remove….916
Install….916
Steering Axle H6.00-7.00XL (H135-155XL, H135-155XL 2 ) (F006, G0….917
Remove….917
Install….917
Wheels and Hubs Repair (All Units)….918
Remove and Disassemble….918
Clean….918
Inspect….918
Assemble and Install….918
Spindles and Bearings Repair (All Units)….920
Remove….920
Clean….920
Assemble and Install….921
Tie Rods Repair (All Units)….922
Remove….922
Clean….922
Install….922
Steering Cylinder Repair….925
Remove and Disassemble….925
Clean and Inspect….925
Assemble and Install….925
Troubleshooting….926
910072-1400SRM0046-(07-2007)-UK-EN….931
toc….931
Differential….931
Safety Precautions Maintenance and Repair….932
General….935
Description….935
Differential Repair….936
Remove….936
Differential Carrier From Axle Housing, Remove….936
Differential and Ring Gear From Differential Carrier, Remove….938
Drive Pinion and Pinion Carrier From Differential Carrier, Remov….940
Disassemble….941
Differential and Ring Gear Assembly, Disassemble….941
Drive Pinion and Pinion Carrier, Disassemble….943
Clean and Inspect….946
Assemble….947
Pinion, Bearings, and Pinion Carrier, Assemble….947
Pinion Bearings, Adjust Preload….947
Press Method….947
Yoke or Flange Method….948
Triple-Lip Seal, Install….949
Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion)….950
Differential and Ring Gear, Assemble….952
Differential Gears Rotating Torque, Check….954
Differential and Ring Gear Assembly, Install….955
Differential Bearings, Preload Adjust….957
Ring Gear, Runout Check….958
Ring Gear Backlash, Adjust….958
Gear Set, Tooth Contact Pattern Check….960
Thrust Screw, Install and Adjust….963
Install….963
Differential Assembly Into Axle Housing, Install….963
Specifications….965
Troubleshooting….970
tables….931
Table 1. Ring Gear Backlash Adjustment Specifications….960
Table 2. Ring and Pinion Tooth Contact Adjustment….961
Table 3. General Specifications….965
Table 4. Rivet Installation Pressure….965
Table 5. Pinion Adjustment….966
Table 6. Pinion Preload Pressure….966
Table 7. Torque Specifications….967
Table 8. Torque Specifications for Metric Hardware….968
Table 9. Torque Specifications for Metric (Fine) Hardware….969
910102-2100SRM0103-(03-2007)-UK-EN….973
toc….973
Tilt Cylinders….973
Safety Precautions Maintenance and Repair….974
General….977
Description….977
Tilt Cylinder Repair….977
Remove….977
Disassemble….977
Clean….977
Assemble….977
Tilt Cylinders With O-Ring or Single-Lip Seals….977
Tilt Cylinders for XM and XMS Models….979
Tilt Cylinders for XL, XLS, and XL 3 Models….980
Tilt Cylinders for H700-800A and Early Model H700-920B….982
Install….983
Tilt Cylinders Using Chevron Packing….983
Install….984
Tilt Cylinder Leak Check….986
Tilt Cylinder Stroke and Mast Tilt Angle Adjustment….988
Torque Specifications….988
Piston Rod Nut….988
Retainer….989
Troubleshooting….991
tables….973
Table 1. Movement Rates (Maximum) for Tilt Cylinders….987
910442-8000SRM0231-(12-2004)-UK-EN….995
toc….995
Metric and Inch (SAE) Fasteners….995
Safety Precautions Maintenance and Repair….996
General….999
Threaded Fasteners….999
Nomenclature, Threads….999
Strength Identification….1000
Cotter (Split) Pins….1000
Fastener Torque Tables….1005
Conversion Table….1007
tables….995
Table 1. Bolts and Screws….1001
Table 2. Studs and Nuts….1002
Table 3. Torque Nuts….1003
Table 4. Torque Nuts With Nylon Insert….1004
Table 5. Torque Values for Metric Fasteners*….1005
Table 6. Torque Values for Inch Fasteners*….1006
Table 7. Conversion Table for Metric and English Units….1007
Table 8. Cotter Pin Dimensional Data….1008
Table 9. Cotter Pin Dimensional Data….1009
Table 10. Cotter Pin Dimensional Data….1010
Table 11. Cotter Pin Dimensional Data….1012
G019 (H300HD, H330HD, H360HD, H360HD-12EC)….1017
1494140-1600SRM0936-(03-2007)-US-EN….1018
toc….1018
Steering System….1018
Safety Precautions Maintenance and Repair….1019
General….1022
Description….1022
Steering Wheel and Column Assembly….1024
General….1024
Steering Wheel and Horn….1024
Remove….1024
Install….1024
Steering Control Unit Repair….1026
General….1026
Description….1026
Operation….1026
Remove….1027
Disassemble….1027
Clean….1030
Assemble and Install….1030
Steering System Air Removal….1036
Steering Relief Pressure Check….1037
Troubleshooting….1037
1494141-1800SRM0937-(03-2007)-US-EN….1042
toc….1042
Dry Brake System….1042
Safety Precautions Maintenance and Repair….1043
General….1046
Description….1046
Operation….1047
Service Brakes….1047
Parking Brake….1049
Air Tank Repair….1050
Relief Valve….1050
Drain Valve….1050
Brake Pedal Valve Repair….1051
Remove….1051
Disassemble, Inspect, and Assemble….1051
Install….1051
Air Chambers Repair….1052
Remove….1052
Disassemble….1052
Inspect….1053
Assemble….1054
Install….1054
Actuator Arms Repair….1054
Remove….1054
Inspect….1055
Install….1055
Brake Assemblies Repair….1056
Brake Shoe, Remove….1056
Camshaft, Remove….1058
Clean….1058
Inspect….1059
Camshaft, Install….1059
Brake Shoe, Install….1060
Air Dryer….1061
Description….1061
Cartridge….1061
Remove….1061
Install….1061
Filter….1061
Remove….1061
Install….1061
Quick-Release Valve….1063
Governor Check and Adjustment for Air Compressor….1063
Brake Shoes Adjustment….1064
Specifications….1065
Troubleshooting….1065
Service Brakes….1065
Service Brakes, Park Function ….1068
tables….1042
Table 1. Air Chambers Operation….1049
1494142-1900SRM0938-(03-2007)-US-EN….1072
toc….1072
Hydraulic System….1072
Safety Precautions Maintenance and Repair….1073
General….1076
Description and Operation….1076
Hydraulic Tank….1076
Hydraulic Pump….1077
Steering Priority Flow Valve….1077
Pilot Valve….1078
Main Control Valve….1080
Unloader Valve….1081
Hydraulic Operation….1082
Checks and Adjustments….1085
Quick Disconnect Fittings….1085
Steering Priority Flow Valve….1085
Steering Relief Pressure….1085
Modulator Valve….1086
Pilot Valve and Pressure Reducing Valve….1086
Accumulator….1087
Filter….1087
Main Control Valve….1087
Relief Pressure Check….1087
Check Valves….1088
Unloader Valve….1088
Hydraulic Pump Repair….1089
Remove….1089
Disassemble….1089
Clean and Inspect….1089
Assemble….1090
Install….1091
Pilot Accumulator Replacement ….1091
Remove….1091
Install….1091
Pilot Valve Repair….1092
Remove….1092
Disassemble….1093
Clean and Inspect….1093
Assemble….1093
Install….1093
Control Levers and Joystick Repair….1094
Remove….1094
Install….1094
Calibration and Diagnostics….1095
General….1095
Description….1095
Lever and Joystick Calibration….1095
Flow Adjustment….1095
Dead Band Value Setting….1096
Lowering Delay….1097
PWM and I/O Module Readouts….1097
Function Disable….1098
General Startup….1098
Minimum system requirements….1098
Install the Hydraulic Controls Program….1098
DelayTimeFile (Reset)….1098
Select the Processor Speed….1099
Hydraulic Controls Program….1099
Calibration….1101
Joystick/Lever Calibration….1101
Levers….1101
Joystick….1101
Valve Flow Adjustment….1102
Diagnostics….1102
Calibration System Shutdown….1102
LED Diagnostics….1103
Electrical Connections….1106
Specifications….1110
tables….1072
Table 1. Main Control Valve Port Settings….1078
Table 2. Processor Speed Settings….1098
Table 3. PWM Board LED Error Codes….1103
Table 4. Altering PT FLT I/O Board LED's (Old Logic)….1104
Table 5. Altering PT FLT I/O Board LED's (New Logic)….1104
Table 6. Fixed PT Logic I/O Boards LED's….1105
Table 7. ECH….1105
Table 8. PWM Driver Module….1106
Table 9. Input/Output Module 1….1107
Table 10. Input/Output Module 2….1108
Table 11. Altering PT FLT….1109
Table 12. Fixed PT FLT….1109
Table 13. ECH….1110
1494953-1400SRM0944-(03-2007)-US-EN….1114
toc….1114
Planetary Drive Axle….1114
Safety Precautions Maintenance and Repair….1115
General….1118
Description….1118
Operation….1120
Identification….1120
Removal….1121
Disassembly….1121
Planetary Spider and Gearing Assembly H8.00-12.00XM (H170-280HD)….1121
Planetary Spider and Gearing Assembly H13.00-14.00XM (H300-330HD….1123
Wheel End….1125
Spindle and Piston Housing….1126
Cleaning….1127
Clean Ground or Polished Parts….1127
Clean Parts With Rough Finish….1127
Clean Axle Assemblies….1127
Drying Cleaned Parts….1127
Corrosion Prevention….1127
Parts Inspection….1128
Tapered Roller Bearings….1128
Bevel Pinion and Ring Gear Sets….1129
Main Differential Assembly….1129
Axle Shafts….1129
Yoke….1129
Brakes….1129
Repair or Replace Parts….1129
Repair Welding….1129
Apply Silicone Gasket Material….1130
Assembly….1130
Spindle and Piston Housing to Axle Housing….1130
Wet Disc Brakes….1131
Adjust Wheel Bearing Preload….1132
Planetary Spider and Gearing Assembly H8.00-12.00XM (H170-280HD)….1133
Planetary Spider and Gearing Assembly H13.00-14.00XM (H300-330HD….1134
Planetary Spider Assembly….1134
Installation….1135
Fill Wet Disc Brakes With Hydraulic Fluid….1135
Torque Specifications….1136
Lubrication Specification….1137
1494955-2000SRM0943-(03-2007)-US-EN….1140
toc….1140
Main Control Valve….1140
Safety Precautions Maintenance and Repair….1141
General….1144
Description….1144
Operation….1147
Lift Section….1147
Tilt/Auxiliary Section….1147
Relief Valves….1147
Unloader Valve….1147
Main Control Valve Repair….1150
Remove….1150
Disassemble….1150
Auxiliary Side….1150
Lift Side….1150
Clean and Inspect….1153
Assemble….1153
Auxiliary Side….1153
Lift Side….1153
Install….1153
Pressure Relief Valve Check and Adjustment….1154
Check and Adjust….1154
Replace….1154
Specifications….1155
Troubleshooting….1155
1498445-1400SRM0945-(03-2007)-US-EN….1160
toc….1160
Planetary Drive Axle….1160
Safety Precautions Maintenance and Repair….1161
General….1164
Description….1164
Operation….1166
Identification….1166
Removal….1167
Disassembly….1167
Brake Drum….1167
Planetary Spider and Gearing Assembly H8.00-12.00XM (H170-280HD)….1168
Dry Brakes….1170
Planetary Spider and Gearing Assembly H13.00-14.00XM (H300-330HD….1170
Spindle and Brake Spider….1172
Cleaning….1173
Ground or Polished Parts….1173
Parts With Rough Finish….1173
Axle Assemblies….1173
Drying Cleaned Parts….1173
Corrosion Prevention….1173
Parts Inspection….1174
Tapered Roller Bearings….1174
Bevel Pinion and Ring Gear Sets….1175
Main Differential Assembly….1175
Axle Shafts….1175
Yoke….1175
Brakes….1175
Repair or Replace Parts….1175
Repair Welding….1175
Apply Silicone Gasket Material….1176
Assembly….1176
Spindle, Brake Spider, and Brake….1176
Wheel End….1177
Adjust Wheel Bearing Preload….1178
Planetary Spider and Gearing Assembly H8.00-12.00XM (H170-280HD)….1179
Planetary Spider and Gearing Assembly H13.00-14.00XM (H300-330HD….1180
Planetary Spider Assembly….1180
Installation….1181
Torque Specifications….1182
Lubrication Specification….1183
1498450-1800SRM0951-(03-2007)-US-EN….1186
toc….1186
Wet Brake System….1186
Safety Precautions Maintenance and Repair….1187
General….1190
Description and Operation….1190
Service Brakes….1190
Parking Brake….1190
Oil Cooler Circuit….1190
Pressure Switch Replacement….1194
Accumulators Replacement….1194
Brake Treadle Valve Repair….1194
Remove and Disassemble….1194
Clean and Inspect….1195
Assemble and Install….1195
Parking Brake Valve Repair….1195
Remove….1195
Clean and Inspect….1195
Repair….1195
Install….1195
Parking Brake Caliper Repair….1196
Remove….1196
Disassemble….1198
Inspect….1198
Install….1198
Adjust….1198
Brake Pad Repair….1199
Inspect….1199
Remove….1199
Install….1199
Seals Repair….1199
Remove….1199
Install….1200
Service Brake Repair….1200
Remove and Disassemble….1200
Drain Lubricating Oil….1200
Drain Coolant Oil….1207
Disconnect Brake Lines….1207
Wheel End With Outer Bearing on Ring Gear Hub Journal H13.00-14….1207
Wheel End With Outer Bearing on Spindle Journal H8.00-12.00XM (H….1208
Brake Disc Housing Assembly Wheel End….1209
Brake Piston Housing….1210
Brake Piston Housing and Wheel Spindle….1211
Inspect….1211
Clean….1213
Assemble….1214
Wheel Spindle….1214
Brake Piston Housing….1214
Piston Assembly….1216
Brake Disc Housing….1216
Duo-Cone Face Seal Into Brake Disc Housing and Into Hub….1218
Check for Correct Installation of Duo-Cone Seal….1219
Wheel Hub to Brake Disc Housing….1220
Adjust….1221
Fill Brake System With Coolant Oil….1221
System Air Removal….1222
Adjust Brake With New Disc Pack….1222
Coolant Change Intervals….1223
Coolant Draining and Filling….1223
Specifications….1225
Minimum Brake Disc Thickness….1228
Hydraulic Fluid for Brake Actuation….1228
Brake Coolant Specifications….1228
Coolant Change Intervals….1228
Hydraulic Fluid Specifications….1228
Troubleshooting….1228
Brake Does Not Apply….1228
Brake Does Not Release….1229
Brake Performance….1229
Brake Leaks Actuation Fluid….1230
Brake Cooling Fluid Leakage….1231
Brake Noise and Vibration….1231
Brake Overheats….1231
tables….1186
Table 1. Brake Pad Adjustment….1198
Table 2. Minimum Brake Disc Thickness….1212
Table 3. Formed Seal Wear Chart….1212
1503241-5000SRM0969-(10-2007)-US-EN….1236
toc….1236
Empty Container Handling Attachment….1236
Safety Precautions Maintenance and Repair….1237
General….1240
Description….1240
Operation….1246
General….1246
Selector Valves….1246
Sideshift Circuit….1246
Extend and Retract Circuit….1246
Twist Lock Circuit and Control….1247
Model 553 – Horizontally Mounted….1247
Model 558 – Vertically Mounted….1247
Lifting Hooks….1247
Model 555….1247
Indicator Lights and LEDs….1247
Lift Interrupt and Override….1248
Overlowering Interrupt and Override….1248
Carriage and Attachment Repair….1248
Remove….1248
Attachment Without Carriage Repair….1249
Remove….1249
Sideshift Cylinders Repair….1250
Remove….1250
Disassemble….1250
Assemble….1250
Extension Cylinders Repair….1251
Remove….1251
Disassemble….1251
Clean and Inspect….1251
Assemble….1251
Install….1251
Vertical End Beams Repair….1253
Remove….1253
Install….1253
Hose Replacement in End Beams….1253
Twist Locks Repair for Model 553….1254
Remove….1254
Disassemble….1254
Clean and Inspect….1254
Assemble….1254
Hooks Replacement for Model 555….1255
Inspect….1255
Remove….1255
Install….1255
Twist Locks Repair for Model 558….1256
Disassemble….1256
Clean and Inspect….1256
Assemble….1256
Bleed the System….1257
Valve Assembly….1257
Slide Pad Replacement….1258
Adjustments….1258
Twist Lock Angle Adjustment….1258
Model 558 Only….1258
LOCKED/NOT LOCKED Sensors Adjustment….1259
Model 553….1259
Model 558….1259
Seated Sensor Adjustment….1259
Model 553….1259
Model 558….1259
Overlowering Protection Sensor Adjustment (Models 553 and 558)….1259
Torque Chart….1260
Maintenance….1260
Additional Attachment Maintenance….1262
Interface Boxes….1263
Model 555….1263
Models 553 and 558….1263
Troubleshooting….1265
tables….1236
Table 1. Torque Chart….1260
Table 2. Inspect and Adjust (See Figure 14 )….1261
Table 3. Lubricate (See Figure 14 )….1262
Table 4. Replace (See Figure 14 )….1262
1553599-4000SRM1062-(03-2007)-US-EN….1282
toc….1282
Masts and Carriages….1282
Safety Precautions Maintenance and Repair….1283
General….1286
Description….1286
Operation….1287
Two-Stage Mast….1287
Three-Stage Mast….1288
Safety Procedures When Working Near Mast….1289
Forks Repair….1292
Remove….1292
Inspect and Adjust….1292
Install….1292
Carriage Repair….1293
Description….1293
Three Function….1293
Four to Six Function….1293
Remove….1293
Disassemble….1294
Clean and Inspect….1296
Assemble….1296
Install….1296
Sideshift Cylinder Repair….1297
Remove….1297
Disassemble….1297
Clean and Inspect….1297
Assemble….1297
Install….1297
Fork Positioner Cylinders Repair….1301
Remove….1301
Disassemble….1301
Clean and Inspect….1301
Assemble….1301
Install….1301
Directional Control Valve Repair….1308
Remove….1308
Disassemble….1308
Clean and Inspect….1308
Assemble….1309
Install….1309
Mast Repair….1309
Two- and Three-Stage Mast….1309
Remove….1309
Disassemble….1314
Clean and Inspect….1316
Assemble….1317
Install….1318
Three-Stage Mast (Four Cylinders)….1318
Remove….1318
Disassemble….1320
Clean and Inspect….1322
Assemble….1322
Install….1322
Fork Carriage Chains….1324
Adjust….1324
Bearing Rollers….1326
Description….1326
Lubrication….1326
Clearance….1326
Remove and Disassemble….1326
Assemble….1327
Mast Profile….1327
Lift Cylinders Description….1327
Piston-Type Cylinders….1327
Displacement-Type Cylinders….1327
Lift Cylinders Repair….1328
Remove….1328
Disassemble….1330
Clean and Inspect….1330
Assemble….1330
Install….1331
Mast Operation Check….1331
Lift and Tilt System Leak Checks….1332
Lift System….1332
Tilt System….1332
Tilt Cylinder Stroke and Backward Tilt Angle Adjustment….1333
Lift Chain Adjustments….1333
Mast Adjustments….1334
Bearing Blocks, Two-Stage Masts….1334
Wear Plates….1334
Carriage Adjustment….1334
Troubleshooting….1336
tables….1282
Table 1. Allowable Mast Movement from Internal Leakage….1332
1556871-2200SRM1105-(03-2007)-US-EN….1340
toc….1340
Instrument Panel Indicators and Senders….1340
Safety Precautions Maintenance and Repair….1341
General….1344
Description….1344
General….1344
Instrument Panel Meters, Indicators, and LCD Display….1344
Connector….1350
Seat Switch Logic….1351
Central Warning Light Output….1351
Buzzer Output….1351
Instrument Panel….1353
Remove….1353
Sender Replacement….1354
Fuel Level Sender (Diesel Engine Only)….1354
Engine Oil Pressure Sender….1355
Brake Pressure Sender….1355
Low Coolant Sender….1355
Vacuum Switch….1355
Specifications….1356
Troubleshooting….1357
tables….1340
Table 1. Instrument Panel and Indicators….1345
Table 2. Pin Description….1350
Table 3. Sender Description….1351
1564053-0600SRM1101-(11-2007)-US-EN….1362
toc….1362
Cummins Diesel/LPG Engine Fault Code Guide….1362
Safety Precautions Maintenance and Repair….1363
General….1366
Fault Codes….1366
Normal Mode….1366
Fault Log Mode….1366
Access….1366
Exit….1367
Clear….1367
Electronic Throttle Calibration….1367
Electronic Throttle Calibration Procedure….1367
tables….1362
Table 1. Error Code Descriptions….1368
1586990-8000SRM1181-(03-2007)-US-EN….1384
toc….1384
Assembly Guide….1384
Safety Precautions Maintenance and Repair….1385
List of All Special Tools and Equipment Needed for the Assembly….1388
General Considerations Before Starting the Job….1388
Preparation of the Components Before Assembly….1389
Liquefied Petroleum Gas (LPG Engines Only)….1389
Remove….1389
Install….1390
Checking of the Wheels….1390
Air Pressure….1390
Drive Wheels….1391
Steer Wheels….1395
Wheel Nut Torque….1398
Mast Label Placement….1399
Safety Procedures When Working Near Mast….1400
Mast Installation….1402
Mast….1402
Tilt Cylinder Pin Installation….1405
Lift Cylinder Hose Connection….1406
Truck Header Hoses and Electrical Cable Connections….1407
Mast Light Connection….1409
Carriage Installation….1410
Carriage Header Hoses and Electrical Cable Connection….1411
Fork Installation….1414
Exhaust Extension Tube Installation….1415
Lights Installation – Operator Compartment….1417
Hydraulic Oil Check….1418
Lubrication Points….1419
Check Points….1420
Checkpoint 1….1420
Checkpoint 2….1420
Checkpoint 3….1420
Checkpoint 4….1420
Checkpoint 5….1420
General Truck Install Procedures….1420
tables….1384
Table 1. Mast Hanger Pins Capscrew Torques….1405
1663926-8000SRM1346-(05-2007)-US-EN….1424
toc….1424
Diagrams….1424
Safety Precautions Maintenance and Repair….1425
1663927-8000SRM1347-(12-2007)-US-EN….1478
toc….1478
Periodic Maintenance….1478
Safety Precautions Maintenance and Repair….1479
General….1484
Serial Number Data….1484
How to Move a Disabled Lift Truck….1485
How to Tow the Lift Truck….1485
How to Put a Lift Truck on Blocks….1485
How to Raise the Drive Tires….1486
How to Raise the Steer Tires….1486
Maintenance Schedule….1487
Empty Container Attachment Maintenance….1494
Maintenance Procedures Every 8 Hours or Daily….1496
How to Make Checks With the Engine Stopped….1496
Safety Labels….1496
Tires and Wheels….1496
Inspection of Forks, Mast, and Lift Chains….1497
Header Hose Assembly….1498
Forks, Adjust….1498
Forks, Remove….1498
Forks, Install….1498
Precleaner for Air Filter….1499
Check for Fuel, Oil, or Coolant Leaks….1499
Coolant Hoses….1499
Engine Air Intake Piping….1499
Drive Belts….1499
Radiator Sections for Engine Coolant, Charge Air Cooler, and Hyd….1500
Engine Compartment….1500
Operator Restraint System (Seat Belt and Seat Rails)….1500
Steering Column Latch….1500
Hydraulic System Oil….1500
Windshield Washer Fluid….1501
Engine Oil….1501
How to Add Fuel to the Lift Truck….1503
Diesel Fuel….1503
Liquefied Petroleum Gas (LPG)….1504
Remove….1504
Fill….1504
Install….1505
How to Make Checks With the Engine Running….1505
Gauges, Lights, Horn, Fuses, and Relays….1505
Engine and Transmission Fault Codes….1508
Cooling System….1508
Diesel Fuel Filter/Water Separator….1509
Electrical System….1509
Engine Oil Pressure….1509
Fuel System….1509
Engine Air Filter….1509
Control Levers and Pedals….1509
Steering System….1509
Parking Brake….1509
Service Brakes….1510
Lift System Operation….1510
Transmission….1510
Transmission Oil….1510
First Inspection After First 100 Hours of Operation….1511
Lift Chains….1511
Hydraulic System Oil Filter….1511
Engine Oil Filter….1511
Transmission Oil Filter….1512
Hydraulic Pilot Valve Oil Screen….1512
Wet Brake System Filter….1512
First Inspection After First 500 Hours of Operation….1512
Cab Mounting Bolts….1512
Maintenance Procedures Every 250 Hours or Monthly….1513
Twist Locks….1513
Lifting Hooks (Model 555)….1513
Empty Container Attachment….1513
Maintenance Procedures Every 250 Hours or 3 Months….1513
Lift Chains….1513
Wheel Nuts….1514
Forks….1514
LPG Crankcase Breather….1514
Mast Bearing Block Surfaces and Strip Bearings….1514
Sideshift Carriage Sliding Surfaces….1515
Fork Pins and Guides….1515
Maintenance Procedures Every 500 Hours or 3 Months….1515
Rod Ends at Sideshift Cylinder….1515
Mast Pivot Pins….1515
Tilt Cylinder Pivot Pins….1515
Steering Axle Tie Rod Pins….1515
King Pins….1515
Shafts for Air Brake Actuator Arms….1515
Drive Shaft….1515
Maintenance Procedures Every 500 Hours or 6 Months….1516
Cab Air Filter….1516
Planetary Drive Axle and Differential….1516
Header Hose Assembly….1516
Hydraulic Tank Breather….1516
Air Compressor (Air Brakes Only)….1516
Spark Plug Wire (LPG Engine Only)….1516
Cooling Fan….1516
Drive Belts….1516
Coolant….1516
Fuel Pump….1516
Engine Oil….1517
Engine Oil Filter….1517
Diesel Fuel Filter….1517
Maintenance Procedures Every 1000 Hours or 6 Months….1517
Extension Cylinder Support Wear Pads (ECH Only)….1517
Brake Accumulator (Wet Brake Only)….1517
Coolant Fan Belt Tensioner….1517
Fan Hub….1519
Pilot Valve Accumulator….1519
LPG Tank Hinges….1520
Cab Door Hinges….1520
LPG Vapor Fuel Filter….1520
Wet Brake System Filter….1520
Maintenance Procedures Every 1000 Hours or 1 Year….1521
Engine Valve Adjustment….1521
Diesel Fuel Filter/Water Separator….1521
Transmission Oil….1521
Transmission Oil Filter….1521
Transmission Breather….1521
Maintenance Procedures Every 1500 Hours or 6 Months….1521
Drive Axle and Differential….1521
Maintenance Procedures Every 2000 Hours or 1 Year….1521
Transmission Calibration….1521
Inching Pedal Sensor Calibration….1521
Parking and Service Brakes….1521
Vibration Damper….1522
Engine and Transmission Isolators….1522
Engine Air Intake Piping….1522
Brake Air Pressure Lines….1522
Spark Plug (LPG Engines Only)….1523
LPG Liquid Fuel Filter….1523
Maintenance Procedures Every 3000 Hours or 1 Year….1524
Pedals, Levers, Seat Rails, and Hinges….1524
Air Dryer Cartridge….1524
Hydraulic System Oil and Filter….1524
Maintenance Procedures Every 3000 Hours or 2 Years….1525
Hydraulic Pilot Valve Oil Screen….1525
Maintenance Procedures Every 4000 Hours or 2 Years….1525
Spark Plug Wire (LPG Engines Only)….1525
Steer Wheels Hub Bearings….1525
Maintenance Procedures Every 5000 Hours….1526
Twist Locks or Hooks….1526
Maintenance Procedures Every 5000 Hours or 3 Years….1526
Air Conditioning….1526
Maintenance Procedures Every 6000 Hours or 2 Years….1526
Turbocharger….1526
Maintenance Procedures Every 12,000 Hours or 5 Years….1527
Cooling System….1527
Safety Procedures When Working Near Mast….1528
Lift and Tilt System Leak Check….1529
Lift System….1529
Tilt System….1529
Wheel and Tire Replacement….1530
Remove Wheels From Lift Truck….1530
Pneumatic Tires….1531
Remove Tire From Wheel….1531
Remove Tire From Two- and Four-Piece Wheel….1531
Install Tire on Wheel….1532
Install Tire on Two- and Four-Piece Wheel….1533
Add Air to Tires….1534
Solid Rubber Tires….1534
Remove Tire From Wheel….1534
Install Tire on Wheel….1536
Wheels, Install….1537
tables….1478
Table 1. Daily Inspections − Condition Check….1488
Table 2. Daily Inspections − Fluid Level Check….1489
Table 3. Daily Inspections − Checks With the Engine Running….1489
Table 4. Initial 100-Hour Check or Change….1490
Table 5. Initial 500-Hour Check or Change….1490
Table 6. Periodic Maintenance Schedule − Inspect and Adjust….1491
Table 7. Periodic Maintenance Schedule − Lubricate….1492
Table 8. Periodic Maintenance Schedule − Change….1493
Table 9. Empty Container Attachment Maintenance − Inspect and ….1495
Table 10. Empty Container Attachment Maintenance − Lubricate….1495
Table 11. Empty Container Attachment Maintenance − Replace….1495
Table 12. Approved LPG Engine Oil Types….1503
Table 13. Valve Adjustment Specifications….1521
Table 14. Allowable Mast Movement from Internal Leakage….1530
1663928-8000SRM1348-(03-2008)-US-EN….1540
toc….1540
Capacities and Specifications….1540
Safety Precautions Maintenance and Repair….1541
Counterweight Weights….1544
Lift Truck Weights….1544
Capacities….1545
Engine Specifications….1546
Hydraulic System….1547
Electrical System….1547
Tire Sizes….1547
Mast Speeds….1548
Torque Specifications, Cummins Diesel….1548
Lubrication System….1548
Torque Specifications, General….1549
Transmission….1549
Driveline and Axle….1549
Counterweight….1549
Differential….1549
Brakes – Wet….1549
Brakes – Dry….1549
Steering….1549
Wheel Nuts….1549
Hydraulic System….1550
Mast….1550
Carriage….1550
Tilt Cylinders….1550
Wiper Arms, Front….1550
1665777-0100SRM1349-(01-2008)-US-EN….1554
toc….1554
Frame….1554
Safety Precautions Maintenance and Repair….1555
General….1558
Description….1558
Air Cleaner….1559
Remove….1559
Install….1559
Exhaust System….1560
Remove….1560
Install….1560
Hood Assembly….1561
Remove….1561
Install….1562
Hydraulic Tank….1562
Remove….1562
Inspect….1564
Clean….1564
Additional Preparations for Repair….1565
Repair….1565
Small Leaks….1565
Large Leaks….1565
Preparations for use After Repair….1565
Install….1566
Fuel Tank….1567
Remove….1567
Repair….1571
Install….1571
Engine….1572
Remove….1572
Install….1577
Counterweight….1578
General….1578
Remove….1579
Install….1580
Label Replacement….1580
tables….1554
Table 1. Counterweight Weights….1578
1665778-0700SRM1350-(03-2007)-US-EN….1584
toc….1584
Multiple Aligned Cooling System….1584
Safety Precautions Maintenance and Repair….1585
General….1588
Description….1589
Radiator….1589
Radiator Cap….1589
Thermostat….1589
Water Pump….1590
Fan and Fan Shroud….1590
Cooling System Checks….1590
Radiator….1590
Thermostat….1590
Water Pump….1591
Exhaust Leaks….1591
Fan and Fan Shroud….1591
Cooling System Repair….1592
Remove….1592
Install….1593
Core Repair….1594
Remove….1594
Install….1594
Radiator Cleaning….1594
Drain….1594
Clean….1594
Fill….1595
Troubleshooting….1595
1665779-2200SRM1351-(04-2007)-US-EN….1600
toc….1600
Electrical System….1600
Safety Precautions Maintenance and Repair….1601
Description….1604
Warning Devices….1609
General….1609
Description….1610
Operator-Controlled Horn….1610
Reverse Warning Horns/Lights….1610
Warning Lights….1610
Strobe Light….1610
Brake Lights….1612
Hazard Lights….1612
Replace….1612
General….1612
Horns….1612
Horn Relay….1612
Light Assemblies….1612
Flashing Unit….1613
Meters, Senders, and Switches….1613
General….1613
1670739-1300SRM1356-(07-2008)-US-EN….1626
toc….1626
Transmission….1626
Safety Precautions Maintenance and Repair….1627
General….1630
Transmission Repair….1630
Remove….1630
Disassemble….1634
Transmission Case, Disassemble….1635
Torque Converter Housing, Disassemble….1652
Forward Clutch, Disassemble….1657
First-Speed Clutch, Disassemble….1659
Reverse and Second-Speed Clutch….1664
Reverse Clutch, Disassemble….1664
Second-Speed Clutch, Disassemble….1669
Third-Speed Clutch, Disassemble….1671
Third Clutch Shaft, Disassemble….1673
Turbine Shaft, Disassemble….1674
Output Shaft, Disassemble….1675
Impeller, Disassemble….1676
Turbine, Disassemble….1678
Clean and Inspect….1680
Housings….1680
Oil Seals and Gaskets….1680
Bearings….1681
Gears and Shafts….1681
Assemble….1681
Turbine, Assemble….1681
Impeller, Assemble….1683
Output Shaft, Assemble….1685
Turbine Shaft, Assemble….1687
Third Clutch Shaft, Assemble….1688
Third-Speed Clutch, Assemble….1689
Reverse and Second-Speed Clutch….1692
Second-Speed Clutch, Assemble….1692
Reverse Clutch, Assemble….1695
First-Speed Clutch, Assemble….1699
Forward Clutch, Assemble….1704
Torque Converter Housing, Assemble….1707
Transmission Case, Assemble….1712
Install….1733
Control Valve Removal and Installation….1735
Remove….1735
Install….1735
Control Valve Disassemble and Assemble….1737
Remove….1737
Transmission Frame Bracket….1737
Control Valve Cover….1737
Control Valve Components….1737
Install….1739
Control Valve Components….1739
Control Valve Cover….1739
Transmission Frame Bracket….1739
Torque Specifications….1740
Torque Specifications for Lubricated or Plated Screw Threads….1740
Troubleshooting….1742
tables….1626
Table 1. Grade 5….1740
Table 2. Grade 8….1740
Table 3. Grades 8.8, 10.9, and 12.9….1741
Table 4. O-ring Port Plug Torque Chart….1742
Table 5. Pipe Plug Torque Chart….1742
1671895-1300SRM1358-(07-2008)-US-EN….1746
toc….1746
Transmission….1746
Safety Precautions Maintenance and Repair….1747
General….1752
Description….1752
General….1752
Operation….1755
Hydraulic Operation….1755
1st/3rd Selector Valve….1757
Cooling and Lubrication….1757
Control System….1759
General….1759
APC200 Controller….1759
Self Test….1759
Protection Modes….1759
Limp Home Mode….1759
Shut Down Mode….1759
Transmission Exceed Codes….1759
Fault Codes….1760
Description….1760
Fault Log Mode….1760
Access….1760
Exit….1760
Clear….1761
Fault Rectification….1761
Hydraulic Control Valve….1762
Hydraulic Control Valve Repair….1763
Solenoid Replacement….1763
Pressure Check….1764
Pressure Specifications….1764
Pressure, Speed, and Temperature Sensors….1765
Pressure Switch….1769
Test….1769
Speed Sensor….1769
Test….1770
Temperature Sensors….1771
Test….1771
Transmission Test and Calibration….1771
Precautions….1771
Stall Test….1771
Description….1771
Stall Test Procedure….1771
Clutch Calibration….1772
Description….1772
Procedure….1773
Inching Calibration….1773
Description….1773
Brake and Inching Pedal Adjustment….1774
Inching Sensor Adjustment….1774
Inching Sensor Calibration….1775
Electrical Specifications….1775
APC200 Operation….1776
General….1776
General Information Group….1776
Fault Codes….1777
Indication of Protection Modes….1777
Test Function Group….1778
Digital Input Test….1779
Analog Input Test….1780
Speed Sensor Test….1780
Output Test….1781
Voltage Test….1782
Calibration Group….1782
Calibration Mode….1782
Clutch Filling Calibration….1783
Heat Up Mode….1783
Inching Sensor Calibration….1784
Inching Pedal Sensor Adjustment….1784
Inching Sensor Calibration….1784
TE-Userlink….1785
Description….1785
Connection….1785
Table 12. Transmission Exceed Codes….1818
Table 13. APC200 Fault Codes….1818
Table 14. Common Calibration Condition Messages….1829
Table 15. Fault Codes During Clutch Calibration….1830
tables….1746
Table 1. Activated Solenoids and Gear Selection….1757
Table 2. Control Valve Pressure Check Ports….1762
Table 3. Transmission Housing Check Ports….1768
Table 4. Sensors and Switches….1769
Table 5. Speed Sensor Check Values….1770
Table 6. Temperature Sensor (In Speed Sensor) Resistance Versus ….1775
Table 7. General Information Group….1777
Table 8. Digital Input Test….1779
Table 9. Analog Input Test….1780
Table 10. Speed Sensor Test….1781
Table 11. Output Test….1781
1689543-0100SRM1383-(09-2008)-US-EN….1834
toc….1834
Operator's Cab….1834
Safety Precautions Maintenance and Repair….1835
General….1842
Description of Operation….1843
Cab Structure….1843
Cab Supporting Frame….1843
Cab Tilt Cylinder….1845
Extending the Cab Tilt Cylinder….1845
Retracting the Cab Tilt Cylinder….1846
Heater System….1846
Air Conditioning….1848
General….1848
Dryer….1849
Control Systems, Sensors, and Switches….1849
Oil Filling for Cab Tilt System….1850
Raising and Lowering Cab….1851
Raise Cab….1851
Lower Cab….1852
Cab….1852
Remove….1852
Install….1854
Cab Door Assembly….1855
Cab Door….1855
Remove….1855
Install….1855
Door Hinge….1855
Remove….1855
Install….1855
Door Latch….1855
Remove….1855
Install….1856
Door Handle….1857
Remove….1857
Install….1857
Door Release….1857
Remove….1857
Install….1857
Door Pushbutton….1857
Remove….1857
Install….1857
Cab Tilt System….1857
Electric Tilt Pump….1857
Remove….1857
Install….1858
Hand Pump….1858
Remove….1858
Install….1858
Cab Tilt Cylinder….1858
Remove….1858
Disassemble….1858
Clean….1860
Inspect….1860
Assemble….1860
Install….1861
Latch….1861
Remove….1861
Install….1861
Brake and Inching Pedals….1862
Brake and Inching Pedals….1862
Remove….1862
Install….1862
Brake Pedal Adjustment….1862
Dry Brake….1862
Wet Brake….1862
Inching Pedal Adjustment….1863
Dry Brake….1863
Wet Brake….1863
Inching Pedal Sensor Adjustment Using Userlink® Program….1863
Inching Pedal Sensor Calibration Procedure Using Userlink® Progr….1864
Inching Pedal Sensor Adjustment Using the APC200….1864
Inching Pedal Sensor Calibration Procedure Using the APC200….1865
Accelerator Pedal Sensor….1866
Check….1866
Adjust….1866
Seat Assembly….1867
Seat….1867
Remove….1867
Install….1867
Seat Cushion….1867
Remove….1867
Install….1867
Back Cushion….1868
Remove….1868
Install….1868
Seat Suspension….1868
Remove….1868
Install….1868
Boot….1868
Remove….1868
Install….1868
Shock Absorber….1868
Remove….1868
Install….1868
Compressor….1869
Remove….1869
Install….1873
Power Assist Armrest….1879
Release Cable….1879
Remove….1879
Install….1879
Gas Spring….1879
Remove….1879
Install….1879
Armrest Assembly….1880
Adjust….1880
Joystick….1880
Remove….1880
Install….1880
Levers….1881
Remove….1881
Install….1881
Rocker Switches….1881
Remove….1881
Install….1881
Cover….1881
Remove….1881
Install….1881
Instrument Panel….1882
Key Switch….1882
Remove….1882
Install….1882
12V Power Socket….1882
Remove….1882
Install….1882
Electric-Operated Heater Control and Fan Control….1883
Remove….1883
Install….1883
Cable-Operated Heater Control and Air Control….1884
Remove….1884
Install….1884
Air Conditioning Switch….1884
Remove….1884
Install….1884
Rocker Switches….1884
Remove….1884
Install….1884
Parking Brake Switch….1885
Remove….1885
Install….1885
Indicator Display….1885
Remove….1885
Install….1885
Instrument Panel Top Console….1886
Remove….1886
Install….1886
Steering Wheel and Column Assembly….1886
Steering Wheel and Horn….1886
Remove….1886
Install….1886
Steering Column Assembly….1888
Remove….1888
Install….1889
Adjustment Mechanism….1889
Remove….1889
Install….1889
Main Warning Lights….1889
Remove….1889
Install….1889
Shift Lever….1890
Remove….1890
Install….1890
Turn Signal Lever….1890
Remove….1890
Install….1890
Window Wipers Replacement….1891
Window Wiper Assembly, Replace….1891
Remove….1891
Install….1891
Window Wiper Motor Replacement….1892
Front Window Wiper Motor Assembly….1892
Remove….1892
Install….1892
Rear Window Wiper Motor Assembly….1892
Remove….1892
Install….1892
Top Window Wiper Motor Assembly….1893
Remove….1893
Install….1893
Window Washer System….1893
Window Washer Reservoir….1893
Remove….1893
Install….1893
Window Washer Motors and Pumps….1893
Remove….1893
Install….1894
Window Washer Hoses….1894
Top/Rear….1894
Remove….1894
Install….1895
Front….1895
Remove….1895
Install….1896
Window Washer Nozzles….1896
Front….1896
Remove….1896
Install….1896
Rear….1896
Remove….1896
Install….1897
Top….1897
Remove….1897
Install….1897
Window Replacement….1897
Front Window….1899
Remove….1899
Install….1899
Rear Window….1899
Remove….1899
Install….1899
Top Window….1900
Remove….1900
Install….1900
Door Window….1900
Upper/Lower Window….1900
Remove….1900
Install….1900
Sliding Window….1900
Front Sliding Window….1900
Remove….1900
Install….1902
Rear Sliding Window….1902
Remove….1902
Install….1902
Weather Strip, Replace….1903
Window Stopper, Replace….1903
Sliding Tracks, Replace….1903
Window Seals, Replace….1903
Sliding Window Frame….1903
Remove….1903
Install….1903
Heater System Repair….1904
Heater Assembly….1904
Access….1904
Remove….1904
Install….1905
Heater Assembly Parts, Replace….1905
Heater Core….1905
Remove….1905
Install….1906
Evaporator Core….1906
Remove….1906
Install….1906
Blower….1907
Remove….1907
Install….1907
Water Valve….1907
Remove….1907
Install….1908
Vent Door….1908
Remove….1908
Install….1908
Push/Pull Cable, Replace….1909
Water Valve Cable….1909
Remove….1909
Install….1909
Vent Door Cable….1910
Remove….1910
Install….1910
Floor Mat….1911
Front….1911
Remove….1911
Install….1912
Rear….1912
Remove….1912
Install….1912
Radio Console….1913
Remove….1913
Install….1913
Air Duct….1913
Front….1913
Remove….1913
Install….1913
Rear….1914
Remove….1914
Install….1914
Accessories….1915
Mirror….1915
Remove….1915
Install….1915
Sunshade….1915
Top….1915
Remove….1915
Install….1915
Rear….1915
Remove….1915
Install….1916
Map Light….1916
Remove….1916
Install….1916
Interior Fan….1916
Remove….1916
Install….1916
Training Seat….1916
Install….1916
Remove….1916
Air Conditioning Technical Detail….1917
Technical Detail….1917
Label Replacement….1918
tables….1834
Table 1. Air Conditioning Specifications….1917
897108-1600SRM0326-(03-2007)-US-EN….1922
toc….1922
Steering Axle….1922
Safety Precautions Maintenance and Repair….1923
General….1926
Description….1926
Steering Axle Assembly Repair….1931
Steering Axle H3.50-5.00XL (H70-110XL) (G005), S3.50-5.50XL (S70….1931
Remove….1931
Install….1931
Steering Axle H6.00-7.00XL (H135-155XL, H135-155XL 2 ) (F006, G0….1932
Remove….1932
Install….1932
Wheels and Hubs Repair (All Units)….1933
Remove and Disassemble….1933
Clean….1933
Inspect….1933
Assemble and Install….1933
Spindles and Bearings Repair (All Units)….1935
Remove….1935
Clean….1935
Assemble and Install….1936
Tie Rods Repair (All Units)….1937
Remove….1937
Clean….1937
Install….1937
Steering Cylinder Repair….1940
Remove and Disassemble….1940
Clean and Inspect….1940
Assemble and Install….1940
Troubleshooting….1941
910072-1400SRM0046-(07-2007)-US-EN….1946
toc….1946
Differential….1946
Safety Precautions Maintenance and Repair….1947
General….1950
Description….1950
Differential Repair….1951
Remove….1951
Differential Carrier From Axle Housing, Remove….1951
Differential and Ring Gear From Differential Carrier, Remove….1953
Drive Pinion and Pinion Carrier From Differential Carrier, Remov….1955
Disassemble….1956
Differential and Ring Gear Assembly, Disassemble….1956
Drive Pinion and Pinion Carrier, Disassemble….1958
Clean and Inspect….1961
Assemble….1962
Pinion, Bearings, and Pinion Carrier, Assemble….1962
Pinion Bearings, Adjust Preload….1962
Press Method….1962
Yoke or Flange Method….1963
Triple-Lip Seal, Install….1964
Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion)….1965
Differential and Ring Gear, Assemble….1967
Differential Gears Rotating Torque, Check….1969
Differential and Ring Gear Assembly, Install….1970
Differential Bearings, Preload Adjust….1972
Ring Gear, Runout Check….1973
Ring Gear Backlash, Adjust….1973
Gear Set, Tooth Contact Pattern Check….1975
Thrust Screw, Install and Adjust….1978
Install….1978
Differential Assembly Into Axle Housing, Install….1978
Specifications….1980
Troubleshooting….1985
tables….1946
Table 1. Ring Gear Backlash Adjustment Specifications….1975
Table 2. Ring and Pinion Tooth Contact Adjustment….1976
Table 3. General Specifications….1980
Table 4. Rivet Installation Pressure….1980
Table 5. Pinion Adjustment….1981
Table 6. Pinion Preload Pressure….1981
Table 7. Torque Specifications….1982
Table 8. Torque Specifications for Metric Hardware….1983
Table 9. Torque Specifications for Metric (Fine) Hardware….1984
910102-2100SRM0103-(03-2007)-US-EN….1988
toc….1988
Tilt Cylinders….1988
Safety Precautions Maintenance and Repair….1989
General….1992
Description….1992
Tilt Cylinder Repair….1992
Remove….1992
Disassemble….1992
Clean….1992
Assemble….1992
Tilt Cylinders With O-Ring or Single-Lip Seals….1992
Tilt Cylinders for XM and XMS Models….1994
Tilt Cylinders for XL, XLS, and XL 3 Models….1995
Tilt Cylinders for H700-800A and Early Model H700-920B….1997
Install….1998
Tilt Cylinders Using Chevron Packing….1998
Install….1999
Tilt Cylinder Leak Check….2001
Tilt Cylinder Stroke and Mast Tilt Angle Adjustment….2003
Torque Specifications….2003
Piston Rod Nut….2003
Retainer….2004
Troubleshooting….2006
tables….1988
Table 1. Movement Rates (Maximum) for Tilt Cylinders….2002
910442-8000SRM0231-(12-2004)-US-EN….2010
toc….2010
Metric and Inch (SAE) Fasteners….2010
Safety Precautions Maintenance and Repair….2011
General….2014
Threaded Fasteners….2014
Nomenclature, Threads….2014
Strength Identification….2015
Cotter (Split) Pins….2015
Fastener Torque Tables….2020
Conversion Table….2022
tables….2010
Table 1. Bolts and Screws….2016
Table 2. Studs and Nuts….2017
Table 3. Torque Nuts….2018
Table 4. Torque Nuts With Nylon Insert….2019
Table 5. Torque Values for Metric Fasteners*….2020
Table 6. Torque Values for Inch Fasteners*….2021
Table 7. Conversion Table for Metric and English Units….2022
Table 8. Cotter Pin Dimensional Data….2023
Table 9. Cotter Pin Dimensional Data….2024
Table 10. Cotter Pin Dimensional Data….2025
Table 11. Cotter Pin Dimensional Data….2027

Hyster G019 (H300HD, H330HD, H360HD, H360HD-12EC & H13.00XM, H14.00XM, H16.00XM-6, H10.00XM-12EC, H12.00XM-12EC Europe) Repair Service Manual

INSTANT DOWNLOAD

Posted on June 5, 2025 by admin

Hyster Forklift Trucks G007 (H170-280HD & H8.00-12.00XM Europe) Repair Service Manual

INSTANT DOWNLOAD

Complete service repair manual for Hyster G007 (H170-280HD & H8.00-12.00XM Europe) Forklift Trucks, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Hyster G007 (H170-280HD & H8.00-12.00XM Europe) workshop service & repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

Hyster G007 (H170-280HD & H8.00-12.00XM Europe) Service Manual.pdf

Total Pages: 1,013 + 1,455 pages
File Format: PDF
Language: English

TABLE OF CONTENTS
CAPACITIES AND SPECIFICATIONS
DIAGRAMS
ELECTRICAL WARNING DEVICES
INCH (SAE) AND METRIC FASTENERS
INSTRUMENT PANEL INDICATORS AND SENDERS
LIFT CYLINDERS
LIFT CYLINDERS_
PERIODIC MAINTENANCE
THE BRAKE SYSTEM
THE CARBURETOR
THE COOLING SYSTEM
THE DRIVE AXLE
THE ELECTRICAL SYSTEM
THE FRAME
THE HYDRAULIC SYSTEM, GEAR PUMP ASSEMBLY
THE ISUZU C240 ENGINE
THE LPG FUEL SYSTEM
THE MAIN CONTROL VALVE
THE MAZDA M4-121G ENGINE
THE SINGLE-SPEED POWERSHIFT TRANSMISSION – REPAIR
THE STEERING AXLE
THE STEERING CONTROL UNIT
THE TILT CYLINDERS
UPRIGHTS – DESCRIPTION
UPRIGHTS – REPAIRS
VISTA UPRIGHTS – DESCRIPTION
VISTA UPRIGHTS – REPAIR
CAPACITIES AND SPECIFICATIONS
DIAGRAMS
ELECTRICAL WARNING DEVICES
INSTRUMENT PANEL INDICATORS AND SENDERS
LIFT CYLINDERS
METRIC AND INCH (SAE) FASTENERS
PERIODIC MAINTENANCE
THE BRAKE SYSTEM
THE CARBURETOR
THE COOLING SYSTEM
THE DRIVE AXLE
THE ELECTRICAL SYSTEM (ISUZU)
THE ELECTRICAL SYSTEM (MAZDA)
THE FRAME
THE HYDRAULIC SYSTEM, GEAR PUMP ASSEMBLY
THE LPG FUEL SYSTEM
THE MAIN CONTROL VALVE
THE SINGLE-SPEED POWERSHIFT TRANSMISSION – DESCRIPTION AND OPERATION
THE SINGLE-SPEED POWERSHIFT TRANSMISSION – REPAIRS
THE STEERING AXLE
THE STEERING CONTROL UNIT.
THE STEERING CONTROL UNIT
THE TILT CYLINDERS
UPRIGHTS – DESCRIPTION
UPRIGHTS – REPAIRS
VISTA UPRIGHTS – DESCRIPTION
VISTA UPRIGHTS – REPAIR

G007 (H170-280HD)…2
1494140-1600SRM0936-(03-2007)-US-EN…3
toc…3
Steering System…3
Safety Precautions Maintenance and Repair…4
General…7
Description…7
Steering Wheel and Column Assembly…9
General…9
Steering Wheel and Horn…9
Remove…9
Install…9
Steering Control Unit Repair…11
General…11
Description…11
Operation…11
Remove…12
Disassemble…12
Clean…15
Assemble and Install…15
Steering System Air Removal…21
Steering Relief Pressure Check…22
Troubleshooting…22
1494141-1800SRM0937-(03-2007)-US-EN…27
toc…27
Dry Brake System…27
Safety Precautions Maintenance and Repair…28
General…31
Description…31
Operation…32
Service Brakes…32
Parking Brake…34
Air Tank Repair…35
Relief Valve…35
Drain Valve…35
Brake Pedal Valve Repair…36
Remove…36
Disassemble, Inspect, and Assemble…36
Install…36
Air Chambers Repair…37
Remove…37
Disassemble…37
Inspect…38
Assemble…39
Install…39
Actuator Arms Repair…39
Remove…39
Inspect…40
Install…40
Brake Assemblies Repair…41
Brake Shoe, Remove…41
Camshaft, Remove…43
Clean…43
Inspect…44
Camshaft, Install…44
Brake Shoe, Install…45
Air Dryer…46
Description…46
Cartridge…46
Remove…46
Install…46
Filter…46
Remove…46
Install…46
Quick-Release Valve…48
Governor Check and Adjustment for Air Compressor…48
Brake Shoes Adjustment…49
Specifications…50
Troubleshooting…50
Service Brakes…50
Service Brakes, Park Function …53
tables…27
Table 1. Air Chambers Operation…34
1494142-1900SRM0938-(03-2007)-US-EN…57
toc…57
Hydraulic System…57
Safety Precautions Maintenance and Repair…58
General…61
Description and Operation…61
Hydraulic Tank…61
Hydraulic Pump…62
Steering Priority Flow Valve…62
Pilot Valve…63
Main Control Valve…65
Unloader Valve…66
Hydraulic Operation…67
Checks and Adjustments…70
Quick Disconnect Fittings…70
Steering Priority Flow Valve…70
Steering Relief Pressure…70
Modulator Valve…71
Pilot Valve and Pressure Reducing Valve…71
Accumulator…72
Filter…72
Main Control Valve…72
Relief Pressure Check…72
Check Valves…73
Unloader Valve…73
Hydraulic Pump Repair…74
Remove…74
Disassemble…74
Clean and Inspect…74
Assemble…75
Install…76
Pilot Accumulator Replacement …76
Remove…76
Install…76
Pilot Valve Repair…77
Remove…77
Disassemble…78
Clean and Inspect…78
Assemble…78
Install…78
Control Levers and Joystick Repair…79
Remove…79
Install…79
Calibration and Diagnostics…80
General…80
Description…80
Lever and Joystick Calibration…80
Flow Adjustment…80
Dead Band Value Setting…81
Lowering Delay…82
PWM and I/O Module Readouts…82
Function Disable…83
General Startup…83
Minimum system requirements…83
Install the Hydraulic Controls Program…83
DelayTimeFile (Reset)…83
Select the Processor Speed…84
Hydraulic Controls Program…84
Calibration…86
Joystick/Lever Calibration…86
Levers…86
Joystick…86
Valve Flow Adjustment…87
Diagnostics…87
Calibration System Shutdown…87
LED Diagnostics…88
Electrical Connections…91
Specifications…95
tables…57
Table 1. Main Control Valve Port Settings…63
Table 2. Processor Speed Settings…83
Table 3. PWM Board LED Error Codes…88
Table 4. Altering PT FLT I/O Board LED's (Old Logic)…89
Table 5. Altering PT FLT I/O Board LED's (New Logic)…89
Table 6. Fixed PT Logic I/O Boards LED's…90
Table 7. ECH…90
Table 8. PWM Driver Module…91
Table 9. Input/Output Module 1…92
Table 10. Input/Output Module 2…93
Table 11. Altering PT FLT…94
Table 12. Fixed PT FLT…94
Table 13. ECH…95
1494953-1400SRM0944-(03-2007)-US-EN…99
toc…99
Planetary Drive Axle…99
Safety Precautions Maintenance and Repair…100
General…103
Description…103
Operation…105
Identification…105
Removal…106
Disassembly…106
Planetary Spider and Gearing Assembly H8.00-12.00XM (H170-280HD)…106
Planetary Spider and Gearing Assembly H13.00-14.00XM (H300-330HD…108
Wheel End…110
Spindle and Piston Housing…111
Cleaning…112
Clean Ground or Polished Parts…112
Clean Parts With Rough Finish…112
Clean Axle Assemblies…112
Drying Cleaned Parts…112
Corrosion Prevention…112
Parts Inspection…113
Tapered Roller Bearings…113
Bevel Pinion and Ring Gear Sets…114
Main Differential Assembly…114
Axle Shafts…114
Yoke…114
Brakes…114
Repair or Replace Parts…114
Repair Welding…114
Apply Silicone Gasket Material…115
Assembly…115
Spindle and Piston Housing to Axle Housing…115
Wet Disc Brakes…116
Adjust Wheel Bearing Preload…117
Planetary Spider and Gearing Assembly H8.00-12.00XM (H170-280HD)…118
Planetary Spider and Gearing Assembly H13.00-14.00XM (H300-330HD…119
Planetary Spider Assembly…119
Installation…120
Fill Wet Disc Brakes With Hydraulic Fluid…120
Torque Specifications…121
Lubrication Specification…122
1494955-2000SRM0943-(03-2007)-US-EN…125
toc…125
Main Control Valve…125
Safety Precautions Maintenance and Repair…126
General…129
Description…129
Operation…132
Lift Section…132
Tilt/Auxiliary Section…132
Relief Valves…132
Unloader Valve…132
Main Control Valve Repair…135
Remove…135
Disassemble…135
Auxiliary Side…135
Lift Side…135
Clean and Inspect…138
Assemble…138
Auxiliary Side…138
Lift Side…138
Install…138
Pressure Relief Valve Check and Adjustment…139
Check and Adjust…139
Replace…139
Specifications…140
Troubleshooting…140
1498445-1400SRM0945-(03-2007)-US-EN…145
toc…145
Planetary Drive Axle…145
Safety Precautions Maintenance and Repair…146
General…149
Description…149
Operation…151
Identification…151
Removal…152
Disassembly…152
Brake Drum…152
Planetary Spider and Gearing Assembly H8.00-12.00XM (H170-280HD)…153
Dry Brakes…155
Planetary Spider and Gearing Assembly H13.00-14.00XM (H300-330HD…155
Spindle and Brake Spider…157
Cleaning…158
Ground or Polished Parts…158
Parts With Rough Finish…158
Axle Assemblies…158
Drying Cleaned Parts…158
Corrosion Prevention…158
Parts Inspection…159
Tapered Roller Bearings…159
Bevel Pinion and Ring Gear Sets…160
Main Differential Assembly…160
Axle Shafts…160
Yoke…160
Brakes…160
Repair or Replace Parts…160
Repair Welding…160
Apply Silicone Gasket Material…161
Assembly…161
Spindle, Brake Spider, and Brake…161
Wheel End…162
Adjust Wheel Bearing Preload…163
Planetary Spider and Gearing Assembly H8.00-12.00XM (H170-280HD)…164
Planetary Spider and Gearing Assembly H13.00-14.00XM (H300-330HD…165
Planetary Spider Assembly…165
Installation…166
Torque Specifications…167
Lubrication Specification…168
1498450-1800SRM0951-(03-2007)-US-EN…171
toc…171
Wet Brake System…171
Safety Precautions Maintenance and Repair…172
General…175
Description and Operation…175
Service Brakes…175
Parking Brake…175
Oil Cooler Circuit…175
Pressure Switch Replacement…179
Accumulators Replacement…179
Brake Treadle Valve Repair…179
Remove and Disassemble…179
Clean and Inspect…180
Assemble and Install…180
Parking Brake Valve Repair…180
Remove…180
Clean and Inspect…180
Repair…180
Install…180
Parking Brake Caliper Repair…181
Remove…181
Disassemble…183
Inspect…183
Install…183
Adjust…183
Brake Pad Repair…184
Inspect…184
Remove…184
Install…184
Seals Repair…184
Remove…184
Install…185
Service Brake Repair…185
Remove and Disassemble…185
Drain Lubricating Oil…185
Drain Coolant Oil…192
Disconnect Brake Lines…192
Wheel End With Outer Bearing on Ring Gear Hub Journal H13.00-14…192
Wheel End With Outer Bearing on Spindle Journal H8.00-12.00XM (H…193
Brake Disc Housing Assembly Wheel End…194
Brake Piston Housing…195
Brake Piston Housing and Wheel Spindle…196
Inspect…196
Clean…198
Assemble…199
Wheel Spindle…199
Brake Piston Housing…199
Piston Assembly…201
Brake Disc Housing…201
Duo-Cone Face Seal Into Brake Disc Housing and Into Hub…203
Check for Correct Installation of Duo-Cone Seal…204
Wheel Hub to Brake Disc Housing…205
Adjust…206
Fill Brake System With Coolant Oil…206
System Air Removal…207
Adjust Brake With New Disc Pack…207
Coolant Change Intervals…208
Coolant Draining and Filling…208
Specifications…210
Minimum Brake Disc Thickness…213
Hydraulic Fluid for Brake Actuation…213
Brake Coolant Specifications…213
Coolant Change Intervals…213
Hydraulic Fluid Specifications…213
Troubleshooting…213
Brake Does Not Apply…213
Brake Does Not Release…214
Brake Performance…214
Brake Leaks Actuation Fluid…215
Brake Cooling Fluid Leakage…216
Brake Noise and Vibration…216
Brake Overheats…216
tables…171
Table 1. Brake Pad Adjustment…183
Table 2. Minimum Brake Disc Thickness…197
Table 3. Formed Seal Wear Chart…197
1503241-5000SRM0969-(10-2007)-US-EN…221
toc…221
Empty Container Handling Attachment…221
Safety Precautions Maintenance and Repair…222
General…225
Description…225
Operation…231
General…231
Selector Valves…231
Sideshift Circuit…231
Extend and Retract Circuit…231
Twist Lock Circuit and Control…232
Model 553 – Horizontally Mounted…232
Model 558 – Vertically Mounted…232
Lifting Hooks…232
Model 555…232
Indicator Lights and LEDs…232
Lift Interrupt and Override…233
Overlowering Interrupt and Override…233
Carriage and Attachment Repair…233
Remove…233
Attachment Without Carriage Repair…234
Remove…234
Sideshift Cylinders Repair…235
Remove…235
Disassemble…235
Assemble…235
Extension Cylinders Repair…236
Remove…236
Disassemble…236
Clean and Inspect…236
Assemble…236
Install…236
Vertical End Beams Repair…238
Remove…238
Install…238
Hose Replacement in End Beams…238
Twist Locks Repair for Model 553…239
Remove…239
Disassemble…239
Clean and Inspect…239
Assemble…239
Hooks Replacement for Model 555…240
Inspect…240
Remove…240
Install…240
Twist Locks Repair for Model 558…241
Disassemble…241
Clean and Inspect…241
Assemble…241
Bleed the System…242
Valve Assembly…242
Slide Pad Replacement…243
Adjustments…243
Twist Lock Angle Adjustment…243
Model 558 Only…243
LOCKED/NOT LOCKED Sensors Adjustment…244
Model 553…244
Model 558…244
Seated Sensor Adjustment…244
Model 553…244
Model 558…244
Overlowering Protection Sensor Adjustment (Models 553 and 558)…244
Torque Chart…245
Maintenance…245
Additional Attachment Maintenance…247
Interface Boxes…248
Model 555…248
Models 553 and 558…248
Troubleshooting…250
tables…221
Table 1. Torque Chart…245
Table 2. Inspect and Adjust (See Figure 14 )…246
Table 3. Lubricate (See Figure 14 )…247
Table 4. Replace (See Figure 14 )…247
1553599-4000SRM1062-(03-2007)-US-EN…267
toc…267
Masts and Carriages…267
Safety Precautions Maintenance and Repair…268
General…271
Description…271
Operation…272
Two-Stage Mast…272
Three-Stage Mast…273
Safety Procedures When Working Near Mast…274
Forks Repair…277
Remove…277
Inspect and Adjust…277
Install…277
Carriage Repair…278
Description…278
Three Function…278
Four to Six Function…278
Remove…278
Disassemble…279
Clean and Inspect…281
Assemble…281
Install…281
Sideshift Cylinder Repair…282
Remove…282
Disassemble…282
Clean and Inspect…282
Assemble…282
Install…282
Fork Positioner Cylinders Repair…286
Remove…286
Disassemble…286
Clean and Inspect…286
Assemble…286
Install…286
Directional Control Valve Repair…293
Remove…293
Disassemble…293
Clean and Inspect…293
Assemble…294
Install…294
Mast Repair…294
Two- and Three-Stage Mast…294
Remove…294
Disassemble…299
Clean and Inspect…301
Assemble…302
Install…303
Three-Stage Mast (Four Cylinders)…303
Remove…303
Disassemble…305
Clean and Inspect…307
Assemble…307
Install…307
Fork Carriage Chains…309
Adjust…309
Bearing Rollers…311
Description…311
Lubrication…311
Clearance…311
Remove and Disassemble…311
Assemble…312
Mast Profile…312
Lift Cylinders Description…312
Piston-Type Cylinders…312
Displacement-Type Cylinders…312
Lift Cylinders Repair…313
Remove…313
Disassemble…315
Clean and Inspect…315
Assemble…315
Install…316
Mast Operation Check…316
Lift and Tilt System Leak Checks…317
Lift System…317
Tilt System…317
Tilt Cylinder Stroke and Backward Tilt Angle Adjustment…318
Lift Chain Adjustments…318
Mast Adjustments…319
Bearing Blocks, Two-Stage Masts…319
Wear Plates…319
Carriage Adjustment…319
Troubleshooting…321
tables…267
Table 1. Allowable Mast Movement from Internal Leakage…317
1556871-2200SRM1105-(03-2007)-US-EN…325
toc…325
Instrument Panel Indicators and Senders…325
Safety Precautions Maintenance and Repair…326
General…329
Description…329
General…329
Instrument Panel Meters, Indicators, and LCD Display…329
Connector…335
Seat Switch Logic…336
Central Warning Light Output…336
Buzzer Output…336
Instrument Panel…338
Remove…338
Sender Replacement…339
Fuel Level Sender (Diesel Engine Only)…339
Engine Oil Pressure Sender…340
Brake Pressure Sender…340
Low Coolant Sender…340
Vacuum Switch…340
Specifications…341
Troubleshooting…342
tables…325
Table 1. Instrument Panel and Indicators…330
Table 2. Pin Description…335
Table 3. Sender Description…336
1564053-0600SRM1101-(11-2007)-US-EN…347
toc…347
Cummins Diesel/LPG Engine Fault Code Guide…347
Safety Precautions Maintenance and Repair…348
General…351
Fault Codes…351
Normal Mode…351
Fault Log Mode…351
Access…351
Exit…352
Clear…352
Electronic Throttle Calibration…352
Electronic Throttle Calibration Procedure…352
tables…347
Table 1. Error Code Descriptions…353
1586990-8000SRM1181-(03-2007)-US-EN…369
toc…369
Assembly Guide…369
Safety Precautions Maintenance and Repair…370
List of All Special Tools and Equipment Needed for the Assembly…373
General Considerations Before Starting the Job…373
Preparation of the Components Before Assembly…374
Liquefied Petroleum Gas (LPG Engines Only)…374
Remove…374
Install…375
Checking of the Wheels…375
Air Pressure…375
Drive Wheels…376
Steer Wheels…380
Wheel Nut Torque…383
Mast Label Placement…384
Safety Procedures When Working Near Mast…385
Mast Installation…387
Mast…387
Tilt Cylinder Pin Installation…390
Lift Cylinder Hose Connection…391
Truck Header Hoses and Electrical Cable Connections…392
Mast Light Connection…394
Carriage Installation…395
Carriage Header Hoses and Electrical Cable Connection…396
Fork Installation…399
Exhaust Extension Tube Installation…400
Lights Installation – Operator Compartment…402
Hydraulic Oil Check…403
Lubrication Points…404
Check Points…405
Checkpoint 1…405
Checkpoint 2…405
Checkpoint 3…405
Checkpoint 4…405
Checkpoint 5…405
General Truck Install Procedures…405
tables…369
Table 1. Mast Hanger Pins Capscrew Torques…390
1663926-8000SRM1346-(05-2007)-US-EN…409
toc…409
Diagrams…409
Safety Precautions Maintenance and Repair…410
1663927-8000SRM1347-(12-2007)-US-EN…463
toc…463
Periodic Maintenance…463
Safety Precautions Maintenance and Repair…464
General…469
Serial Number Data…469
How to Move a Disabled Lift Truck…470
How to Tow the Lift Truck…470
How to Put a Lift Truck on Blocks…470
How to Raise the Drive Tires…471
How to Raise the Steer Tires…471
Maintenance Schedule…472
Empty Container Attachment Maintenance…479
Maintenance Procedures Every 8 Hours or Daily…481
How to Make Checks With the Engine Stopped…481
Safety Labels…481
Tires and Wheels…481
Inspection of Forks, Mast, and Lift Chains…482
Header Hose Assembly…483
Forks, Adjust…483
Forks, Remove…483
Forks, Install…483
Precleaner for Air Filter…484
Check for Fuel, Oil, or Coolant Leaks…484
Coolant Hoses…484
Engine Air Intake Piping…484
Drive Belts…484
Radiator Sections for Engine Coolant, Charge Air Cooler, and Hyd…485
Engine Compartment…485
Operator Restraint System (Seat Belt and Seat Rails)…485
Steering Column Latch…485
Hydraulic System Oil…485
Windshield Washer Fluid…486
Engine Oil…486
How to Add Fuel to the Lift Truck…488
Diesel Fuel…488
Liquefied Petroleum Gas (LPG)…489
Remove…489
Fill…489
Install…490
How to Make Checks With the Engine Running…490
Gauges, Lights, Horn, Fuses, and Relays…490
Engine and Transmission Fault Codes…493
Cooling System…493
Diesel Fuel Filter/Water Separator…494
Electrical System…494
Engine Oil Pressure…494
Fuel System…494
Engine Air Filter…494
Control Levers and Pedals…494
Steering System…494
Parking Brake…494
Service Brakes…495
Lift System Operation…495
Transmission…495
Transmission Oil…495
First Inspection After First 100 Hours of Operation…496
Lift Chains…496
Hydraulic System Oil Filter…496
Engine Oil Filter…496
Transmission Oil Filter…497
Hydraulic Pilot Valve Oil Screen…497
Wet Brake System Filter…497
First Inspection After First 500 Hours of Operation…497
Cab Mounting Bolts…497
Maintenance Procedures Every 250 Hours or Monthly…498
Twist Locks…498
Lifting Hooks (Model 555)…498
Empty Container Attachment…498
Maintenance Procedures Every 250 Hours or 3 Months…498
Lift Chains…498
Wheel Nuts…499
Forks…499
LPG Crankcase Breather…499
Mast Bearing Block Surfaces and Strip Bearings…499
Sideshift Carriage Sliding Surfaces…500
Fork Pins and Guides…500
Maintenance Procedures Every 500 Hours or 3 Months…500
Rod Ends at Sideshift Cylinder…500
Mast Pivot Pins…500
Tilt Cylinder Pivot Pins…500
Steering Axle Tie Rod Pins…500
King Pins…500
Shafts for Air Brake Actuator Arms…500
Drive Shaft…500
Maintenance Procedures Every 500 Hours or 6 Months…501
Cab Air Filter…501
Planetary Drive Axle and Differential…501
Header Hose Assembly…501
Hydraulic Tank Breather…501
Air Compressor (Air Brakes Only)…501
Spark Plug Wire (LPG Engine Only)…501
Cooling Fan…501
Drive Belts…501
Coolant…501
Fuel Pump…501
Engine Oil…502
Engine Oil Filter…502
Diesel Fuel Filter…502
Maintenance Procedures Every 1000 Hours or 6 Months…502
Extension Cylinder Support Wear Pads (ECH Only)…502
Brake Accumulator (Wet Brake Only)…502
Coolant Fan Belt Tensioner…502
Fan Hub…504
Pilot Valve Accumulator…504
LPG Tank Hinges…505
Cab Door Hinges…505
LPG Vapor Fuel Filter…505
Wet Brake System Filter…505
Maintenance Procedures Every 1000 Hours or 1 Year…506
Engine Valve Adjustment…506
Diesel Fuel Filter/Water Separator…506
Transmission Oil…506
Transmission Oil Filter…506
Transmission Breather…506
Maintenance Procedures Every 1500 Hours or 6 Months…506
Drive Axle and Differential…506
Maintenance Procedures Every 2000 Hours or 1 Year…506
Transmission Calibration…506
Inching Pedal Sensor Calibration…506
Parking and Service Brakes…506
Vibration Damper…507
Engine and Transmission Isolators…507
Engine Air Intake Piping…507
Brake Air Pressure Lines…507
Spark Plug (LPG Engines Only)…508
LPG Liquid Fuel Filter…508
Maintenance Procedures Every 3000 Hours or 1 Year…509
Pedals, Levers, Seat Rails, and Hinges…509
Air Dryer Cartridge…509
Hydraulic System Oil and Filter…509
Maintenance Procedures Every 3000 Hours or 2 Years…510
Hydraulic Pilot Valve Oil Screen…510
Maintenance Procedures Every 4000 Hours or 2 Years…510
Spark Plug Wire (LPG Engines Only)…510
Steer Wheels Hub Bearings…510
Maintenance Procedures Every 5000 Hours…511
Twist Locks or Hooks…511
Maintenance Procedures Every 5000 Hours or 3 Years…511
Air Conditioning…511
Maintenance Procedures Every 6000 Hours or 2 Years…511
Turbocharger…511
Maintenance Procedures Every 12,000 Hours or 5 Years…512
Cooling System…512
Safety Procedures When Working Near Mast…513
Lift and Tilt System Leak Check…514
Lift System…514
Tilt System…514
Wheel and Tire Replacement…515
Remove Wheels From Lift Truck…515
Pneumatic Tires…516
Remove Tire From Wheel…516
Remove Tire From Two- and Four-Piece Wheel…516
Install Tire on Wheel…517
Install Tire on Two- and Four-Piece Wheel…518
Add Air to Tires…519
Solid Rubber Tires…519
Remove Tire From Wheel…519
Install Tire on Wheel…521
Wheels, Install…522
tables…463
Table 1. Daily Inspections − Condition Check…473
Table 2. Daily Inspections − Fluid Level Check…474
Table 3. Daily Inspections − Checks With the Engine Running…474
Table 4. Initial 100-Hour Check or Change…475
Table 5. Initial 500-Hour Check or Change…475
Table 6. Periodic Maintenance Schedule − Inspect and Adjust…476
Table 7. Periodic Maintenance Schedule − Lubricate…477
Table 8. Periodic Maintenance Schedule − Change…478
Table 9. Empty Container Attachment Maintenance − Inspect and …480
Table 10. Empty Container Attachment Maintenance − Lubricate…480
Table 11. Empty Container Attachment Maintenance − Replace…480
Table 12. Approved LPG Engine Oil Types…488
Table 13. Valve Adjustment Specifications…506
Table 14. Allowable Mast Movement from Internal Leakage…515
1663928-8000SRM1348-(03-2008)-US-EN…525
toc…525
Capacities and Specifications…525
Safety Precautions Maintenance and Repair…526
Counterweight Weights…529
Lift Truck Weights…529
Capacities…530
Engine Specifications…531
Hydraulic System…532
Electrical System…532
Tire Sizes…532
Mast Speeds…533
Torque Specifications, Cummins Diesel…533
Lubrication System…533
Torque Specifications, General…534
Transmission…534
Driveline and Axle…534
Counterweight…534
Differential…534
Brakes – Wet…534
Brakes – Dry…534
Steering…534
Wheel Nuts…534
Hydraulic System…535
Mast…535
Carriage…535
Tilt Cylinders…535
Wiper Arms, Front…535
1665777-0100SRM1349-(01-2008)-US-EN…539
toc…539
Frame…539
Safety Precautions Maintenance and Repair…540
General…543
Description…543
Air Cleaner…544
Remove…544
Install…544
Exhaust System…545
Remove…545
Install…545
Hood Assembly…546
Remove…546
Install…547
Hydraulic Tank…547
Remove…547
Inspect…549
Clean…549
Additional Preparations for Repair…550
Repair…550
Small Leaks…550
Large Leaks…550
Preparations for use After Repair…550
Install…551
Fuel Tank…552
Remove…552
Repair…556
Install…556
Engine…557
Remove…557
Install…562
Counterweight…563
General…563
Remove…564
Install…565
Label Replacement…565
tables…539
Table 1. Counterweight Weights…563
1665778-0700SRM1350-(03-2007)-US-EN…569
toc…569
Multiple Aligned Cooling System…569
Safety Precautions Maintenance and Repair…570
General…573
Description…574
Radiator…574
Radiator Cap…574
Thermostat…574
Water Pump…575
Fan and Fan Shroud…575
Cooling System Checks…575
Radiator…575
Thermostat…575
Water Pump…576
Exhaust Leaks…576
Fan and Fan Shroud…576
Cooling System Repair…577
Remove…577
Install…578
Core Repair…579
Remove…579
Install…579
Radiator Cleaning…579
Drain…579
Clean…579
Fill…580
Troubleshooting…580
1665779-2200SRM1351-(04-2007)-US-EN…585
toc…585
Electrical System…585
Safety Precautions Maintenance and Repair…586
Description…589
Warning Devices…594
General…594
Description…595
Operator-Controlled Horn…595
Reverse Warning Horns/Lights…595
Warning Lights…595
Strobe Light…595
Brake Lights…597
Hazard Lights…597
Replace…597
General…597
Horns…597
Horn Relay…597
Light Assemblies…597
Flashing Unit…598
Meters, Senders, and Switches…598
General…598
1670739-1300SRM1356-(07-2008)-US-EN…611
toc…611
Transmission…611
Safety Precautions Maintenance and Repair…612
General…615
Transmission Repair…615
Remove…615
Disassemble…619
Transmission Case, Disassemble…620
Torque Converter Housing, Disassemble…637
Forward Clutch, Disassemble…642
First-Speed Clutch, Disassemble…644
Reverse and Second-Speed Clutch…649
Reverse Clutch, Disassemble…649
Second-Speed Clutch, Disassemble…654
Third-Speed Clutch, Disassemble…656
Third Clutch Shaft, Disassemble…658
Turbine Shaft, Disassemble…659
Output Shaft, Disassemble…660
Impeller, Disassemble…661
Turbine, Disassemble…663
Clean and Inspect…665
Housings…665
Oil Seals and Gaskets…665
Bearings…666
Gears and Shafts…666
Assemble…666
Turbine, Assemble…666
Impeller, Assemble…668
Output Shaft, Assemble…670
Turbine Shaft, Assemble…672
Third Clutch Shaft, Assemble…673
Third-Speed Clutch, Assemble…674
Reverse and Second-Speed Clutch…677
Second-Speed Clutch, Assemble…677
Reverse Clutch, Assemble…680
First-Speed Clutch, Assemble…684
Forward Clutch, Assemble…689
Torque Converter Housing, Assemble…692
Transmission Case, Assemble…697
Install…718
Control Valve Removal and Installation…720
Remove…720
Install…720
Control Valve Disassemble and Assemble…722
Remove…722
Transmission Frame Bracket…722
Control Valve Cover…722
Control Valve Components…722
Install…724
Control Valve Components…724
Control Valve Cover…724
Transmission Frame Bracket…724
Torque Specifications…725
Torque Specifications for Lubricated or Plated Screw Threads…725
Troubleshooting…727
tables…611
Table 1. Grade 5…725
Table 2. Grade 8…725
Table 3. Grades 8.8, 10.9, and 12.9…726
Table 4. O-ring Port Plug Torque Chart…727
Table 5. Pipe Plug Torque Chart…727
1671895-1300SRM1358-(07-2008)-US-EN…731
toc…731
Transmission…731
Safety Precautions Maintenance and Repair…732
General…737
Description…737
General…737
Operation…740
Hydraulic Operation…740
1st/3rd Selector Valve…742
Cooling and Lubrication…742
Control System…744
General…744
APC200 Controller…744
Self Test…744
Protection Modes…744
Limp Home Mode…744
Shut Down Mode…744
Transmission Exceed Codes…744
Fault Codes…745
Description…745
Fault Log Mode…745
Access…745
Exit…745
Clear…746
Fault Rectification…746
Hydraulic Control Valve…747
Hydraulic Control Valve Repair…748
Solenoid Replacement…748
Pressure Check…749
Pressure Specifications…749
Pressure, Speed, and Temperature Sensors…750
Pressure Switch…754
Test…754
Speed Sensor…754
Test…755
Temperature Sensors…756
Test…756
Transmission Test and Calibration…756
Precautions…756
Stall Test…756
Description…756
Stall Test Procedure…756
Clutch Calibration…757
Description…757
Procedure…758
Inching Calibration…758
Description…758
Brake and Inching Pedal Adjustment…759
Inching Sensor Adjustment…759
Inching Sensor Calibration…760
Electrical Specifications…760
APC200 Operation…761
General…761
General Information Group…761
Fault Codes…762
Indication of Protection Modes…762
Test Function Group…763
Digital Input Test…764
Analog Input Test…765
Speed Sensor Test…765
Output Test…766
Voltage Test…767
Calibration Group…767
Calibration Mode…767
Clutch Filling Calibration…768
Heat Up Mode…768
Inching Sensor Calibration…769
Inching Pedal Sensor Adjustment…769
Inching Sensor Calibration…769
TE-Userlink…770
Description…770
Connection…770
Table 12. Transmission Exceed Codes…803
Table 13. APC200 Fault Codes…803
Table 14. Common Calibration Condition Messages…814
Table 15. Fault Codes During Clutch Calibration…815
tables…731
Table 1. Activated Solenoids and Gear Selection…742
Table 2. Control Valve Pressure Check Ports…747
Table 3. Transmission Housing Check Ports…753
Table 4. Sensors and Switches…754
Table 5. Speed Sensor Check Values…755
Table 6. Temperature Sensor (In Speed Sensor) Resistance Versus …760
Table 7. General Information Group…762
Table 8. Digital Input Test…764
Table 9. Analog Input Test…765
Table 10. Speed Sensor Test…766
Table 11. Output Test…766
1689543-0100SRM1383-(09-2008)-US-EN…819
toc…819
Operator's Cab…819
Safety Precautions Maintenance and Repair…820
General…827
Description of Operation…828
Cab Structure…828
Cab Supporting Frame…828
Cab Tilt Cylinder…830
Extending the Cab Tilt Cylinder…830
Retracting the Cab Tilt Cylinder…831
Heater System…831
Air Conditioning…833
General…833
Dryer…834
Control Systems, Sensors, and Switches…834
Oil Filling for Cab Tilt System…835
Raising and Lowering Cab…836
Raise Cab…836
Lower Cab…837
Cab…837
Remove…837
Install…839
Cab Door Assembly…840
Cab Door…840
Remove…840
Install…840
Door Hinge…840
Remove…840
Install…840
Door Latch…840
Remove…840
Install…841
Door Handle…842
Remove…842
Install…842
Door Release…842
Remove…842
Install…842
Door Pushbutton…842
Remove…842
Install…842
Cab Tilt System…842
Electric Tilt Pump…842
Remove…842
Install…843
Hand Pump…843
Remove…843
Install…843
Cab Tilt Cylinder…843
Remove…843
Disassemble…843
Clean…845
Inspect…845
Assemble…845
Install…846
Latch…846
Remove…846
Install…846
Brake and Inching Pedals…847
Brake and Inching Pedals…847
Remove…847
Install…847
Brake Pedal Adjustment…847
Dry Brake…847
Wet Brake…847
Inching Pedal Adjustment…848
Dry Brake…848
Wet Brake…848
Inching Pedal Sensor Adjustment Using Userlink® Program…848
Inching Pedal Sensor Calibration Procedure Using Userlink® Progr…849
Inching Pedal Sensor Adjustment Using the APC200…849
Inching Pedal Sensor Calibration Procedure Using the APC200…850
Accelerator Pedal Sensor…851
Check…851
Adjust…851
Seat Assembly…852
Seat…852
Remove…852
Install…852
Seat Cushion…852
Remove…852
Install…852
Back Cushion…853
Remove…853
Install…853
Seat Suspension…853
Remove…853
Install…853
Boot…853
Remove…853
Install…853
Shock Absorber…853
Remove…853
Install…853
Compressor…854
Remove…854
Install…858
Power Assist Armrest…864
Release Cable…864
Remove…864
Install…864
Gas Spring…864
Remove…864
Install…864
Armrest Assembly…865
Adjust…865
Joystick…865
Remove…865
Install…865
Levers…866
Remove…866
Install…866
Rocker Switches…866
Remove…866
Install…866
Cover…866
Remove…866
Install…866
Instrument Panel…867
Key Switch…867
Remove…867
Install…867
12V Power Socket…867
Remove…867
Install…867
Electric-Operated Heater Control and Fan Control…868
Remove…868
Install…868
Cable-Operated Heater Control and Air Control…869
Remove…869
Install…869
Air Conditioning Switch…869
Remove…869
Install…869
Rocker Switches…869
Remove…869
Install…869
Parking Brake Switch…870
Remove…870
Install…870
Indicator Display…870
Remove…870
Install…870
Instrument Panel Top Console…871
Remove…871
Install…871
Steering Wheel and Column Assembly…871
Steering Wheel and Horn…871
Remove…871
Install…871
Steering Column Assembly…873
Remove…873
Install…874
Adjustment Mechanism…874
Remove…874
Install…874
Main Warning Lights…874
Remove…874
Install…874
Shift Lever…875
Remove…875
Install…875
Turn Signal Lever…875
Remove…875
Install…875
Window Wipers Replacement…876
Window Wiper Assembly, Replace…876
Remove…876
Install…876
Window Wiper Motor Replacement…877
Front Window Wiper Motor Assembly…877
Remove…877
Install…877
Rear Window Wiper Motor Assembly…877
Remove…877
Install…877
Top Window Wiper Motor Assembly…878
Remove…878
Install…878
Window Washer System…878
Window Washer Reservoir…878
Remove…878
Install…878
Window Washer Motors and Pumps…878
Remove…878
Install…879
Window Washer Hoses…879
Top/Rear…879
Remove…879
Install…880
Front…880
Remove…880
Install…881
Window Washer Nozzles…881
Front…881
Remove…881
Install…881
Rear…881
Remove…881
Install…882
Top…882
Remove…882
Install…882
Window Replacement…882
Front Window…884
Remove…884
Install…884
Rear Window…884
Remove…884
Install…884
Top Window…885
Remove…885
Install…885
Door Window…885
Upper/Lower Window…885
Remove…885
Install…885
Sliding Window…885
Front Sliding Window…885
Remove…885
Install…887
Rear Sliding Window…887
Remove…887
Install…887
Weather Strip, Replace…888
Window Stopper, Replace…888
Sliding Tracks, Replace…888
Window Seals, Replace…888
Sliding Window Frame…888
Remove…888
Install…888
Heater System Repair…889
Heater Assembly…889
Access…889
Remove…889
Install…890
Heater Assembly Parts, Replace…890
Heater Core…890
Remove…890
Install…891
Evaporator Core…891
Remove…891
Install…891
Blower…892
Remove…892
Install…892
Water Valve…892
Remove…892
Install…893
Vent Door…893
Remove…893
Install…893
Push/Pull Cable, Replace…894
Water Valve Cable…894
Remove…894
Install…894
Vent Door Cable…895
Remove…895
Install…895
Floor Mat…896
Front…896
Remove…896
Install…897
Rear…897
Remove…897
Install…897
Radio Console…898
Remove…898
Install…898
Air Duct…898
Front…898
Remove…898
Install…898
Rear…899
Remove…899
Install…899
Accessories…900
Mirror…900
Remove…900
Install…900
Sunshade…900
Top…900
Remove…900
Install…900
Rear…900
Remove…900
Install…901
Map Light…901
Remove…901
Install…901
Interior Fan…901
Remove…901
Install…901
Training Seat…901
Install…901
Remove…901
Air Conditioning Technical Detail…902
Technical Detail…902
Label Replacement…903
tables…819
Table 1. Air Conditioning Specifications…902
897108-1600SRM0326-(03-2007)-US-EN…907
toc…907
Steering Axle…907
Safety Precautions Maintenance and Repair…908
General…911
Description…911
Steering Axle Assembly Repair…916
Steering Axle H3.50-5.00XL (H70-110XL) (G005), S3.50-5.50XL (S70…916
Remove…916
Install…916
Steering Axle H6.00-7.00XL (H135-155XL, H135-155XL 2 ) (F006, G0…917
Remove…917
Install…917
Wheels and Hubs Repair (All Units)…918
Remove and Disassemble…918
Clean…918
Inspect…918
Assemble and Install…918
Spindles and Bearings Repair (All Units)…920
Remove…920
Clean…920
Assemble and Install…921
Tie Rods Repair (All Units)…922
Remove…922
Clean…922
Install…922
Steering Cylinder Repair…925
Remove and Disassemble…925
Clean and Inspect…925
Assemble and Install…925
Troubleshooting…926
910072-1400SRM0046-(07-2007)-US-EN…931
toc…931
Differential…931
Safety Precautions Maintenance and Repair…932
General…935
Description…935
Differential Repair…936
Remove…936
Differential Carrier From Axle Housing, Remove…936
Differential and Ring Gear From Differential Carrier, Remove…938
Drive Pinion and Pinion Carrier From Differential Carrier, Remov…940
Disassemble…941
Differential and Ring Gear Assembly, Disassemble…941
Drive Pinion and Pinion Carrier, Disassemble…943
Clean and Inspect…946
Assemble…947
Pinion, Bearings, and Pinion Carrier, Assemble…947
Pinion Bearings, Adjust Preload…947
Press Method…947
Yoke or Flange Method…948
Triple-Lip Seal, Install…949
Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion)…950
Differential and Ring Gear, Assemble…952
Differential Gears Rotating Torque, Check…954
Differential and Ring Gear Assembly, Install…955
Differential Bearings, Preload Adjust…957
Ring Gear, Runout Check…958
Ring Gear Backlash, Adjust…958
Gear Set, Tooth Contact Pattern Check…960
Thrust Screw, Install and Adjust…963
Install…963
Differential Assembly Into Axle Housing, Install…963
Specifications…965
Troubleshooting…970
tables…931
Table 1. Ring Gear Backlash Adjustment Specifications…960
Table 2. Ring and Pinion Tooth Contact Adjustment…961
Table 3. General Specifications…965
Table 4. Rivet Installation Pressure…965
Table 5. Pinion Adjustment…966
Table 6. Pinion Preload Pressure…966
Table 7. Torque Specifications…967
Table 8. Torque Specifications for Metric Hardware…968
Table 9. Torque Specifications for Metric (Fine) Hardware…969
910102-2100SRM0103-(03-2007)-US-EN…973
toc…973
Tilt Cylinders…973
Safety Precautions Maintenance and Repair…974
General…977
Description…977
Tilt Cylinder Repair…977
Remove…977
Disassemble…977
Clean…977
Assemble…977
Tilt Cylinders With O-Ring or Single-Lip Seals…977
Tilt Cylinders for XM and XMS Models…979
Tilt Cylinders for XL, XLS, and XL 3 Models…980
Tilt Cylinders for H700-800A and Early Model H700-920B…982
Install…983
Tilt Cylinders Using Chevron Packing…983
Install…984
Tilt Cylinder Leak Check…986
Tilt Cylinder Stroke and Mast Tilt Angle Adjustment…988
Torque Specifications…988
Piston Rod Nut…988
Retainer…989
Troubleshooting…991
tables…973
Table 1. Movement Rates (Maximum) for Tilt Cylinders…987
910442-8000SRM0231-(12-2004)-US-EN…995
toc…995
Metric and Inch (SAE) Fasteners…995
Safety Precautions Maintenance and Repair…996
General…999
Threaded Fasteners…999
Nomenclature, Threads…999
Strength Identification…1000
Cotter (Split) Pins…1000
Fastener Torque Tables…1005
Conversion Table…1007
tables…995
Table 1. Bolts and Screws…1001
Table 2. Studs and Nuts…1002
Table 3. Torque Nuts…1003
Table 4. Torque Nuts With Nylon Insert…1004
Table 5. Torque Values for Metric Fasteners*…1005
Table 6. Torque Values for Inch Fasteners*…1006
Table 7. Conversion Table for Metric and English Units…1007
Table 8. Cotter Pin Dimensional Data…1008
Table 9. Cotter Pin Dimensional Data…1009
Table 10. Cotter Pin Dimensional Data…1010
Table 11. Cotter Pin Dimensional Data…1012
G007 (H8.00-12.00XM Europe)…1017
1494123-0100SRM0927-(01-2006)-UK-EN…1018
toc…1018
Frame…1018
Safety Precautions Maintenance and Repair…1019
General…1022
Description…1022
Counterweight Repair…1022
Remove…1022
Install…1024
Fenders…1024
Remove…1024
Install…1024
Side Counterweights H13.00-16.00XM (H300-360HD)…1024
Side Counterweight, Replace…1024
Hood and Air Cleaner Repair…1025
Remove…1025
Install…1027
Hydraulic Tank Repair…1027
Remove…1027
Repairs, All Units…1028
Small Leaks…1028
Large Leaks…1029
Clean…1029
Steam Method…1029
Chemical Solution Method…1030
Other Methods of Preparation for Repair…1030
Install…1030
Fuel Tank Repair…1031
Remove…1031
Repairs…1031
Install…1031
Cooling System and Radiator Repair…1033
Remove…1033
Install…1034
Engine and Transmission Repair…1035
Hyster T-50 Transmission, Remove…1035
Hyster T-50 Transmission, Install…1036
TE-10 Transmission…1037
Remove…1037
Install…1040
Label Replacement…1042
1494140-1600SRM0936-(03-2007)-UK-EN…1050
toc…1050
Steering System…1050
Safety Precautions Maintenance and Repair…1051
General…1054
Description…1054
Steering Wheel and Column Assembly…1056
General…1056
Steering Wheel and Horn…1056
Remove…1056
Install…1056
Steering Control Unit Repair…1058
General…1058
Description…1058
Operation…1058
Remove…1059
Disassemble…1059
Clean…1062
Assemble and Install…1062
Steering System Air Removal…1068
Steering Relief Pressure Check…1069
Troubleshooting…1069
1494141-1800SRM0937-(03-2007)-UK-EN…1074
toc…1074
Dry Brake System…1074
Safety Precautions Maintenance and Repair…1075
General…1078
Description…1078
Operation…1079
Service Brakes…1079
Parking Brake…1081
Air Tank Repair…1082
Relief Valve…1082
Drain Valve…1082
Brake Pedal Valve Repair…1083
Remove…1083
Disassemble, Inspect, and Assemble…1083
Install…1083
Air Chambers Repair…1084
Remove…1084
Disassemble…1084
Inspect…1085
Assemble…1086
Install…1086
Actuator Arms Repair…1086
Remove…1086
Inspect…1087
Install…1087
Brake Assemblies Repair…1088
Brake Shoe, Remove…1088
Camshaft, Remove…1090
Clean…1090
Inspect…1091
Camshaft, Install…1091
Brake Shoe, Install…1092
Air Dryer…1093
Description…1093
Cartridge…1093
Remove…1093
Install…1093
Filter…1093
Remove…1093
Install…1093
Quick-Release Valve…1095
Governor Check and Adjustment for Air Compressor…1095
Brake Shoes Adjustment…1096
Specifications…1097
Troubleshooting…1097
Service Brakes…1097
Service Brakes, Park Function …1100
tables…1074
Table 1. Air Chambers Operation…1081
1494142-1900SRM0938-(03-2007)-UK-EN…1104
toc…1104
Hydraulic System…1104
Safety Precautions Maintenance and Repair…1105
General…1108
Description and Operation…1108
Hydraulic Tank…1108
Hydraulic Pump…1109
Steering Priority Flow Valve…1109
Pilot Valve…1110
Main Control Valve…1112
Unloader Valve…1113
Hydraulic Operation…1114
Checks and Adjustments…1117
Quick Disconnect Fittings…1117
Steering Priority Flow Valve…1117
Steering Relief Pressure…1117
Modulator Valve…1118
Pilot Valve and Pressure Reducing Valve…1118
Accumulator…1119
Filter…1119
Main Control Valve…1119
Relief Pressure Check…1119
Check Valves…1120
Unloader Valve…1120
Hydraulic Pump Repair…1121
Remove…1121
Disassemble…1121
Clean and Inspect…1121
Assemble…1122
Install…1123
Pilot Accumulator Replacement …1123
Remove…1123
Install…1123
Pilot Valve Repair…1124
Remove…1124
Disassemble…1125
Clean and Inspect…1125
Assemble…1125
Install…1125
Control Levers and Joystick Repair…1126
Remove…1126
Install…1126
Calibration and Diagnostics…1127
General…1127
Description…1127
Lever and Joystick Calibration…1127
Flow Adjustment…1127
Dead Band Value Setting…1128
Lowering Delay…1129
PWM and I/O Module Readouts…1129
Function Disable…1130
General Startup…1130
Minimum system requirements…1130
Install the Hydraulic Controls Program…1130
DelayTimeFile (Reset)…1130
Select the Processor Speed…1131
Hydraulic Controls Program…1131
Calibration…1133
Joystick/Lever Calibration…1133
Levers…1133
Joystick…1133
Valve Flow Adjustment…1134
Diagnostics…1134
Calibration System Shutdown…1134
LED Diagnostics…1135
Electrical Connections…1138
Specifications…1142
tables…1104
Table 1. Main Control Valve Port Settings…1110
Table 2. Processor Speed Settings…1130
Table 3. PWM Board LED Error Codes…1135
Table 4. Altering PT FLT I/O Board LED's (Old Logic)…1136
Table 5. Altering PT FLT I/O Board LED's (New Logic)…1136
Table 6. Fixed PT Logic I/O Boards LED's…1137
Table 7. ECH…1137
Table 8. PWM Driver Module…1138
Table 9. Input/Output Module 1…1139
Table 10. Input/Output Module 2…1140
Table 11. Altering PT FLT…1141
Table 12. Fixed PT FLT…1141
Table 13. ECH…1142
1494145-8000SRM0940-(03-2008)-UK-EN…1146
toc…1146
Capacities and Specifications…1146
Safety Precautions Maintenance and Repair…1147
Lift Truck Weights…1150
Capacities…1150
Engine Specifications…1151
Perkins Diesel…1151
Cummins Diesel/LPG…1152
Hydraulic System…1153
Electrical System…1154
Tire Sizes…1154
Mast Speeds…1154
Perkins Diesel…1154
Cummins Diesel/LPG…1155
Torque Specifications, Cummins Diesel…1156
Lubrication System…1156
Torque Specifications, Perkins Diesel…1156
Engine…1156
Cylinder Head Assembly…1156
Piston and Connecting Rod Assemblies…1156
Crankshaft Assembly…1156
Timing Case and Drive Assembly…1157
Turbocharger…1157
Lubrication System…1157
Fuel System…1157
Cooling System…1157
Flywheel and Housing…1157
Aspiration System…1158
Electrical Equipment…1158
Auxiliary Equipment…1158
Torque Specifications – Perkins, Tier 2…1158
Cylinder Head Assembly…1158
Piston and Connecting Rod Assemblies…1158
Crankshaft Assembly…1158
Timing Case and Drive Assembly…1158
Turbocharger…1159
Lubrication System…1159
Fuel System…1159
Cooling System…1159
Flywheel…1159
Auxiliary Equipment…1159
Torque Specifications, General…1160
Transmission…1160
Driveline and Axle…1160
Differential…1160
Brakes – Wet…1160
Brakes – Dry…1160
Steering…1160
Hydraulic System…1161
Mast…1161
Carriage…1161
Tilt Cylinders…1161
Frame…1161
Wiper Arms, Front…1161
Hyster T-50 Transmission Pressures (Powershift and Automatic)…1162
TE-10 Transmission Specifications…1163
Electrical…1163
Hydraulic Cooler Lines…1163
Torque Specifications for Lubricated or Plated Screw Threads…1164
tables…1146
Table 1. Temperature Sensor (In Speed Sensor) Resistance vs Temp…1163
Table 2. Grade 5…1164
Table 3. Grade 8…1164
Table 4. Grades 8.8, 10.9, and 12.9…1164
Table 5. O-ring Port Plug Torque Chart…1165
Table 6. Pipe Plug Torque Chart…1165
1494953-1400SRM0944-(03-2007)-UK-EN…1168
toc…1168
Planetary Drive Axle…1168
Safety Precautions Maintenance and Repair…1169
General…1172
Description…1172
Operation…1174
Identification…1174
Removal…1175
Disassembly…1175
Planetary Spider and Gearing Assembly H8.00-12.00XM (H170-280HD)…1175
Planetary Spider and Gearing Assembly H13.00-14.00XM (H300-330HD…1177
Wheel End…1179
Spindle and Piston Housing…1180
Cleaning…1181
Clean Ground or Polished Parts…1181
Clean Parts With Rough Finish…1181
Clean Axle Assemblies…1181
Drying Cleaned Parts…1181
Corrosion Prevention…1181
Parts Inspection…1182
Tapered Roller Bearings…1182
Bevel Pinion and Ring Gear Sets…1183
Main Differential Assembly…1183
Axle Shafts…1183
Yoke…1183
Brakes…1183
Repair or Replace Parts…1183
Repair Welding…1183
Apply Silicone Gasket Material…1184
Assembly…1184
Spindle and Piston Housing to Axle Housing…1184
Wet Disc Brakes…1185
Adjust Wheel Bearing Preload…1186
Planetary Spider and Gearing Assembly H8.00-12.00XM (H170-280HD)…1187
Planetary Spider and Gearing Assembly H13.00-14.00XM (H300-330HD…1188
Planetary Spider Assembly…1188
Installation…1189
Fill Wet Disc Brakes With Hydraulic Fluid…1189
Torque Specifications…1190
Lubrication Specification…1191
1494955-2000SRM0943-(03-2007)-UK-EN…1194
toc…1194
Main Control Valve…1194
Safety Precautions Maintenance and Repair…1195
General…1198
Description…1198
Operation…1201
Lift Section…1201
Tilt/Auxiliary Section…1201
Relief Valves…1201
Unloader Valve…1201
Main Control Valve Repair…1204
Remove…1204
Disassemble…1204
Auxiliary Side…1204
Lift Side…1204
Clean and Inspect…1207
Assemble…1207
Auxiliary Side…1207
Lift Side…1207
Install…1207
Pressure Relief Valve Check and Adjustment…1208
Check and Adjust…1208
Replace…1208
Specifications…1209
Troubleshooting…1209
1498445-1400SRM0945-(03-2007)-UK-EN…1214
toc…1214
Planetary Drive Axle…1214
Safety Precautions Maintenance and Repair…1215
General…1218
Description…1218
Operation…1220
Identification…1220
Removal…1221
Disassembly…1221
Brake Drum…1221
Planetary Spider and Gearing Assembly H8.00-12.00XM (H170-280HD)…1222
Dry Brakes…1224
Planetary Spider and Gearing Assembly H13.00-14.00XM (H300-330HD…1224
Spindle and Brake Spider…1226
Cleaning…1227
Ground or Polished Parts…1227
Parts With Rough Finish…1227
Axle Assemblies…1227
Drying Cleaned Parts…1227
Corrosion Prevention…1227
Parts Inspection…1228
Tapered Roller Bearings…1228
Bevel Pinion and Ring Gear Sets…1229
Main Differential Assembly…1229
Axle Shafts…1229
Yoke…1229
Brakes…1229
Repair or Replace Parts…1229
Repair Welding…1229
Apply Silicone Gasket Material…1230
Assembly…1230
Spindle, Brake Spider, and Brake…1230
Wheel End…1231
Adjust Wheel Bearing Preload…1232
Planetary Spider and Gearing Assembly H8.00-12.00XM (H170-280HD)…1233
Planetary Spider and Gearing Assembly H13.00-14.00XM (H300-330HD…1234
Planetary Spider Assembly…1234
Installation…1235
Torque Specifications…1236
Lubrication Specification…1237
1498450-1800SRM0951-(03-2007)-UK-EN…1240
toc…1240
Wet Brake System…1240
Safety Precautions Maintenance and Repair…1241
General…1244
Description and Operation…1244
Service Brakes…1244
Parking Brake…1244
Oil Cooler Circuit…1244
Pressure Switch Replacement…1248
Accumulators Replacement…1248
Brake Treadle Valve Repair…1248
Remove and Disassemble…1248
Clean and Inspect…1249
Assemble and Install…1249
Parking Brake Valve Repair…1249
Remove…1249
Clean and Inspect…1249
Repair…1249
Install…1249
Parking Brake Caliper Repair…1250
Remove…1250
Disassemble…1252
Inspect…1252
Install…1252
Adjust…1252
Brake Pad Repair…1253
Inspect…1253
Remove…1253
Install…1253
Seals Repair…1253
Remove…1253
Install…1254
Service Brake Repair…1254
Remove and Disassemble…1254
Drain Lubricating Oil…1254
Drain Coolant Oil…1261
Disconnect Brake Lines…1261
Wheel End With Outer Bearing on Ring Gear Hub Journal H13.00-14…1261
Wheel End With Outer Bearing on Spindle Journal H8.00-12.00XM (H…1262
Brake Disc Housing Assembly Wheel End…1263
Brake Piston Housing…1264
Brake Piston Housing and Wheel Spindle…1265
Inspect…1265
Clean…1267
Assemble…1268
Wheel Spindle…1268
Brake Piston Housing…1268
Piston Assembly…1270
Brake Disc Housing…1270
Duo-Cone Face Seal Into Brake Disc Housing and Into Hub…1272
Check for Correct Installation of Duo-Cone Seal…1273
Wheel Hub to Brake Disc Housing…1274
Adjust…1275
Fill Brake System With Coolant Oil…1275
System Air Removal…1276
Adjust Brake With New Disc Pack…1276
Coolant Change Intervals…1277
Coolant Draining and Filling…1277
Specifications…1279
Minimum Brake Disc Thickness…1282
Hydraulic Fluid for Brake Actuation…1282
Brake Coolant Specifications…1282
Coolant Change Intervals…1282
Hydraulic Fluid Specifications…1282
Troubleshooting…1282
Brake Does Not Apply…1282
Brake Does Not Release…1283
Brake Performance…1283
Brake Leaks Actuation Fluid…1284
Brake Cooling Fluid Leakage…1285
Brake Noise and Vibration…1285
Brake Overheats…1285
tables…1240
Table 1. Brake Pad Adjustment…1252
Table 2. Minimum Brake Disc Thickness…1266
Table 3. Formed Seal Wear Chart…1266
1503241-5000SRM0969-(03-2007)-UK-EN…1290
toc…1290
Empty Container Handling Attachment…1290
Safety Precautions Maintenance and Repair…1291
General…1294
Description…1294
Operation…1299
General…1299
Selector Valves…1299
Sideshift Circuit…1299
Extend and Retract Circuit…1299
Twist Lock Circuit and Control…1300
Model 553 – Horizontally Mounted…1300
Model 558 – Vertically Mounted…1300
Lifting Hooks…1300
Model 555…1300
Indicator Lights and LEDs…1300
Lift Interrupt and Override…1301
Overlowering Interrupt and Override…1301
Carriage and Attachment Repair…1301
Remove…1301
Attachment Without Carriage Repair…1302
Remove…1302
Sideshift Cylinders Repair…1303
Remove…1303
Disassemble…1303
Assemble…1303
Extension Cylinders Repair…1304
Remove…1304
Disassemble…1304
Clean and Inspect…1304
Assemble…1304
Install…1304
Vertical End Beams Repair…1306
Remove…1306
Install…1306
Hose Replacement in End Beams…1306
Twist Locks Repair for Model 553…1307
Remove…1307
Disassemble…1307
Clean and Inspect…1307
Assemble…1307
Hooks Replacement for Model 555…1308
Inspect…1308
Remove…1308
Install…1308
Twist Locks Repair for Model 558…1309
Disassemble…1309
Clean and Inspect…1309
Assemble…1309
Bleed the System…1310
Valve Assembly…1310
Slide Pad Replacement…1311
Adjustments…1311
Twist Lock Angle Adjustment…1311
Model 558 Only…1311
LOCKED/NOT LOCKED Sensors Adjustment…1312
Model 553…1312
Model 558…1312
Seated Sensor Adjustment…1312
Model 553…1312
Model 558…1312
Overlowering Protection Sensor Adjustment (Models 553 and 558)…1312
Torque Chart…1313
Maintenance…1313
Additional Attachment Maintenance…1315
Interface Boxes…1316
Model 555…1316
Models 553 and 558…1316
Troubleshooting…1318
tables…1290
Table 1. Torque Chart…1313
Table 2. Inspect and Adjust (See Figure 14 )…1314
Table 3. Lubricate (See Figure 14 )…1315
Table 4. Replace (See Figure 14 )…1315
1541323-0600SRM1068-(05-2004)-UK-EN…1336
toc…1336
Perkins Tier 2 Diesel Engines…1336
Safety Precautions Maintenance and Repair…1337
General…1344
General Safety Rules…1344
Description…1345
Engine Serial Number Codes…1347
Engine Data…1347
Engine Removal and Installation…1348
Cylinder Head Assembly Repair…1348
Valve Cover…1348
Remove…1348
Install…1349
Rocker Arm Assembly…1349
Remove…1349
Disassemble…1349
Inspect…1349
Assemble…1349
Install…1349
Valve Clearance Adjustments…1350
Valve Springs…1351
Cylinder Head Assembly…1352
Remove…1352
Install…1354
Valves and Valve Springs…1357
Remove…1357
Inspect…1357
Install…1358
Valve Guides…1358
Inspect…1358
Remove…1358
Install…1358
Cylinder Head and Valve Seats…1359
Inspect…1359
Repair…1360
New Valve Seats, Install…1360
Piston and Connecting Rod Assemblies Repair…1360
Rod Bearings…1361
Remove…1361
Install…1361
Piston and Connecting Rod Assembly…1362
Service Note…1362
Remove…1362
Install…1363
Piston Rings…1364
Remove…1364
Inspect…1364
Install…1365
Piston and Connecting Rod…1365
Disassemble…1365
Inspect…1365
How to Select Correct Replacements…1366
Install…1367
Piston Cooling Jets…1367
Remove…1367
Install…1368
Crankshaft Assembly Repair…1368
General…1368
Crankshaft Pulley…1369
Remove…1369
Inspect…1369
Install…1369
Rear Oil Seal…1370
Remove…1370
Install…1370
Main Bearings…1371
Remove…1371
Inspect…1372
Install…1372
Thrust Washers…1372
Crankshaft Axial Movement, Check…1372
Remove…1373
Install…1373
Crankshaft…1374
Remove…1374
Inspect…1374
Install…1375
Flywheel…1376
Remove…1376
Ring Gear, Replace…1376
Install…1376
Flywheel Housing…1377
Remove…1377
Install…1377
Timing Case and Timing Gears Repair…1378
General…1378
Timing Case Cover…1378
Remove…1378
Install…1379
Front Oil Seal…1379
Remove…1379
Install…1379
Crankshaft Pulley Wear Sleeve…1380
Install…1380
Idler Gear and Hub…1380
Remove…1380
Install…1381
Air Compressor Drive, Bendix…1382
Disassemble…1382
Assemble…1382
Fuel Injection Pump Gear…1383
Remove…1383
Install…1384
Camshaft Gear…1384
Remove…1384
Install…1385
Crankshaft Gear…1385
Remove…1385
Install…1386
Timing Case…1386
Remove…1386
Install…1386
Camshaft and Tappets…1387
Remove…1387
Install…1388
Cylinder Block Assembly Repair…1388
Description…1388
Cylinder Block…1388
Disassemble…1388
Inspect…1389
Assemble…1389
Cylinder Liner…1390
Inspect…1390
Cylinder Liner Condition, Check…1390
Remove…1391
Service Liner, Install…1392
Partially Finished Liner, Install…1393
Engine Timing…1394
Description…1394
How to Set Number One Piston to TDC on Compression Stroke…1395
How to Set Number One Piston to TDC on Compression Stroke (Alter…1396
How to Set Number One Piston to 4° After TDC on Compression Stro…1397
Valve Timing, Check…1398
Fuel Injection Pump Timing, Check…1399
Turbocharger…1399
General…1399
Remove…1399
Install…1400
Impeller and Compressor Housing, Clean…1400
Waste-Gate Valve Check…1401
Closed Circuit Breather System (CCB)…1402
CCB Assembly, Remove…1402
Closed Circuit Drain Valve, Remove…1402
CCB Assembly, Install…1402
Closed Circuit Drain Valve, Install…1402
Lubrication System Repair…1403
General…1403
Oil Filter, Replace…1403
Oil Filter Head…1403
Remove…1403
Install…1403
Oil Filter Head Bypass Valve…1404
Remove and Install…1404
Oil Sump…1404
Remove…1404
Install…1404
Oil Pump…1405
Remove…1405
Inspect…1405
Install…1406
Relief Valve…1407
Remove…1407
Disassemble…1407
Inspect…1407
Assemble…1407
Install…1407
Idler Gear Shaft, Replace…1407
Remove…1408
Remove (Alternative)…1408
Install…1409
Install (Alternative)…1409
Fuel System Repair…1410
Description…1410
Fuel Injection Pump…1412
Remove…1412
Install…1414
Fuel System Air Removal…1415
Fuel Filter, Replace…1417
Fuel Injectors…1417
Remove…1418
Inspect…1418
Install…1418
Fuel Lift Pump…1419
Remove…1419
Disassemble…1419
Assemble…1419
Install…1420
Test…1420
Cooling System Repair…1421
General…1421
Thermostat…1421
Remove…1421
Install…1422
Test…1422
Coolant Pump…1422
Remove…1422
Disassemble…1423
Assemble…1425
Install…1427
Fan and Fan Drive…1428
Remove…1428
Install…1428
Oil Cooler…1428
Remove…1428
Disassemble and Assemble…1429
Install…1429
Electrical Equipment Repair…1430
Drive Belts…1430
Alternator…1430
Remove…1430
Install…1430
Electronic Control Module (ECM)…1431
Remove…1431
Inspect…1431
Install…1431
Voltage Load and Protection Module (VLPM)…1432
Remove…1432
Install…1432
Engine Speed and Timing Sensor…1432
Remove…1432
Install…1433
Pressure Sensors (Engine Oil and Air Intake)…1433
Remove…1433
Install…1434
Temperature Sensor…1434
Remove…1434
Install…1435
Starter Motor…1435
Remove…1435
Install…1435
Cold Start Aid…1435
Air Compressor…1435
General…1435
Repair…1436
Remove…1436
Install…1436
Rotary Exhauster Replacement…1437
Remove…1437
Clean…1437
Install…1437
Engine Specifications…1438
Cylinder Head Assembly…1438
Piston and Connecting Rods…1441
Crankshaft Assembly…1442
Crankshaft Overhaul…1443
Timing Case and Drive Assembly…1445
Engine Block Assembly…1446
Turbocharger…1447
Lubrication System…1448
Cooling System…1450
Flywheel and Housing…1450
Electrical Equipment…1450
Torque Specifications…1451
Cylinder Head Assembly…1451
Piston and Connecting Rod Assemblies…1451
Crankshaft Assembly…1451
Timing Case and Drive Assembly…1451
Turbocharger…1451
Lubrication System…1451
Fuel System…1451
Cooling System…1452
Flywheel…1452
Auxiliary Equipment…1452
Special Torque Specifications…1452
Flywheel and Housing…1452
Electrical Equipment…1452
Auxiliary Equipment…1452
Special Tools…1453
Troubleshooting…1458
Turbocharger Troubleshooting…1460
tables…1336
Table 1. Cylinder Head…1438
Table 2. Valve Guides…1438
Table 3. Inlet Valves…1439
Table 4. Exhaust Valves…1439
Table 5. Valve Springs…1440
Table 6. Tappets…1440
Table 7. Rocker Arm Shaft…1440
Table 8. Rocker Arms and Bushings…1440
Table 9. Pistons…1441
Table 10. Piston Rings…1441
Table 11. Piston Pins…1441
Table 12. Connecting Rods…1441
Table 13. Small End Bushings…1442
Table 14. Connecting Rod Bearings…1442
Table 15. Piston Cooling Jets…1442
Table 16. Crankshaft…1442
Table 17. Main Bearings…1443
Table 18. Crankshaft Thrust Washers…1443
Table 19. Crankshaft Heat Treatment…1443
Table 20. Crankshaft Overhaul Specifications…1443
Table 21. Maximum Variation (Run-Out)…1445
Table 22. Camshaft…1445
Table 23. Camshaft Thrust Washer…1445
Table 24. Camshaft Gear…1445
Table 25. Gear for Fuel Injection Pump…1445
Table 26. Crankshaft Gear…1446
Table 27. Idler Gear and Hub…1446
Table 28. Cylinder Block…1446
Table 29. Cylinder Liners…1446
Table 30. Cylinder Liner Specifications (Partially Finished)…1447
Table 31. Oil Pump…1448
Table 32. Idler Gear for Oil Pump…1448
Table 33. Relief Valve…1448
Table 34. Oil Filter…1448
Table 35. Bosch Fuel Injection Pump…1448
Table 36. Fuel Injector Codes…1449
Table 37. Fuel Pump…1450
Table 38. Fuel Filter…1450
Table 39. Coolant Pump…1450
Table 40. Thermostat…1450
Table 41. Fan Drive Housing…1450
Table 42. Limits for Flywheel Run Out and Alignment (Total Indic…1450
Table 43. Alternator…1450
Table 44. Starter Motor…1450
Table 45. Cold Start Aid…1450
Table 46. List of Possible Causes…1458
Table 47. List of Possible Causes…1460
1553599-4000SRM1062-(03-2007)-UK-EN…1464
toc…1464
Masts and Carriages…1464
Safety Precautions Maintenance and Repair…1465
General…1468
Description…1468
Operation…1469
Two-Stage Mast…1469
Three-Stage Mast…1470
Safety Procedures When Working Near Mast…1471
Forks Repair…1474
Remove…1474
Inspect and Adjust…1474
Install…1474
Carriage Repair…1475
Description…1475
Three Function…1475
Four to Six Function…1475
Remove…1475
Disassemble…1476
Clean and Inspect…1478
Assemble…1478
Install…1478
Sideshift Cylinder Repair…1479
Remove…1479
Disassemble…1479
Clean and Inspect…1479
Assemble…1479
Install…1479
Fork Positioner Cylinders Repair…1483
Remove…1483
Disassemble…1483
Clean and Inspect…1483
Assemble…1483
Install…1483
Directional Control Valve Repair…1490
Remove…1490
Disassemble…1490
Clean and Inspect…1490
Assemble…1491
Install…1491
Mast Repair…1491
Two- and Three-Stage Mast…1491
Remove…1491
Disassemble…1496
Clean and Inspect…1498
Assemble…1499
Install…1500
Three-Stage Mast (Four Cylinders)…1500
Remove…1500
Disassemble…1502
Clean and Inspect…1504
Assemble…1504
Install…1504
Fork Carriage Chains…1506
Adjust…1506
Bearing Rollers…1508
Description…1508
Lubrication…1508
Clearance…1508
Remove and Disassemble…1508
Assemble…1509
Mast Profile…1509
Lift Cylinders Description…1509
Piston-Type Cylinders…1509
Displacement-Type Cylinders…1509
Lift Cylinders Repair…1510
Remove…1510
Disassemble…1512
Clean and Inspect…1512
Assemble…1512
Install…1513
Mast Operation Check…1513
Lift and Tilt System Leak Checks…1514
Lift System…1514
Tilt System…1514
Tilt Cylinder Stroke and Backward Tilt Angle Adjustment…1515
Lift Chain Adjustments…1515
Mast Adjustments…1516
Bearing Blocks, Two-Stage Masts…1516
Wear Plates…1516
Carriage Adjustment…1516
Troubleshooting…1518
tables…1464
Table 1. Allowable Mast Movement from Internal Leakage…1514
1556599-0100SRM1100-(09-2008)-UK-EN…1522
toc…1522
Operator's Cab…1522
Safety Precautions Maintenance and Repair…1523
General…1526
Cab Repair…1527
Rear Cab Assembly…1527
Bottom Cab Assembly…1528
Raising and Lowering Cab…1528
Raise Cab…1528
Lower Cab…1529
Cab Repair…1529
Remove…1529
Install…1530
Oil Filling for Tilt System…1531
Inching and Brake Pedals…1532
Brake Pedal, Adjust…1532
Inching Pedal, Adjust…1532
Inching Pedal Sensor, Adjust…1532
Throttle Pedal Sensor…1533
Check…1533
Adjust…1533
Seat Assembly Removal…1534
Power Assist Armrest…1534
Adjust…1534
Steering Column Repair…1535
Remove…1535
Install…1535
Window Wipers Replacement…1536
Window Wiper Assembly, Replace…1536
Front Window Wiper Motor Assembly, Replace…1536
Rear Window Wiper Motor Assembly, Replace…1537
Top Window Wiper Motor Assembly, Replace…1537
Window Washer Motors and Pumps…1538
Window Wiper and Washer Operating Switches…1538
Window Replacement…1539
Front Window, Replace…1540
Rear Window, Replace…1540
Top Window, Replace…1540
Door Window, Replace…1541
Heater and Air Conditioning Assembly…1542
Heater Parts, Replace…1543
Heat Control Knob/Switches…1543
Heat Control Knob/Cable…1543
Adjust…1543
Air Control Knob/Cable…1544
Adjust…1544
Air Filter, Replace…1544
Air Conditioning Condenser Fan(s)…1545
Remove…1545
Install…1545
Instruments, Switches, and Controls…1545
Switches…1545
Controls…1546
Fuses and Relays…1547
Fuse Panel…1547
Fuses…1547
Relays…1548
Label Replacement…1549
Electrical Schematics…1549
1556600-1300SRM1082-(09-2008)-UK-EN…1552
toc…1552
Transmission…1552
Safety Precautions Maintenance and Repair…1553
Description of Operation…1558
General…1558
Torque Convertor, Pump Drive, and Pressure Regulating Valve…1558
Input Shaft and Directional Clutches…1558
Range Clutches…1560
Output Section…1560
Transmission Controls…1561
Operation of the Valve…1562
Selection of Range…1566
Pressure Switch…1566
Electric Solenoid Controls…1567
Transmission Specifications…1583
Transmission Identification…1583
Weight, Dimensions, and Oil Capacity…1583
Transmission Repair…1585
Remove…1585
Disassemble…1587
Transmission Case, Disassemble…1588
Torque Converter Housing, Disassemble…1605
Forward Clutch, Disassemble…1610
First-Speed Clutch, Disassemble…1612
Reverse and Second-Speed Clutch…1617
Reverse Clutch, Disassemble…1617
Second-Speed Clutch, Disassemble…1622
Third-Speed Clutch, Disassemble…1624
Third Clutch Shaft, Disassemble…1626
Turbine Shaft, Disassemble…1627
Output Shaft, Disassemble…1628
Impeller, Disassemble…1629
Turbine, Disassemble…1631
Clean and Inspect…1633
Housings…1633
Oil Seals and Gaskets…1634
Bearings…1634
Gears and Shafts…1634
Assemble…1635
Turbine, Assemble…1635
Impeller, Assemble…1636
Output Shaft, Assemble…1638
Turbine Shaft, Assemble…1640
Third Clutch Shaft, Assemble…1641
Third-Speed Clutch, Assemble…1642
Reverse and Second-Speed Clutch…1645
Second-Speed Clutch, Assemble…1645
Reverse Clutch, Assemble…1648
First-Speed Clutch, Assemble…1652
Forward Clutch, Assemble…1657
Torque Converter Housing, Assemble…1660
Transmission Case, Assemble…1665
Install…1686
Control Valve Repair…1688
Remove…1688
Disassemble and Assemble…1688
Clean and Inspect…1690
Housings…1690
Oil Seals and Gaskets…1690
Install…1691
Stall Test…1692
Transmission Calibration and Electrical Troubleshooting…1693
Userlink®…1693
Connection…1693
Clutch Filling Calibration…1693
Purpose…1693
Clutch Filling Calibration Procedure…1694
Alternative Clutch Filling Calibration Procedure…1694
Heat-up Mode…1695
Heat-up Mode Stall Test…1695
Inching Pedal Calibration [Up to S/N 2325 (F019)] and [Up to 300…1696
Purpose…1696
Brake Pedal Adjustment…1696
Dry Brake…1696
Wet Brake…1696
Inching Pedal Adjustment…1696
Inching Pedal Sensor Adjustment…1697
Inching Pedal Calibration Procedure…1697
Verification/Adjustment of Inching Pedal Sensor When the Pedal i…1697
Manual Inching Pedal Sensor Calibration Procedure…1698
Inching Pedal Calibration [S/N 2326 and Up (F019)], [S/N 3002 an…1698
Purpose…1698
Brake Pedal Adjustment…1698
Dry Brake…1698
Wet Brake…1698
Inching Pedal Adjustment…1699
Dry Brake…1699
Wet Brake…1699
Inching Pedal Sensor Adjustment Using Userlink® Program…1699
Inching Pedal Sensor Calibration Procedure Using Userlink® Progr…1700
Inching Pedal Sensor Adjustment Using the APC200…1700
Inching Pedal Sensor Calibration Procedure Using the APC200…1701
Troubleshooting…1701
Transmission Display Warning Codes…1701
Access…1701
Clear…1702
Exit…1702
Limp Home Mode…1737
Shutdown Mode…1738
Pressure Feedback Sensor…1738
Transmission Oil Pressure Check…1738
Pressure and Temperature Specifications…1738
Electrical Specifications…1743
Hydraulic Cooler Lines Specifications…1743
Torque Specifications…1743
Torque Specifications for Lubricated or Plated Screw Threads…1743
Troubleshooting…1746
tables…1552
Table 1. Controller Connector J2 Wire to Pin Number Cross Refere…1702
Table 2. Controller Connector J1 Wire to Pin Number Cross Refere…1703
Table 3. Common Calibration Condition Messages…1705
Table 4. Calibration Codes During Calibration…1706
Table 5. Error Codes During Calibration…1706
Table 6. Display Warning Codes…1707
Table 7. Display Warning Exceed Codes…1736
Table 8. Type of Warning Codes…1737
Table 9. Temperature Sensor (In Speed Sensor) Resistance Versus …1743
Table 10. Grade 5…1743
Table 11. Grade 8…1744
Table 12. Grades 8.8, 10.9, and 12.9…1745
Table 13. O-ring Port Plug Torque Chart…1745
Table 14. Pipe Plug Torque Chart…1746
1556602-8000SRM1099-(06-2006)-UK-EN…1754
toc…1754
Periodic Maintenance…1754
Safety Precautions Maintenance and Repair…1755
General…1760
How to Move Disabled Lift Truck…1760
How to Tow Lift Truck…1760
How to Put Lift Truck on Blocks…1761
How to Raise Drive Tires…1761
How to Raise Steering Tires…1761
Maintenance Schedule…1763
Empty Container Attachment Maintenance…1775
Maintenance Procedures Every 8 Hours or Daily…1777
How to Make Checks With Engine Stopped…1777
Safety Labels…1777
Forks…1777
Adjust…1777
Remove…1777
Install…1777
Forks, Mast, and Lift Chains, Inspect…1778
Operator Restraint System…1779
Steering Column Latch…1780
Tires and Wheels…1780
Fuel, Oil, or Coolant Leaks, Check…1781
Air Intake Piping…1781
Cooling Fan…1781
Crankcase Breather Tube…1781
Drive Belts…1782
Hydraulic System Oil…1782
Cab Hydraulic System…1783
Engine Oil…1783
Cooling System…1785
Battery…1786
Fuel System (Diesel Engines Only)…1786
Water Separator/Fuel Filter (Diesel Engines Only)…1786
How to Make Checks With Engine Running…1787
Fault Codes…1787
Access…1787
Exit…1787
Clear…1787
Gauges, Lights, Horn and Fuses…1787
Control Levers and Pedals…1790
Steering System…1790
Air Filters…1791
Transmission Oil…1791
Brakes…1791
Lift System Operation…1791
Attachments…1791
Maintenance Procedures Every 250 Hours or Every 2 Months…1792
Empty Container Handler…1792
Maintenance Procedures Every 500 Hours or Every 3 Months…1792
Lift Chains…1792
Lubrication…1792
Adjust…1792
Drive Shaft…1792
Steering Axle…1793
Wheel Nuts…1793
Shafts for Brake Actuators…1793
Drive Axle and Differential…1793
Hydraulic Tank Breather…1793
Cabin Air Filter, Heater…1793
Air Filter, Engine…1793
Engine Oil and Filter…1793
Drive Belts…1794
Perkins…1794
Cummins…1794
Mast…1795
Bearing Rollers (Three-Stage Only)…1796
Lubrication…1796
Clearance…1796
General Lubrication…1796
Fork Wear and Damage Check…1796
Lift Chains Wear Check…1797
Empty Container Handler…1797
Maintenance Procedures Every 500 Hours or 6 Months…1797
Charge Air Cooler…1797
Dry Brakes Air Compressor (Cummins)…1797
Fuel Pump (Cummins)…1798
Fuel Filter…1798
Perkins…1798
Remove…1798
Install…1798
Cummins…1799
Remove…1799
Install…1799
Fuel System Air Removal (Perkins)…1799
Fuel System Air Removal (Cummins)…1799
Fuel Injection Pump Without Vent Tube…1799
Coolant…1801
Maintenance Procedures Every 1000 Hours or 6 Months…1801
Transmission Oil and Filter, Change…1801
Fuel Injection Pump Timing (Perkins Only)…1801
Valve Adjustment…1801
Perkins…1801
Differential and Drive Axle…1801
Pilot Accumulator Pressure Charge Check…1802
Maintenance Procedures Every 1000 Hours or Yearly…1802
Coolant Fan Belt Tensioner…1802
Belt Driven Fan Hub…1804
Valve Adjustment…1804
Cummins…1804
Accumulator and Wet Brakes…1805
Wet Brake Oil Filter…1805
Air Dryer Cartridge (Dry Brakes)…1805
Air Compressor Air Filter (Dry Brakes)…1805
Maintenance Procedures Every 2000 Hours or Yearly…1806
Hydraulic System…1806
Hydraulic Oil Filter, Change…1806
Hydraulic Oil, Change…1806
Hydraulic Pilot Valve Filter, Change…1806
Transmission Calibration…1807
Wheel Bearings…1807
Steer Wheels…1807
Drive Wheels…1807
Service Brakes…1807
Cleaning Procedures (Dry Brake Axle)…1807
Maintenance Procedures Every 2000 Hours or 2 Years…1808
Air Compressor Discharge Lines…1808
Rubber Vibration Damper…1809
Engine Coolant…1809
Maintenance Procedures Every 5000 Hours…1809
Empty Container Handler…1809
Safety Procedures When Working Near Mast…1810
Fuel Injectors Check…1810
Perkins…1810
Lift and Tilt System Leak Check…1811
Lift System…1811
Tilt System…1812
Welding Repairs…1813
Wheel and Tire Replacement…1813
Remove Wheels From Lift Truck…1813
Pneumatic Tires…1814
Remove Tire From Wheel…1814
Remove Tire From Three- and Four-Piece Wheel…1814
Install Tire on Wheel…1815
Install Three- or Four-Piece Wheel in Tire…1816
Add Air to Tires…1817
Solid Rubber Tires…1817
Remove Tire From Wheel…1817
Install Tire on Wheel…1819
Wheels, Install…1820
tables…1754
Table 1. Daily Inspections − Condition Check…1764
Table 2. Daily Inspections − Fluid Level Check…1765
Table 3. Daily Inspections − Checks With the Engine Running…1766
Table 4. First Inspection After First 100 Hours of Operation…1767
Table 5. Periodic Maintenance Schedule − Inspect and Adjust…1767
Table 6. Periodic Maintenance Schedule − Lubricate…1770
Table 7. Periodic Maintenance Schedule − Change…1771
Table 8. Empty Container Attachment Maintenance − Inspect and …1775
Table 9. Empty Container Attachment Maintenance − Lubricate…1776
Table 10. Empty Container Attachment Maintenance − Replace…1776
Table 11. Nominal Valve Clearance…1805
Table 12. Allowable Mast Movement from Internal Leakage…1812
1556604-8000SRM1103-(11-2006)-UK-EN…1824
toc…1824
Diagrams…1824
Safety Precautions Maintenance and Repair…1825
1556871-2200SRM1105-(03-2007)-UK-EN…1912
toc…1912
Instrument Panel Indicators and Senders…1912
Safety Precautions Maintenance and Repair…1913
General…1916
Description…1916
General…1916
Instrument Panel Meters, Indicators, and LCD Display…1916
Connector…1922
Seat Switch Logic…1923
Central Warning Light Output…1923
Buzzer Output…1923
Instrument Panel…1925
Remove…1925
Sender Replacement…1926
Fuel Level Sender (Diesel Engine Only)…1926
Engine Oil Pressure Sender…1927
Brake Pressure Sender…1927
Low Coolant Sender…1927
Vacuum Switch…1927
Specifications…1928
Troubleshooting…1929
tables…1912
Table 1. Instrument Panel and Indicators…1917
Table 2. Pin Description…1922
Table 3. Sender Description…1923
1564053-0600SRM1101-(11-2007)-UK-EN…1934
toc…1934
Cummins Diesel/LPG Engine Fault Code Guide…1934
Safety Precautions Maintenance and Repair…1935
General…1938
Fault Codes…1938
Normal Mode…1938
Fault Log Mode…1938
Access…1938
Exit…1939
Clear…1939
Electronic Throttle Calibration…1939
Electronic Throttle Calibration Procedure…1939
tables…1934
Table 1. Error Code Descriptions…1940
1566673-0600SRM1158-(06-2005)-UK-EN…1956
toc…1956
Perkins Tier 2 Diesel Engine Electronic Troubleshooting Guide…1956
Safety Precautions Maintenance and Repair…1957
Electronic Troubleshooting…1980
System Operation…1980
Electronic Controls…1980
Engine Governor…1981
Timing Considerations…1981
Fuel Injection…1981
Diagnostic Codes…1981
Diagnostic Fault Codes…1981
Diagnostic Event Codes…1981
Programmable Parameters…1982
Passwords…1982
Electronic Service Tools…1982
Electronic Service Tool (EST)…1982
Connecting the Electronic Service Tool and the Communication Ada…1982
Support for the Electronic Service Tool…1983
Optional Service Tools…1983
Diagnostic Codes…1983
Engine Display Warning Codes…1987
Access…1987
Exit…1987
Clear…1987
Replacing the ECM…1989
Self Diagnostics…1990
Glossary…1991
Sensors and Electrical Connectors…1994
Engine Wiring Information…1997
Harness Wire Identification…2001
Diagnostic Code Reader…2001
General…2001
Reference Documents…2001
Abbreviations…2001
Environmental Specification…2001
Hardware…2002
Connection Cable…2003
Software…2003
Engine Communication…2003
User Controls…2003
Power Supply…2003
Display Screen…2003
Operation Controls…2003
Audible Warning…2004
Operation Instructions…2004
How to Connect the Diagnostic Code Reader to the Engine…2004
How to Turn ON the Diagnostic Code Reader…2004
How to use the Display Screen…2004
How to Operate the Diagnostic Code Reader…2005
Main Menu…2005
Active Codes…2005
Inactive Codes…2005
How to Clear Codes…2006
Status Lamp…2006
Data List…2007
Diagnostics…2007
Programming Parameters…2008
Passwords…2008
Factory Passwords…2008
Customer Passwords…2009
Flash Programming…2009
Flash Programming a Personality Module…2009
WinFlash Error Messages…2009
System Configuration Parameters…2010
Full Load Setting…2010
Full Torque Setting…2010
Rating Interlock…2010
Engine Serial Number…2010
ECM Software Release Date…2010
Troubleshooting Without A Diagnostic Code…2011
Alternator Noise (Noisy Operation)…2011
Probable Causes…2011
Recommended Actions…2011
Alternator Drive Belts…2011
Alternator Drive Pulley…2011
Alternator Bearings…2011
Alternator Will Not Charge (Charging Problem)…2011
Probable Causes…2011
Recommended Actions…2011
Alternator Drive Belts…2011
Charging Circuit…2011
Alternator or Regulator…2011
Battery…2011
Probable Causes…2011
Recommended Actions…2011
Faulty Battery…2011
Auxiliary Device…2011
Cannot Reach Top Engine RPM…2011
Probable Causes…2012
Recommended Actions…2012
Diagnostic Codes…2012
Fuel Supply…2012
Air Intake and Exhaust System…2012
Individual Malfunctioning Cylinders…2012
Valve Lash…2012
Check for Low Compression…2012
Check the Fuel Injection Nozzles…2013
Check the Turbocharger…2013
ECM Parameters…2013
Check the Signal for the Throttle Position Sensor…2013
Coolant in Engine Oil…2013
Probable Causes…2013
Recommended Actions…2013
Engine Oil Cooler Core…2013
Cylinder Head Gasket…2013
Cylinder Head…2014
Cylinder Block…2014
Coolant Temperature Is Too High…2014
Probable Causes…2014
Recommended Actions…2014
Radiator Fins…2014
Coolant Level…2014
Radiator Cap and/or Pressure Relief Valve…2014
Combustion Gases in the Cooling System…2014
Water Temperature Regulator…2014
Restriction in the Coolant System…2014
Coolant Temperature Gauge…2014
Coolant Pump…2014
Excessive Load on the System…2014
ECM Will Not Accept Factory Passwords…2015
Probable Causes…2015
Recommended Actions…2015
ECM Will Not Communicate With Other Systems or Display Modules…2015
Probable Causes…2015
Recommended Actions…2015
Electronic Service Tool Will Not Communicate With ECM…2015
Probable Causes…2015
Recommended Actions…2015
Engine Cranks but Will Not Start…2016
Probable Causes…2016
Recommended Actions…2016
Diagnostic Codes…2016
Visual Checks…2016
Crank Without Injection…2016
Starting Motor Solenoid or Starting Circuit…2016
Valve Lash…2016
Fuel Injection Nozzles…2016
Air Inlet Heater Starting Aid…2017
Air Intake and Exhaust System…2017
Low Compression…2017
Fuel Supply…2017
Engine Has Early Wear…2017
Probable Causes…2017
Recommended Actions…2017
Dirt in Engine Oil…2017
Leaks in Air Intake System…2017
Low Oil Pressure…2017
Engine Misfires, Runs Rough or Is Unstable…2018
Probable Causes…2018
Recommended Actions…2018
Logged Codes…2018
Fuel Supply…2018
Air Intake and Exhaust System…2018
Individual Malfunctioning Cylinders…2018
Valve Lash…2018
Check for Low Compression…2018
Check the Fuel Injection Nozzles…2019
Check the Air Inlet Heater Starting Aid…2019
Check the Engine Speed/Timing Sensors…2019
Check the Signal for the Throttle Position Sensor…2019
Check the Fuel Injection Pump…2019
Engine Oil in Cooling System…2019
Probable Causes…2019
Recommended Actions…2019
Engine Oil Cooler Core…2019
Cylinder Head Gasket…2020
Cylinder Head…2020
Engine Speed Does Not Change…2020
Probable Causes…2020
Recommended Repairs…2020
Diagnostic Codes…2020
Engine Stalls at Low RPM…2020
Probable Causes…2020
Recommended Actions…2020
Diagnostic Codes…2020
Fuel Injection Nozzles…2020
Fuel Supply…2020
Accessory Equipment…2021
Power Mode Control…2021
Engine Vibration…2021
Probable Causes…2021
Recommended Actions…2021
Engine Supports…2021
Malfunctioning Individual Cylinder…2021
Valve Lash…2021
Check for Low Compression (cylinder pressure)…2021
Check the Fuel Injection Nozzles…2021
Turbocharger…2022
Engine Will Not Crank…2022
Probable Causes…2022
Recommended Repairs…2022
Machine Security System…2022
Battery Cables and/or Batteries…2022
Starting Motor Solenoid or Starting Circuit…2022
Starting Motor and/or Flywheel Ring Gear…2022
Electrical Power Supply…2022
Internal Engine Problem…2022
Excessive Black Smoke…2022
Probable Causes…2022
Recommended Actions…2023
Air Intake System or Exhaust System…2023
Individual Malfunctioning Cylinder…2023
Valve Lash…2023
Low Compression (cylinder pressure)…2023
Check the Fuel Injection Nozzles…2023
Check the Turbocharger…2023
Broken 5-Volt Supply Wire…2024
Verifying the ECM Software…2024
Excessive Engine Oil Consumption…2024
Probable Causes…2024
Recommended Actions…2024
Oil Level…2024
Engine Crankcase Breather…2024
Air Intake and Exhaust System…2024
Turbocharger…2024
Low Compression (cylinder pressure)…2024
Excessive Valve Lash…2025
Probable Causes…2025
Recommended Actions…2025
Lubrication…2025
Valve Lash…2025
Valve Train Components…2025
Excessive White Smoke…2025
Probable Causes…2025
Recommended Actions…2025
Fuel Supply…2025
Individual Malfunctioning Cylinder…2026
Valve Lash…2026
Low Compression (cylinder pressure)…2026
Air Inlet Heater Starting Aid…2026
Fuel Injection Nozzles…2026
Coolant Temperature Sensor Circuit…2026
Engine Pressure Sensors…2026
Intake Air Temperature Is Too High…2026
Probable Causes…2026
Recommended Repairs…2026
High Ambient Air Temperature…2026
Coolant Temperature…2026
Check for High Intake Air Restriction and/or High Altitude…2027
Intake Air Restriction…2027
High Altitude…2027
Check the Intake Manifold Air Temperature Sensor and/or the Circ…2027
Check for Sufficient Coolant Flow Through the Aftercooler (if eq…2027
Check for Sufficient Flow of Air Through the Aftercooler (if equ…2027
Intermittent Engine Shutdown…2027
Probable Causes…2027
Recommended Actions…2027
Logged Codes…2027
Fuel Supply…2027
Engine Protection Device…2027
Electrical Connectors…2028
Intermittent Low Power or Power Cutout…2028
Probable Causes…2028
Recommended Repairs…2028
Diagnostic Codes…2028
Electrical Connectors…2028
Fuel Supply…2028
Check the Intake Manifold Pressure…2029
Air Intake and Exhaust System…2029
Individual Malfunctioning Cylinders…2029
Valve Lash…2029
Check for Low Compression…2029
Check the Fuel Injection Nozzles…2029
Check the Turbocharger…2029
ECM Parameters…2030
Electronic System Problem…2030
Low Engine Oil Pressure…2030
Probable Causes…2030
Recommended Actions…2030
Engine Oil Level…2030
Engine Oil Pressure Gauge…2030
Engine Oil Bypass Valves…2030
Piston Cooling Jets …2031
Engine Oil Suction Tube…2031
Engine Oil Pump…2031
Bearing Clearance…2031
Low Power/Poor or No Response to Throttle…2031
Probable Causes…2031
Recommended Actions…2031
Diagnostic Codes…2031
Fuel Supply…2031
Air Intake and Exhaust System…2031
Individual Malfunctioning Cylinders…2032
Valve Lash…2032
Check for Low Compression…2032
Check the Fuel Injection Nozzles…2032
Check the Turbocharger…2032
ECM Parameters…2032
Electronic System Problem…2033
Mechanical Noise (Knock) in Engine…2033
Probable Causes…2033
Recommended Actions…2033
Accessory Equipment…2033
Valve Train Components…2033
Connecting Rod and Main Bearings…2033
Noise Coming from Cylinder…2033
Probable Causes…2033
Recommended Actions…2033
Fuel Quality…2033
Fuel Injection Nozzles…2033
Valve Lash…2033
Poor Acceleration or Response…2034
Probable Causes…2034
Recommended Repairs…2034
Diagnostic Codes…2034
Fuel Supply…2034
Individual Malfunctioning Cylinder…2034
Valve Lash…2034
Check for Low Compression…2034
Check the Fuel Injection Nozzles…2034
Check the Turbocharger…2035
ECM Parameters…2035
Check Intake Manifold Pressure…2035
Troubleshooting With a Diagnostic Code…2035
CID 0041 FMI 03 8V Sensor Power Supply, Voltage More Than Normal…2035
Conditions Which Generate This Code…2035
System Response…2035
Possible Performance Effect…2035
Troubleshooting…2035
Results…2035
CID 0091 FMI 02 Throttle Position Sensor Erratic or Intermittent…2035
Conditions Which Generate This Code…2035
System Response…2036
Possible Performance Effect…2036
Troubleshooting…2036
Test Step 1…2036
Results…2036
CID 0091 FMI 03 Throttle Position Sensor Open Circuit or Shorted…2036
Conditions Which Generate This Code…2036
System Response…2036
Possible Performance Effect…2036
CID 0091 FMI 04 Throttle Position Sensor Shorted Low…2036
Conditions Which Generate This Code…2036
System Response…2036
Possible Performance Effect…2036
Troubleshooting…2036
Results…2036
CID 0091 FMI 08 Throttle Position Sensor Abnormal Signal…2036
Conditions Which Generate This Code…2036
System Response…2036
Troubleshooting…2037
Results…2037
CID 0091 FMI 12 Throttle Position Sensor Out of Calibration…2037
Conditions Which Generate This Code…2037
Possible Performance Effect…2037
Troubleshooting…2037
Results…2037
CID 0100 FMI 03 Engine Oil Pressure Sensor Open Circuit or Short…2037
Conditions Which Generate This Code…2037
System Response…2037
Troubleshooting…2037
Results…2037
CID 0100 FMI 04 Engine Oil Pressure Sensor Shorted Low…2037
Conditions Which Generate This Code…2037
System Response…2037
Troubleshooting…2037
Results…2037
CID 0100 FMI 10 Engine Oil Pressure Sensor, Power Supply Open Ci…2038
Conditions Which Generate This Code…2038
System Response…2038
Possible Performance Effect…2038
Results…2038
CID 0102 FMI 03 Intake Manifold Pressure Sensor, Open Circuit or…2038
Conditions Which Generate This Code…2038
System Response…2038
Possible Performance Effect…2038
Results…2038
CID 0102 FMI 04 Intake Manifold Pressure Sensor Shorted Low…2038
Conditions Which Generate This Code…2038
System Response…2038
Possible Performance Effect…2038
Results…2038
CID 0102 FMI 10 Intake Manifold Pressure Sensor Power Supply Ope…2039
Conditions Which Generate This Code…2039
System Response…2039
Results…2039
CID 0105 FMI 03 Intake Manifold Temperature Sensor Open Circuit …2039
Conditions Which Generate This Code…2039
System Response…2039
Possible Performance Effect…2039
Troubleshooting…2039
Results…2039
CID 0105 FMI 04 Intake Manifold Temperature Sensor Shorted Low…2039
Conditions Which Generate This Code…2039
System Response…2039
Possible Performance Effect…2039
Troubleshooting…2039
Results…2039
CID 0110 FMI 03 Engine Coolant Temperature Sensor Open Circuit o…2039
Conditions Which Generate This Code…2039
System Response…2040
Possible Performance Effect…2040
Troubleshooting…2040
Results…2040
CID 0110 FMI 04 Engine Coolant Temperature Sensor Shorted Low…2040
Conditions Which Generate This Code…2040
System Response…2040
Possible Performance Effect…2040
Troubleshooting…2040
Results…2040
CID 0174 FMI 02 Fuel Temperature Sensor Erratic, Intermittent…2040
Conditions Which Generate This Code…2040
System Response…2040
Possible Performance Effect…2040
Troubleshooting…2040
Results…2040
CID 0247 FMI 09 J1939 Datalink, Abnormal Update…2041
Conditions Which Generate This Code…2041
System Response…2041
Results…2041
CID 0253 FMI 02 Incorrect ECM Software…2041
Conditions Which Generate This Code…2041
System Response…2041
Possible Performance Effect…2041
Troubleshooting…2041
Expected Result…2041
Results…2041
CID 0262 FMI 03 5V Sensor Power Supply, Voltage More Than Normal…2041
Conditions Which Generate This Code…2041
System Response…2041
Possible Performance Effect…2041
Troubleshooting…2041
Results…2041
CID 0262 FMI 04 5V Sensor Power Supply, Voltage Less Than Normal…2042
Conditions Which Generate This Code…2042
System Response…2042
Possible Performance Effect…2042
Troubleshooting…2042
Results…2042
CID 0266 FMI 02 Incorrect Crank-Without-Inject Inputs…2042
Conditions Which Generate This Code…2042
System Response…2042
Possible Performance Effect…2042
CID 0320 FMI 02 Speed and Timing Sensor Intermittent Loss of Sig…2042
Conditions Which Generate This Code…2042
System Response…2042
Possible Performance Effect…2042
Results…2042
CID 0320 FMI 11 Speed and Timing Sensor Loss of Signal…2042
Conditions Which Generate This Code…2042
System Response…2042
Possible Performance Effect…2042
Results…2043
CID 0342 FMI 02 Speed and Timing Sensor No. 2 Intermittent Signa…2043
Conditions Which Generate This Code…2043
System Response…2043
Possible Performance Effect…2043
Test Step 1…2043
Results…2043
Test Step 2…2043
Results…2043
CID 0774 FMI 02 Throttle Position Sensor No. 2 Erratic or Interm…2043
Conditions Which Generate This Code…2043
System Response…2043
Possible Performance Effect…2043
Results…2043
CID 0774 FMI 03 Throttle Position Sensor No. 2 Open Circuit or S…2043
Conditions Which Generate This Code…2043
System Response…2044
Possible Performance Effect…2044
Troubleshooting…2044
Results…2044
CID 0774 FMI 04 Throttle Position Sensor No. 2 Shorted Low…2044
Conditions Which Generate This Code…2044
System Response…2044
Possible Performance Effect…2044
Troubleshooting…2044
Results…2044
CID 0774 FMI 08 Throttle Position Sensor No. 2 Abnormal Signal…2044
Conditions Which Generate This Code…2044
System Response…2044
Possible Performance Effect…2044
Results…2044
CID 0774 FMI 12 Throttle Position Sensor No. 2 Out of Calibratio…2044
Conditions Which Generate This Code…2044
System Response…2044
Possible Performance Effect…2044
Results…2044
CID 1627 FMI 03 Fuel Injection Pump Relay Did Not Turn Off…2045
Conditions Which Generate This Code…2045
System Response…2045
Possible Performance Effect…2045
Results…2045
CID 1684 FMI 00 Fuel Injection Pump, Fuel Temperature More Than …2045
Conditions Which Generate This Code…2045
System Response…2045
Possible Performance Effect…2045
Test Step 1…2045
Results…2045
Test Step 2…2045
Results…2045
CID 1684 FMI 02 Fuel Injection Pump, Software Failure…2045
Conditions Which Generate This Code…2045
System Response…2045
Possible Performance Effect…2045
Troubleshooting…2045
Results…2046
CID 1684 FMI 03 Fuel Injection Pump, Fueling Fault…2046
Conditions Which Generate This Code…2046
System Response…2046
Possible Performance Effect…2046
Troubleshooting…2046
Results…2046
CID 1684 FMI 04 Fuel Injection Pump, Supply Voltage Fault…2046
Conditions Which Generate This Code…2046
System Response…2046
Possible Performance Effect…2046
Troubleshooting…2046
Results…2046
CID 1684 FMI 05 Fuel Injection Pump, Invalid Pulse Width…2046
Conditions Which Generate This Code…2046
Troubleshooting…2046
Results…2047
CID 1684 FMI 07 Fuel Injection Pump, Mechanical Fault…2047
Conditions Which Generate This Code…2047
System Response…2047
Possible Performance Effect…2047
Troubleshooting…2047
Results…2047
CID 1684 FMI 08 Fuel Injection Pump, Crankshaft Reference Fault…2047
Conditions Which Generate This Code…2047
System Response…2047
Possible Performance Effect…2047
Troubleshooting…2047
Test Step 1…2047
Results…2047
Test Step 2…2047
Results…2047
Test Step 3…2047
Results…2048
Test Step 4…2048
Expected Result…2048
Results…2048
CID 1684 FMI 09 Fuel Injection Pump, CAN Fault…2048
Conditions Which Generate This Code…2048
System Response…2048
Possible Performance Effect…2048
Troubleshooting…2048
Expected Result…2048
Results…2048
CID 1684 FMI 10 Fuel Injection Pump, Fuel Shutoff Signal Error…2048
Conditions Which Generate This Code…2048
System Response…2048
Troubleshooting…2048
Test Step 1…2048
Results…2049
Test Step 2…2049
Results…2049
Test Step 3…2049
Results…2049
CID 1684 FMI 11 Fuel Injection Pump, Internal Sensor Fault…2049
Conditions Which Generate This Code…2049
System Response…2049
Possible Performance Effect…2049
Troubleshooting…2049
Test Step 1…2049
Results…2049
Test Step 2…2049
Results…2049
CID 1684 FMI 14 Fuel Injection Pump, No Communications…2049
Conditions Which Generate This Code…2049
System Response…2049
Troubleshooting…2049
Test Step 1…2049
Results…2049
Test Step 2…2050
Results…2050
Test Step 3…2050
Results…2050
CID 1743 FMI 02 Engine Speed Mode Selection Switch State, Invali…2050
Conditions Which Generate This Code…2050
System Response…2050
Possible Performance Effect…2050
Troubleshooting…2050
Results…2050
CID 1894 FMI 02 Set Speed Control Disengage Switch State, Invali…2050
Conditions Which Generate This Code…2050
System Response…2050
CID 1895 FMI 02 Set Speed Control Speed Toggle Switch, Invalid S…2050
Conditions Which Generate This Code…2050
System Response…2050
Troubleshooting With an Event Code…2051
Event Codes…2051
Programmable Engine Parameters…2051
E015 High Engine Coolant Temperature Derate…2051
Conditions Which Generate This Code…2051
System Response…2051
Possible Performance Effect…2051
Troubleshooting…2051
Results…2051
E016 High Engine Coolant Temperature Shutdown…2051
Conditions Which Generate This Code…2051
System Response…2051
Possible Performance Effect…2051
Troubleshooting…2051
Results…2051
E017 High Engine Coolant Temperature Warning…2051
Conditions Which Generate This Code…2051
System Response…2051
Possible Performance Effect…2051
Troubleshooting…2051
Results…2051
E025 High Intake Air Temperature Derate…2052
Conditions Which Generate This Code…2052
System Response…2052
Possible Performance Effect…2052
Troubleshooting…2052
Results…2052
E027 High Intake Air Temperature Warning…2052
Conditions Which Generate This Code:…2052
System Response…2052
Possible Performance Effect…2052
Troubleshooting…2052
Results…2052
E040 Low Engine Oil Pressure Shutdown…2052
Conditions Which Generate This Code…2052
System Response…2052
Possible Performance Effect…2052
Troubleshooting…2052
Results…2052
E054 High Fuel Temperature Derate…2053
Conditions Which Generate This Code…2053
System Response…2053
Troubleshooting…2053
Test Step 1 – Check for Diagnostic Codes…2053
Expected Result…2053
Results…2053
Test Step 2 – Perform a Check of the Fuel System…2053
Expected Result…2053
Results…2053
E056 High Fuel Temperature Warning…2053
Conditions Which Generate This Code…2053
System Response…2053
Troubleshooting…2053
Test Step 1 – Check for Diagnostic Codes…2053
Expected Result…2053
Results…2054
Test Step 2 – Perform a Check of the Fuel System…2054
Expected Result…2054
Results…2054
E100 Low Engine Oil Pressure Warning…2054
Conditions Which Generate This Code…2054
System Response…2054
Possible Performance Effect…2054
Troubleshooting…2054
Test Step 1 – Check for Active Diagnostic Codes…2054
Expected Result…2054
Results…2054
Test Step 2 – Perform a Check of the Engine Lubrication System…2054
Expected Result…2054
Results…2054
E190 Engine Overspeed Warning…2055
Conditions Which Generate This Code…2055
System Response…2055
Possible Performance Effect…2055
Troubleshooting…2055
Engine Overspeed Warning…2055
Expected Result…2055
Results…2055
E442 Engine Failed to Stop With a No-Fuel Command…2055
Conditions Which Generate This Code…2055
System Response…2055
Possible Performance Effect…2055
Troubleshooting…2055
Test Step 1…2055
Results…2055
Test Step 2…2055
Results…2055
E883 Engine Failed to Stop When Fuel Solenoid Disengaged…2055
Conditions Which Generate This Code…2055
System Response…2055
Possible Performance Effect…2056
Troubleshooting…2056
Test Step 1…2056
Results…2056
Test Step 2…2056
Results…2056
Test Step 3…2056
Results…2056
Diagnostic Function Tests…2056
5-Volt Engine Pressure Sensor Supply Circuit – Test…2056
System Operation Description…2056
Background Information…2056
Test Step 1…2057
Inspect Electrical Connectors and Wiring…2057
Expected Result…2057
Results…2058
Test Step 2…2058
Check for Active Diagnostic Codes…2058
Expected Result…2058
Results…2058
Test Step 3…2058
Disconnect the ECM Engine Harness Connector From the ECM…2058
Expected Result…2059
Results…2059
Test Step 4…2059
Disconnect the +5V Sensors While Active Diagnostic Codes are Bei…2059
Expected Result…2060
Results…2060
Test Step 5…2060
Check the Engine Harness…2060
Expected Result…2060
Results…2060
Air Inlet Heater Circuit – Test…2060
System Operation Description…2060
Test Step 1…2061
Inspect Electrical Connectors and Wiring…2061
Expected Result…2061
Results…2061
Test Step 2…2061
Check the Supply to the Power Relay for the Air Inlet Heater Sta…2061
Expected Result…2062
Results…2062
Test Step 3…2062
Check the Output From the Power Relay for the Air Inlet Heater S…2062
Expected Result…2062
Results…2062
Test Step 4…2062
Ground the Input to the Power Relay at the MIC…2062
Expected Result…2062
Results…2062
Test Step 5…2062
Ground the Input to the Power Relay at the ECM Connector…2062
Expected Result…2062
Results…2062
Test Step 6…2063
Override the Air Inlet Heater Starting Aid to Test the ECM…2063
Results…2063
Checking Idle Validation Switching Point (Throttle Sensor) With …2063
Expected Result…2063
Analog Throttle Position Sensor Circuit – Test…2063
System Operation Description…2063
Checking the Throttle Sensor With Unconnected Output C…2064
Expected Result…2064
Test Step 1…2064
Check for Connector Damage…2064
Expected Result…2065
Results…2065
Test Step 2…2065
Check for Active Diagnostic Codes…2065
Expected Result…2065
Results…2065
Test Step 3…2065
Check the Throttle Position With the Electronic Service Tool…2065
Expected Result…2065
Results…2065
Test Step 4…2065
Check the Voltage at the Throttle Position Sensor…2065
Expected Result…2065
Results…2065
Test Step 5…2066
Disconnect the Throttle Position Sensor and Check for Active Dia…2066
Expected Result…2066
Results…2066
Test Step 6…2066
Check the Throttle Selection Status With the Electronic Service …2066
Expected Result…2066
Results…2066
Test Step 7…2067
Disconnect the Supply Terminals of the Throttle Position Sensor …2067
Expected Result…2067
Results…2067
Test Step 8…2067
Check the Position of Throttle Position Sensor…2067
Expected Result…2067
Results…2068
Test Step 9…2068
Check the Throttle Position Sensor at the ECM…2068
Expected Result…2068
Results…2068
CAN Data Link Circuit – Test…2068
System Operation Description…2068
Test Step 1…2069
Inspect Electrical Connectors and Wiring…2069
Expected Result…2069
Results…2069
Test Step 2…2069
Check the CAN Data Link Between the ECM and P40 Fuel Injection P…2069
Expected Result…2069
Results…2069
Test Step 3…2069
Check the CAN Data Link Between the ECM and P40 Fuel Injection P…2069
Expected Result…2069
Results…2070
Test Step 4…2070
Verify the Supply Voltage at the Fuel Injection Pump…2070
Expected Result…2070
Results…2070
Data Link Circuit – Test…2070
System Operation Description…2070
Background Information…2071
Communication…2071
Test Step 1…2071
Inspect Electrical Connectors and Wiring…2071
Expected Result…2071
Results…2071
Test Step 2…2071
Determine the Type of Problem With the Data Link…2071
Expected Result…2071
Results…2072
Test Step 3…2072
Check the Battery Voltage at the ECM…2072
Expected Result…2072
Results…2072
Test Step 4…2072
Check the Battery Voltage That is Coming to the Data Link Connec…2072
Expected Result…2073
Results…2073
Test Step 5…2073
Connect the Electronic Service Tool Directly to the ECM…2073
Expected Result…2073
Results…2073
Test Step 6…2073
Change Electronic Service Tool Components…2073
Expected Result…2074
Results…2074
Test Step 7…2074
Connect an Electronic Service Tool and the ECM to Another Batter…2074
Expected Result…2074
Results…2074
Electrical Connectors – Inspect…2074
System Operation Description…2074
Background Information…2075
Test Step 1…2078
Check the Locking of the DT Connector (Deutsch) and the Lock Rin…2078
Expected Result…2078
Results…2078
Test Step 2…2079
Check the Socket Head Screw on the Connector for the Electronic …2079
Expected Result…2079
Results…2079
Test Step 3…2079
Perform a Pull Test on Each Wire Terminal Connection…2079
Expected Result…2079
Results…2079
Test Step 4…2079
Monitor the Electronic Service Tool While the Wiring and the Con…2079
Expected Result…2080
Results…2080
Test Step 5…2080
Check Wires for Nicks and/or Abrasions in the Insulation…2080
Expected Result…2080
Results…2080
Test Step 6…2080
Check Connectors for Moisture or Corrosion…2080
Expected Result…2081
Results…2081
Test Step 7…2081
Inspect the Connector Terminals…2081
Expected Result…2081
Results…2081
Test Step 8…2081
Check Individual Pin Retention Into the Socket…2081
Expected Result…2082
Results…2082
Electrical Power Supply Circuit – Test…2082
System Operation Description…2082
Background Information…2082
Test Step 1…2083
Check the Batteries…2083
Expected Result…2083
Results…2083
Test Step 2…2084
Inspect Electrical Connectors and Wiring…2084
Expected Result…2084
Results…2084
Test Step 3…2084
Check the Battery Voltage at the ECM…2084
Expected Result…2084
Results…2085
Test Step 4…2085
Use the Bypass Harness for the Electronic Service Tool to Bypass…2085
Expected Result…2086
Results…2086
Engine Pressure Sensor Open or Short Circuit – Test…2086
System Operation Description…2086
Background Information…2086
Test Step 1…2086
Check for Active +5V Sensor Supply Diagnostic Codes…2086
Expected Result…2087
Results…2087
Test Step 2…2087
Verify All Active Diagnostic Codes…2087
Expected Result…2087
Results…2087
Test Step 3…2087
Inspect Electrical Connectors And Wiring…2087
Expected Result…2088
Results…2088
Test Step 4…2088
Verify That the Diagnostic Code is Still Active…2088
Expected Result…2088
Results…2088
Test Step 5…2088
Disconnect the Sensor to Create an Open Circuit…2088
Expected Result…2088
Results…2088
Test Step 6…2088
Measure the Sensor Supply Voltage…2088
Expected Result…2089
Results…2089
Test Step 7…2089
Determine if the Short Circuit is in the Connector or in the Sen…2089
Expected Result…2089
Results…2089
Test Step 8…2089
Create a Short Circuit Between the Signal and the Common Termina…2089
Expected Result…2090
Results…2090
Test Step 9…2090
Check the Operation of the ECM by Creating Open and Short Circui…2090
Expected Result…2090
Results…2090
Test Step 10…2091
Bypass the Harness Wiring Between the ECM and the Sensor Connect…2091
Expected Result…2091
Results…2091
Engine Speed/Timing Sensor Circuit – Test…2091
System Operation Description…2091
Test Step 1…2092
Inspect the Electrical Connectors and Cables…2092
Expected Result…2092
Results…2092
Test Step 2…2092
Check the Installation of the Engine Speed/Timing Sensors…2092
Expected Result…2092
Results…2092
Test Step 3…2092
Measure the Sensor Resistance Through the Wiring Harness…2092
Expected Result…2093
Results…2093
Test Step 4…2093
Measure the Resistance of the Sensor…2093
Expected Result…2093
Results…2093
Test Step 5…2094
Measure the Resistance of the Cables Between the Fuel Injection …2094
Expected Result…2094
Results…2094
Test Step 6…2094
Check the Continuity of the Cables From the ECM to the Fuel Inje…2094
Expected Result…2094
Results…2095
Engine Temperature Sensor Open or Short Circuit – Test…2095
System Operation Description…2095
Background Information…2095
Test Step 1…2096
Verify All Active Diagnostic Codes…2096
Expected Result…2096
Results…2096
Test Step 2…2096
Inspect Electrical Connectors and Wiring…2096
Expected Result…2096
Results…2097
Test Step 3…2097
Verify That the Diagnostic Code is Still Active…2097
Expected Result…2097
Results…2097
Test Step 4…2097
Disconnect the Sensor to Create an Open Circuit…2097
Expected Result…2097
Results…2097
Test Step 5…2097
Create a Short Circuit Between the Signal and the Common Termina…2097
Expected Result…2098
Results…2098
Test Step 6…2098
Check the Operation of the ECM by Creating an Open and a Short C…2098
Expected Result…2098
Results…2098
Test Step 7…2098
Bypass the Harness Wiring Between the ECM and the Sensor Connect…2098
Expected Result…2099
Results…2099
Fuel Injection Pump Circuit – Test…2099
System Operation Description…2099
Background Information…2099
Test Step 1…2099
Check the Batteries…2099
Expected Result…2099
Results…2100
Test Step 2…2100
Inspect the Electrical Connectors and Wiring…2100
Expected Result…2101
Results…2101
Test Step 3…2101
Check the Supply Voltage at the Machine Interface Connector…2101
Expected Result…2101
Results…2101
Test Step 4…2101
Check the Supply Voltage at the Fuel Injection Pump…2101
Expected Result…2101
Results…2101
Test Step 5…2102
Check the Supply to the Power Relay for the Fuel Injection Pump…2102
Expected Result…2102
Results…2102
Test Step 6…2102
Check the Output of the Power Relay for the Fuel Injection Pump…2102
Expected Result…2102
Results…2102
Test Step 7…2102
Check the Voltage at the Relay Coil for the Fuel Injection Pump…2102
Expected Result…2102
Results…2102
Test Step 8…2103
Check the Output of the ECM Fuel Pump Power Control at the Machi…2103
Expected Result…2103
Results…2103
Test Step 9…2103
Check the Output of the Fuel Injection Pump Power Control at the…2103
Expected Result…2103
Results…2103
Test Step 10…2103
Measure the Voltage at the Pump Power Supply…2103
Expected Result…2104
Results…2104
Test Step 11…2104
Check the Voltage Load Protection Module (VLPM)…2104
Expected Result…2105
Results…2105
Indicator Lamp Circuit – Test…2105
System Operation Description…2105
Test Step 1…2105
Inspect Electrical Connectors and Wiring…2105
Results…2106
Test Step 2…2106
Inspect the Lamp, the Fuse, and the Power Supply…2106
Expected Result…2106
Results…2106
Test Step 3…2106
Inspect the Input to the Lamp at the ECM connector…2106
Expected Result…2106
Results…2107
Test Step 4…2107
Test the Individual Lamp Circuits…2107
Expected Result…2107
Results…2107
Test Step 5…2107
Check the Voltage at the ECM…2107
Expected Result…2107
Results…2107
Idle Validation Circuit – Test…2107
System Operation Description…2107
Test Step 1…2107
Expected Result…2107
Results…2108
tables…1956
Table 1. Electronic Service Tool…1982
Table 2. Optional Service Tools…1983
Table 3. CID FMI Codes and J Code FMI Codes…1984
Table 4. Event Codes and CID FMI Codes…1986
Table 5. Diagnostics Supported Over J1939…1987
Table 6. Events Supported Over J1939…1989
Table 7. Engine Connectors…1996
Table 8. Color Codes for the Harness Wire…2001
Table 9. Pin Connections for Perkins Deutsch Socket Connector…2003
Table 10. Suspect Parameter Numbers…2007
Table 11. Failure Mode Indicators (FMI) Codes…2008
Table 12. Engine Oil Pressure Trip and Reset Points…2052
1586990-8000SRM1181-(03-2007)-UK-EN…2112
toc…2112
Assembly Guide…2112
Safety Precautions Maintenance and Repair…2113
List of All Special Tools and Equipment Needed for the Assembly…2116
General Considerations Before Starting the Job…2116
Preparation of the Components Before Assembly…2117
Liquefied Petroleum Gas (LPG Engines Only)…2117
Remove…2117
Install…2118
Checking of the Wheels…2118
Air Pressure…2118
Drive Wheels…2119
Steer Wheels…2123
Wheel Nut Torque…2126
Mast Label Placement…2127
Safety Procedures When Working Near Mast…2128
Mast Installation…2130
Mast…2130
Tilt Cylinder Pin Installation…2133
Lift Cylinder Hose Connection…2134
Truck Header Hoses and Electrical Cable Connections…2135
Mast Light Connection…2137
Carriage Installation…2138
Carriage Header Hoses and Electrical Cable Connection…2139
Fork Installation…2142
Exhaust Extension Tube Installation…2143
Lights Installation – Operator Compartment…2145
Hydraulic Oil Check…2146
Lubrication Points…2147
Check Points…2148
Checkpoint 1…2148
Checkpoint 2…2148
Checkpoint 3…2148
Checkpoint 4…2148
Checkpoint 5…2148
General Truck Install Procedures…2148
tables…2112
Table 1. Mast Hanger Pins Capscrew Torques…2133
1612615-5000SRM1221-(11-2006)-UK-EN…2152
toc…2152
Extendable Container Attachment (Elme)…2152
Safety Precautions Maintenance and Repair…2153
General…2158
Description…2158
Operation…2162
General…2162
Optional Powered Pile Slope…2162
Sideshift…2163
Extend and Retract Circuit…2164
Container locking Model 582…2166
Sequence Valve…2166
Pilot Check Valve…2167
Container Locking Model 583…2168
Container Locking Model 584…2168
Container Locking Model 585…2169
Container Locking Models 586, 588, and 589…2169
Electrical System…2171
Indicator Lights…2171
Flashing Indicator Lights…2172
Automatic Locking…2172
Lift Interrupt and Override…2172
Overlowering Interrupt and Override…2172
Second Container Detection Sensor (Model 582 Only)…2173
Carriage and Attachment Removal…2173
Carriage…2173
Spreader…2174
Sideshift Cylinder Removal and Installation…2174
Remove…2174
Install…2174
Extension Cylinder Removal and Installation…2175
Remove…2175
Upper, Right-Hand…2175
Lower, Left-Hand…2175
Install…2175
Floating End Beams Repair…2176
Remove…2176
Install…2176
Hose, Replace…2177
Twist Lock Repair for Model 582…2178
Remove…2178
Upper Twist Lock…2178
Lower Twist Lock…2178
Disassemble…2179
Clean and Inspect…2179
Assemble…2180
Install…2180
Hook Repair for Model 584 and 585…2180
Remove…2180
Inspect…2180
Install…2180
Side Clamp Replacement for Model 584…2181
Remove…2181
Install…2182
Twist Lock Repair for Models 586, 588, and 589…2182
Disassemble…2182
Clean and Inspect…2182
Assemble…2183
Extension Beam Repair…2184
Remove…2184
Inspect…2184
Assemble…2185
Cylinder Repair…2186
Extension Cylinder…2186
Disassemble…2186
Clean and Inspect…2186
Assemble…2186
Guide for Extension Cylinder…2187
Remove…2187
Install…2187
Sideshift Cylinder, Powered Pile Slope Cylinder, Retract Cylinde…2187
Disassemble…2187
Assemble…2187
Wear Pad Replacement…2188
General…2188
Floating End Beam Wear Pads…2188
Upper Wear Pads…2188
Lower Wear Pads…2188
Main Frame Wear Pads at Large (Right-Hand) Extension Beam…2188
Main Frame Wear Pads at Small (Left-Hand) Extension Beam…2188
Guide for Extension Cylinder…2189
Large Extension Beam Internal Wear Pads…2190
Spreader Frame…2190
Upper Wear Pads…2190
Lower Wear Pads…2190
Powered Pile Slope Carriage…2190
Upper Wear Pads…2190
Lower Wear Pads…2190
Adjustments…2190
Twist Lock Angle Adjustment…2190
Model 586, 588 and 589…2190
LOCKED/NOT LOCKED Sensors Adjustment…2191
Model 582…2191
Model 586, 588 and 589…2191
Side Clamp Open/Closed Sensor Adjustment (Model 584)…2191
Hook in Sensor Adjustment (Model 584)…2191
Seated Sensor Adjustment…2192
Model 582…2192
Model 586, 588 and 589…2192
Overlowering Protection Sensor Adjustment (All 580 Models)…2192
Schematics…2193
tables…2152
Table 1. Elme Schematic Overview…2193
897108-1600SRM0326-(03-2007)-UK-EN…2280
toc…2280
Steering Axle…2280
Safety Precautions Maintenance and Repair…2281
General…2284
Description…2284
Steering Axle Assembly Repair…2289
Steering Axle H3.50-5.00XL (H70-110XL) (G005), S3.50-5.50XL (S70…2289
Remove…2289
Install…2289
Steering Axle H6.00-7.00XL (H135-155XL, H135-155XL 2 ) (F006, G0…2290
Remove…2290
Install…2290
Wheels and Hubs Repair (All Units)…2291
Remove and Disassemble…2291
Clean…2291
Inspect…2291
Assemble and Install…2291
Spindles and Bearings Repair (All Units)…2293
Remove…2293
Clean…2293
Assemble and Install…2294
Tie Rods Repair (All Units)…2295
Remove…2295
Clean…2295
Install…2295
Steering Cylinder Repair…2298
Remove and Disassemble…2298
Clean and Inspect…2298
Assemble and Install…2298
Troubleshooting…2299
897934-0700SRM0626-(11-2001)-UK-EN…2304
toc…2304
Cooling System…2304
Safety Precautions Maintenance and Repair…2305
General…2308
Description…2309
Radiator…2309
Radiator Cap…2309
Thermostat…2309
Water Pump…2310
Fan and Fan Shroud…2310
Cooling System Checks…2310
Radiator…2310
Thermostat…2310
Water Pump…2311
Exhaust Leaks…2311
Fan and Fan Shroud…2311
Radiator Cleaning…2311
Drain…2311
Clean…2311
Fill…2312
Troubleshooting…2313
899784-2200SRM0002-(10-2003)-UK-EN…2316
toc…2316
Alternator with Regulator…2316
Safety Precautions Maintenance and Repair…2317
General…2320
Description…2320
Alternator Repair…2322
Alternator Type A…2322
Remove and Disassemble…2322
Clean…2323
Assemble…2324
Install…2324
Alternator Type B…2327
Remove and Disassemble…2327
Clean…2327
Assemble…2328
Install…2329
General Check and Adjustment…2330
Low Output Check (Type A or Type B)…2330
High Output Check (Type A or Type B)…2332
Brushes Circuit Check…2333
Delco Alternators…2333
Motorola Alternators…2334
Diodes Check…2335
Diode Bridge Check…2335
Delco and Leece-Neville Alternators…2335
Motorola Alternators…2335
Rotor Field Winding Check…2336
Stator Windings Check…2337
Voltage Regulator Check…2337
Troubleshooting…2337
910072-1400SRM0046-(07-2007)-UK-EN…2342
toc…2342
Differential…2342
Safety Precautions Maintenance and Repair…2343
General…2346
Description…2346
Differential Repair…2347
Remove…2347
Differential Carrier From Axle Housing, Remove…2347
Differential and Ring Gear From Differential Carrier, Remove…2349
Drive Pinion and Pinion Carrier From Differential Carrier, Remov…2351
Disassemble…2352
Differential and Ring Gear Assembly, Disassemble…2352
Drive Pinion and Pinion Carrier, Disassemble…2354
Clean and Inspect…2357
Assemble…2358
Pinion, Bearings, and Pinion Carrier, Assemble…2358
Pinion Bearings, Adjust Preload…2358
Press Method…2358
Yoke or Flange Method…2359
Triple-Lip Seal, Install…2360
Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion)…2361
Differential and Ring Gear, Assemble…2363
Differential Gears Rotating Torque, Check…2365
Differential and Ring Gear Assembly, Install…2366
Differential Bearings, Preload Adjust…2368
Ring Gear, Runout Check…2369
Ring Gear Backlash, Adjust…2369
Gear Set, Tooth Contact Pattern Check…2371
Thrust Screw, Install and Adjust…2374
Install…2374
Differential Assembly Into Axle Housing, Install…2374
Specifications…2376
Troubleshooting…2381
tables…2342
Table 1. Ring Gear Backlash Adjustment Specifications…2371
Table 2. Ring and Pinion Tooth Contact Adjustment…2372
Table 3. General Specifications…2376
Table 4. Rivet Installation Pressure…2376
Table 5. Pinion Adjustment…2377
Table 6. Pinion Preload Pressure…2377
Table 7. Torque Specifications…2378
Table 8. Torque Specifications for Metric Hardware…2379
Table 9. Torque Specifications for Metric (Fine) Hardware…2380
910102-2100SRM0103-(03-2007)-UK-EN…2384
toc…2384
Tilt Cylinders…2384
Safety Precautions Maintenance and Repair…2385
General…2388
Description…2388
Tilt Cylinder Repair…2388
Remove…2388
Disassemble…2388
Clean…2388
Assemble…2388
Tilt Cylinders With O-Ring or Single-Lip Seals…2388
Tilt Cylinders for XM and XMS Models…2390
Tilt Cylinders for XL, XLS, and XL 3 Models…2391
Tilt Cylinders for H700-800A and Early Model H700-920B…2393
Install…2394
Tilt Cylinders Using Chevron Packing…2394
Install…2395
Tilt Cylinder Leak Check…2397
Tilt Cylinder Stroke and Mast Tilt Angle Adjustment…2399
Torque Specifications…2399
Piston Rod Nut…2399
Retainer…2400
Troubleshooting…2402
tables…2384
Table 1. Movement Rates (Maximum) for Tilt Cylinders…2398
910107-2200SRM0106-(02-2001)-UK-EN…2406
toc…2406
Starter…2406
Safety Precautions Maintenance and Repair…2407
General…2410
Description and Operation…2410
Starter Repair…2412
Remove…2412
Disassemble…2412
Clean…2413
Assemble…2413
Install…2414
General Checks and Adjustments…2414
Troubleshooting…2417
910442-8000SRM0231-(12-2004)-UK-EN…2422
toc…2422
Metric and Inch (SAE) Fasteners…2422
Safety Precautions Maintenance and Repair…2423
General…2426
Threaded Fasteners…2426
Nomenclature, Threads…2426
Strength Identification…2427
Cotter (Split) Pins…2427
Fastener Torque Tables…2432
Conversion Table…2434
tables…2422
Table 1. Bolts and Screws…2428
Table 2. Studs and Nuts…2429
Table 3. Torque Nuts…2430
Table 4. Torque Nuts With Nylon Insert…2431
Table 5. Torque Values for Metric Fasteners*…2432
Table 6. Torque Values for Inch Fasteners*…2433
Table 7. Conversion Table for Metric and English Units…2434
Table 8. Cotter Pin Dimensional Data…2435
Table 9. Cotter Pin Dimensional Data…2436
Table 10. Cotter Pin Dimensional Data…2437
Table 11. Cotter Pin Dimensional Data…2439
Aurora_AC…2444
912-100-0148_engl_1.pdf…0
Compressors – Applications, Conditions of Use and Liability…2445
…0
Filling procedure for refrigerants…0
Do not exceed the maximum operating pressure of the compressor. (see type label)…2451
Compressors are machines under pressure and as such require special care in handling…2451
Only qualified personnel are allowed to perform any work on refrigeration compressors…2451
The national safety regulations, accident prevention regulations, technical rules and specific regulations must be taken into account abolutely…2451
Never put the safety switch out of action…2451
Prior to commissioning, check wether all teh components installed by the user have been fastened expertly and connected pressure-tight with the compressor…2451
Prior to starting the compressor open discharge shut-off valve and suction shut-off valve…2451
Do not start the cmpressor in vacuum. Operate the compressor only when the system is charged…2451
Caution! Danger of burning because of high surface temperatures…2451
Never grab rotating parts during operation. Danger of injury!…2451
Avoid all contact with the liquid refrigerant. Any parts of skin that come into contact with it must be treated like chilblains. Wear goggles to protect eyes. If refrigerant nevertheless gets into the eyes, consult a doctor immediately. Wear leather glov…2451
Before repairing refrigerant circuits, all refrigerant must be suctioned off as instructed. Note: Even when the unit is empty, there may be some residual pressure. It is advisable to loosen the screws slowly to allow residual pressure to subside. Refri…2451
No welding may be performed on any part of the unit or in the near vicinity while it is closed. Regardless whether the unit is filled with refrigerant or empty, heating causes excess pressure which can damage the unit or cause an explosion…2451
Full bottles of refrigerant must not be thrown or…2451
It is essential to ensure that the refrigerant system is does not become contaminated with chlorine, substances containing chlorine, oil or grease. Evacuation and filling units must be used for R 134a only…2451
4. Troubleshooting…2452
…2452
…2452
Check refrigerant level and pressure as instructed in the Technical Information sheet for the unit…2452
By wrong refrigerant level there is a danger of compressor malfunction…2452
The outcome of too much refrigerant is a oil attenuation and reflux of the refrigerant can cause damages on the valve plate…2452
With undercharged refrigerant the compressor will become hotwhich caused a failure. The sealing will be damaged…2452
Faulty shaft seals:On older compressors the shaft seal can be damaged when the unit is switched on for first time after a prolonged period of disuse, e.g. if the air-conditioner has not been used during the winter. Seals may become brittle as a result o…2452
NoisesMechanical faults in compressors are generally indicated by unusual noises or by unusually quiet or noisy operation. The normal noise made by the seals during operation does not indicate a fault. The most common noises are caused by problems with…2452
Electrical faultsA 5A fuse is used for the magnetic coupling on the compressor. The magnetic coupling can be checked by applying the required voltage to the connection socket while the vehicle engine is running. The coupling should start up with a click…2452
912-100-0007_e.pdf…0
Technical modifications reserved…2453
912-100-0258_e.pdf…0
Condenser unit, 24V…2464
…2464
…2464
…2464
…2464
part no.:175-FR2-0002…2464
Safety advices…2464
– we reserve the right to make technical modifications -…2464
1Safety advices…2465
Maintenance work on the refrigeration circuit:…2465
…2466
2.2Condenser blowers…2466
5Electrical connection…2467
every six months – authorised workshop:…2468
…2468
…2468
…2468
State of the refrigerant hoses…2468
State of the condenser…2468
A contaminated condenser has a minimised condensing performance. The cleaning is carried out by blow-out or spraying (do not use a high-pressure cleaner)…2468
every month sight checks – Operator…2469
…2469
…2469
…2469
State of the refrigerant hoses…2469
State of the condenser…2469
Check condenser of contamination by dust, insects or parts of plants…2469
A contaminated condenser has a minimised condensing performance. The cleaning is carried out by blow-out or spraying (do not use a high-pressure cleaner)…2469
Installation of replacement parts…2469
8Technical data…2469
9Fault diagnosis…2470

Hyster Forklift Trucks G007 (H170-280HD & H8.00-12.00XM Europe) Repair Service Manual

INSTANT DOWNLOAD

Posted on June 5, 2025 by admin

Hyster Forklift Trucks G006 (H135-155XL & H6.00-7.00XL Europe) Repair Service Manual

INSTANT DOWNLOAD

Complete service repair manual for Hyster G006 (H135-155XL & H6.00-7.00XL Europe) Forklift Trucks, with all the shop information to maintain, diagnose, repair, and rebuild like professional mechanics.

Hyster G006 (H135-155XL & H6.00-7.00XL Europe) workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

Hyster G006 (H135-155XL & H6.00-7.00XL Europe) Service Manual.pdf

Total Pages: 1,355 + 2,184 pages
File Format: PDF
Language: English

G006 (H135-155XL)…2
100322-frame…5
INTRODUCTION…5
GENERAL…5
DESCRIPTION…5
REPAIRS…6
COUNTERWEIGHT…6
Removal…6
Installation…6
HOOD…6
Removal…6
Installation…7
OVERHEAD GUARD…7
Removal…7
Installation…7
OPERATOR RESTRAINT SYSTEM…7
HYDRAULIC TANK…8
Removal…8
Inspection…8
Repairs, Small Leaks…8
Repairs, Large Leaks…8
Cleaning…8
Steam Method of Cleaning…9
Chemical Solution Method of Cleaning…9
Other Methods Of Preparation For Repair…9
Installation…9
FUEL TANK…9
Removal…9
Repairs…10
Installation…10
RADIATOR…10
Removal…10
Installation…10
ENGINE…10
Removal…10
Installation…10
SAFETY LABELS…11
CAB…13
Cab Replacement…13
Window Replacement…13
Windshield Wipers and Heater…13
1300324…15
TWO-SPEED POWERSHIFT TRANSMISSION (HYSTER T-40) Description And Operation…15
GENERAL…15
MECHANICAL DESCRIPTION…15
Torque Converter…15
Transmission Pump…16
Shaft Assemblies…17
Input Shaft…17
Forward Clutch Shaft…17
Clutch Assemblies…17
FORWARD LOW AND HIGH CLUTCH ASSEMBLIES…19
REVERSE LOW AND HIGH CLUTCH ASSEMBLIES…21
Countershaft…23
Output Shaft…23
HYDRAULIC OPERATION…24
Torque Converter…24
Seal Rings…25
CONTROL VALVE…25
System Pressure Regulator…28
Clutch Pressure Regulator…28
Torque Converter Regulator…28
Inching Spool…28
Direction Spool, Direction Control Lever…29
Direction Spool, Monotrol Pedal…29
Range Spool…30
Drain Spool…30
Accumulator…30
Modulator Spool…30
Operation (See…30
LUBRICATION CIRCUIT…31
MONOTROL PEDAL…31
OIL FLOW DIAGRAMS…33
Neutral…33
Forward-Low…34
Forward-Low-Inching…35
Reverse Low…36
1300325…38
TWO-SPEED POWERSHIFT TRANSMISSION (HYSTER T-40)…38
GENERAL…38
TRANSMISSION…38
Removal, Transmission And Torque Converter…38
Transmission, Disassembly…40
Reverse-Low Clutch, Disassembly…41
Reverse-High Clutch, Disassembly…43
Forward-Low Clutch, Disassembly…44
Forward-High Clutch, Disassembly…45
Cleaning and Inspection…46
ASSEMBLY, FORWARD LOW AND HIGH CLUTCHES…46
Forward Clutches, Assembly…48
Reverse-Low CLutch, Assembly…52
Reverse Clutches, Assembly…54
Transmission, Assembly…59
Torque Converter, Installation…63
CONTROL VALVE…64
Removal…64
Disassembly…64
Assembly…65
Installation…67
MONOTROL PEDAL…67
Removal and Disassembly…67
Assembly and Installation…68
CHECKS AND ADJUSTMENTS…70
STALL TEST…70
LINKAGE ADJUSTMENTS…70
Linkage For The Inching Pedal, H6.00-7.00XL (H135-155XL)…70
Linkage For The Inching Pedal, S6.00-7.00XL (S135-155XL)…73
Linkage For The Range Lever H6.00-7.00XL (H135-155XL)…75
Linkage For The Direction Control Lever, H6.00-7.00XL (H135-155XL)…75
Linkage For The Range Lever, S6.00-7.00XL (S135-155XL)…77
Linkage For The Direction Control Lever S6.00-7.00XL (S135-155XL)…78
CHECK THE OIL PRESSURE FOR THE TRANSMISSION…78
System Pressure Check Port…78
Torque Converter Check Port…78
Clutch Pressure Check Port…79
Inching Pressure…79
Solenoid Check Ports (MONOTROL Control Only)…79
Lubrication Pressure Check Ports…79
SPECIFICATIONS…80
TROUBLESHOOTING…80
1300344…85
INTRODUCTION…85
GENERAL…85
DESCRIPTION…85
OPERATION…86
REPAIRS…86
REMOVAL…86
DISASSEMBLY…86
CLEANING AND INSPECTION…87
ASSEMBLY…87
INSTALLATION…89
CHECKS AND ADJUSTMENTS…89
ADJUST THE DIRECTION CONTROL LINKAGE…89
130061…90
INTRODUCTION…90
GENERAL…90
DESCRIPTION…90
Oil Clutch Assembly, H6.00-7.00XL (H135-155XL)…90
Manual Transmission…92
REPAIRS…92
OIL CLUTCH ASSEMBLY…92
Removal and Disassembly…92
Cleaning…92
Inspection…92
Assembly and Installation…93
TRANSMISSION…93
Removal, H6.00-7.00XL (H135-155XL)…93
Disassembly…94
Cleaning…96
Inspection…96
Assembly…97
Installation, H6.00-7.00XL (H135-155XL)…101
CHECKS AND ADJUSTMENTS…102
ADJUSTING THE CLUTCH PEDAL LINKAGE, H6.00-7.00XL (H135-155XL)…102
TROUBLESHOOTING-OIL CLUTCH ASSEMBLY…103
TROUBLESHOOTING-MANUAL TRANSMISSION…105
1400046…107
DIFFERENTIAL…107
GENERAL…107
DESCRIPTION…107
REPAIRS…108
REMOVAL…108
DISASSEMBLY…108
ASSEMBLY…108
Assemble The Pinion, Bearings And Pinion Carrier…108
Adjust Preload For Pinion Bearings…108
Adjust Thickness Of Shim Set For The Pinion Carrier (Depth Of Pinion)…109
Assemble The Differential And Ring Gear…111
Assemble Differential Pinion And Side Gear Assembly…112
Check The Rotating Torque Of Differential Gears…113
Install The Differential And Ring Gear Assembly…114
Adjust Preload Of The Differential Bearings…115
Check Runout Of Ring Gear…115
Adjust The Gear Clearance…115
Check Tooth Contact Pattern Of The Gear Set…116
Installation Into The Axle Housing…116
SPECIFICATIONS…119
TABLE 1. GENERAL SPECIFICATIONS…119
TABLE 2. RIVET INSTALLATION PRESSURE…119
TABLE 3. PINION PRELOAD PRESSURE…119
TABLE 4. PINION ADJUSTMENT…119
TABLE 5. TORQUE SPECIFICATIONS…120
TABLE 6. TORQUE SPECIFICATIONS FOR METRIC HARDWARE…121
TROUBLESHOOTING…122
140049…124
INTRODUCTION…124
GENERAL…124
DESCRIPTION…124
REPAIRS…124
DISASSEMBLY…125
CLEANING…127
ASSEMBLY…127
TROUBLESHOOTING…129
1552002-0600SRM1070-(06-2007)-US-EN…130
toc…130
Perkins Diesel Engines…130
Safety Precautions Maintenance and Repair…131
General…138
General Safety Rules…138
Description…139
Engine Serial Number Codes…141
Engine Data…141
Engine Removal and Installation…142
Cylinder Head Assembly Repair…143
Engine Breather…143
Remove…143
Install…143
Valve Cover…144
Remove…144
Install…144
Rocker Arm Assembly…145
Remove…145
Disassemble…145
Inspect…145
Assemble…146
Install…146
Valve Clearance Adjustments…147
Valve Springs…147
Cylinder Head Assembly…149
Remove…149
Inspect…150
Install…150
Valves and Valve Springs…152
Remove…152
Inspect…152
Install…153
Valve Guides…153
Inspect…153
Remove…154
Install…154
Valve Seats…155
Inspect…155
Repair…155
New Valve Seats, Install…156
Piston and Connecting Rod Assemblies Repair…157
General…157
Rod Bearings…157
Remove…157
Install…158
Piston and Connecting Rod Assembly…159
Service Note…159
Remove…159
Disassemble…159
Inspect…159
How to Select Correct Replacements…161
Assemble…161
Install…162
Piston Cooling Jets…164
Remove…164
Install…164
Crankshaft Assembly Repair…165
General…165
Crankshaft Pulley…165
Remove…165
Inspect…165
Install…165
Rear Oil Seal…166
Remove…166
Install…166
Crankshaft Flange Wear Sleeve…168
Remove…168
Install…168
Main Bearings…169
Remove…169
Inspect…169
Install…169
Thrust Washers…170
Crankshaft Axle Movement, Check…170
Remove…171
Install…171
Crankshaft…172
Remove…172
Inspect…172
Install…173
Crankshaft Timing Ring…174
Remove…174
Install…175
Flywheel…175
Remove…175
Ring Gear, Replace…175
Install…175
Flywheel Housing…176
Remove…176
Install…176
Timing Case and Timing Gears Repair…177
General…177
Timing Case Cover…177
Remove…177
Install…177
Front Oil Seal…178
Remove, With Timing Case Installed…178
Install, With Timing Case Installed…179
Remove, With Timing Case Removed…180
Install, With Timing Case Removed…180
Crankshaft Pulley Wear Sleeve, Install…180
Fuel Pump Gear…181
Remove…181
Install…182
Idler Gear and Hub…183
Remove…183
Disassemble…184
Standard Idler Gear and Hub Assembly…184
Heavy Duty Idler Gear and Hub Assembly…184
Assemble…185
Standard Idler Gear and Hub Assembly…185
Heavy Duty Idler Gear and Hub Assembly…185
Install…186
Camshaft Gear…186
Remove…186
Install…187
Crankshaft Gear…187
Remove…187
Install…187
Timing Case…188
Remove…188
Install…189
Power Take-Off (PTO) Adaptor…190
Remove…190
Disassemble…190
Assemble…191
Install…191
Camshaft and Tappets…191
Remove…191
Install…191
Cylinder Block Assembly Repair…192
General…192
Cylinder Block…192
Disassemble…192
Inspect…193
Assemble…193
Cylinder Bore…193
Inspect…193
Cylinder Liner Condition Check…193
Engine Timing…194
General…194
How to Set Number One Piston to TDC on Compression Stroke…194
Fuel Injection Pump Timing, Check…195
Fuel Injection Pump Timing, Adjust…196
Lubrication System Repair…198
General…198
Oil Filter, Replace…198
Oil Filter Head…199
Remove…199
Install…199
Oil Sump…199
Remove…199
Install…200
Oil Pump…201
Remove…201
Inspect…201
Install…201
Oil Strainer and Suction Pipe…202
Remove…202
Install…202
Relief Valve…203
Remove…203
Install…203
Dipstick Tube…203
Remove and Install…203
Fuel System Repair…204
General…204
Cold Start Advance Unit (KSB)…204
Typical Fuel System…205
Fuel Filter…207
Remove…207
Install…207
Fuel Injectors…208
Remove…208
Install…209
Fuel System Air Removal…210
Bosch EVPE Fuel Injection Pump…210
General…210
Remove…211
Install…212
Cooling System Repair…212
General…212
Thermostat…214
Remove…214
Install…214
Test…214
Coolant Pump…215
Remove…215
Disassemble…215
Assemble…216
Install…217
Fan…218
Remove and Install…218
Fan Drive…218
Remove…218
Install…218
Oil Cooler…218
Remove…218
Disassemble and Assemble…219
Install…219
Coolant Bypass Hose…219
Removal…219
Install…219
Electrical Equipment Repair…220
Drive Belt…220
Check…220
Adjust…220
Remove…220
Install…220
Alternator…221
Remove…221
Install…221
Fault Diagnosis…221
Normal Operation:…221
If the Warning Lamp is Not Illuminated When the Ignition Switch …222
If the Warning Light Continues to be Illuminated When the Altern…222
Starter Motor…223
Remove…223
Install…223
Test…223
Starting Aid…223
Remove…223
Install…224
Check…224
Power Supply Continuity…224
Operation…224
Pressure Sensor…225
Remove…225
Install…226
Temperature Sensor…226
Remove…226
Install…227
Engine Specifications…227
Cylinder Head Assembly…227
Piston and Connecting Rods…230
Crankshaft Assembly…232
Crankshaft Overhaul…232
Timing Case and Drive Assembly…234
Engine Block Assembly…235
Lubrication System…235
Fuel System…236
Cooling System…237
Flywheel and Housing…238
Electrical Equipment…238
Torque Specifications…238
Special Torque Specifications…239
Cylinder Head Assembly…239
Piston and Connecting Rod Assemblies…239
Crankshaft Assembly…239
Timing Case and Drive Assembly…239
Cylinder block…239
Fuel System…239
Lubrication System…239
Cooling System…240
Flywheel and Housing…240
Electrical Equipment…240
Special Tools…241
Troubleshooting…245
tables…130
Table 1. Cylinder Head…227
Table 2. Valve Guides…228
Table 3. Inlet Valves…228
Table 4. Exhaust Valves…229
Table 5. Valve Springs…230
Table 6. Tappets…230
Table 7. Rocker Arm Shaft…230
Table 8. Rocker Arms and Bushings…230
Table 9. Pistons…230
Table 10. Piston Rings…230
Table 11. Piston Pins…231
Table 12. Connecting Rods…231
Table 13. Small End Bushings…231
Table 14. Connecting Rod Bearings…231
Table 15. Piston Cooling Jets…232
Table 16. Crankshaft Overhaul Specifications…232
Table 17. Maximum Variation (Run-out)…233
Table 18. Camshaft…234
Table 19. Camshaft Thrust Washer…234
Table 20. Camshaft Gear…234
Table 21. Gear for Fuel Pump…234
Table 22. Crankshaft Gear…234
Table 23. Idler Gear and Hub…234
Table 24. Timing Gear Backlash Values…235
Table 25. Cylinder Block…235
Table 26. Oil Pump…235
Table 27. Idler Gear for Oil Pump…235
Table 28. Relief Valve…236
Table 29. Oil Filter…236
Table 30. Bosch Fuel Injection Pump…236
Table 31. Fuel Injector Settings…236
Table 32. Fuel Pump…237
Table 33. Fuel Filter…237
Table 34. Coolant Pump…237
Table 35. Thermostat…237
Table 36. Fan Drive Housing…237
Table 37. Limits for Flywheel Run Out and Alignment (Total Indic…238
Table 38. Alternator…238
Table 39. Starter Motor…238
Table 40. Starting Aids…238
Table 41. List of Possible Causes…246
1559540-0900SRM1088-(05-2006)-US-EN…250
toc…250
Electronic Controlled LPG/Gasoline Fuel System…250
Safety Precautions Maintenance and Repair…251
General…256
Fuel System Warnings and Cautions…256
Glossary…257
Description and Operation of LPG Fuel System…261
Propane Fuel System…261
LPG Fuel Tank…263
Service Line…263
Fuel Filter…263
Low Pressure Lock-Off (LPL)…264
Low Pressure Regulator (LPR)…264
Air Fuel Mixer…264
Throttle Control Device…265
Drive By Cable…265
Three-Way Catalytic (TWC) Muffler…266
Electronic Control Module (ECM)…266
Heated Exhaust Gas Oxygen (HEGO) Sensor…269
Description and Operation of Gasoline Fuel System…269
Gasoline Fuel System Throttle Body Injection (TBI), 3.0L Engine …269
Gasoline Multi-Point Fuel Injection (MPFI) System, 4.3L Only…271
Gasoline Fuel Storage Tank…271
Gasoline Fuel Pump…271
Fuel Filter…271
Fuel Pressure Regulator, 3.0L Only…273
Fuel Rail and Pressure Regulator, 4.3L Only…273
Fuel Injector…273
Throttle Control Device…273
Drive By Cable…273
Three-Way Catalytic Muffler…274
Electronic Control Module (ECM)…275
Heated Exhaust Gas Oxygen (HEGO) Sensor…276
LPG Fuel System Repair…277
Propane Fuel System Pressure Relief…277
Propane Fuel System Leak Test…277
Propane Fuel Filter Replacement…277
Remove…277
Install…278
Low Pressure Lock-Off (LPL) Replacement…278
Remove…278
Install…278
Pressure Trim Valve (PTV) Replacement…280
Remove…280
Install…280
Low Pressure Regulator…280
Remove…280
Install…280
Fuel Trim Valve (FTV) Solenoid Replacement…281
Remove…281
Install…281
Temperature Manifold Absolute Pressure (TMAP)…284
Remove…284
Install…284
Throttle Body Replacement…284
Remove…284
Install…285
Mixer Replacement…285
Remove…285
Install…285
Coolant Hose Replacement…285
Remove…285
Install…286
Vapor Hose Replacement…286
Remove…286
Install…286
Balance Line Hose Replacement…286
Remove…286
Install…286
PTV Hose Replacement…286
Remove…286
Install…286
FTV Hose Replacement…287
Remove…287
Install…287
Throttle Position Sensor (TPS) Replacement…287
Foot Pedal Position (FPP) Sensor Replacement…289
Electronic Control Module (ECM) Replacement…292
Remove…292
Install…292
Heated Exhaust Gas Oxygen (HEGO) Sensor Replacement…293
Remove…293
Install…293
Three-Way Catalytic Muffler (TWC) Replacement…293
Remove…293
Install…293
Restricted Exhaust System Diagnosis…293
Exhaust System Description…293
Tools Required…293
Diagnostic Tool…293
Check at Heated Exhaust Gas Oxygen Sensor (HEGO)…294
Gasoline Fuel System Repair…294
Gasoline MPFI and TBI Fuel System Pressure Relief…294
Gasoline Fuel System Leak Test…295
Throttle Body Injector (TBI) Assembly Replacement, 3.0L Only…295
Remove…295
Install…295
Throttle Body Assembly Replacement, 3.0L Only…297
Remove…297
Install…297
Throttle Body Assembly Replacement, 4.3L Only…297
Remove…297
Install…298
Fuel Rail Replacement, Gasoline 4.3L Only…300
Remove…300
Install…300
Injector Replacement, Gasoline 4.3L Only…300
Remove…300
Install…300
Injector Replacement, Gasoline 3.0L Only…301
Remove…301
Install…301
Temperature Manifold Absolute Pressure (TMAP) Replacement…301
Remove…301
Install…301
Throttle Position Sensor (TPS) Replacement…301
Foot Pedal Position (FPP) Sensor Replacement…304
Electronic Control Module (ECM) Replacement…307
Remove…307
Install…307
Heated Exhaust Gas Oxygen (HEGO) Sensor Replacement…307
Remove…307
Install…308
Three-Way Catalytic Muffler (TWC) Replacement…308
Remove…308
Install…308
Restricted Exhaust System Diagnosis…308
Exhaust System Description…308
Tools Required…308
Diagnostic Tool…308
Check at Heated Exhaust Gas Oxygen Sensor (HEGO)…308
LPG System Diagnosis…309
Fuel System Description…309
Diagnostic Aids…310
Tools Required…310
Duty Cycle Monitoring Tool…310
Diagnostic Tool…310
Pressure Gauges…310
Test Description…310
Gasoline System Diagnosis…318
Fuel System Description, 3.0L Only…318
Fuel System Description, 4.3L Only…318
Diagnostic Aids…319
Tools Required…319
Diagnostic Tool…319
Test Description…319
LPG Symptom Diagnosis…326
Gasoline Symptom Diagnosis…340
Wire Harness Repair…350
On Vehicle Service Wiring Harness Repair…350
Connectors and Terminals…351
Twisted/Shielded Cable Repair…351
Twisted Leads Repair…352
Micro-Pack…353
Metri-Pack…354
Remove…354
Weather-Pack…355
Weather-Pack Terminal Repair…356
tables…250
Table 1. TPS Replacement Procedure…287
Table 2. FPP Replacement Procedure…290
Table 3. TPS Replacement Procedure…302
Table 4. FPP Replacement Procedure…305
Table 5. LPG Fuel System Diagnosis…310
Table 6. Fuel Control Diagnosis…314
Table 7. Gasoline Fuel System Diagnosis, 3.0L Only…320
Table 8. Gasoline Fuel System Diagnosis, 4.3L Only…323
Table 9. Preliminary Checks…326
Table 10. Intermittent …328
Table 11. No Start…329
Table 12. Hard Start…331
Table 13. Cuts Out or Misses…332
Table 14. Hesitation, Sag, or Stumble…333
Table 15. Backfire…334
Table 16. Lack of Power, Sluggishness, or Sponginess…335
Table 17. Poor Fuel Economy…336
Table 18. Rough, Unstable, Incorrect Idle, or Stalling…337
Table 19. Surges or Chuggles…339
Table 20. Preliminary Checks…340
Table 21. Intermittent…341
Table 22. No Start…342
Table 23. Hard Start…343
Table 24. Cuts Out or Misses…344
Table 25. Hesitation, Sag, or Stumble…345
Table 26. Backfire…346
Table 27. Lack of Power, Sluggishness, or Sponginess…347
Table 28. Poor Fuel Economy…348
Table 29. Rough, Unstable, Incorrect Idle, or Stalling…349
Table 30. Surges or Chuggles…350
1559545-2200SRM1090-(04-2005)-US-EN…360
toc…360
Electronic Control Module (ECM) Diagnostic Troubleshooting…360
Safety Precautions Maintenance and Repair…361
General…370
Description of ECM Based Diagnostics…370
Definition of Terms…370
Diagnostics Overview of the Spectrum Fuel System…370
Malfunction Indicator Lamp (MIL)…371
Spectrum Diagnostic Trouble Codes (DTC)…371
Using a Laptop Computer to Diagnose the Spectrum System…371
Installing the Spectrum Diagnostic Software…372
Connecting a Laptop Computer to the Spectrum System…372
Diagnostic Communication Error…372
Diagnostic Trouble Codes…373
Checking Diagnostic Trouble Codes…373
Clearing Diagnostic Trouble Codes…373
DATA Stream…374
Reading Sensor and Actuator Values…374
Graphing and Data Logging…375
Ignition System Test…376
Disabling Ignition Outputs…376
Injector Test…377
Disabling Injectors…377
Throttle Test…377
Using a Diagnostic Jumper to Diagnose the ECI System…378
On-Board Diagnostics System Check/Malfunction Indicator Lamp…379
Circuit Description…379
Preliminary and Intermittent Checks…382
GM 3.0L Wiring Schematics and Connectors…384
GM 3.0L Diagnostic Trouble Codes…398
DTC 111 – IAT High Voltage Motorola® TMAP…398
Circuit Description…398
Conditions for Setting the DTC…398
DTC 112 – IAT Low Voltage Motorola® TMAP…401
Circuit Description…401
Conditions for Setting the DTC…401
DTC 113 – IAT Higher Than Expected 1 Motorola® TMAP…403
Circuit Description…403
Conditions for Setting the DTC…403
Diagnostic Aids…404
DTC 114 – IAT Higher Than Expected 2 Motorola® TMAP…405
Circuit Description…405
Conditions for Setting the DTC…405
Diagnostic Aids…405
DTC 115 – Oil Pressure Low…406
Circuit Description…406
Conditions for Setting the DTC…406
DTC 121 – ECT Voltage High…409
Circuit Description…409
Conditions for Setting the DTC…410
DTC 122 – ECT Voltage Low…413
Circuit Description…413
Conditions for Setting the DTC…413
DTC 123 – ECT Higher Than Expected 1…415
Circuit Description…415
Conditions for Setting the DTC…415
DTC 124 – ECT Higher Than Expected 2…417
Circuit Description…417
Conditions for Setting the DTC…417
DTC 131 – MAP High Pressure Motorola® TMAP…419
Circuit Description…419
Conditions for Setting the DTC…419
Diagnostic Aids…419
DTC 132 – MAP Low Voltage Motorola® TMAP…422
Circuit Description…422
Conditions for Setting the DTC…422
DTC 134 – BP High Pressure Motorola® TMAP…426
Circuit Description…426
Conditions for Setting the DTC…426
DTC 135 – BP Low Pressure Motorola® TMAP…427
Circuit Description…427
Conditions for Setting the DTC…427
DTC 142 – Crank Sync Noise…431
Circuit Description…431
Conditions for setting the DTC…431
DTC 143 – Never Crank Synced At Start…435
Circuit Description…435
Conditions for Setting the DTC…435
DTC 144 – Camshaft Sensor Loss…438
Circuit Description…438
Conditions for Setting the DTC…438
DTC 145 – Camshaft Sensor Noise…441
Circuit Description…441
Conditions for Setting the DTC…441
DTC 211 – Closed Loop Multiplier High (LPG)…444
Circuit Description…444
Conditions for Setting the DTC…444
Diagnostic Aids…444
DTC 212 – HO 2 S Open/Inactive…447
Circuit Description…447
Conditions for Setting the DTC…447
DTC 221 – Closed Loop Multiplier High (Gasoline)…449
Circuit Description…449
Conditions for Setting the DTC…449
Diagnostic Aids…450
DTC 222 – Closed Loop Multiplier Low (Gasoline)…453
Circuit Description…453
Conditions for Setting the DTC…453
Diagnostic Aids…453
DTC 224 – Closed Loop Multiplier Low (LPG)…455
Circuit Description…455
Conditions for Setting the DTC…455
Diagnostic Aids…455
DTC 241 – Adaptive Lean Fault (High Limit-Gasoline)…457
Circuit Description…457
Conditions for Setting the DTC…457
Diagnostic Aids…457
DTC 242 – Adaptive Rich Fault (Low Limit-Gasoline)…460
Circuit Description…460
Conditions for Setting the DTC…460
Diagnostic Aids…460
DTC 243 – Adaptive Learn High (LPG)…463
Circuit Description…463
Conditions for Setting the DTC…463
Diagnostic Aids…463
DTC 244 – Adaptive Learn Low (LPG)…466
Circuit Description…466
Conditions for Setting the DTC…466
Diagnostic Aids…466
DTC 261 – System Voltage High…469
Circuit Description…469
Conditions for Setting the DTC…469
DTC 262 – System Voltage Low…471
Circuit Description…471
Conditions for Setting the DTC…471
DTC 411 – Injector Driver 1 Open…473
Circuit Description…473
Conditions for Setting the DTC…473
DTC 412 – Injector Driver 1 Shorted…476
Circuit Description…476
Conditions for Setting the DTC…476
DTC 511 – COP Failure…479
Circuit Description…479
Conditions for Setting the DTC…479
DTC 512 – Invalid Interrupt…481
Circuit Description…481
Conditions for Setting the DTC…481
DTC 513 – A/D Loss…483
Circuit Description…483
Conditions for Setting the DTC…483
DTC 514 – RTI 1 Loss…485
Circuit Description…485
Conditions for Setting the DTC…485
DTC 515 – Flash Checksum Invalid…487
Circuit Description…487
Conditions for Setting the DTC…487
DTC 516 – Ram Failure…489
Circuit Description…489
Conditions for Setting the DTC…489
DTC 531 – External 5V Ref Lower Than Expected…491
Circuit Description…491
Conditions for Setting the DTC…491
DTC 532 – External 5V Ref Higher Than Expected…493
Circuit Description…493
Conditions for Setting the DTC…493
DTC 555 – RTI 2 Loss…495
Circuit Description…495
Conditions for Setting the DTC…495
DTC 556 – RTI 3 Loss…497
Circuit Description…497
Conditions for Setting the DTC…497
DTC 611 – FPP High Voltage…499
Circuit Description…499
Conditions for Setting the DTC…499
DTC 612 – FPP Low Voltage…503
Circuit Description…503
Conditions for Setting the DTC…503
DTC 631 – TPS1 Signal Voltage High…507
Circuit Description…507
Conditions for Setting the DTC…507
DTC 632 – TPS1 Signal Voltage Low…510
Circuit Description…510
Conditions for Setting the DTC…510
DTC 638 – Throttle Unable To Close…513
Circuit Description…513
Conditions for Setting the DTC…513
Diagnostic Aids…514
DTC 651 – Maximum Govern Speed Override…516
Circuit Description…516
Conditions for Setting the DTC…516
Diagnostic Aids…516
DTC 652 – Fuel Rev Limit…519
Circuit Description…519
Conditions for Setting the DTC…519
Diagnostic Aids…519
DTC 653 – Spark Rev Limit…521
Circuit Description…521
Conditions for Setting the DTC…521
Diagnostic Aids…521
GM 4.3L Wiring Schematics and Connectors…525
GM 4.3L Diagnostic Trouble Codes…542
DTC 111 – IAT High Voltage Bosch® TMAP…542
Circuit Description…542
Conditions for Setting the DTC…542
DTC 111 – IAT High Voltage Motorola® TMAP…545
Circuit Description…545
Conditions for Setting the DTC…545
DTC 112 – IAT Low Voltage Bosch® TMap…547
Circuit Description…547
Conditions for Setting the DTC…548
DTC 112 – IAT Low Voltage Motorola® TMAP…550
Circuit Description…550
Conditions for Setting the DTC…550
DTC 113 – IAT Higher Than Expected 1 Bosch® TMAP…553
Circuit Description…553
Conditions for Setting the DTC…553
Diagnostic Aids…553
DTC 113 – IAT Higher Than Expected 1 Motorola® TMAP…554
Circuit Description…554
Conditions for Setting the DTC…554
Diagnostic Aids…554
DTC 114 – IAT Higher Than Expected 2 Bosch® TMAP€…555
Circuit Description…555
Conditions for Setting the DTC…555
Diagnostic Aids…555
DTC 114 – IAT Higher Than Expected 2 Motorola® TMAP…556
Circuit Description…556
Conditions for Setting the DTC…556
Diagnostic Aids…556
DTC 115 – Oil Pressure Low…557
Circuit Description…557
Conditions for Setting the DTC…557
DTC 121 – ECT Voltage High…559
Circuit Description…559
Conditions for Setting the DTC…560
DTC 122 – ECT Voltage Low…563
Circuit Description…563
Conditions for Setting the DTC…563
DTC 123 – ECT Higher Than Expected 1…566
Circuit Description…566
Conditions for Setting the DTC…566
DTC 124 – ECT Higher Than Expected 2…568
Circuit Description…568
Conditions for Setting the DTC…568
DTC 131 – MAP High Pressure Bosch® TMAP…569
Circuit Description…569
Conditions for Setting the DTC…569
Diagnostic Aids…569
DTC 131 – MAP High Pressure Motorola® TMAP…573
Circuit Description…573
Conditions for Setting the DTC…573
Diagnostic Aids…573
DTC 132 – MAP Low Voltage Bosch® TMAP…576
Circuit Description…576
Conditions for Setting the DTC…576
DTC 132 – MAP Low Voltage Motorola® TMAP…579
Circuit Description…579
Conditions for Setting the DTC…579
DTC 134 – BP High Pressure Bosch® TMAP…584
Circuit Description…584
Conditions for Setting the DTC…584
DTC 134 – BP High Pressure Motorola® TMAP…586
Circuit Description…586
Conditions for Setting the DTC…586
DTC 135 – BP Low Pressure Bosch® TMAP…588
Circuit Description…588
Conditions for Setting the DTC…588
DTC 135 – BP Low Pressure Motorola® TMAP…592
Circuit Description…592
Conditions for Setting the DTC…592
DTC 142 – Crank Sync Noise…595
Circuit Description…595
Conditions for setting the DTC…595
DTC 143 – Never Crank Synced At Start…599
Circuit Description…599
Conditions for Setting the DTC…599
DTC 144 – Camshaft Sensor Loss…602
Circuit Description…602
Conditions for Setting the DTC…602
DTC 145 – Camshaft Sensor Noise…605
Circuit Description…605
Conditions for Setting the DTC…605
DTC 211 – Closed Loop Multiplier High (LPG)…608
Circuit Description…608
Conditions for Setting the DTC…608
Diagnostic Aids…609
DTC 212 – HO 2 S Open/Inactive…611
Circuit Description…611
Conditions for Setting the DTC…611
DTC 221 – Closed Loop Multiplier High (Gasoline)…614
Circuit Description…614
Conditions for Setting the DTC…614
Diagnostic Aids…614
DTC 222 – Closed Loop Multiplier Low (Gasoline)…617
Circuit Description…617
Conditions for Setting the DTC…617
Diagnostic Aids…617
DTC 224 – Closed Loop Multiplier Low (LPG)…619
Circuit Description…619
Conditions for Setting the DTC…619
Diagnostic Aids…620
DTC 241 – Adaptive Lean Fault (High Limit-Gasoline)…621
Circuit Description…621
Conditions for Setting the DTC…621
Diagnostic Aids…621
DTC 242 – Adaptive Rich Fault (Low Limit-Gasoline)…624
Circuit Description…624
Conditions for Setting the DTC…624
Diagnostic Aids…624
DTC 243 – Adaptive Learn High (LPG)…627
Circuit Description…627
Conditions for Setting the DTC…627
Diagnostic Aids…627
DTC 244 – Adaptive Learn Low (LPG)…630
Circuit Description…630
Conditions for Setting the DTC…630
Diagnostic Aids…630
DTC 261 – System Voltage High…633
Circuit Description…633
Conditions for Setting the DTC…633
DTC 262 – System Voltage Low…635
Circuit Description…635
Conditions for Setting the DTC…635
DTC 511 – COP Failure…637
Circuit Description…637
Conditions for Setting the DTC…637
DTC 512 – Invalid Interrupt…639
Circuit Description…639
Conditions for Setting the DTC…639
DTC 513 – A/D Loss…641
Circuit Description…641
Conditions for Setting the DTC…641
DTC 514 – RTI 1 Loss…643
Circuit Description…643
Conditions for Setting the DTC…643
DTC 515 – Flash Checksum Invalid…645
Circuit Description…645
Conditions for Setting the DTC…645
DTC 516 – Ram Failure…647
Circuit Description…647
Conditions for Setting the DTC…647
DTC 531 – External 5V Ref Lower Than Expected…649
Circuit Description…649
Conditions for Setting the DTC…649
DTC 532 – External 5V Ref Higher Than Expected…651
Circuit Description…651
Conditions for Setting the DTC…651
DTC 555 – RTI 2 Loss…653
Circuit Description…653
Conditions for Setting the DTC…653
DTC 556 – RTI 3 Loss…655
Circuit Description…655
Conditions for Setting the DTC…655
DTC 611 – FPP High Voltage…657
Circuit Description…657
Conditions for Setting the DTC…657
DTC 612 – FPP Low Voltage…661
Circuit Description…661
Conditions for Setting the DTC…661
DTC 631 – TPS1 Signal Voltage High…665
Circuit Description…665
Conditions for Setting the DTC…665
DTC 632 – TPS1 Signal Voltage Low…668
Circuit Description…668
Conditions for Setting the DTC…668
DTC 638 – Throttle Unable To Close…671
Circuit Description…671
Conditions for Setting the DTC…671
Diagnostic Aids…672
DTC 651 – Maximum Govern Speed Override…674
Circuit Description…674
Conditions for Setting the DTC…674
Diagnostic Aids…674
DTC 652 – Fuel Rev Limit…677
Circuit Description…677
Conditions for Setting the DTC…677
Diagnostic Aids…677
DTC 653 – Spark Rev Limit…679
Circuit Description…679
Conditions for Setting the DTC…679
Diagnostic Aids…679
Wire Harness Repair…682
On Vehicle Service Wiring Harness Repair…682
Connectors and Terminals…683
Twisted/Shielded Cable Repair…683
Twisted Leads Repair…684
Micro-Pack…685
Metri-Pack…685
Remove…685
Weather-Pack…687
Weather-Pack Terminal Repair…688
tables…360
Table 1. OBD System Check…380
Table 2. Preliminary Checks…382
Table 3. Intermittent Checks…383
Table 4. Communication Port C002…384
Table 5. Coil Connector C003…384
Table 6. Fuel System Interface C004…384
Table 7. Oil Pressure Connector C005…385
Table 8. Distributor Connector C006…385
Table 9. Magnetic Pickup Connector C007…385
Table 10. Heated Oxygen Sensor C008…385
Table 11. Throttle Position Sensor Connector C009…386
Table 12. Foot Pedal Position Connector C010…386
Table 13. Governor Motor Connector C011…386
Table 14. TMAP Connector C012…386
Table 15. Starter Solenoid C013…387
Table 16. Engine Coolant Temperature C014…387
Table 17. Battery Connector C015…387
Table 18. Alternator Connection C016…387
Table 19. Battery Connector C017…387
Table 20. Alternator Connector C018…388
Table 21. Instrument Panel Connector C019…388
Table 22. Instrument Panel Connector C020…388
Table 23. Instrument Panel Connector C021…389
Table 24. Fuel Trim Valve Connector C022…389
Table 25. Fuel Lockoff Connector C023…389
Table 26. Pressure Trim Valve Connector C024…390
Table 27. Throttle Body Injector Connector C025…390
Table 28. Relay and Fuse Center…390
Table 29. DTC 111 – IAT Voltage High (Motorola® TMAP)…399
Table 30. DTC 112 – IAT Low Voltage (Motorola® TMAP)…402
Table 31. DTC 115 – Oil Pressure Low…407
Table 32. Temperature Resistance…409
Table 33. DTC 121 – ECT VOLTAGE HIGH…410
Table 34. DTC 122 – ECT Voltage Low…414
Table 35. DTC 123 – ECT Higher Than Expected 1…416
Table 36. DTC 124 – ECT Higher Than Expected 2…418
Table 37. DTC 131 – MAP HIGH PRESSURE (Motorola® TMAP)…420
Table 38. DTC 132 – MAP Low Voltage (Motorola® TMAP)…423
Table 39. DTC 134 – BP High Pressure (Motorola® TMAP)…426
Table 40. DTC 135 – BP Low Pressure (Motorola® TMAP)…428
Table 41. DTC 142 – Crank Sync Noise…432
Table 42. DTC 143 – Never Crank Synced At Start…435
Table 43. DTC 144 – Camshaft Sensor Loss…438
Table 44. DTC 145 – Camshaft Sensor Noise…441
Table 45. DTC 211 – Closed Loop Multiplier High (LPG)…445
Table 46. DTC 212 – HO 2 S Open/Inactive…448
Table 47. DTC 221 – Closed Loop Multiplier High (Gasoline)…451
Table 48. DTC 222 – Closed Loop Multiplier Low (Gasoline)…454
Table 49. DTC 224 – Closed Loop Multiplier Low (LPG)…456
Table 50. DTC 241 – Adaptive Lean Fault (High Limit-Gasoline)…458
Table 51. DTC 242 – Adaptive Rich Fault (Low Limit-Gasoline)…461
Table 52. DTC 243 – Adaptive Learn High (LPG)…464
Table 53. DTC 244 – Adaptive Learn Low (LPG)…467
Table 54. DTC 261 – System Voltage High…470
Table 55. DTC 262 – System Voltage Low…471
Table 56. DTC 411 – Injector Driver 1 Open…474
Table 57. DTC 412 – Injector Driver 1 Shorted…477
Table 58. DTC 511 – COP Failure…480
Table 59. DTC 512 – Invalid Interrupt…482
Table 60. DTC 513 – A/D Loss…484
Table 61. DTC 514 – RTI 1 Loss…486
Table 62. DTC 515 – Flash Checksum Invalid…488
Table 63. DTC 516 – Ram Failure…490
Table 64. DTC 531 – External 5V Ref Lower Than Expected…492
Table 65. DTC 532 – External 5 V Ref Higher Than Expected…494
Table 66. DTC 555 – RTI 2 Loss…496
Table 67. DTC 556 – RTI 3 Loss…498
Table 68. DTC 611 – FPP High Voltage…500
Table 69. DTC 612 – FPP Low Voltage…504
Table 70. DTC 631 – TPS1 Signal Voltage High…508
Table 71. DTC 632 – TPS1 Signal Voltage Low…511
Table 72. DTC 638 – Throttle Unable To Close…514
Table 73. DTC 651 – Maximum Govern Speed Override…517
Table 74. DTC 652 – Fuel Rev Limit…520
Table 75. DTC 653 – Spark Rev Limit…522
Table 76. Communication Port C002…525
Table 77. Injector Connector C003…525
Table 78. Injector Connector C004…525
Table 79. Oil Pressure Connector C005…526
Table 80. Throttle Position Sensor 1 Connector C006…526
Table 81. Foot Pedal Position Connector C006A…526
Table 82. Coil Connector C007…526
Table 83. Module Connector C008…527
Table 84. Crank Sensor Connector C009…527
Table 85. EGO Sensor Connector C010…527
Table 86. Cam Connector C011…528
Table 87. Throttle Connector C012…528
Table 88. Bosch TMAP Connector C013 (Gasoline Fuel System Only)…528
Table 89. Motorola TMAP Connector C013 (LPG Fuel System Only)…529
Table 90. Starter Solenoid Connector C014…529
Table 91. ECT Connector C015…529
Table 92. Starter Relay C016…529
Table 93. Power Relay C017…529
Table 94. Fuel Pump Relay C018…529
Table 95. Battery Connector C019…530
Table 96. Alternator Connector C020…530
Table 97. Alternator Connector C021…530
Table 98. Instrument Panel Connector C022…530
Table 99. Instrument Panel Connector C023…531
Table 100. Instrument Panel Connector C024…531
Table 101. Fuel Trim Valve Connector C025…531
Table 102. Fuel Lockoff Connector C026…532
Table 103. Pressure Trim Valve Connector C027…532
Table 104. Injector 1 Connector C028…532
Table 105. Injector 2 Connector C029…533
Table 106. Injector 3 Connector C030…533
Table 107. Injector 4 Connector C031…533
Table 108. Injector 5 Connector C032…534
Table 109. Injector 6 Connector C033…534
Table 110. Relay and Fuse Center…534
Table 111. DTC 111 – IAT Voltage High (Bosch® TMAP)…543
Table 112. DTC 111 – IAT Voltage High (Motorola® TMAP)…546
Table 113. DTC 112 – IAT Low Voltage (Bosch® TMAP)…548
Table 114. DTC 112 – IAT Low Voltage (Motorola® TMAP)…551
Table 115. DTC 115 – Oil Pressure Low…557
Table 116. Temperature Resistance…560
Table 117. DTC 121 – ECT VOLTAGE HIGH…561
Table 118. DTC 122 – ECT Voltage Low…564
Table 119. DTC 123 – ECT Higher Than Expected 1…567
Table 120. DTC 124 – ECT Higher Than Expected 2…569
Table 121. DTC 131 – MAP High Pressure (Bosch® TMAP)…570
Table 122. DTC 131 – MAP HIGH PRESSURE (Motorola® TMAP)…574
Table 123. DTC 132 – MAP Low Voltage (Bosch® TMAP)…577
Table 124. DTC 132 – MAP Low Voltage (Motorola® TMAP)…580
Table 125. DTC 134 – BP High Pressure (Bosch® TMAP)…585
Table 126. DTC 134 – BP High Pressure (Motorola® TMAP)…587
Table 127. DTC 135 – BP Low Pressure (Bosch® TMAP)…588
Table 128. DTC 135 – BP Low Pressure (Motorola® TMAP)…592
Table 129. DTC 142 – Crank Sync Noise…596
Table 130. DTC 143 – Never Crank Synced At Start…599
Table 131. DTC 144 – Camshaft Sensor Loss…602
Table 132. DTC 145 – Camshaft Sensor Noise…605
Table 133. DTC 211 – Closed Loop Multiplier High (LPG)…609
Table 134. DTC 212 – HO 2 S Open/Inactive…612
Table 135. DTC 221 – Closed Loop Multiplier High (Gasoline)…615
Table 136. DTC 222 – Closed Loop Multiplier Low (Gasoline)…618
Table 137. DTC 224 – Closed Loop Multiplier Low (LPG)…620
Table 138. DTC 241 – Adaptive Lean Fault (High Limit-Gasoline)…622
Table 139. DTC 242 – Adaptive Rich Fault (Low Limit-Gasoline)…625
Table 140. DTC 243 – Adaptive Learn High (LPG)…628
Table 141. DTC 244 – Adaptive Learn Low (LPG)…631
Table 142. DTC 261 – System Voltage High…634
Table 143. DTC 262 – System Voltage Low…635
Table 144. DTC 511 – COP Failure…638
Table 145. DTC 512 – Invalid Interrupt…640
Table 146. DTC 513 – A/D Loss…642
Table 147. DTC 514 – RTI 1 Loss…644
Table 148. DTC 515 – Flash Checksum Invalid…646
Table 149. DTC 516 – Ram Failure…648
Table 150. DTC 531 – External 5V Ref Lower Than Expected…650
Table 151. DTC 532 – External 5 V Ref Higher Than Expected…652
Table 152. DTC 555 – RTI 2 Loss…654
Table 153. DTC 556 – RTI 3 Loss…656
Table 154. DTC 611 – FPP High Voltage…658
Table 155. DTC 612 – FPP Low Voltage…661
Table 156. DTC 631 – TPS1 Signal Voltage High…666
Table 157. DTC 632 – TPS1 Signal Voltage Low…669
Table 158. DTC 638 – Throttle Unable To Close…672
Table 159. DTC 651 – Maximum Govern Speed Override…675
Table 160. DTC 652 – Fuel Rev Limit…678
Table 161. DTC 653 – Spark Rev Limit…681
1559550-2200SRM1097-(07-2008)-US-EN…692
toc…692
High Voltage Switch (HVS) Ignition…692
Safety Precautions Maintenance and Repair…693
Description…696
Distributor Ignition (DI) System…696
Crankshaft Position (CKP) Sensor…696
Camshaft Position (CMP) Sensor…696
Ignition Coil and Ignition Control Module (ICM)…696
Secondary Ignition Components…696
Spark Plugs and Wires…696
Spark Plug Wire Inspection…696
Spark Plug Wire Replacement…696
Remove…696
Install…697
Spark Plug Inspection…697
Usage…697
Inspection…697
Visual Inspection…699
Spark Plug Replacement…699
Remove…699
Install…700
Distributor Repair…700
Inspect…700
Overhaul…701
Disassemble…701
Assemble…703
Replace…704
Remove…704
Install Procedure 1…706
Install Procedure 2…706
Ignition Coil Replacement…708
Remove…708
Install…708
Ignition Control Module Replacement…709
Remove…709
Install…709
Camshaft Position (CMP) Sensor Replacement…710
Remove…710
Install…711
Crankshaft Position (CKP) Sensor Replacement…712
Remove…712
Install…712
Wire Harness Repair…713
On Vehicle Service Wiring Harness Repair…713
Connectors and Terminals…713
Twisted/Shielded Cable Repair…714
Twisted Leads Repair…715
Micro-Pack…716
Metri-Pack…716
Remove…716
Weather-Pack…718
Weather-Pack Terminal Repair…718
Specifications and Special Tools…720
System Diagnosis…721
tables…692
Table 1. Ignition System Specifications…720
Table 2. Fastener Tightening Specifications…720
Table 3. Special Tools…721
Table 4. Distributor Ignition (DI)…721
1600326…730
STEERING AXLE…730
GENERAL…730
DESCRIPTION…730
REPAIRS…731
STEERING AXLE, H3.50-5.50XL (H70-110XL) and S3.50-5.50XL (S70-120XL), E3.50-5.50XL (E70-120XL, E70-120XL3)…731
Removal…731
Installation…731
STEERING AXLE, H6.00-7.00XL (H135-155XL) H8.00-16.00XL (H165-360L)…732
Removal…732
Installation…733
WHEELS AND HUBS, ALL UNITS…733
Removal and Disassembly…733
Cleaning…734
Assembly and Installation…734
SPINDLES AND BEARINGS, ALL UNITS…734
Removal…734
Cleaning…735
Assembly and Installation…735
TIE RODS, ALL UNITS…735
Removal…735
Cleaning…736
Installation…736
STEERING CYLINDER…737
Removal and Disassembly…737
Cleaning and Inspection…737
Assembly and Installation…737
TROUBLESHOOTING…738
160054…739
INTRODUCTION…739
GENERAL…739
DESCRIPTION…739
OPERATION…739
REPAIRS…739
STEERING WHEEL AND COLUMN ASSEMBLY…739
TYPE "A" STEERING COLUMN ASSEMBLY…741
Removal And Disassembly…741
Assembly And Installation…741
TYPE "A" STEERING COLUMN…742
TYPE "A" STEERING COLUMN…743
TYPE "B" STEERING COLUMN…744
Removal And Disassembly…744
Assembly And Installation…744
TYPE "B" STEERING COLUMN…745
Disassembly of Steering Control Unit…746
Cleaning of Steering Control Unit…746
Assembly of Steering Control Unit…748
CHECKS AND ADJUSTMENTS…751
REMOVE AIR FROM THE SYSTEM…751
TROUBLESHOOTING…752
1800327…753
INTRODUCTION…753
GENERAL…753
DESCRIPTION…753
OPERATION…753
BRAKE BOOSTER AND MASTER CYLINDER…753
SERVICE BRAKE ASSEMBLY…756
PARKING BRAKE…756
REPAIRS…757
BRAKE SHOE ASSEMBLIES…757
Removal And Disassembly…757
Cleaning And Inspection…757
Assembly And Installation…758
MASTER CYLINDER…760
Removal…760
Disassembly…760
Assembly…761
Installation…762
BRAKE BOOSTER…762
Removal…762
Disassembly…762
Cleaning and Inspection…762
Assembly…762
Installation…763
CHECKS AND ADJUSTMENTS…764
REMOVE AIR FROM THE BRAKE SYSTEM…764
ADJUST THE BRAKE PEDAL…764
ADJUST THE BRAKE SHOES…765
ADJUST THE PARKING BRAKE…765
ADJUST THE PARKING BRAKE SWITCH…765
CHECK THE RELIEF VALVE ON THE BRAKE BOOSTER…765
TROUBLESHOOTING…766
1900328…768
INTRODUCTION…768
GENERAL…768
DESCRIPTION AND OPERATION…768
Hydraulic pumps…768
Main Control Valve…769
Steering Control Unit…769
Brake Valve…769
Oil Clutch…769
TROUBLESHOOTING…771
190097…773
INTRODUCTION…773
DESCRIPTION…773
OPERATION…773
Flow Control Valve…775
Relief Valve…775
REPAIRS…776
REMOVAL…776
DISASSEMBLY…776
CLEANING…778
INSPECTION…778
ASSEMBLY…779
INSTALLATION…780
CHECKS AND ADUSTMENTS…781
CHECK THE OUTPUT OF THE PUMP…781
CHECK FOR AIR IN THE HYDRAULIC SYSTEM…781
TROUBLESHOOTING…783
190098…786
INTRODUCTION…786
GENERAL…786
DESCRIPTION…786
OPERATION…786
Pump…786
Relief Valve…787
REPAIRS…788
REMOVAL…788
DISASSEMBLY…788
ASSEMBLY…789
INSTALLATION…790
CHECKS AND ADJUSTMENTS…790
CHECKING THE RELIEF PRESSURE OF THE RELIEF VALVE…790
Lift Trucks With Internal Combustion Engines…790
Electric Lift Trucks…790
Electric Lift Trucks With Adjustable Relief Valve…791
SPECIFICATIONS…792
TROUBLESHOOTING…792
200090…793
INTRODUCTION…793
GENERAL…793
DESCRIPTION…793
OPERATION…795
Lift Spool…795
Tilt Spool…795
Relief Valve, Single–Stage…798
Relief Valve, Two–Stage…799
REPAIRS…799
REMOVAL AND DISASSEMBLY…799
CLEANING AND INSPECTION…800
ASSEMBLY…800
INSTALLATION…800
CHECKS AND ADJUSTMENTS…800
ADJUST THE SINGLE–STAGE RELIEF VALVE…800
ADJUST THE TWO–STAGE RELIEF VALVE…801
ADJUST THE RELIEF VALVE ON THE AUXILIARY CONTROL VALVE, H60–110E ONLY…802
TROUBLESHOOTING…802
2100103…804
INTRODUCTION…804
GENERAL…804
DESCRIPTION…804
REPAIRS…804
REMOVAL…804
DISASSEMBLY…804
CLEANING…804
ASSEMBLY…804
Tilt Cylinders with O-Rings or Single Lip Seals…804
Tilt Cylinders for the XM and XMS Models…805
Tilt Cylinders for H700 800A and Early Model H700 920B…807
INSTALLATION…807
Tilt Cylinders Using Chevron Packing…808
CHECKS AND ADJUSTMENTS…810
CHECK THE TILT CYLINDERS FOR LEAKS…810
ADJUST THE TILT CYLINDER STROKE AND THE MAST TILT ANGLE…810
TABLE 1. MOVEMENT RATES (MAXIMUM) FOR TILT CYLINDERS…811
TABLE 2. TORQUE SPECIFICATIONS FOR THE TILT CYLINDERS…812
TROUBLESHOOTING…814
2200106…815
INTRODUCTION…815
GENERAL…815
DESCRIPTION AND OPERATION…815
REPAIRS…817
REMOVAL…817
DISSASEMBLY…817
CLEANING…818
ASSEMBLY…818
INSTALLATION…818
CHECKS AND ADJUSTMENTS…819
GENERAL…819
TROUBLESHOOTING…821
2200107…823
HIGH ENERGY IGNITION (HEI)…823
DESCRIPTION…823
REPAIRS…825
DISTRIBUTOR…825
Removal…825
Disassembly…825
Assembly…830
INSTALLATION, IF THE CRANKSHAFT WAS NOT ROTATED WHEN DISTRIBUTOR WAS REMOVED…831
NSTALLATION, IF THE CRANKSHAFT WAS ROTATED WHEN THE DISTRIBUTOR WAS REMOVED…832
IGNITION COIL…832
Removal, Some 4 And 6 Cylinder Models…832
Installation, Some 4 And 6 Cylinder Models…833
Removal, V8, Some 4 And 6 Cylinder Models…833
Installation, V8, Some 4 And 6 Cylinder Models…834
ELECTRONIC MODULE…835
Removal…835
Installation…835
SENSING COIL…836
Removal…836
Installation…836
SPARK PLUGS…836
Removal…836
Installation…837
CHECKS AND ADJUSTMENTS…837
Visual Checks…837
Check The High Voltage Wires…837
Checking The Ignition Coil…837
Coil In Distributor Cap Design…837
Separate Coil Design…838
Checking The Sensing Coil…838
Check The Electronic Module…839
Ignition Timing Adjustment…839
Ignition System, GM V8-366 (6-litre)…840
Ignition Timing and Idle Speed Adjustment, GM V6-LPG (4.3-litre)…840
SPECIFICATIONS…840
TROUBLESHOOTING…841
2200143…842
INTRODUCTION…842
GENERAL…842
DESCRIPTION…842
GENERAL…842
STEERING COLUMN GAUGES, METERS AND INDICATORS…845
LED DISPLAY PANEL…845
Battery Discharge Indicators…845
Brush Wear Indicators…846
Motor Temperature Indicators…847
"LX" SERIES DISPLAY PANEL…848
Hourmeter Functions…849
Battery Indicator Function…849
Status Code Function…849
"ZX" SERIES DISPLAY PANELS…849
Display Panel…850
Basic Display Panels…850
Performance Display…852
Brush Wear Indicators…855
CHECKS AND ADJUSTMENTS…855
GENERAL…855
REPLACEMENT…856
GENERAL…856
METER REPLACEMENT…856
SENDER REPLACEMENT…857
Fuel Level Sender…857
Pressure And Temperature Sender…857
I.T.W. DISPLAY PANEL…858
Removal…858
DISPLAY PANELS FOR THE EV – 100/200ZX MOTOR CONTROLLERS, COLUMN MOUNT…859
Removal…859
Replacing Display Panel Assembly…859
Indicator LEDs…859
Battery Indicators…859
Digital Display (Performance Disply Panel Only)…859
Status Code Or Performance Level Switches And Indicator LEDs (Performance Display Panel Only)…859
Replacing Parts Of The Basic Display Panel…860
Replacing Parts Of The Performance Display Panel…862
DISPLAY PANELS FOR THE EV-100/200ZX MOTOR CONTROLLERS, DASH MOUNT…862
Removal And Replacement…862
SPECIFICATIONS…863
TROUBLESHOOTING…864
22002…865
INTRODUCTION…865
GENERAL…865
DESCRIPTION…865
REPAIRS…867
GENERAL…867
REMOVAL AND DISASSEMBLY (Type A)…867
CLEANING…867
ASSEMBLY (Type A)…868
REMOVAL AND DISAASSEMBLY (Type B)…870
CLEANING…872
ASSEMBLY (Type B)…872
INSTALLATION (Type A and Type B)…873
CHECKS AND ADJUSTMENTS…873
GENERAL…873
CHECK THE ALTERNATOR FOR LOW OUTPUT (Type A or Type B)…874
CHECK THE ALTERNATOR FOR HIGH OUTPUT (Type A or Type B)…875
CHECK THE CIRCUIT FOR THE BRUSHES…877
Delco Alternators…877
Motorola Alternators…877
CHECK THE DIODES…877
CHECK THE DIODE BRIDGE…877
Delco and Leece–Neville Alternators…877
Motorola Alternators…877
CHECK THE FIELD WINDING FOR THE ROTOR…878
CHECK THE WINDINGS IN THE STATOR…878
CHECK THE VOLTAGE REGULATOR…879
TROUBLESHOOTING…879
2200468…880
ELECTRONIC ENGINE CONTROL, TROUBLESHOOTING AND REPAIR…880
GENERAL…880
Engine Data…880
LIGHT BULB CHECK…880
SYSTEM CHECK…882
TROUBLESHOOTING WITH THE FAULT MONITOR SYSTEM IN THE ECM…882
How To Clear A Code…883
Fault In The ECM…883
Fault In The PROM…884
CalPak Not Installed…884
Fuel Control…884
Idle Air Control (IAC)…884
Fuel Pump Circuit…884
Coolant Temperature Sensor (CTS)…885
Manifold Absolute Pressuer Sensor (MAP)…885
Throttle Position Sensodr (TPS)…885
Output Check, Throttle Position Sensor…885
Electronic Spark Timing…885
Engine Crank Signal…886
Distributor Reference Signal…886
TROUBLESHOOTING CHARTS…887
CHART A-1-No "Check Engine" Light…887
Circuit Description, "Check Engine" Light…887
CHART A-1-No "Check Engine" Light…888
CHART A-2-No ALDL Data Or No Code 12 From "Check Engine" Light. The "Check Engine" Light Is Continuosly Illuminated…889
Circuit Description, "Check Engine" Light…889
CHART A-2-No ALDL Data Or No Code 12 From "Check Engine" Light. The "Check Engine" Light Is Continuously Illuminated…890
CHART A-3-Starter Cranks The Engine, But Will Not Run…891
Circuit Description…892
CHART A-4-Fuel Injector Circuit…893
Circuit Description…893
CHART A-5-Fuel Pump Relay Circuit…895
Circuit Description…895
CHART A-6-Fuel System Pressure Test…897
Circuit Description…897
CHART A-7-MAP Output Check…899
Circuit Description…899
CHART A-8-Engine Crank Signal Check…901
Circuit Description…901
CHART A-9-Ignition System Troubleshooting…902
CHART A-9 Ignition System Troubleshooting Chart…903
CHART A-10-Idle Air Control (IAC) System…905
Circuit Description…905
FAULT CODES…907
CODE 14-Coolant Temperature Sensor Circuit (Indicates High Temperature)…907
Circuit Description…907
CODE 15-Coolant Temperature Sensor Circuit (Indicates Low Temperature…909
Circuit Description…909
CODE 21-Throttle Position Sensor Circuit (Signal Voltage High) …911
Circuit Description…911
CODE 22-Throttle Position Sensor Circuit (Signal Voltage Low) …913
Circuit Description…913
CODE 31-Engine Governor Circuit…915
Circuit Description…915
CODE 33-MAP Sensor Circuit, Signal Voltage High (Low Vacuum…917
Circuit Description…917
CODE 34-MAP Sensor Circuit, Signal Voltage Low (High Vacuum)…919
Circuit Description…919
CODE 42-Electronic Spark Timing (EST)…921
Circuit Description…921
CODE 54-Fuel Pump Circuit (Low Voltage)…923
Circuit Description…923
CODE 51-PROM In The ECM Has A Fault …925
CODE 52-Fuel CalPak Is Missing…925
CODE 55-ECM Has A Fault…925
TROUBLESHOOTING, POOR OPERATION…925
General…925
Make A Careful Visual Check…925
FAULT: Fuel Usage Too High…925
FAULT: Codes Or Performance That Is Not Regular…926
FAULT: "Dieseling"…926
FAULT: "Backfire"…926
FAULT: Rough Idle or Engine Stalls During Idle…926
FAULT: Smoke In The Exhaust Gases…927
FAULT: Engine is Difficult To Start…927
FAULT: Variation In Engine Power When The Throttle Is Held Steady…928
FAULT: Decreased Engine Power…928
FAULT: "Detontion"…928
FAULT: Engine Momentarily Does Not Increase Power When Throttle Changes…929
FAULT: One Cylinder In The Engine Does Not Operate Correctly. The Engine Does Not Idle Correctly…929
REPAIRS, FUEL SYSTEM COMPONENTS …931
General…931
Vacuum Ports…931
Throttle Body Injection (TBI) Unit…931
TBI Unit, Removal…931
TBI Unit, Cleaning and Inspection…932
TBI Unit, Installation…932
Cover For Fuel Meter Body, Replacement…932
Fuel Injectors…933
Fuel Injectors, Removal…933
Fuel Injectors, Installation…934
Pressure Regulator, Removal…934
Pressure Regulator, Inspection…934
Pressure Regulator, Installation …934
Fuel Meter Body, Removal…935
Fuel Meter Body, Installation…935
Throttle Position Sensor (TPS), Removal…935
Throttle Position Sensor (TPS), Installation…935
Idle Air Control (IAC) Valve, Removal…936
Cleaning and Inspection…936
Idle Air Control (IAC) Valve, Installation…936
Governor Throttle Drive Assembly, Removal…936
Governor Throttle Drive Assembly, Inspection…936
Cleaning and Lubrication…937
Governor Throttle Drive Assembly, Installation…937
Governor Drive Motor, Removal…938
Governor Drive Motor, Cleaning and Lubrication…938
Governor Drive Motor, Installation…939
Governor Drive Motor, Inspection…939
Throttle Body, Removal and Disassembly…939
Throttle Body, Inspection…939
Throttle Body, Assembly and Installation…939
Fuel Pump, Removal and Disassembly…940
Fuel Pump, Inspection…940
REPAIRS, ELECTRICAL COMPONENTS…940
General…940
Ignition Coil Test…940
Ignition Module Test…941
Distributor, Removal…941
Distributor, Disassembly…942
Distributor, Assembly…942
Distributor, Installation…943
Firing Order…944
Ignition Timing…944
Ignition Coil, Removal…945
Ignition Coil, Installation…945
Procedures For Spark Plugs, Spark Plug Wires And Boots …945
Troubleshooting of Spark Plugs…946
Coolant Temperature Sensor (CTS), Replacement …947
Manifold Absolute Pressure (MAP) Sensor, Replacement…947
Oil Pressure Switch, Replacement…948
Coolant Temperature Sender, Replacement…948
Wire Harness…948
Connectors And Terminals…948
Electronic Control Module (ECM)…952
ECM CONNECTOR A-B IDENTIFICATION…956
ECM CONNECTOR C-D IDENTIFICATION…957
SPECIAL TOOLS…958
2200765…961
INTRODUCTION…961
GENERAL…961
DESCRIPTION…961
What MSTS Does…961
How MSTS Begins Operation…962
OPERATION…963
Distributor…963
Ignition Coil …963
Ignition Module…963
When the Engine Is Being Started…964
When the Engine Is Running …964
Manifold Absolute Pressure (MAP) Sensor…965
Engine Coolant Temperature (ECT) Sensor…966
MSTS Module Corrections…966
TROUBLESHOOTING…968
GENERAL…968
TOOLS AND EQUIPMENT…969
MSTS…970
TROUBLESHOOTING PROCEDURE…970
Where To Start…970
Visual/Physical Inspection…970
Knowledge/Tools Required…970
Damage From Static Discharge (Static Electricity)…971
TROUBLESHOOTING INFORMATION…971
Malfunction Indicator Lamp (MIL)…971
Connecting The CodeMate Tester…971
Reading Diagnostic Trouble Codes (DTC)…972
Clearing Diagnostic Trouble Codes (DTC's)…972
On-Board DIAGNOSTIC (ODB) System Check…973
NO MALFUNCTION INDICATOR LAMP…975
Circuit Description…975
Test Description…975
NO DTC-12, MALFUNCTION INDICATOR LAMP ON…977
Circuit Description…977
Test Description…977
STARTER ROTATES ENGINE, ENGINE DOES NOT RUN…979
Test Description…979
DTC-14 ENGINE COOLANT TEMPERATURE SENSOR (ECT) (LOW TEMPERATURE INDICATED)…982
Circuit Description…982
Test Description…982
DTC-15 ENGINE COOLANT TEMPERATURE SENSOR (ECT) (HIGH TEMPERATURE INDICATED)…984
Circuit Description…984
Test Description…984
DTC-34 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR…986
Circuit Description…986
Test Description…986
DTC-41 ELECTRONIC SPARK TIMING (EST OPEN CIRCUIT)…989
Circuit Description…989
Test Description…989
DTC-42 ELECTRONIC SPARK TIMING (EST GROUNDED CIRCUIT)…991
Circuit Description…991
Test Description…991
DTC 51 MSTS FAILURE…993
Circuit Description…993
REPAIRS…993
DISTRIBUTOR…993
Removal…993
Disassembly…994
Inspection…994
Assembly…994
Installation…995
Ignition Timing…995
IGNITION MODULE…995
Test For A Fault…995
Ignition Module Replacement…996
SENSING COIL…997
Test For A Fault…997
Sensing Coil Replacement…997
IGNITION COIL…997
Test For A Fault…997
Removal…998
Installation…998
MSTS MODULE…998
Removal…998
Installation…998
ECT SENSOR REPLACEMENT…998
MAP SENSOR REPLACEMENT…999
2200781…1001
INTRODUCTION…1001
GENERAL…1001
DESCRIPTION AND OPERATION…1001
GENERAL…1001
ELECTRONIC CONTROL MODULE (ECM)…1001
Diagnostic Connector…1004
How The ECM Begins Operation…1004
ELECTRONIC ENGINE CONTROL…1005
What The ECM Does…1005
Distributor…1006
Ignition Module…1007
When the Engine Is Being Started…1007
When the Engine Is Running…1009
Electronic Control Module (ECM) With Ignition Module Distributor, Corrections…1009
FUEL CONTROL…1009
Throttle Body Injection…1010
Fuel Injectors…1011
Fuel Pressure Regulator…1011
Throttle Position Sensor…1011
Idle Air Control…1011
GM 4.3L Engine Governor System…1012
GM 3.0L Engine Governor System…1013
Vacuum Ports…1014
Fuel Pump…1014
ECM SENSORS AND CONTROLLERS…1015
Manifold Absolute Pressure (MAP)…1015
Engine Coolant Temperature (ECT) Sensor…1016
2200782…1017
INTRODUCTION…1017
GENERAL…1017
TROUBLESHOOTING PROCEDURE…1017
HOW THIS SECTION IS ARRANGED…1017
Where Do I Start…1017
VISUAL/PHYSICAL INSPECTION…1017
KNOWLEDGE/TOOLS REQUIRED…1017
DAMAGE FROM STATIC DISCHARGE (STATIC ELECTRICITY)…1017
TROULBLESHOOTING INFORMATION…1018
Malfunction Indicator Lamp (MIL)…1018
Reading Diagnostic Trouble Codes (DTC)…1018
Clearing Diagnostic Trouble Codes (DTC)…1019
TABLE 1. ECM DIAGNOSTIC CODES AVAILABLE…1022
Diagnostic Mode…1022
Field Service Mode…1022
ECM Learning Ability…1022
TABLE 2. SCAN TOOL INFORMATION…1023
On-Board DIAGNOSTIC (OBD) System Check…1024
TROUBLESHOOTING CHARTS…1026
GENERAL…1026
TOOLS AND TEST EQUIPMENT…1027
CHART A-1 No Malfuntion Indicator Lamp…1028
CIRCUIT DESCRIPTION…1028
CHART A-2 – No Scan Data, No DTC12, Malfunction Indicator Lamp On…1030
CIRCUIT DESCRIPTION…1030
CHART A-3 – The Starter Rotates The Engine, Engine Will Not Run…1032
CIRCUIT DESCRIPTION…1032
CHART A-4 – Fuel Injector Circuit…1034
CIRCUIT DESCRIPTION…1034
CHART A-5 – Fuel Pump Relay Circuit…1036
CIRCUIT DESCRIPTION…1036
CHART A-6 – Fuel System Troubleshooting (1 of 3)…1038
CIRCUIT DESCRIPTION…1038
FUEL PRESSURE CHECK…1042
CHART A-7 – Ingition System Troubleshooting…1043
DTC 14 ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT (LOW TEMPERATURE INDICATED)…1046
CIRCUIT DESCRIPTION…1046
DTC 15 ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT (HIGH TEMPERATURE INDICATED)…1048
CIRCUIT DESCRIPTION …1048
CODE 15 – Engine Coolant Temperature Sensor Circuit (High Temperature Indicated)…1049
DTC 21 THROTTLE POSITION SENSOR CIRCUIT (SIGNAL VOLTAGE HIGH)…1050
CIRCUIT DESCRIPTION…1050
CODE 21 – Throttle Position Sensor Circuit (Signal Voltage High)…1051
DTC 22 THROTTLE POSITION SENSOR CIRCUIT (SIGNAL VOLTAGE LOW)…1052
CIRCUIT DESCRIPTION…1052
DTC 31 ENGINE GOVERNOR CIRCUIT…1054
CIRCUIT DESCRIPTION…1054
DTC 33 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR CIRCUIT (SIGNAL VOLTAGE HIGH – LOW VACUUM)…1056
CIRCUIT DESCRIPTION…1056
DCT 34 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR CIRCUIT (SIGNAL VOLTAGE – HIGH VACUUM)…1058
CIRCUIT DESCRIPTION…1058
DTC 41 ELECTRONIC SPARK TIMING (EST) – OPEN EST CIRCUIT …1060
CIRCUIT DESCRIPTION…1060
DTC 42 – ELECTRONIC SPARK TIMING (EST) – GROUNDED EST CIRCUIT, OPEN OR GROUNDED BYPASS CIRCUIT…1062
CIRCUIT DESCRIPTION…1062
DTC 51 ECM FAILURE…1064
CIRCUIT DESCRIPTION…1064
TROUBLESHOOTING, PERFORMANCE…1065
GENERAL …1065
Make A Careful Visual Check…1065
FAULT: Codes Or Performance That Is Not Regular…1065
Fault: Loss Of Diagnostic Trouble Code (DTC) Memory…1065
FAULT: Engine Quits While Driving…1065
Additional Checks…1065
FAULT: Engine Is Difficult To Start…1066
FAULT: Variation In Engine Power When The Throttle Is Held Steady…1066
FAULT: Decreased Engine Power…1067
FAULT: Detonation…1067
FAULT Engine Momentarily Does Not Increase Power When Throttle Changes…1068
FAULT: One Or More Cylinders Do Not Operate Correctly. The Engine Does Not Idle Correctly…1068
FAULT: Rough Idle Or Engine Stalls During Idle…1069
FAULT: Fuel Usage Too High…1069
FAULT: Dieseling…1070
FAULT: Backfire…1070
SYSTEM TEST CHARTS…1071
GENERAL…1071
ENGINE COOLANT TEMPERATURE (ECT) SENSOR TEST…1071
THROTTLE POSITION (TP) SENSOR CHECK…1072
MINIMUN IDLE SPEED…1072
Adjustment…1072
CHART B-1 IDLE AIR CONTROL (IAC) SYSTEM CHECK…1073
CIRCUIT DESCRIPTION…1073
CHART B-2 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR OUTPUT TEST…1075
CIRCUIT DESCRIPTION…1075
CHART B-3 CHECK THE GOVERNOR SYSTEM…1078
GOVERNOR SYSTEM NOT OPERATING CORRECTLY…1078
Check The Function Of Governor System…1078
CHECK THE PVC SYSTEM…1078
REPAIRS…1080
FUEL SYSTEM COMPONENTS…1080
General…1080
Fuel Pressure Relief Procedure…1080
Fuel Pump Replacement…1080
TBI Unit, Removal…1081
TBI Unit, Cleaning and Inspection…1082
TBI Unit, Installation…1082
Fuel Meter Body, Removal…1084
Fuel Meter Body, Installation…1084
Fuel Injector, Removal…1084
Fuel Injector, Installation…1085
Pressure Regulator, Removal…1085
Pressure Regulator, Inspection…1085
Pressure Regulator, Installation…1085
Throttle Position Sensor (TPS), Removal…1086
Throttle Position Sensor (TPS), Installation…1086
Idle Air Control (IAC) Valve, Removal…1086
Cleaning and Inspection…1086
Idle Air Control (IAC) Valve, Installation…1086
GOVERNOR SYSTEM (3.0L ENGINE)…1087
Governor Module Replacement…1087
Governor Motor Replacement…1087
Throttle Cables, Installation and Adjustment…1087
CHECK THE MONOTROL PEDAL…1088
GOVERNOR SYSTEM (4.3L ENGINE)…1088
Governor Throttle Drive Assembly, Removal…1088
Governor Throttle Drive Assembly, Inspection…1089
Governor Throttle Drive Assembly, Installation…1089
Governor Drive Motor, Removal…1090
Governor Drive Motor, Cleaning and Lubrication…1090
Governor Drive Motor, Installation…1091
Governor Drive Motor, Inspection…1091
IGNITION SYSTEM COMPONENTS…1092
ECM Replacement…1092
Function Check…1092
Distributor, Removal…1092
Distributor, Disassembly…1092
Distributor, Inspection…1092
Distributor, Assembly…1093
Distributor, Installation…1093
Firing Order…1094
Distributor, Ignition Timing…1094
IGNITION MODULE…1094
Test For A Fault…1094
Replacement…1095
Sensing Coil Test…1096
Sensing Coil Replacement…1096
Ignition Coil Test…1096
Ignition Coil, Removal…1096
Ignition Coil, Installation…1097
SENSORS…1097
Engine Coolant Temperature (ECT) Sensor Replacement…1097
MAP Sensor Replacement…1097
PCV SYSTEM…1097
Replacement…1097
WIRING…1098
Connectors And Terminals…1098
Procedures For Spark Plugs, Spark Plug Wires, And Boots…1101
WIRING DIAGRAM…1101
TROUBLESHOOTING OF SPARK PLUGS…1102
ECM CONNECTOR J1 IDENTIFICATION…1106
ECM CONNECTOR J2 IDENTIFICATION…1107
SPECIAL TOOLS…1108
4000135…1110
SAFETY PROCEDURES WHEN WORKING NEAR THE MAST…1110
SAFETY PROCEDURES WHEN WORKING NEAR THE MAST…1110
LIFT CYLINDERS…1113
GENERAL…1113
DESCRIPTION…1113
Lowering Control Valve…1113
Cylinders (General)…1116
Cylinders (H520-620B,H700-800A)…1118
Cylinders (H360-460B)…1119
Cylinders (Two-Speed)…1119
REPAIRS…1120
REMOVAL OF THE LIFT CYLINDER WITHOUT REMOVING THE MAST…1120
Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast…1120
Standard and Full Free-Lift Masts with the Lift Cylinder to a Crosshead…1124
Masts that have Two Cylinders, A Main Lift Cylinder and a Free-Lift Cylinder…1122
DISASSEMBLY…1122
ASSEMBLY…1124
INSTALLATION OF THE LIFT CYLINDER IN THE MAST…1124
Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast…1124
Standard and Full-Free-Lift Masts with the Lift Cylinder Fastened to a Crosshead…1124
CHEVRON PACKING…1125
LIFT CYLINDERS FOR VISTA MASTS…1128
DESCRIPTION…1128
Lowering Control Valve…1130
REMOVAL…1131
DISASSEMBLY…1131
ASSEMBLY…1131
INSTALLATION…1132
Main Lift Cylinders…1132
Free-Lift Cylinders…1132
CHECKS AND ADJUSTMENTS…1133
CHECK FOR LEAKS IN LIFT SYSTEM…1133
TROUBLESHOOTING…1134
SPECIFICATIONS…1135
4000329…1136
INTRODUCTION…1136
GENERAL…1136
DESCRIPTION AND OPERATION…1136
GENERAL…1136
SAFETY PROCEDURE WHEN WORKING NEAR THE MAST…1137
TWO-STAGE MAST…1138
THREE-STAGE MAST…1139
REPAIRS…1140
CARRIAGE…1140
REMOVAL…1140
Disassembly,Side Shift Carriage…1141
Assembly, Side Shift Carriage…1141
Installation…1143
TWO-STAGE MAST…1144
Removal…1144
Disassembly…1144
Cleaning and Inspection…1145
Assembly…1145
Installation…1146
THREE-STAGE MAST…1147
Removal…1147
Disassembly…1147
Cleaning and Inspection…1148
Assembly…1148
Installation…1149
CHECKS AND ADJUSTMENTS…1149
CHECK THE OPERATION OF THE MAST…1149
CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM…1150
Lift System…1150
Tilt System…1150
ADJUST THE TILT CYLINDER STROKE AND THE BACKWARD TILT ANGLE…1150
LIFT CHAIN ADJUSTMENT…1151
MAST ADJUSTMENT…1152
CARRIAGE ADJUSTMENT…1153
TROUBLESHOOTING…1155
600104GM…1156
GM 4.3 LITRE V-6 AND 5.7 LITRE V-8 ENGINES…1156
DESCRIPTION…1156
ENGINE, REMOVAL AND INSTALLATION…1156
CYLINDER HEAD…1156
Removal And Disassembly…1156
Cleaning And Inspection…1156
Repairs, Valve Guides and Seats…1156
Studs For The Rocker Arms…1157
Valve Springs…1157
ASSEMBLY AND INSTALLATION…1158
CYLINDER BLOCK, CLEANING AND INSPECTION…1159
PISTON BORE PREPARTION…1159
ENGINE MOUNTS…1159
LUBRICATION SYSTEM…1159
Oil Pump, Removal and Disassembly…1159
Cleaning and Inspection…1159
Oil Pump, Assembly and Installation…1159
TIMING COVER, TIMING SPROCKETS, CAMSHAFT AND CAM FOLLOWERS…1160
Timing Cover, Removal…1160
Installation…1160
Timing Sprockets, Removal…1161
Timing Sprockets, Installation…1161
Camshaft, Removal…1161
Camshaft, Inspection…1161
Camshaft, Installation…1162
Hydraulic Valve Lifters, Removal…1162
Hydraulic Valve Lifters, Disassembly…1162
Hydraulic Valve Lifters, Cleaning And Inspection…1162
Hydraulic Valve Lifters, Assembly…1163
CRANKSHAFT…1163
Removal…1163
Inspection and Repair…1164
How To Check The Clearance Between The Main Bearings And Their Journals…1164
Installation…1165
PISTON AND CONNECTING ROD ASSEMBLIES…1166
Connecting Rod Bearings, Replacement…1166
Piston And Connecting Rod Assemblies, Removal…1167
Disassembly…1167
Piston, Cleaning And Inspection…1168
Cylinder Bores, Inspection And Repair…1168
Piston Rings…1169
Assembly…1169
Piston And Connecting Rod Assemblies, Installation…1170
FLYWHEEL AND FLYWEEL HOUSING…1170
Flywheel Repair For V-6 Engines…1170
Flywheel For V-6 Engines, Installation…1170
Flywheel Housing, H3.5-5.00XL (H70-110XL)…1170
Engine Adapter, H6.00-7.00XL (H135-155XL)…1170
Ring Gear Replacement (Flywheel) For V-8 Engines…1171
Flywheel For V-8 Engines, Flywheel Housing…1171
COOLANT PUMP…1172
FAN MOUNT…1172
CHECKS AND ADJUSTEMENTS…1173
Valve Clearance Adjustment…1173
ENGINE SPECIFICATIONS…1173
ENGINE SPECIFICATIONS…1173
Engine Data…1173
Cylinder head…1173
Hydraulic Valve Lifter…1174
Camshaft…1174
Pistons…1174
Crankshaft…1175
Connecting Rods…1175
Cooling System…1175
Lubrication System…1175
TORQUE SPECIFICATIONS FOR CAPSCREWS AND BOLTS…1176
TROUBLESHOOTING…1177
600105-Perkins…1179
INTRODUCTION…1179
GENERAL…1179
DESCRIPTION…1179
ENGINE SERIAL NUMBER CODES…1180
REMOVAL AND INSTALLATION…1180
ENGINE…1180
CYLINDER HEAD…1180
Removal…1180
Installation…1181
Cylinder Head Repairs…1182
OIL PUMP…1184
Removal…1184
Disassembly…1184
Inspection…1184
Assembly…1185
Installation…1185
RELIEF VALVE…1186
TIMING GEAR CASE AND TIMING GEARS…1186
Removal…1186
Installation…1187
PISTONS AND CONNECTING RODS…1188
Removal…1188
Disassembly…1188
Inspection…1189
Assembly…1190
Installation…1190
CRANKSHAFT AND MAIN BEARINGS…1191
Removal…1191
Inspection…1191
Assembly…1192
CAMSHAFT AND CAM FOLLOWERS…1193
Removal…1193
Inspection…1194
Assembly…1194
FLYWHEEL AND FLYWHEEL HOUSING…1195
Removal…1195
Repairs…1195
Installation…1195
STEERING PUMP DRIVE…1195
Removal…1195
Installation…1196
PCV VALVE…1196
FUEL SYSTEM…1196
FUEL PUMP…1196
Removal…1196
Disassembly…1196
Assembly…1196
Installation…1197
FUEL INJECTION PUMP…1197
Removal…1197
Repairs…1197
Installation…1197
FUEL INJECTORS…1197
Removal…1197
Repairs…1198
Installation…1198
COLD START AID…1198
Description…1198
Removal…1198
Installation…1198
COOLING SYSTEM…1199
THERMOSTAT…1199
Removal…1199
Inspection…1199
Installation…1199
WATER PUMP…1199
Removal…1199
Disassembly…1199
Assembly…1199
Installation…1199
CHECKS AND ADJUSTMENTS…1199
CHECKING THE INJECTORS…1199
Repairs…1200
Installation…1200
REMOVING AIR FROM THE FUEL SYSTEM…1200
CHECKING THE TIMING MARKS…1201
Method A…1201
Method B…1202
CHECKING THE TIMING ANGLE OF THE FUEL INJECTION PUMP WITH THE SPECIAL TOOL…1203
VALVE CLEARANCE ADJUSTMENT…1204
ADJUSTING THE THROTTLE LINKAGE…1204
TROUBLESHOOTING…1206
SPECIFICATIONS…1207
TORQUE SPECIFICATIONS…1210
600590-gm…1211
GM 4.3 LITRE V-6…1211
INTRODUCTION…1211
DESCRIPTION…1211
ENGINE, REMOVAL AND INSTALLATION …1212
CYLINDER HEAD…1212
Removal And Disassembly…1212
Cleaning And Inspection…1212
Repairs, Valve Guides and Seats…1212
Repairs, Valves …1213
Repairs, Valve Seats…1213
Valve Springs…1214
Studs For The Rocker Arms (Early Models)…1215
Studs For The Rocker Arms (Late Models)…1216
Assembly And Installation…1216
CYLINDER BLOCK, CLEANING AND INSPECTION…1218
PISTON BORE PREPARATION…1218
ENGINE MOUNTS…1218
LUBRICATION SYSTEM…1218
Oil Pump, Removal and Disassembly…1218
Cleaning and Inspection…1219
Oil Pump, Assembly and Installation…1219
Oil Sump, Installation…1219
TIMING COVER, TIMING SPROCKETS, CAMSHAFT AND VALVE LIFTERS…1220
Timing Cover, Removal…1220
Installation…1221
Timing Sprockets, Removal…1222
Timing Sprockets, Installation…1222
Camshaft, Removal…1222
Camshaft, Inspection…1222
Camshaft, Installation…1222
Balance Shaft, Removal…1223
Balance Shaft, Installation…1224
Hydraulic Valve Lifters, Removal…1225
Hydraulic Valve Lifters, Disassembly…1225
Hydraulic Valve Lifters, Cleaning And Inspection…1225
Hydraulic Valve Lifters, Assembly…1226
Hydraulic Valve Lifters, Installation…1226
CRANKSHAFT…1227
Removal…1227
Inspection and Repair…1227
How To Check The Clearance Between The Main Bearings And Their Journals…1228
Installation…1229
PISTON AND CONNECTING ROD ASSEMBLIES…1230
Connecting Rod Bearings, Replacement…1230
Piston And Connecting Rod Assemblies, Removal…1231
Disassembly…1231
Piston, Cleaning And Inspection…1231
Cylinder Bores, Inspection And Repair…1232
Piston Rings…1233
Assembly…1233
Piston And Connecting Rod Assemblies, Installation…1234
FLYWHEEL AND FLYWHEEL HOUSING…1234
Flywheel Repairs…1234
Flywheel, Installation …1234
Flywheel Housing…1235
Engine Adapter…1235
COOLANT PUMP…1235
THERMOSTAT…1235
FAN MOUNT, EARLY MODELS…1235
FAN MOUNT ASSEMBLY, LATE MODELS…1236
DRIVE BELT, INSTALLATION…1237
CHECKS AND ADJUSTMENTS…1239
VALVE CLEARANCE ADJUSTMENT, EARLY MODELS…1239
VALVE CLEARANCE ADJUSTMENT, NEW MODELS…1239
CHECK THE COMPRESSION…1239
ENGINE SPECIFICATIONS…1240
Engine Data…1240
Engine Data…1240
Cylinder head…1240
Hydraulic Valve Lifter…1240
Camshaft…1240
Pistons…1240
Crankshaft…1241
Connecting Rods…1241
Connecting Rods…1241
Balance Shaft…1241
Cooling System…1241
Lubrication System…1241
TORQUE SPECIFICATIONS…1242
TROUBLESHOOTING…1243
600705…1246
PERKINS DIESEL ENGINES, 1004-42 (AR), 1006-60 (YG), 1006-60T (YH)…1246
GENERAL…1246
General Safety Rules…1246
DESCRIPTION…1248
Engine Serial Number Codes…1249
Engine Data…1250
1004-42 (AR) ENGINE (Low Governed Speed)…1250
1004-42 (AR) ENGINE (High Governed Speed)…1250
1006-60 (YG) ENGINE…1250
1006-60 (YH) ENGINE…1250
REMOVAL AND INSTALLATION…1251
Lifting The Engine…1251
CYLINDER HEAD ASSEMBLY…1251
VALVE COVER…1251
Removal…1251
Installation…1252
ROCKER ARM ASSEMBLY…1252
Removal…1252
Installation…1252
Disassembly…1252
Inspection…1253
Assembly…1253
VALVE CLEARANCE ADJUSTMENTS…1253
Four Cylinder Engines…1253
Six Cylinder Engines…1254
VALVE SPRINGS…1254
CYLINDER HEAD ASSEMBLY…1255
Removal…1255
Installation…1258
VALVES AND VALVE SPRINGS…1262
Removal…1262
Inspection…1263
Installation…1263
VALVE GUIDES…1263
Inspection…1263
Removal…1264
Installation…1264
CYLINDER HEAD AND VALVE SEATS…1265
Inspection…1265
Repair…1265
Installation Of New Valve Seats…1266
PISTON AND CONNECTING ROD ASSEMBLIES…1266
ROD BEARINGS…1267
Removal…1267
Installation…1268
PISTON AND CONNECTING ROD ASSEMBLY…1268
Service Note…1268
Removal…1269
Installation…1269
PISTON RINGS…1270
Removal…1270
Inspection…1270
Installation…1271
PISTON AND CONNECTING ROD…1272
Disassembly…1272
Inspection…1273
How To Select the Correct Replacements…1273
Installation…1274
PISTON COOLING JETS…1274
Removal…1274
Installation…1274
CRANKSHAFT ASSEMBLY…1275
GENERAL…1275
CRANKSHAFT PULLEY…1276
Removal, Engine AR…1276
Removal, Engine YG and YH…1276
Inspection…1276
Installation, Engine AR…1277
Installation, Engine YG and YH…1277
REAR OIL SEAL…1278
Replacement…1278
MAIN BEARINGS…1279
Removal…1279
Inspection…1279
Installation…1280
THRUST WASHERS…1280
Check The Axial Movement Of The Crankshaft…1280
Removal…1281
Installation…1281
CRANKSHAFT…1282
Removal…1282
Inspection…1282
Installation…1282
FLYWHEEL…1284
Removal…1284
Ring Gear (Replacement)…1284
Installation…1284
FLYWHEEL HOUSING…1285
Removal…1285
Installation…1285
TIMING CASE AND TIMING GEARS…1286
GENERAL…1286
TIMING CASE COVER…1286
Removal…1286
Installation…1286
FRONT OIL SEAL…1287
Removal…1287
Installation…1287
CRANKSHAFT PULLEY WEAR SLEEVE…1288
Installation…1288
IDLER GEAR AND HUB…1288
Removal…1288
Installation…1289
AIR COMPRESSOR DRIVE, BENDIX…1290
Disassembly…1290
Compressor Drive, Assembly…1291
GEAR FOR THE FUEL INJECTION PUMP…1291
Removal…1291
Installation…1292
CAMSHAFT GEAR…1293
Removal…1293
Installation…1293
CRANKSHAFT GEAR…1294
Removal…1294
Installation…1294
TIMING CASE…1294
Removal…1294
Installation…1295
CAMSHAFT AND TAPPETS…1296
Removal…1296
Installation…1296
CYLINDER BLOCK ASSEMBLY…1297
DESCRIPTION…1297
CYLINDER BLOCK…1297
Disassembly…1297
Inspection…1298
Assembly…1298
CYLINDER BORE (4-CYLINDER ENGINES)…1298
CYLINDER BORE (6-CYLINDER ENGINES)…1299
Inspection…1299
To Check the Condition of a Cylinder Liner…1299
Removal…1300
Installation (Service Liner)…1301
Installation (Partially Finished Liner)…1302
ENGINE TIMING…1303
GENERAL DESCRIPTION…1303
How To Set Number 1 Piston To TDC On The Compression Stroke…1304
How To Set Number 1 Piston To TDC On The Compression Stroke (Alternate Procedure)…1305
Check The Valve Timing…1305
Check The Timing Of The Fuel Injection Pump…1306
TURBOCHARGER, ENGINE YH…1307
GENERAL…1307
Removal…1307
Installation…1307
Clean The Impeller And Compressor Housing…1308
LUBRICATION SYSTEM…1309
GENERAL…1309
OIL FILTER, REPLACEMENT…1309
FILTER HEAD…1310
To Remove and to Install…1310
OIL SUMP…1310
Removal…1310
Installation…1311
OIL PUMP…1311
Removal…1311
Inspection…1311
Installation…1312
RELIEF VALVE…1313
Removal…1313
Disassembly…1313
Inspection…1314
Assembly…1314
Installation…1314
IDLER GEAR SHAFT, REPLACEMENT…1314
Removal…1314
Removal, Alternative…1315
Installation…1316
Installation, Alternative…1316
Installation, Alternative for 4-Cylinder Engines Only…1316
FUEL SYSTEM…1317
DESCRIPTION…1317
FUEL INJECTION PUMP…1317
Removal…1317
Installation…1318
FUEL INJECTION PUMP, CHECKS AND ADJUSTMENTS…1319
REMOVE AIR FROM THE FUEL SYSTEM…1320
FUEL FILTER (REPLACEMENT)…1321
Canister Type…1321
Quick Release Canister Type…1321
FUEL INJECTORS…1322
Removal…1322
Inspection…1323
Installation…1323
FUEL PUMP…1324
Removal…1324
Disassembly…1324
Assembly…1325
Installation…1325
Test…1326
COOLING SYSTEM…1326
GENERAL…1326
THERMOSTAT…1326
Thermostats…1326
Remove…1326
Install…1326
Test…1326
COOLANT PUMP…1327
Removal…1327
Disassembly…1328
Assembly…1329
Installation…1332
FAN AND FAN DRIVE…1333
Removal…1333
Installation…1333
OIL COOLER (6-CYLINDER ENGINES)…1333
Removal…1333
Disassembly And Assembly…1333
Installation…1334
By-Pass Valve, Oil Cooler…1334
ELECTRICAL EQUIPMENT…1334
DRIVE BELTS…1334
ALTERNATOR…1335
Removal…1335
Installation…1335
STARTER MOTOR…1335
Removal…1335
Installation…1336
COLD START AID…1336
AIR COMPRESSOR, ENGINES YG AND YH…1336
GENERAL…1336
Air Compressor, Removal…1336
Air Compressor, Installation…1337
ENGINE SPECIFICATIONS…1338
CYLINDER HEAD ASSEMBLY…1338
Cylinder Head…1338
Valve Guides…1339
Inlet Valve…1339
Exhaust Valves…1340
Valve Springs…1340
Tappets…1340
Rocker Arm Shaft…1341
Rocker Arms And Bushings…1341
PISTON AND CONNECTING RODS…1341
Pistons (Engine AR)…1341
Pistons (Engine YG and YH)…1341
Piston Rings (Engine AR)…1341
Piston Rings (Engines YG and YH)…1342
Piston Pins…1342
Connecting Rods…1342
Small End Bushings…1343
Connecting Rod,Bearings, Engines AR And YG…1343
Connecting Rod,Bearings, Engines YH…1343
Piston Cooling Jets…1343
CRANKSHAFT ASSEMBLY…1343
Crankshaft…1343
Main Bearings…1344
Crankshaft Thrust Washers…1344
Crankshaft Heat Treatment…1344
Crankshaft Overhaul…1344
TIMING CASE AND DRIVE ASSEMBLY…1346
Camshaft…1346
Camshaft Thrust Washer…1346
Camshaft Gear…1346
Gear For Fuel Injection Pump…1346
Crankshaft Gear…1346
Idler Gear And Hub…1346
ENGINE BLOCK ASSEMBLY…1347
Cylinder Block (Engine AR)…1347
Cylinder Bore Specifications (Engine AR)…1347
Cylinder Block (Engine YG and YH)…1348
Cylinder LIners (Engine YG and YH)…1348
Cylinder Liner Specifications (Partially Finished)…1348
TURBOCHARGER…1349
LUBRICATION SYSTEM…1349
Oil Pump, Engine AR…1349
Oil Pump, Engine YG and YH…1349
Idler Gear for Oil Pump…1349
Relief Valve…1349
Oil Filter…1350
FUEL SYSTEM…1350
Lucas Fuel Injection Pump…1350
Fuel Injector Codes…1351
Fuel Pump, Engine AR…1351
Fuel Pump, Engines YG And YH…1351
Fuel Filter…1352
COOLING SYSTEM…1352
Coolant Pump…1352
Thermostat…1352
Fan Drive Housing…1352
FLYWHEEL AND HOUSING…1352
Limits for Flywheel "Run Out" and Alignment (Total Indicator Reading)…1352
ELECTRICAL EQUIPMENT…1352
Alternator…1352
Starter Motor…1352
Cold Start Aid…1352
TORQUE SPECIFICATIONS…1353
SPECIAL TORQUE SPECIFICATIONS…1355
SPECIAL TOOLS…1356
TROUBLESHOOTING…1360
List of Possible Causes…1361
700626…1363
COOLING SYSTEM…1363
INTRODUCTION…1363
DESCRIPTION…1363
RADIATOR…1363
RADIATOR CAP…1363
THERMOSTAT…1363
WATER PUMP…1364
FAN AND FAN SHROUD…1364
REPAIRS…1364
COOLING SYSTEM CHECKS…1364
Exhaust Leaks…1364
RADIATOR…1364
Checks…1364
Cleaning The Radiator…1364
Drain The Cooling System…1366
Fill The Cooling System…1366
WATER PUMP…1366
Checks…1366
THERMOSTAT…1367
Checks…1367
FAN AND FAN SHROUD…1367
TROUBLESHOOTING…1368
8000331…1369
LIFT TRUCK WEIGHTS…1369
CAPACITIES…1369
TIRE SIZES…1369
TIRE PRESSURE…1369
ELECTRICAL SYSTEM…1369
WHEEL NUT TORQUE…1369
ENGINE SPECIFICATIONS -GASOLINE/LPG…1370
HYDRAULIC SYSTEM…1370
MAST SPEEDS…1370
TRANSMISSION OIL PRESSURES…1371
TORQUE SPECIFICATIONS…1371
8000332…1374
ELECTRICAL SCHEMATIC (GASOLINE & LPG)…1374
ELECTRICAL SCHEMATIC (DIESEL, PERKINS 4.2482)…1376
ELECTRICAL SCHEMATIC (DIESEL, PERKINS 1004.4)…1378
HYDRAULIC SCHEMATIC…1380
HYDRAULIC SCHEMATIC, POWERSHIFT TRANSMISSION WITH MANUAL CONTROL…1381
HYDRAULIC SCHEMATIC, POWERSHIFT TRANSMISSION WITH MONOTROL PEDAL…1382
8000519…1383
897104-0100SRM0322-(02-2007)-US-EN…1401
toc…1401
Frame…1401
Safety Precautions Maintenance and Repair…1402
General…1405
Description…1405
Counterweight Repair…1406
Remove…1406
Install…1406
Hood Repair…1407
Remove…1407
Install…1407
Overhead Guard Repair…1407
Remove…1407
Install…1407
Operator Restraint System Repair…1408
Automatic Locking Retractor (ALR)…1408
Emergency Locking Retractor (ELR)…1408
Hydraulic Tank Repair…1410
Remove…1410
Inspect…1410
Small Leaks Repair…1410
Large Leaks Repair…1410
Clean…1410
Steam Method…1411
Chemical Solution Method…1411
Other Methods of Preparation for Repair…1411
Install…1411
Fuel Tank Repair…1412
Remove…1412
Repair…1412
Install…1412
Radiator Repair…1412
Remove…1412
Install…1412
Engine Repair…1413
Remove…1413
Install…1413
Throttle Pedal Adjustment…1415
Perkins 1104C-44(RE) Diesel Engine…1415
Safety Labels…1416
Cab Repair…1418
Cab, Replace…1418
Window, Replace…1418
Windshield Wipers and Heater…1418
tables…1401
Table 1. Material Specifications for Cab Windows…1420
897106-1300SRM0324-(10-2003)-US-EN…1423
toc…1423
Two-Speed Powershift Transmission…1423
Safety Precautions Maintenance and Repair…1424
General…1427
Mechanical Description…1427
Torque Converter…1427
Transmission Pump…1428
Shaft Assemblies…1428
Input Shaft…1429
Forward Clutch Shaft…1429
Clutch Assemblies…1429
Countershaft…1436
Output Shaft…1436
Hydraulic Operation…1437
Torque Converter…1437
Seal Rings…1438
Control Valve…1438
System Pressure Regulator…1441
Clutch Pressure Regulator…1441
Torque Converter Regulator…1442
Inching Spool…1442
Direction Spool, Direction Control Lever…1442
Direction Spool, MONOTROL Pedal…1443
Range Spool…1443
Drain Spool…1444
Accumulator…1444
Modulator Spool…1444
Operation…1444
Lubrication Circuit…1445
MONOTROL Pedal…1445
Oil Flow Diagrams…1447
Neutral…1447
Forward-Low…1448
Forward-Low-Inching…1449
Reverse-Low…1450
897107-1300SRM0325-(10-2003)-US-EN…1453
toc…1453
Two-Speed Powershift Transmission…1453
Safety Precautions Maintenance and Repair…1454
General…1457
Transmission Repair…1457
Transmission and Torque Converter, Remove…1457
Transmission, Disassemble…1459
Reverse-Low Clutch, Disassemble…1462
Reverse-High Clutch, Disassemble…1465
Forward-Low Clutch, Disassemble…1468
Forward-High Clutch, Disassemble…1471
Clean and Inspect…1473
Forward Low and High Clutches Assembly…1474
Forward Clutches, Assemble…1476
Reverse-Low Clutch, Assemble…1482
Reverse Clutches, Assemble…1484
Transmission, Assemble…1491
Torque Converter, Install…1498
Control Valve Repair…1499
Remove…1499
Disassemble…1500
Assemble…1501
Install…1503
MONOTROL Pedal…1503
Remove and Disassemble…1503
Assemble and Install…1503
Stall Test…1506
Linkage Adjustments…1507
Linkage for Inching Pedal H6.00-7.00XL (H135-155XL, H135-155XL 2…1507
Linkage for Inching Pedal S6.00-7.00XL (S135-155XL, S135-155XL 2…1510
Linkage for Range Lever – Early Model H6.00-7.00XL (H135-155XL) …1513
Linkage for Direction Control Lever – Early Model H6.00-7.00XL (…1513
Linkage for Range Lever – Later Model H6.00-7.00XL (H135-155XL, …1515
Linkage for Direction Control Lever – Later Model H6.00-7.00XL (…1517
Linkage for Range Lever S6.00-7.00XL (S135-155XL, S135-155XL 2 )…1519
Linkage for Direction Control Lever S6.00-7.00XL (S135-155XL, S1…1519
Oil Pressure Check…1521
System Pressure Check Port…1521
Torque Converter Check Port…1521
Clutch Pressure Check Port…1521
Inching Pressure…1522
Solenoid Check Ports (MONOTROL Control Only)…1522
Lubrication Pressure Check Ports…1522
Specifications…1523
Troubleshooting…1523
Correct System Pressure: 1300 ±124 kPa ( 189 ±18 psi)…1526
Correct Clutch Pressure: 924 ±69 kPa ( 134 ±10 psi)…1527
Correct Solenoid Pressure (MONOTROL Only): 965 ±138 kPa ( 140 ±2…1528
Torque Converter Pressure: 834 ±69 kPa ( 121 ±10 psi)…1528
Lubrication Pressure: 83 ±21 kPa ( 12 ±3 psi)…1528
tables…1453
Table 1. Stall Speed Specifications…1506
897108-1600SRM0326-(03-2007)-US-EN…1531
toc…1531
Steering Axle…1531
Safety Precautions Maintenance and Repair…1532
General…1535
Description…1535
Steering Axle Assembly Repair…1540
Steering Axle H3.50-5.00XL (H70-110XL) (G005), S3.50-5.50XL (S70…1540
Remove…1540
Install…1540
Steering Axle H6.00-7.00XL (H135-155XL, H135-155XL 2 ) (F006, G0…1541
Remove…1541
Install…1541
Wheels and Hubs Repair (All Units)…1542
Remove and Disassemble…1542
Clean…1542
Inspect…1542
Assemble and Install…1542
Spindles and Bearings Repair (All Units)…1544
Remove…1544
Clean…1544
Assemble and Install…1545
Tie Rods Repair (All Units)…1546
Remove…1546
Clean…1546
Install…1546
Steering Cylinder Repair…1549
Remove and Disassemble…1549
Clean and Inspect…1549
Assemble and Install…1549
Troubleshooting…1550
897109-1800SRM0327-(09-2003)-US-EN…1555
toc…1555
Brake System…1555
Safety Precautions Maintenance and Repair…1556
General…1559
Description…1559
Operation…1560
Brake Booster and Master Cylinder…1560
Brake Booster…1560
Master Cylinder…1561
Service Brake Assembly…1562
Parking Brake…1563
Brake Shoe Assemblies Repair…1564
Remove and Disassemble…1564
Clean and Inspect…1565
Cleaning Procedures…1565
Inspect…1565
Assemble and Install…1566
Master Cylinder Repair…1567
Remove…1567
Disassemble…1567
Assemble…1569
Install…1569
Brake Booster Repair…1569
Remove…1569
Disassemble…1569
Clean and Inspect…1571
Assemble…1571
Install…1571
Brake System Air Removal…1571
Brake Pedal Adjustment…1572
Brake Shoes Adjustment…1573
Parking Brake Adjustment…1573
Parking Brake Switch Adjustment…1573
Brake Booster Relief Valve Check…1573
Troubleshooting…1574
897110-1900SRM0328-(09-2003)-US-EN…1579
toc…1579
Hydraulic System…1579
Safety Precautions Maintenance and Repair…1580
General…1583
Description and Operation…1583
Hydraulic Pumps…1585
Main Control Valve…1585
Control Valve Lever…1586
Steering Control Unit…1586
Brake Valve…1586
Oil Clutch, H6.00-7.00XL (H135-155XL) (F006)…1587
Troubleshooting…1587
Lift, Lower, and Tilt Circuit…1588
Steering, Brake, and Oil Clutch System…1589
897111-4000SRM0329-(10-2003)-US-EN…1593
toc…1593
Masts…1593
Safety Precautions Maintenance and Repair…1594
General…1597
Description and Operation…1597
General…1597
Safety Procedures When Working Near Mast…1598
Two-Stage Mast…1598
Three-Stage Mast…1600
Carriage Repair…1602
Remove…1602
Sideshift Carriage, Disassemble…1602
Sideshift Carriage, Assemble…1603
Install…1603
Two-Stage Mast Repair…1605
Remove…1605
Disassemble…1606
Clean and Inspect…1607
Assemble…1608
Install…1608
Three-Stage Mast Repair…1610
Remove…1610
Disassemble…1610
Clean and Inspect…1610
Assemble…1610
Install…1612
Mast Operation Check…1612
Lift and Tilt System Leaks Check…1613
Lift System…1613
Tilt System…1613
Tilt Cylinder Stroke and Backward Tilt Angle Adjustment…1614
Lift Chain Adjustments…1614
Mast Adjustments…1617
Carriage Adjustment…1617
Troubleshooting…1619
tables…1593
Table 1. Mast Parts Weight…1606
Table 2. Hook-Type Carriage Chain Adjustment…1615
Table 3. Pin-Type Carriage Chain Adjustment…1615
897113-8000SRM0331-(09-2003)-US-EN…1623
toc…1623
Capacities and Specifications…1623
Safety Precautions Maintenance and Repair…1624
Lift Truck Weights…1627
Capacities…1627
Tire Sizes…1628
Tire Pressure…1628
Electrical System…1628
Wheel Nut Torque…1628
Engine Specifications…1629
Hydraulic System…1629
Mast Speeds…1630
Transmission Oil Pressures…1630
Torque Specifications…1631
Engine – GM 4.3L V-6…1631
Engine – Perkins 4.2482…1631
Engine – Perkins 1004.4…1631
Clutch…1631
Manual Transmission…1632
Powershift Transmission…1632
Speed Reducer…1632
Drive Axle…1632
Steering System…1632
Brake System…1632
Hydraulic System…1633
Tilt Cylinder…1633
Mast…1633
897123-8000SRM0341-(06-2007)-US-EN…1637
toc…1637
Periodic Maintenance…1637
Safety Precautions Maintenance and Repair…1638
General…1643
Serial Number Data…1643
How to Move Disabled Truck…1643
How to Tow Lift Truck…1643
How to Put Lift Truck on Blocks…1644
How to Raise Drive Tires…1644
How to Raise Steering Tires…1644
Maintenance Schedule…1645
Maintenance Procedures Every 8 Hours or Daily…1658
How to Make Checks With Engine Stopped…1658
Hydraulic System Oil…1658
Engine Oil…1660
Drive Belts…1660
Intake Manifold Rubber Cap…1661
Cooling System…1661
Air Filter…1661
Fuel System…1662
Primary Fuel Filter, Diesel Engine…1662
Battery…1662
Tires and Wheels…1662
Forks…1663
Adjust…1663
Remove and Install…1665
Forks, Mast, and Lift Chains, Inspect…1666
Operator Restraint System…1667
Automatic Locking Retractor (ALR)…1667
Emergency Locking Retractor (ELR)…1667
Safety Labels…1668
How to Make Checks With Engine Running…1669
Gauges, Lights, Horn, and Fuses…1669
Oil Level, Powershift Transmission…1670
Oil Level, Oil Clutch System, H3.50-5.00XL (H70-110XL)…1671
Control Levers and Pedals…1671
Lift System Operation…1671
Inching/Brake Pedal…1671
Service Brakes…1671
Parking Brake…1672
Steering System…1672
Maintenance Procedures Every 250 Hours or 6 Weeks…1672
Engine Oil and Filter, GM V-6 Engine…1672
Lift Chains, Lubrication…1672
Drive Shafts…1672
Mast Lubrication…1673
Crankcase Breather, GM V-6…1674
Air Filter, GM V-6 EPA Compliant Engine …1674
Maintenance Procedures Every 350 Hours or 2 Months…1675
Engine Oil and Filter, Perkins 4.2482 Diesel Engine…1675
Drive Belts…1675
Perkins Diesel Engine…1675
GM V-6 Engine (Early Models)…1675
GM V-6 Engine (Late Models)…1676
Brake Fluid…1678
Lift Chains Wear Check…1678
Forks Wear and Damage Check…1678
Steering Axle Lubrication…1678
Fuel System, Checks and Adjustments…1679
Diesel Fuel System…1679
LPG Carburetor (Early Models)…1679
Gasoline Carburetor (Early Models)…1680
Fuel Injection (Late Models)…1680
Crankcase Breather, Perkins 4.2482 Diesel Engine…1680
Hydraulic Tank Breather…1680
Cooling System, Clean Debris from Radiator Core…1680
Maintenance Procedures Every 500 Hours or 3 Months…1681
Engine Oil and Filter, Perkins Diesel Engine…1681
Crankcase Breather, Perkins Diesel Engine…1681
PCV Valve, GM V-6…1681
Maintenance Procedures Every 1000 Hours or 6 Months…1681
Manifold Heat Valve, GM V-6 (Early Models)…1681
Ignition System, GM V-6…1681
Valve Clearance Adjustment…1681
Fuel Filter, Replace (Diesel Engine)…1682
Fuel System Air Removal (Perkins 1004-4 Diesel Engine)…1682
Fuel Injection Pump With Vent Tube…1682
Fuel Injection Pump With Vent Screw…1683
Fuel System Air Removal (Perkins 4.2482 Diesel Engine)…1685
Oil Level Check in Transmission…1685
Manual Transmission, H3.50-5.00XL (H70-110XL)…1685
Speed Reducer for Powershift Transmission, H3.50-5.00XL (H70-110…1685
Manual Transmission, H6.00-7.00XL (H135-155XL)…1685
Differential and Drive Axle for Powershift Transmission, H6.00-7…1685
Differential, Speed Reducer, and Drive Axle for Manual Transmiss…1686
Control Levers and Pedals, Lubricate…1686
Crankcase Breather, Replace…1686
Cooling System, GM V-6 EPA Compliant Engine…1686
Spark Plug Replacement…1686
Remove…1686
Install…1687
LPG Fuel Filter GM V-6 EPA Compliant Engine, Replace…1687
Inspect Engine Electrical System, Connectors, and FCVS Connectio…1688
Maintenance Procedures Every 2000 Hours or Yearly…1688
Hydraulic System…1688
Hydraulic Oil and Filter, H3.50-5.00XL (H70-110XL), Replace…1688
Hydraulic Oil and Filter, H6.00-7.00XL (H135-155XL, H135-155XL 2…1689
Oil Change and Oil Filter Replacement, Powershift Transmission, …1689
Oil Change, Manual Transmission, H3.50-5.00XL (H70-110XL)…1689
Oil Change, Manual Transmission, H6.00-7.00XL (H135-155XL)…1689
Oil Change, Speed Reducer, Powershift Transmission, H3.50-5.00XL…1689
Oil and Filter Change, Oil Clutch System, H3.50-5.00XL (H70-110X…1690
Oil Change, Differential and Drive Axle, Powershift Transmission…1690
Oil Change, Differential, Speed Reducer, and Drive Axle, Manual …1690
Cooling System…1690
PCV Valve, GM V-6…1690
Service Brakes…1691
LPG Filter, Replace…1691
Gasoline Fuel Filter, Replace…1692
Hood Latch Check, H3.50-5.00XL (H70-110XL)…1692
Air Filter Element, GM V-6 EPA Compliant Engine…1692
Oxygen Sensor GM V-6 EPA Compliant Engine…1692
Inspect Low Pressure Regulator (LPR) for Oil Buildup and Leaks…1693
Check Throttle Shaft for Sticking…1694
Inspect Exhaust Manifold and Piping for Leaks…1694
Test LPG/GAS Regulator Pressure…1694
Safety Procedures When Working Near Mast…1694
Lift Chain Adjustments…1696
Fuel Injectors Repair…1698
Lift and Tilt System Leak Check…1699
Lift Cylinders, Leak Check…1699
Tilt Cylinders, Leak Check…1699
Welding Repairs…1700
Overhead Guard Changes…1700
Wheel and Tire Replacement…1701
Remove Wheels From Lift Truck…1701
Remove Wheels From Tire…1701
Remove Tire From Two-Piece Wheel…1703
Remove Tire From Three- and Four-Piece Wheels…1705
Install Wheel in Tire…1706
Install Three- or Four-Piece Wheel in Tire…1707
Install Two-Piece Wheel in Tire…1708
Add Air to Pneumatic Tires…1709
Wheels, Install…1709
Solid Rubber Tires Repair…1710
Wheel, Tire Remove…1710
Wheel, Tire Install…1712
SIT Tire, Change for H3.50-5.00XL (G005), and H6.00-7.00XL (F006…1714
Remove SIT Solid Tire From Wheel…1714
Install SIT Solid Tire on Wheel…1715
Adhesives and Sealants…1716
Hydraulic Oil, Lubricant, and Coolant Specifications…1717
tables…1637
Table 1. Maintenance Schedule…1647
Table 2. Hook-Type Carriage Chain Adjustment…1697
Table 3. Pin-Type Carriage Chain Adjustment…1697
897501-8000SRM0519-(06-2007)-US-EN…1721
toc…1721
Diagrams…1721
Safety Precautions Maintenance and Repair…1722
897800-0600SRM0590-(08-2005)-US-EN…1809
toc…1809
GM Engines…1809
Safety Precautions Maintenance and Repair…1810
General…1813
Description…1813
Engine Removal and Installation…1814
Cylinder Head Repair…1814
Remove and Disassemble…1814
Clean and Inspect…1814
Valve Guides and Seats, Repairs…1815
Valves, Repair…1815
Valve Seats, Repair…1816
Valve Springs…1816
Rocker Arm Studs (Early Models)…1818
Rocker Arm Studs (Late Models)…1818
Assemble and Install…1819
Cylinder Block Cleaning and Inspection…1822
Piston Bore Preparation…1822
Engine Mounts Installation…1823
Lubrication System Repair…1823
Oil Pump, Remove and Disassemble…1823
Clean and Inspect…1823
Oil Pump, Assemble and Install…1824
Oil Sump, Install…1824
Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters…1825
Timing Cover…1825
Remove…1825
Install…1827
Timing Sprockets…1827
Remove…1827
Install…1827
Camshaft…1828
Remove…1828
Inspect…1828
Install…1828
Balance Shaft…1829
Remove…1829
Install…1830
Hydraulic Valve Lifters…1830
Remove…1830
Disassemble…1831
Clean and Inspect…1831
Assemble…1831
Install…1832
Crankshaft Repair…1833
Remove…1833
Inspect and Repair…1833
How to Check Clearance Between Main Bearings and Their Journals…1834
Install…1835
Piston and Connecting Rod Assemblies Repair…1836
Connecting Rod Bearings, Replace…1836
Piston and Connecting Rod Assemblies, Remove…1837
Disassemble…1837
Piston, Clean and Inspect…1838
Cylinder Bores, Inspect and Repair…1838
Piston Rings…1839
Assemble…1840
Piston and Connecting Rod Assemblies, Install…1840
Flywheel and Flywheel Housing Repair…1841
Flywheel, Repair…1841
Flywheel, Install…1841
H3.50-5.00XL (H70-110XL), S3.50-5.50XL (S70-120XL), S6.00-7.00XL…1841
H6.00-7.00XL (H135-155XL)…1841
Flywheel Housing H3.50-5.00XL (H70-110XL), H3.50-5.50XM (H70-120…1841
Engine Adapter H6.00-7.00XL (H135-155XL)…1841
Coolant Pump Repair…1842
Thermostat Replacement…1842
Fan Mount Repair (Early Models)…1842
Fan Mount Assembly Repair (Late Models)…1842
Drive Belt Installation…1844
Valve Clearance Adjustment (Early Models)…1845
Valve Clearance Adjustment (New Models)…1846
Compression Check…1846
Engine Specifications…1847
Engine Data…1847
Cylinder Head…1847
Hydraulic Valve Lifter…1848
Camshaft…1848
Pistons…1848
Crankshaft…1849
Connecting Rods…1849
Balance Shaft…1850
Cooling System…1850
Lubrication System…1850
Torque Specifications…1850
Troubleshooting…1851
tables…1809
Table 1. Piston Rings Arrangement on Piston…1840
897934-0700SRM0626-(11-2001)-US-EN…1857
toc…1857
Cooling System…1857
Safety Precautions Maintenance and Repair…1858
General…1861
Description…1862
Radiator…1862
Radiator Cap…1862
Thermostat…1862
Water Pump…1863
Fan and Fan Shroud…1863
Cooling System Checks…1863
Radiator…1863
Thermostat…1863
Water Pump…1864
Exhaust Leaks…1864
Fan and Fan Shroud…1864
Radiator Cleaning…1864
Drain…1864
Clean…1864
Fill…1865
Troubleshooting…1866
899783-2000SRM0090-(10-2003)-US-EN…1869
toc…1869
Main Control Valve…1869
Safety Precautions Maintenance and Repair…1870
General…1873
Description…1873
Operation…1876
Lift Spool…1876
Tilt Spool…1877
Tilt Backward…1877
Tilt Forward…1878
Single-Stage Relief Valve…1880
Two-Stage Relief Valve…1881
Main Control Valve Repair…1882
Remove and Disassemble…1882
Clean and Inspect…1882
Assemble…1882
Install…1883
Single-Stage Relief Valve Adjustment…1883
Two-Stage Relief Valve…1884
Auxiliary Control Valve Relief Valve Adjustment (H60-110E Only)…1884
Troubleshooting…1885
tables…1869
Table 1. Relief Pressures (Oil temperature at 55 to 66 C ( 131 t…1883
899784-2200SRM0002-(12-2004)-US-EN…1889
toc…1889
Alternator with Regulator…1889
Safety Precautions Maintenance and Repair…1890
General…1893
Description…1893
Alternator Repair…1895
Alternator Type A…1895
Remove and Disassemble…1895
Clean…1896
Assemble…1897
Install…1897
Alternator Type B…1900
Remove and Disassemble…1900
Clean…1900
Assemble…1901
Install…1902
General Check and Adjustment…1903
Low Output Check (Type A or Type B)…1903
High Output Check (Type A or Type B)…1905
Brushes Circuit Check…1906
Delco Alternators…1906
Motorola Alternators…1907
Diodes Check…1908
Diode Bridge Check…1908
Delco and Leece-Neville Alternators…1908
Motorola Alternators…1908
Rotor Field Winding Check…1909
Stator Windings Check…1910
Voltage Regulator Check…1910
Troubleshooting…1910
900347…1915
WEBER CARBURETOR WITH GOVERNOR…1915
GENERAL…1915
DESCRIPTION…1915
Carburetor…1915
Governor…1915
OPERATION…1916
Carburetor, Float System…1916
Carburetor, Idle System…1916
Carburetor, Main Metering System…1916
Carburetor, Power System…1917
Carburetor, Accelerator Pump System…1917
Carburetor, Choke System…1918
GOVERNOR…1919
REPAIRS…1920
CARBURETOR…1920
Removal…1920
Disassembly…1920
Cleaning…1920
Assembly…1920
Installation…1921
GOVERNOR…1921
CHECKS AND ADJUSTMENTS…1922
GENERAL…1922
CHOKE SYSTEM…1922
ELECTRIC CHOKE…1922
IDLE MIXTURE ADJUSTMENT…1923
IDLE SPEED ADJUSTMENT…1923
THROTTLE LINKAGE ADJUSTMENT…1924
TROUBLESHOOTING…1925
900348…1926
INTRODUCTION…1926
GENERAL…1926
DESCRIPTION AND OPERATION…1926
Fuel Tank…1927
Fuel Filter and Fuel Valve Unit…1927
Vaporizer…1928
Carburetor…1929
Governor…1930
REPAIRS…1932
LPG TANK…1932
Removal…1932
Installation…1932
HYDROSTATIC RELIEF VALVE…1932
Removal and Installation…1932
FILTER UNIT…1934
Replacement Of The Fuel Filter Element…1934
Replacement of the Diaphragm and Fuel Valve …1934
REPLACEMENT OF THE HOSES…1934
VAPORIZER…1934
Removal…1934
Vaporizer Disassembly…1936
Cleaning…1936
Inspection…1936
Vaporizer Assembly…1936
Installation…1938
CARBURETOR…1938
Removal…1938
Disassembly…1938
Cleaning…1939
Assembly…1939
Installation…1939
GOVERNOR…1939
CHECKS AND ADJUSTMENTS…1940
CHECK THE FILTER UNIT…1940
CHECK THE VAPORIZER…1940
Pressure Reducer Valve…1940
Vapor Valve…1940
ADJUST THE CARBURETOR…1941
Idle Mixture…1941
Idle Speed …1941
Power Mixture…1941
ADJUST THE THROTTLE LINKAGE…1941
TROUBLESHOOTING…1942
910072-1400SRM0046-(07-2007)-US-EN…1945
toc…1945
Differential…1945
Safety Precautions Maintenance and Repair…1946
General…1949
Description…1949
Differential Repair…1950
Remove…1950
Differential Carrier From Axle Housing, Remove…1950
Differential and Ring Gear From Differential Carrier, Remove…1952
Drive Pinion and Pinion Carrier From Differential Carrier, Remov…1954
Disassemble…1955
Differential and Ring Gear Assembly, Disassemble…1955
Drive Pinion and Pinion Carrier, Disassemble…1957
Clean and Inspect…1960
Assemble…1961
Pinion, Bearings, and Pinion Carrier, Assemble…1961
Pinion Bearings, Adjust Preload…1961
Press Method…1961
Yoke or Flange Method…1962
Triple-Lip Seal, Install…1963
Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion)…1964
Differential and Ring Gear, Assemble…1966
Differential Gears Rotating Torque, Check…1968
Differential and Ring Gear Assembly, Install…1969
Differential Bearings, Preload Adjust…1971
Ring Gear, Runout Check…1972
Ring Gear Backlash, Adjust…1972
Gear Set, Tooth Contact Pattern Check…1974
Thrust Screw, Install and Adjust…1977
Install…1977
Differential Assembly Into Axle Housing, Install…1977
Specifications…1979
Troubleshooting…1984
tables…1945
Table 1. Ring Gear Backlash Adjustment Specifications…1974
Table 2. Ring and Pinion Tooth Contact Adjustment…1975
Table 3. General Specifications…1979
Table 4. Rivet Installation Pressure…1979
Table 5. Pinion Adjustment…1980
Table 6. Pinion Preload Pressure…1980
Table 7. Torque Specifications…1981
Table 8. Torque Specifications for Metric Hardware…1982
Table 9. Torque Specifications for Metric (Fine) Hardware…1983
910073-1400SRM0049-(09-2003)-US-EN…1987
toc…1987
Drive Axle…1987
Safety Precautions Maintenance and Repair…1988
General…1991
Description…1991
Drive Axle Repair…1992
Disassemble (Type 1 Shown)…1992
Clean…1995
Inspect…1995
Assemble (Type 1 Shown)…1996
Torque Specifications…1999
Troubleshooting…2000
910076-1600SRM0054-(10-2003)-US-EN…2003
toc…2003
Steering Control Unit…2003
Safety Precautions Maintenance and Repair…2004
General…2007
Description…2007
Operation…2007
Steering Wheel and Column Assembly Repair…2009
Steering Column Assembly Repair…2009
Type A Steering Column Assembly…2009
Remove and Disassemble…2009
Assemble and Install…2011
Type B Steering Column Assembly…2013
Remove and Disassemble…2013
Assemble and Install…2013
Steering Control Unit…2016
Disassemble…2016
Clean…2019
Assemble…2020
System Air Removal…2025
Troubleshooting…2025
910091-1900SRM0097-(07-2006)-US-EN…2029
toc…2029
Hydraulic Gear Pumps…2029
Safety Precautions Maintenance and Repair…2030
Description…2033
Operation…2034
Flow Control Valve…2034
Relief Valve…2035
Hydraulic Gear Pump Repair…2035
Remove…2035
Disassemble…2036
Clean…2036
Inspect…2037
Assemble…2040
Install…2042
Pump Output Check…2042
Method No. 1…2042
Method No. 2…2043
Hydraulic System Air Check…2044
Troubleshooting…2045
910102-2100SRM0103-(03-2007)-US-EN…2051
toc…2051
Tilt Cylinders…2051
Safety Precautions Maintenance and Repair…2052
General…2055
Description…2055
Tilt Cylinder Repair…2055
Remove…2055
Disassemble…2055
Clean…2055
Assemble…2055
Tilt Cylinders With O-Ring or Single-Lip Seals…2055
Tilt Cylinders for XM and XMS Models…2057
Tilt Cylinders for XL, XLS, and XL 3 Models…2058
Tilt Cylinders for H700-800A and Early Model H700-920B…2060
Install…2061
Tilt Cylinders Using Chevron Packing…2061
Install…2062
Tilt Cylinder Leak Check…2064
Tilt Cylinder Stroke and Mast Tilt Angle Adjustment…2066
Torque Specifications…2066
Piston Rod Nut…2066
Retainer…2067
Troubleshooting…2069
tables…2051
Table 1. Movement Rates (Maximum) for Tilt Cylinders…2065
910107-2200SRM0106-(12-2004)-US-EN…2073
toc…2073
Starter…2073
Safety Precautions Maintenance and Repair…2074
General…2077
Description and Operation…2077
Starter Repair…2079
Remove…2079
Disassemble…2079
Clean…2080
Assemble…2080
Install…2081
General Checks and Adjustments…2081
Troubleshooting…2084
910110-2200SRM0143-(02-2007)-US-EN…2089
toc…2089
Instrument Panel Indicators and Senders…2089
Safety Precautions Maintenance and Repair…2090
General…2093
Description…2094
Steering Column Gauges, Meters, and Indicators…2094
LED Display Panel…2094
Battery Discharge Indicators…2094
Brush Wear Indicators…2100
Motor Temperature Indicators…2100
LX Series Display Panel…2102
Hourmeter Functions…2103
Battery Indicator Function…2103
Status Code Function…2103
ZX Series Display Panels…2105
Display Panel…2105
Basic Display Panels…2105
Performance Display…2107
Brush Wear Indicators…2111
Adjustments – General…2111
Replacement – General Information…2111
Meter Replacement…2112
Sender Replacement…2113
Fuel Level Sender…2113
Pressure and Temperature Sender…2113
Seat Sensor, Operator Presence System (OPS)…2114
Remove…2114
Install…2114
Operator Presence System Module Replacement…2114
Remove…2115
Install…2116
ITW Display Panel Replacement…2117
Remove…2117
Column Mount Display Panel (EV-100/200ZX Motor Controllers) Repl…2117
Remove…2117
Display Panel Assembly, Replace…2117
Indicator LEDs…2118
Battery Indicators…2118
Digital Display (Performance Display Panel Only)…2118
Status Code or Performance Level Switches and Indicator LEDs (Pe…2119
Basic Display Panel, Replace Parts…2119
Performance Display Panel, Replace Parts…2121
Dash Mount Display Panel (EV100/200ZX Motor Controllers) Replace…2121
Remove and Replace…2121
Specifications…2122
Meter Specifications…2122
Sender Specifications…2122
Troubleshooting…2123
Meter…2123
Troubleshooting for Operator Presence System…2124
tables…2089
Table 1. Troubleshooting Procedure for Operator Presence Module…2124
910119-4000SRM0135-(10-2003)-US-EN…2129
toc…2129
Lift Cylinders…2129
Safety Precautions Maintenance and Repair…2130
Safety Procedures When Working Near Mast…2133
General…2137
Description…2137
Lowering Control Valve…2137
Cylinders (General)…2140
Cylinders (H520-620B, H700-800A)…2140
Retainer, Install…2140
Cylinders (H360-460B)…2142
Cylinders (Two-Speed)…2144
Lift Cylinder Repair…2146
Lift Cylinder Removal Without Removing Mast…2146
Standard Masts With Main Lift Cylinder Fastened to Crossmember o…2146
Standard and Full Free-Lift Masts With Lift Cylinder Fastened to…2146
Masts That Have Two Cylinders, Main Lift Cylinder and Free-Lift …2146
Disassemble…2148
Assemble…2148
Lift Cylinder Installation in Mast…2150
Standard Masts With Main Lift Cylinder Fastened to Crossmember o…2150
Standard and Full Free-Lift Masts With Lift Cylinder Fastened to…2150
Chevron-Style Packing…2150
Chevron-Style Packing Installation on Piston…2151
Chevron-Style Packing Installation in Packing Gland…2153
Lift Cylinders for VISTA® Masts…2154
Description…2154
Lowering Control Valve…2154
Remove…2156
Disassemble…2157
Assemble…2158
Install…2159
Main Lift Cylinders…2159
Free-Lift Cylinder…2159
Lift System Leak Check…2160
Specifications…2161
Troubleshooting…2162
tables…2129
Table 1. Lift Trucks with Two-Speed Lift Cylinders…2145
Table 2. Cylinder Retainer Torque Specifications and Weight Guid…2161
910442-8000SRM0231-(12-2004)-US-EN…2165
toc…2165
Metric and Inch (SAE) Fasteners…2165
Safety Precautions Maintenance and Repair…2166
General…2169
Threaded Fasteners…2169
Nomenclature, Threads…2169
Strength Identification…2170
Cotter (Split) Pins…2170
Fastener Torque Tables…2175
Conversion Table…2177
tables…2165
Table 1. Bolts and Screws…2171
Table 2. Studs and Nuts…2172
Table 3. Torque Nuts…2173
Table 4. Torque Nuts With Nylon Insert…2174
Table 5. Torque Values for Metric Fasteners*…2175
Table 6. Torque Values for Inch Fasteners*…2176
Table 7. Conversion Table for Metric and English Units…2177
Table 8. Cotter Pin Dimensional Data…2178
Table 9. Cotter Pin Dimensional Data…2179
Table 10. Cotter Pin Dimensional Data…2180
Table 11. Cotter Pin Dimensional Data…2182
G006 (H6.00-7.00XL Europe)…2187
1552002-0600SRM1070-(06-2007)-UK-EN…2188
toc…2188
Perkins Diesel Engines…2188
Safety Precautions Maintenance and Repair…2189
General…2196
General Safety Rules…2196
Description…2197
Engine Serial Number Codes…2199
Engine Data…2199
Engine Removal and Installation…2200
Cylinder Head Assembly Repair…2201
Engine Breather…2201
Remove…2201
Install…2201
Valve Cover…2202
Remove…2202
Install…2202
Rocker Arm Assembly…2203
Remove…2203
Disassemble…2203
Inspect…2203
Assemble…2204
Install…2204
Valve Clearance Adjustments…2205
Valve Springs…2205
Cylinder Head Assembly…2207
Remove…2207
Inspect…2208
Install…2208
Valves and Valve Springs…2210
Remove…2210
Inspect…2210
Install…2211
Valve Guides…2211
Inspect…2211
Remove…2212
Install…2212
Valve Seats…2213
Inspect…2213
Repair…2213
New Valve Seats, Install…2214
Piston and Connecting Rod Assemblies Repair…2215
General…2215
Rod Bearings…2215
Remove…2215
Install…2216
Piston and Connecting Rod Assembly…2217
Service Note…2217
Remove…2217
Disassemble…2217
Inspect…2217
How to Select Correct Replacements…2219
Assemble…2219
Install…2220
Piston Cooling Jets…2222
Remove…2222
Install…2222
Crankshaft Assembly Repair…2223
General…2223
Crankshaft Pulley…2223
Remove…2223
Inspect…2223
Install…2223
Rear Oil Seal…2224
Remove…2224
Install…2224
Crankshaft Flange Wear Sleeve…2226
Remove…2226
Install…2226
Main Bearings…2227
Remove…2227
Inspect…2227
Install…2227
Thrust Washers…2228
Crankshaft Axle Movement, Check…2228
Remove…2229
Install…2229
Crankshaft…2230
Remove…2230
Inspect…2230
Install…2231
Crankshaft Timing Ring…2232
Remove…2232
Install…2233
Flywheel…2233
Remove…2233
Ring Gear, Replace…2233
Install…2233
Flywheel Housing…2234
Remove…2234
Install…2234
Timing Case and Timing Gears Repair…2235
General…2235
Timing Case Cover…2235
Remove…2235
Install…2235
Front Oil Seal…2236
Remove, With Timing Case Installed…2236
Install, With Timing Case Installed…2237
Remove, With Timing Case Removed…2238
Install, With Timing Case Removed…2238
Crankshaft Pulley Wear Sleeve, Install…2238
Fuel Pump Gear…2239
Remove…2239
Install…2240
Idler Gear and Hub…2241
Remove…2241
Disassemble…2242
Standard Idler Gear and Hub Assembly…2242
Heavy Duty Idler Gear and Hub Assembly…2242
Assemble…2243
Standard Idler Gear and Hub Assembly…2243
Heavy Duty Idler Gear and Hub Assembly…2243
Install…2244
Camshaft Gear…2244
Remove…2244
Install…2245
Crankshaft Gear…2245
Remove…2245
Install…2245
Timing Case…2246
Remove…2246
Install…2247
Power Take-Off (PTO) Adaptor…2248
Remove…2248
Disassemble…2248
Assemble…2249
Install…2249
Camshaft and Tappets…2249
Remove…2249
Install…2249
Cylinder Block Assembly Repair…2250
General…2250
Cylinder Block…2250
Disassemble…2250
Inspect…2251
Assemble…2251
Cylinder Bore…2251
Inspect…2251
Cylinder Liner Condition Check…2251
Engine Timing…2252
General…2252
How to Set Number One Piston to TDC on Compression Stroke…2252
Fuel Injection Pump Timing, Check…2253
Fuel Injection Pump Timing, Adjust…2254
Lubrication System Repair…2256
General…2256
Oil Filter, Replace…2256
Oil Filter Head…2257
Remove…2257
Install…2257
Oil Sump…2257
Remove…2257
Install…2258
Oil Pump…2259
Remove…2259
Inspect…2259
Install…2259
Oil Strainer and Suction Pipe…2260
Remove…2260
Install…2260
Relief Valve…2261
Remove…2261
Install…2261
Dipstick Tube…2261
Remove and Install…2261
Fuel System Repair…2262
General…2262
Cold Start Advance Unit (KSB)…2262
Typical Fuel System…2263
Fuel Filter…2265
Remove…2265
Install…2265
Fuel Injectors…2266
Remove…2266
Install…2267
Fuel System Air Removal…2268
Bosch EVPE Fuel Injection Pump…2268
General…2268
Remove…2269
Install…2270
Cooling System Repair…2270
General…2270
Thermostat…2272
Remove…2272
Install…2272
Test…2272
Coolant Pump…2273
Remove…2273
Disassemble…2273
Assemble…2274
Install…2275
Fan…2276
Remove and Install…2276
Fan Drive…2276
Remove…2276
Install…2276
Oil Cooler…2276
Remove…2276
Disassemble and Assemble…2277
Install…2277
Coolant Bypass Hose…2277
Removal…2277
Install…2277
Electrical Equipment Repair…2278
Drive Belt…2278
Check…2278
Adjust…2278
Remove…2278
Install…2278
Alternator…2279
Remove…2279
Install…2279
Fault Diagnosis…2279
Normal Operation:…2279
If the Warning Lamp is Not Illuminated When the Ignition Switch …2280
If the Warning Light Continues to be Illuminated When the Altern…2280
Starter Motor…2281
Remove…2281
Install…2281
Test…2281
Starting Aid…2281
Remove…2281
Install…2282
Check…2282
Power Supply Continuity…2282
Operation…2282
Pressure Sensor…2283
Remove…2283
Install…2284
Temperature Sensor…2284
Remove…2284
Install…2285
Engine Specifications…2285
Cylinder Head Assembly…2285
Piston and Connecting Rods…2288
Crankshaft Assembly…2290
Crankshaft Overhaul…2290
Timing Case and Drive Assembly…2292
Engine Block Assembly…2293
Lubrication System…2293
Fuel System…2294
Cooling System…2295
Flywheel and Housing…2296
Electrical Equipment…2296
Torque Specifications…2296
Special Torque Specifications…2297
Cylinder Head Assembly…2297
Piston and Connecting Rod Assemblies…2297
Crankshaft Assembly…2297
Timing Case and Drive Assembly…2297
Cylinder block…2297
Fuel System…2297
Lubrication System…2297
Cooling System…2298
Flywheel and Housing…2298
Electrical Equipment…2298
Special Tools…2299
Troubleshooting…2303
tables…2188
Table 1. Cylinder Head…2285
Table 2. Valve Guides…2286
Table 3. Inlet Valves…2286
Table 4. Exhaust Valves…2287
Table 5. Valve Springs…2288
Table 6. Tappets…2288
Table 7. Rocker Arm Shaft…2288
Table 8. Rocker Arms and Bushings…2288
Table 9. Pistons…2288
Table 10. Piston Rings…2288
Table 11. Piston Pins…2289
Table 12. Connecting Rods…2289
Table 13. Small End Bushings…2289
Table 14. Connecting Rod Bearings…2289
Table 15. Piston Cooling Jets…2290
Table 16. Crankshaft Overhaul Specifications…2290
Table 17. Maximum Variation (Run-out)…2291
Table 18. Camshaft…2292
Table 19. Camshaft Thrust Washer…2292
Table 20. Camshaft Gear…2292
Table 21. Gear for Fuel Pump…2292
Table 22. Crankshaft Gear…2292
Table 23. Idler Gear and Hub…2292
Table 24. Timing Gear Backlash Values…2293
Table 25. Cylinder Block…2293
Table 26. Oil Pump…2293
Table 27. Idler Gear for Oil Pump…2293
Table 28. Relief Valve…2294
Table 29. Oil Filter…2294
Table 30. Bosch Fuel Injection Pump…2294
Table 31. Fuel Injector Settings…2294
Table 32. Fuel Pump…2295
Table 33. Fuel Filter…2295
Table 34. Coolant Pump…2295
Table 35. Thermostat…2295
Table 36. Fan Drive Housing…2295
Table 37. Limits for Flywheel Run Out and Alignment (Total Indic…2296
Table 38. Alternator…2296
Table 39. Starter Motor…2296
Table 40. Starting Aids…2296
Table 41. List of Possible Causes…2304
1559540-0900SRM1088-(05-2006)-UK-EN…2308
toc…2308
Electronic Controlled LPG/Gasoline Fuel System…2308
Safety Precautions Maintenance and Repair…2309
General…2314
Fuel System Warnings and Cautions…2314
Glossary…2315
Description and Operation of LPG Fuel System…2319
Propane Fuel System…2319
LPG Fuel Tank…2321
Service Line…2321
Fuel Filter…2321
Low Pressure Lock-Off (LPL)…2322
Low Pressure Regulator (LPR)…2322
Air Fuel Mixer…2322
Throttle Control Device…2323
Drive By Cable…2323
Three-Way Catalytic (TWC) Muffler…2324
Electronic Control Module (ECM)…2324
Heated Exhaust Gas Oxygen (HEGO) Sensor…2327
Description and Operation of Gasoline Fuel System…2327
Gasoline Fuel System Throttle Body Injection (TBI), 3.0L Engine …2327
Gasoline Multi-Point Fuel Injection (MPFI) System, 4.3L Only…2329
Gasoline Fuel Storage Tank…2329
Gasoline Fuel Pump…2329
Fuel Filter…2329
Fuel Pressure Regulator, 3.0L Only…2331
Fuel Rail and Pressure Regulator, 4.3L Only…2331
Fuel Injector…2331
Throttle Control Device…2331
Drive By Cable…2331
Three-Way Catalytic Muffler…2332
Electronic Control Module (ECM)…2333
Heated Exhaust Gas Oxygen (HEGO) Sensor…2334
LPG Fuel System Repair…2335
Propane Fuel System Pressure Relief…2335
Propane Fuel System Leak Test…2335
Propane Fuel Filter Replacement…2335
Remove…2335
Install…2336
Low Pressure Lock-Off (LPL) Replacement…2336
Remove…2336
Install…2336
Pressure Trim Valve (PTV) Replacement…2338
Remove…2338
Install…2338
Low Pressure Regulator…2338
Remove…2338
Install…2338
Fuel Trim Valve (FTV) Solenoid Replacement…2339
Remove…2339
Install…2339
Temperature Manifold Absolute Pressure (TMAP)…2342
Remove…2342
Install…2342
Throttle Body Replacement…2342
Remove…2342
Install…2343
Mixer Replacement…2343
Remove…2343
Install…2343
Coolant Hose Replacement…2343
Remove…2343
Install…2344
Vapor Hose Replacement…2344
Remove…2344
Install…2344
Balance Line Hose Replacement…2344
Remove…2344
Install…2344
PTV Hose Replacement…2344
Remove…2344
Install…2344
FTV Hose Replacement…2345
Remove…2345
Install…2345
Throttle Position Sensor (TPS) Replacement…2345
Foot Pedal Position (FPP) Sensor Replacement…2347
Electronic Control Module (ECM) Replacement…2350
Remove…2350
Install…2350
Heated Exhaust Gas Oxygen (HEGO) Sensor Replacement…2351
Remove…2351
Install…2351
Three-Way Catalytic Muffler (TWC) Replacement…2351
Remove…2351
Install…2351
Restricted Exhaust System Diagnosis…2351
Exhaust System Description…2351
Tools Required…2351
Diagnostic Tool…2351
Check at Heated Exhaust Gas Oxygen Sensor (HEGO)…2352
Gasoline Fuel System Repair…2352
Gasoline MPFI and TBI Fuel System Pressure Relief…2352
Gasoline Fuel System Leak Test…2353
Throttle Body Injector (TBI) Assembly Replacement, 3.0L Only…2353
Remove…2353
Install…2353
Throttle Body Assembly Replacement, 3.0L Only…2355
Remove…2355
Install…2355
Throttle Body Assembly Replacement, 4.3L Only…2355
Remove…2355
Install…2356
Fuel Rail Replacement, Gasoline 4.3L Only…2358
Remove…2358
Install…2358
Injector Replacement, Gasoline 4.3L Only…2358
Remove…2358
Install…2358
Injector Replacement, Gasoline 3.0L Only…2359
Remove…2359
Install…2359
Temperature Manifold Absolute Pressure (TMAP) Replacement…2359
Remove…2359
Install…2359
Throttle Position Sensor (TPS) Replacement…2359
Foot Pedal Position (FPP) Sensor Replacement…2362
Electronic Control Module (ECM) Replacement…2365
Remove…2365
Install…2365
Heated Exhaust Gas Oxygen (HEGO) Sensor Replacement…2365
Remove…2365
Install…2366
Three-Way Catalytic Muffler (TWC) Replacement…2366
Remove…2366
Install…2366
Restricted Exhaust System Diagnosis…2366
Exhaust System Description…2366
Tools Required…2366
Diagnostic Tool…2366
Check at Heated Exhaust Gas Oxygen Sensor (HEGO)…2366
LPG System Diagnosis…2367
Fuel System Description…2367
Diagnostic Aids…2368
Tools Required…2368
Duty Cycle Monitoring Tool…2368
Diagnostic Tool…2368
Pressure Gauges…2368
Test Description…2368
Gasoline System Diagnosis…2376
Fuel System Description, 3.0L Only…2376
Fuel System Description, 4.3L Only…2376
Diagnostic Aids…2377
Tools Required…2377
Diagnostic Tool…2377
Test Description…2377
LPG Symptom Diagnosis…2384
Gasoline Symptom Diagnosis…2398
Wire Harness Repair…2408
On Vehicle Service Wiring Harness Repair…2408
Connectors and Terminals…2409
Twisted/Shielded Cable Repair…2409
Twisted Leads Repair…2410
Micro-Pack…2411
Metri-Pack…2412
Remove…2412
Weather-Pack…2413
Weather-Pack Terminal Repair…2414
tables…2308
Table 1. TPS Replacement Procedure…2345
Table 2. FPP Replacement Procedure…2348
Table 3. TPS Replacement Procedure…2360
Table 4. FPP Replacement Procedure…2363
Table 5. LPG Fuel System Diagnosis…2368
Table 6. Fuel Control Diagnosis…2372
Table 7. Gasoline Fuel System Diagnosis, 3.0L Only…2378
Table 8. Gasoline Fuel System Diagnosis, 4.3L Only…2381
Table 9. Preliminary Checks…2384
Table 10. Intermittent …2386
Table 11. No Start…2387
Table 12. Hard Start…2389
Table 13. Cuts Out or Misses…2390
Table 14. Hesitation, Sag, or Stumble…2391
Table 15. Backfire…2392
Table 16. Lack of Power, Sluggishness, or Sponginess…2393
Table 17. Poor Fuel Economy…2394
Table 18. Rough, Unstable, Incorrect Idle, or Stalling…2395
Table 19. Surges or Chuggles…2397
Table 20. Preliminary Checks…2398
Table 21. Intermittent…2399
Table 22. No Start…2400
Table 23. Hard Start…2401
Table 24. Cuts Out or Misses…2402
Table 25. Hesitation, Sag, or Stumble…2403
Table 26. Backfire…2404
Table 27. Lack of Power, Sluggishness, or Sponginess…2405
Table 28. Poor Fuel Economy…2406
Table 29. Rough, Unstable, Incorrect Idle, or Stalling…2407
Table 30. Surges or Chuggles…2408
1559545-2200SRM1090-(04-2005)-UK-EN…2418
toc…2418
Electronic Control Module (ECM) Diagnostic Troubleshooting…2418
Safety Precautions Maintenance and Repair…2419
General…2428
Description of ECM Based Diagnostics…2428
Definition of Terms…2428
Diagnostics Overview of the Spectrum Fuel System…2428
Malfunction Indicator Lamp (MIL)…2429
Spectrum Diagnostic Trouble Codes (DTC)…2429
Using a Laptop Computer to Diagnose the Spectrum System…2429
Installing the Spectrum Diagnostic Software…2430
Connecting a Laptop Computer to the Spectrum System…2430
Diagnostic Communication Error…2430
Diagnostic Trouble Codes…2431
Checking Diagnostic Trouble Codes…2431
Clearing Diagnostic Trouble Codes…2431
DATA Stream…2432
Reading Sensor and Actuator Values…2432
Graphing and Data Logging…2433
Ignition System Test…2434
Disabling Ignition Outputs…2434
Injector Test…2435
Disabling Injectors…2435
Throttle Test…2435
Using a Diagnostic Jumper to Diagnose the ECI System…2436
On-Board Diagnostics System Check/Malfunction Indicator Lamp…2437
Circuit Description…2437
Preliminary and Intermittent Checks…2440
GM 3.0L Wiring Schematics and Connectors…2442
GM 3.0L Diagnostic Trouble Codes…2456
DTC 111 – IAT High Voltage Motorola® TMAP…2456
Circuit Description…2456
Conditions for Setting the DTC…2456
DTC 112 – IAT Low Voltage Motorola® TMAP…2459
Circuit Description…2459
Conditions for Setting the DTC…2459
DTC 113 – IAT Higher Than Expected 1 Motorola® TMAP…2461
Circuit Description…2461
Conditions for Setting the DTC…2461
Diagnostic Aids…2462
DTC 114 – IAT Higher Than Expected 2 Motorola® TMAP…2463
Circuit Description…2463
Conditions for Setting the DTC…2463
Diagnostic Aids…2463
DTC 115 – Oil Pressure Low…2464
Circuit Description…2464
Conditions for Setting the DTC…2464
DTC 121 – ECT Voltage High…2467
Circuit Description…2467
Conditions for Setting the DTC…2468
DTC 122 – ECT Voltage Low…2471
Circuit Description…2471
Conditions for Setting the DTC…2471
DTC 123 – ECT Higher Than Expected 1…2473
Circuit Description…2473
Conditions for Setting the DTC…2473
DTC 124 – ECT Higher Than Expected 2…2475
Circuit Description…2475
Conditions for Setting the DTC…2475
DTC 131 – MAP High Pressure Motorola® TMAP…2477
Circuit Description…2477
Conditions for Setting the DTC…2477
Diagnostic Aids…2477
DTC 132 – MAP Low Voltage Motorola® TMAP…2480
Circuit Description…2480
Conditions for Setting the DTC…2480
DTC 134 – BP High Pressure Motorola® TMAP…2484
Circuit Description…2484
Conditions for Setting the DTC…2484
DTC 135 – BP Low Pressure Motorola® TMAP…2485
Circuit Description…2485
Conditions for Setting the DTC…2485
DTC 142 – Crank Sync Noise…2489
Circuit Description…2489
Conditions for setting the DTC…2489
DTC 143 – Never Crank Synced At Start…2493
Circuit Description…2493
Conditions for Setting the DTC…2493
DTC 144 – Camshaft Sensor Loss…2496
Circuit Description…2496
Conditions for Setting the DTC…2496
DTC 145 – Camshaft Sensor Noise…2499
Circuit Description…2499
Conditions for Setting the DTC…2499
DTC 211 – Closed Loop Multiplier High (LPG)…2502
Circuit Description…2502
Conditions for Setting the DTC…2502
Diagnostic Aids…2502
DTC 212 – HO 2 S Open/Inactive…2505
Circuit Description…2505
Conditions for Setting the DTC…2505
DTC 221 – Closed Loop Multiplier High (Gasoline)…2507
Circuit Description…2507
Conditions for Setting the DTC…2507
Diagnostic Aids…2508
DTC 222 – Closed Loop Multiplier Low (Gasoline)…2511
Circuit Description…2511
Conditions for Setting the DTC…2511
Diagnostic Aids…2511
DTC 224 – Closed Loop Multiplier Low (LPG)…2513
Circuit Description…2513
Conditions for Setting the DTC…2513
Diagnostic Aids…2513
DTC 241 – Adaptive Lean Fault (High Limit-Gasoline)…2515
Circuit Description…2515
Conditions for Setting the DTC…2515
Diagnostic Aids…2515
DTC 242 – Adaptive Rich Fault (Low Limit-Gasoline)…2518
Circuit Description…2518
Conditions for Setting the DTC…2518
Diagnostic Aids…2518
DTC 243 – Adaptive Learn High (LPG)…2521
Circuit Description…2521
Conditions for Setting the DTC…2521
Diagnostic Aids…2521
DTC 244 – Adaptive Learn Low (LPG)…2524
Circuit Description…2524
Conditions for Setting the DTC…2524
Diagnostic Aids…2524
DTC 261 – System Voltage High…2527
Circuit Description…2527
Conditions for Setting the DTC…2527
DTC 262 – System Voltage Low…2529
Circuit Description…2529
Conditions for Setting the DTC…2529
DTC 411 – Injector Driver 1 Open…2531
Circuit Description…2531
Conditions for Setting the DTC…2531
DTC 412 – Injector Driver 1 Shorted…2534
Circuit Description…2534
Conditions for Setting the DTC…2534
DTC 511 – COP Failure…2537
Circuit Description…2537
Conditions for Setting the DTC…2537
DTC 512 – Invalid Interrupt…2539
Circuit Description…2539
Conditions for Setting the DTC…2539
DTC 513 – A/D Loss…2541
Circuit Description…2541
Conditions for Setting the DTC…2541
DTC 514 – RTI 1 Loss…2543
Circuit Description…2543
Conditions for Setting the DTC…2543
DTC 515 – Flash Checksum Invalid…2545
Circuit Description…2545
Conditions for Setting the DTC…2545
DTC 516 – Ram Failure…2547
Circuit Description…2547
Conditions for Setting the DTC…2547
DTC 531 – External 5V Ref Lower Than Expected…2549
Circuit Description…2549
Conditions for Setting the DTC…2549
DTC 532 – External 5V Ref Higher Than Expected…2551
Circuit Description…2551
Conditions for Setting the DTC…2551
DTC 555 – RTI 2 Loss…2553
Circuit Description…2553
Conditions for Setting the DTC…2553
DTC 556 – RTI 3 Loss…2555
Circuit Description…2555
Conditions for Setting the DTC…2555
DTC 611 – FPP High Voltage…2557
Circuit Description…2557
Conditions for Setting the DTC…2557
DTC 612 – FPP Low Voltage…2561
Circuit Description…2561
Conditions for Setting the DTC…2561
DTC 631 – TPS1 Signal Voltage High…2565
Circuit Description…2565
Conditions for Setting the DTC…2565
DTC 632 – TPS1 Signal Voltage Low…2568
Circuit Description…2568
Conditions for Setting the DTC…2568
DTC 638 – Throttle Unable To Close…2571
Circuit Description…2571
Conditions for Setting the DTC…2571
Diagnostic Aids…2572
DTC 651 – Maximum Govern Speed Override…2574
Circuit Description…2574
Conditions for Setting the DTC…2574
Diagnostic Aids…2574
DTC 652 – Fuel Rev Limit…2577
Circuit Description…2577
Conditions for Setting the DTC…2577
Diagnostic Aids…2577
DTC 653 – Spark Rev Limit…2579
Circuit Description…2579
Conditions for Setting the DTC…2579
Diagnostic Aids…2579
GM 4.3L Wiring Schematics and Connectors…2583
GM 4.3L Diagnostic Trouble Codes…2600
DTC 111 – IAT High Voltage Bosch® TMAP…2600
Circuit Description…2600
Conditions for Setting the DTC…2600
DTC 111 – IAT High Voltage Motorola® TMAP…2603
Circuit Description…2603
Conditions for Setting the DTC…2603
DTC 112 – IAT Low Voltage Bosch® TMap…2605
Circuit Description…2605
Conditions for Setting the DTC…2606
DTC 112 – IAT Low Voltage Motorola® TMAP…2608
Circuit Description…2608
Conditions for Setting the DTC…2608
DTC 113 – IAT Higher Than Expected 1 Bosch® TMAP…2611
Circuit Description…2611
Conditions for Setting the DTC…2611
Diagnostic Aids…2611
DTC 113 – IAT Higher Than Expected 1 Motorola® TMAP…2612
Circuit Description…2612
Conditions for Setting the DTC…2612
Diagnostic Aids…2612
DTC 114 – IAT Higher Than Expected 2 Bosch® TMAP€…2613
Circuit Description…2613
Conditions for Setting the DTC…2613
Diagnostic Aids…2613
DTC 114 – IAT Higher Than Expected 2 Motorola® TMAP…2614
Circuit Description…2614
Conditions for Setting the DTC…2614
Diagnostic Aids…2614
DTC 115 – Oil Pressure Low…2615
Circuit Description…2615
Conditions for Setting the DTC…2615
DTC 121 – ECT Voltage High…2617
Circuit Description…2617
Conditions for Setting the DTC…2618
DTC 122 – ECT Voltage Low…2621
Circuit Description…2621
Conditions for Setting the DTC…2621
DTC 123 – ECT Higher Than Expected 1…2624
Circuit Description…2624
Conditions for Setting the DTC…2624
DTC 124 – ECT Higher Than Expected 2…2626
Circuit Description…2626
Conditions for Setting the DTC…2626
DTC 131 – MAP High Pressure Bosch® TMAP…2627
Circuit Description…2627
Conditions for Setting the DTC…2627
Diagnostic Aids…2627
DTC 131 – MAP High Pressure Motorola® TMAP…2631
Circuit Description…2631
Conditions for Setting the DTC…2631
Diagnostic Aids…2631
DTC 132 – MAP Low Voltage Bosch® TMAP…2634
Circuit Description…2634
Conditions for Setting the DTC…2634
DTC 132 – MAP Low Voltage Motorola® TMAP…2637
Circuit Description…2637
Conditions for Setting the DTC…2637
DTC 134 – BP High Pressure Bosch® TMAP…2642
Circuit Description…2642
Conditions for Setting the DTC…2642
DTC 134 – BP High Pressure Motorola® TMAP…2644
Circuit Description…2644
Conditions for Setting the DTC…2644
DTC 135 – BP Low Pressure Bosch® TMAP…2646
Circuit Description…2646
Conditions for Setting the DTC…2646
DTC 135 – BP Low Pressure Motorola® TMAP…2650
Circuit Description…2650
Conditions for Setting the DTC…2650
DTC 142 – Crank Sync Noise…2653
Circuit Description…2653
Conditions for setting the DTC…2653
DTC 143 – Never Crank Synced At Start…2657
Circuit Description…2657
Conditions for Setting the DTC…2657
DTC 144 – Camshaft Sensor Loss…2660
Circuit Description…2660
Conditions for Setting the DTC…2660
DTC 145 – Camshaft Sensor Noise…2663
Circuit Description…2663
Conditions for Setting the DTC…2663
DTC 211 – Closed Loop Multiplier High (LPG)…2666
Circuit Description…2666
Conditions for Setting the DTC…2666
Diagnostic Aids…2667
DTC 212 – HO 2 S Open/Inactive…2669
Circuit Description…2669
Conditions for Setting the DTC…2669
DTC 221 – Closed Loop Multiplier High (Gasoline)…2672
Circuit Description…2672
Conditions for Setting the DTC…2672
Diagnostic Aids…2672
DTC 222 – Closed Loop Multiplier Low (Gasoline)…2675
Circuit Description…2675
Conditions for Setting the DTC…2675
Diagnostic Aids…2675
DTC 224 – Closed Loop Multiplier Low (LPG)…2677
Circuit Description…2677
Conditions for Setting the DTC…2677
Diagnostic Aids…2678
DTC 241 – Adaptive Lean Fault (High Limit-Gasoline)…2679
Circuit Description…2679
Conditions for Setting the DTC…2679
Diagnostic Aids…2679
DTC 242 – Adaptive Rich Fault (Low Limit-Gasoline)…2682
Circuit Description…2682
Conditions for Setting the DTC…2682
Diagnostic Aids…2682
DTC 243 – Adaptive Learn High (LPG)…2685
Circuit Description…2685
Conditions for Setting the DTC…2685
Diagnostic Aids…2685
DTC 244 – Adaptive Learn Low (LPG)…2688
Circuit Description…2688
Conditions for Setting the DTC…2688
Diagnostic Aids…2688
DTC 261 – System Voltage High…2691
Circuit Description…2691
Conditions for Setting the DTC…2691
DTC 262 – System Voltage Low…2693
Circuit Description…2693
Conditions for Setting the DTC…2693
DTC 511 – COP Failure…2695
Circuit Description…2695
Conditions for Setting the DTC…2695
DTC 512 – Invalid Interrupt…2697
Circuit Description…2697
Conditions for Setting the DTC…2697
DTC 513 – A/D Loss…2699
Circuit Description…2699
Conditions for Setting the DTC…2699
DTC 514 – RTI 1 Loss…2701
Circuit Description…2701
Conditions for Setting the DTC…2701
DTC 515 – Flash Checksum Invalid…2703
Circuit Description…2703
Conditions for Setting the DTC…2703
DTC 516 – Ram Failure…2705
Circuit Description…2705
Conditions for Setting the DTC…2705
DTC 531 – External 5V Ref Lower Than Expected…2707
Circuit Description…2707
Conditions for Setting the DTC…2707
DTC 532 – External 5V Ref Higher Than Expected…2709
Circuit Description…2709
Conditions for Setting the DTC…2709
DTC 555 – RTI 2 Loss…2711
Circuit Description…2711
Conditions for Setting the DTC…2711
DTC 556 – RTI 3 Loss…2713
Circuit Description…2713
Conditions for Setting the DTC…2713
DTC 611 – FPP High Voltage…2715
Circuit Description…2715
Conditions for Setting the DTC…2715
DTC 612 – FPP Low Voltage…2719
Circuit Description…2719
Conditions for Setting the DTC…2719
DTC 631 – TPS1 Signal Voltage High…2723
Circuit Description…2723
Conditions for Setting the DTC…2723
DTC 632 – TPS1 Signal Voltage Low…2726
Circuit Description…2726
Conditions for Setting the DTC…2726
DTC 638 – Throttle Unable To Close…2729
Circuit Description…2729
Conditions for Setting the DTC…2729
Diagnostic Aids…2730
DTC 651 – Maximum Govern Speed Override…2732
Circuit Description…2732
Conditions for Setting the DTC…2732
Diagnostic Aids…2732
DTC 652 – Fuel Rev Limit…2735
Circuit Description…2735
Conditions for Setting the DTC…2735
Diagnostic Aids…2735
DTC 653 – Spark Rev Limit…2737
Circuit Description…2737
Conditions for Setting the DTC…2737
Diagnostic Aids…2737
Wire Harness Repair…2740
On Vehicle Service Wiring Harness Repair…2740
Connectors and Terminals…2741
Twisted/Shielded Cable Repair…2741
Twisted Leads Repair…2742
Micro-Pack…2743
Metri-Pack…2743
Remove…2743
Weather-Pack…2745
Weather-Pack Terminal Repair…2746
tables…2418
Table 1. OBD System Check…2438
Table 2. Preliminary Checks…2440
Table 3. Intermittent Checks…2441
Table 4. Communication Port C002…2442
Table 5. Coil Connector C003…2442
Table 6. Fuel System Interface C004…2442
Table 7. Oil Pressure Connector C005…2443
Table 8. Distributor Connector C006…2443
Table 9. Magnetic Pickup Connector C007…2443
Table 10. Heated Oxygen Sensor C008…2443
Table 11. Throttle Position Sensor Connector C009…2444
Table 12. Foot Pedal Position Connector C010…2444
Table 13. Governor Motor Connector C011…2444
Table 14. TMAP Connector C012…2444
Table 15. Starter Solenoid C013…2445
Table 16. Engine Coolant Temperature C014…2445
Table 17. Battery Connector C015…2445
Table 18. Alternator Connection C016…2445
Table 19. Battery Connector C017…2445
Table 20. Alternator Connector C018…2446
Table 21. Instrument Panel Connector C019…2446
Table 22. Instrument Panel Connector C020…2446
Table 23. Instrument Panel Connector C021…2447
Table 24. Fuel Trim Valve Connector C022…2447
Table 25. Fuel Lockoff Connector C023…2447
Table 26. Pressure Trim Valve Connector C024…2448
Table 27. Throttle Body Injector Connector C025…2448
Table 28. Relay and Fuse Center…2448
Table 29. DTC 111 – IAT Voltage High (Motorola® TMAP)…2457
Table 30. DTC 112 – IAT Low Voltage (Motorola® TMAP)…2460
Table 31. DTC 115 – Oil Pressure Low…2465
Table 32. Temperature Resistance…2467
Table 33. DTC 121 – ECT VOLTAGE HIGH…2468
Table 34. DTC 122 – ECT Voltage Low…2472
Table 35. DTC 123 – ECT Higher Than Expected 1…2474
Table 36. DTC 124 – ECT Higher Than Expected 2…2476
Table 37. DTC 131 – MAP HIGH PRESSURE (Motorola® TMAP)…2478
Table 38. DTC 132 – MAP Low Voltage (Motorola® TMAP)…2481
Table 39. DTC 134 – BP High Pressure (Motorola® TMAP)…2484
Table 40. DTC 135 – BP Low Pressure (Motorola® TMAP)…2486
Table 41. DTC 142 – Crank Sync Noise…2490
Table 42. DTC 143 – Never Crank Synced At Start…2493
Table 43. DTC 144 – Camshaft Sensor Loss…2496
Table 44. DTC 145 – Camshaft Sensor Noise…2499
Table 45. DTC 211 – Closed Loop Multiplier High (LPG)…2503
Table 46. DTC 212 – HO 2 S Open/Inactive…2506
Table 47. DTC 221 – Closed Loop Multiplier High (Gasoline)…2509
Table 48. DTC 222 – Closed Loop Multiplier Low (Gasoline)…2512
Table 49. DTC 224 – Closed Loop Multiplier Low (LPG)…2514
Table 50. DTC 241 – Adaptive Lean Fault (High Limit-Gasoline)…2516
Table 51. DTC 242 – Adaptive Rich Fault (Low Limit-Gasoline)…2519
Table 52. DTC 243 – Adaptive Learn High (LPG)…2522
Table 53. DTC 244 – Adaptive Learn Low (LPG)…2525
Table 54. DTC 261 – System Voltage High…2528
Table 55. DTC 262 – System Voltage Low…2529
Table 56. DTC 411 – Injector Driver 1 Open…2532
Table 57. DTC 412 – Injector Driver 1 Shorted…2535
Table 58. DTC 511 – COP Failure…2538
Table 59. DTC 512 – Invalid Interrupt…2540
Table 60. DTC 513 – A/D Loss…2542
Table 61. DTC 514 – RTI 1 Loss…2544
Table 62. DTC 515 – Flash Checksum Invalid…2546
Table 63. DTC 516 – Ram Failure…2548
Table 64. DTC 531 – External 5V Ref Lower Than Expected…2550
Table 65. DTC 532 – External 5 V Ref Higher Than Expected…2552
Table 66. DTC 555 – RTI 2 Loss…2554
Table 67. DTC 556 – RTI 3 Loss…2556
Table 68. DTC 611 – FPP High Voltage…2558
Table 69. DTC 612 – FPP Low Voltage…2562
Table 70. DTC 631 – TPS1 Signal Voltage High…2566
Table 71. DTC 632 – TPS1 Signal Voltage Low…2569
Table 72. DTC 638 – Throttle Unable To Close…2572
Table 73. DTC 651 – Maximum Govern Speed Override…2575
Table 74. DTC 652 – Fuel Rev Limit…2578
Table 75. DTC 653 – Spark Rev Limit…2580
Table 76. Communication Port C002…2583
Table 77. Injector Connector C003…2583
Table 78. Injector Connector C004…2583
Table 79. Oil Pressure Connector C005…2584
Table 80. Throttle Position Sensor 1 Connector C006…2584
Table 81. Foot Pedal Position Connector C006A…2584
Table 82. Coil Connector C007…2584
Table 83. Module Connector C008…2585
Table 84. Crank Sensor Connector C009…2585
Table 85. EGO Sensor Connector C010…2585
Table 86. Cam Connector C011…2586
Table 87. Throttle Connector C012…2586
Table 88. Bosch TMAP Connector C013 (Gasoline Fuel System Only)…2586
Table 89. Motorola TMAP Connector C013 (LPG Fuel System Only)…2587
Table 90. Starter Solenoid Connector C014…2587
Table 91. ECT Connector C015…2587
Table 92. Starter Relay C016…2587
Table 93. Power Relay C017…2587
Table 94. Fuel Pump Relay C018…2587
Table 95. Battery Connector C019…2588
Table 96. Alternator Connector C020…2588
Table 97. Alternator Connector C021…2588
Table 98. Instrument Panel Connector C022…2588
Table 99. Instrument Panel Connector C023…2589
Table 100. Instrument Panel Connector C024…2589
Table 101. Fuel Trim Valve Connector C025…2589
Table 102. Fuel Lockoff Connector C026…2590
Table 103. Pressure Trim Valve Connector C027…2590
Table 104. Injector 1 Connector C028…2590
Table 105. Injector 2 Connector C029…2591
Table 106. Injector 3 Connector C030…2591
Table 107. Injector 4 Connector C031…2591
Table 108. Injector 5 Connector C032…2592
Table 109. Injector 6 Connector C033…2592
Table 110. Relay and Fuse Center…2592
Table 111. DTC 111 – IAT Voltage High (Bosch® TMAP)…2601
Table 112. DTC 111 – IAT Voltage High (Motorola® TMAP)…2604
Table 113. DTC 112 – IAT Low Voltage (Bosch® TMAP)…2606
Table 114. DTC 112 – IAT Low Voltage (Motorola® TMAP)…2609
Table 115. DTC 115 – Oil Pressure Low…2615
Table 116. Temperature Resistance…2618
Table 117. DTC 121 – ECT VOLTAGE HIGH…2619
Table 118. DTC 122 – ECT Voltage Low…2622
Table 119. DTC 123 – ECT Higher Than Expected 1…2625
Table 120. DTC 124 – ECT Higher Than Expected 2…2627
Table 121. DTC 131 – MAP High Pressure (Bosch® TMAP)…2628
Table 122. DTC 131 – MAP HIGH PRESSURE (Motorola® TMAP)…2632
Table 123. DTC 132 – MAP Low Voltage (Bosch® TMAP)…2635
Table 124. DTC 132 – MAP Low Voltage (Motorola® TMAP)…2638
Table 125. DTC 134 – BP High Pressure (Bosch® TMAP)…2643
Table 126. DTC 134 – BP High Pressure (Motorola® TMAP)…2645
Table 127. DTC 135 – BP Low Pressure (Bosch® TMAP)…2646
Table 128. DTC 135 – BP Low Pressure (Motorola® TMAP)…2650
Table 129. DTC 142 – Crank Sync Noise…2654
Table 130. DTC 143 – Never Crank Synced At Start…2657
Table 131. DTC 144 – Camshaft Sensor Loss…2660
Table 132. DTC 145 – Camshaft Sensor Noise…2663
Table 133. DTC 211 – Closed Loop Multiplier High (LPG)…2667
Table 134. DTC 212 – HO 2 S Open/Inactive…2670
Table 135. DTC 221 – Closed Loop Multiplier High (Gasoline)…2673
Table 136. DTC 222 – Closed Loop Multiplier Low (Gasoline)…2676
Table 137. DTC 224 – Closed Loop Multiplier Low (LPG)…2678
Table 138. DTC 241 – Adaptive Lean Fault (High Limit-Gasoline)…2680
Table 139. DTC 242 – Adaptive Rich Fault (Low Limit-Gasoline)…2683
Table 140. DTC 243 – Adaptive Learn High (LPG)…2686
Table 141. DTC 244 – Adaptive Learn Low (LPG)…2689
Table 142. DTC 261 – System Voltage High…2692
Table 143. DTC 262 – System Voltage Low…2693
Table 144. DTC 511 – COP Failure…2696
Table 145. DTC 512 – Invalid Interrupt…2698
Table 146. DTC 513 – A/D Loss…2700
Table 147. DTC 514 – RTI 1 Loss…2702
Table 148. DTC 515 – Flash Checksum Invalid…2704
Table 149. DTC 516 – Ram Failure…2706
Table 150. DTC 531 – External 5V Ref Lower Than Expected…2708
Table 151. DTC 532 – External 5 V Ref Higher Than Expected…2710
Table 152. DTC 555 – RTI 2 Loss…2712
Table 153. DTC 556 – RTI 3 Loss…2714
Table 154. DTC 611 – FPP High Voltage…2716
Table 155. DTC 612 – FPP Low Voltage…2719
Table 156. DTC 631 – TPS1 Signal Voltage High…2724
Table 157. DTC 632 – TPS1 Signal Voltage Low…2727
Table 158. DTC 638 – Throttle Unable To Close…2730
Table 159. DTC 651 – Maximum Govern Speed Override…2733
Table 160. DTC 652 – Fuel Rev Limit…2736
Table 161. DTC 653 – Spark Rev Limit…2739
1559550-2200SRM1097-(07-2008)-UK-EN…2750
toc…2750
High Voltage Switch (HVS) Ignition…2750
Safety Precautions Maintenance and Repair…2751
Description…2754
Distributor Ignition (DI) System…2754
Crankshaft Position (CKP) Sensor…2754
Camshaft Position (CMP) Sensor…2754
Ignition Coil and Ignition Control Module (ICM)…2754
Secondary Ignition Components…2754
Spark Plugs and Wires…2754
Spark Plug Wire Inspection…2754
Spark Plug Wire Replacement…2754
Remove…2754
Install…2755
Spark Plug Inspection…2755
Usage…2755
Inspection…2755
Visual Inspection…2757
Spark Plug Replacement…2757
Remove…2757
Install…2758
Distributor Repair…2758
Inspect…2758
Overhaul…2759
Disassemble…2759
Assemble…2761
Replace…2762
Remove…2762
Install Procedure 1…2764
Install Procedure 2…2764
Ignition Coil Replacement…2766
Remove…2766
Install…2766
Ignition Control Module Replacement…2767
Remove…2767
Install…2767
Camshaft Position (CMP) Sensor Replacement…2768
Remove…2768
Install…2769
Crankshaft Position (CKP) Sensor Replacement…2770
Remove…2770
Install…2770
Wire Harness Repair…2771
On Vehicle Service Wiring Harness Repair…2771
Connectors and Terminals…2771
Twisted/Shielded Cable Repair…2772
Twisted Leads Repair…2773
Micro-Pack…2774
Metri-Pack…2774
Remove…2774
Weather-Pack…2776
Weather-Pack Terminal Repair…2776
Specifications and Special Tools…2778
System Diagnosis…2779
tables…2750
Table 1. Ignition System Specifications…2778
Table 2. Fastener Tightening Specifications…2778
Table 3. Special Tools…2779
Table 4. Distributor Ignition (DI)…2779
897104-0100SRM0322-(02-2007)-UK-EN…2788
toc…2788
Frame…2788
Safety Precautions Maintenance and Repair…2789
General…2792
Description…2792
Counterweight Repair…2793
Remove…2793
Install…2793
Hood Repair…2794
Remove…2794
Install…2794
Overhead Guard Repair…2794
Remove…2794
Install…2794
Operator Restraint System Repair…2795
Automatic Locking Retractor (ALR)…2795
Emergency Locking Retractor (ELR)…2795
Hydraulic Tank Repair…2797
Remove…2797
Inspect…2797
Small Leaks Repair…2797
Large Leaks Repair…2797
Clean…2797
Steam Method…2798
Chemical Solution Method…2798
Other Methods of Preparation for Repair…2798
Install…2798
Fuel Tank Repair…2799
Remove…2799
Repair…2799
Install…2799
Radiator Repair…2799
Remove…2799
Install…2799
Engine Repair…2800
Remove…2800
Install…2800
Throttle Pedal Adjustment…2802
Perkins 1104C-44(RE) Diesel Engine…2802
Safety Labels…2803
Cab Repair…2805
Cab, Replace…2805
Window, Replace…2805
Windshield Wipers and Heater…2805
tables…2788
Table 1. Material Specifications for Cab Windows…2807
897106-1300SRM0324-(10-2003)-UK-EN…2810
toc…2810
Two-Speed Powershift Transmission…2810
Safety Precautions Maintenance and Repair…2811
General…2814
Mechanical Description…2814
Torque Converter…2814
Transmission Pump…2815
Shaft Assemblies…2815
Input Shaft…2816
Forward Clutch Shaft…2816
Clutch Assemblies…2816
Countershaft…2823
Output Shaft…2823
Hydraulic Operation…2824
Torque Converter…2824
Seal Rings…2825
Control Valve…2825
System Pressure Regulator…2828
Clutch Pressure Regulator…2828
Torque Converter Regulator…2829
Inching Spool…2829
Direction Spool, Direction Control Lever…2829
Direction Spool, MONOTROL Pedal…2830
Range Spool…2830
Drain Spool…2831
Accumulator…2831
Modulator Spool…2831
Operation…2831
Lubrication Circuit…2832
MONOTROL Pedal…2832
Oil Flow Diagrams…2834
Neutral…2834
Forward-Low…2835
Forward-Low-Inching…2836
Reverse-Low…2837
897107-1300SRM0325-(10-2003)-UK-EN…2840
toc…2840
Two-Speed Powershift Transmission…2840
Safety Precautions Maintenance and Repair…2841
General…2844
Transmission Repair…2844
Transmission and Torque Converter, Remove…2844
Transmission, Disassemble…2846
Reverse-Low Clutch, Disassemble…2849
Reverse-High Clutch, Disassemble…2852
Forward-Low Clutch, Disassemble…2855
Forward-High Clutch, Disassemble…2858
Clean and Inspect…2860
Forward Low and High Clutches Assembly…2861
Forward Clutches, Assemble…2863
Reverse-Low Clutch, Assemble…2869
Reverse Clutches, Assemble…2871
Transmission, Assemble…2878
Torque Converter, Install…2885
Control Valve Repair…2886
Remove…2886
Disassemble…2887
Assemble…2888
Install…2890
MONOTROL Pedal…2890
Remove and Disassemble…2890
Assemble and Install…2890
Stall Test…2893
Linkage Adjustments…2894
Linkage for Inching Pedal H6.00-7.00XL (H135-155XL, H135-155XL 2…2894
Linkage for Inching Pedal S6.00-7.00XL (S135-155XL, S135-155XL 2…2897
Linkage for Range Lever – Early Model H6.00-7.00XL (H135-155XL) …2900
Linkage for Direction Control Lever – Early Model H6.00-7.00XL (…2900
Linkage for Range Lever – Later Model H6.00-7.00XL (H135-155XL, …2902
Linkage for Direction Control Lever – Later Model H6.00-7.00XL (…2904
Linkage for Range Lever S6.00-7.00XL (S135-155XL, S135-155XL 2 )…2906
Linkage for Direction Control Lever S6.00-7.00XL (S135-155XL, S1…2906
Oil Pressure Check…2908
System Pressure Check Port…2908
Torque Converter Check Port…2908
Clutch Pressure Check Port…2908
Inching Pressure…2909
Solenoid Check Ports (MONOTROL Control Only)…2909
Lubrication Pressure Check Ports…2909
Specifications…2910
Troubleshooting…2910
Correct System Pressure: 1300 ±124 kPa ( 189 ±18 psi)…2913
Correct Clutch Pressure: 924 ±69 kPa ( 134 ±10 psi)…2914
Correct Solenoid Pressure (MONOTROL Only): 965 ±138 kPa ( 140 ±2…2915
Torque Converter Pressure: 834 ±69 kPa ( 121 ±10 psi)…2915
Lubrication Pressure: 83 ±21 kPa ( 12 ±3 psi)…2915
tables…2840
Table 1. Stall Speed Specifications…2893
897108-1600SRM0326-(03-2007)-UK-EN…2918
toc…2918
Steering Axle…2918
Safety Precautions Maintenance and Repair…2919
General…2922
Description…2922
Steering Axle Assembly Repair…2927
Steering Axle H3.50-5.00XL (H70-110XL) (G005), S3.50-5.50XL (S70…2927
Remove…2927
Install…2927
Steering Axle H6.00-7.00XL (H135-155XL, H135-155XL 2 ) (F006, G0…2928
Remove…2928
Install…2928
Wheels and Hubs Repair (All Units)…2929
Remove and Disassemble…2929
Clean…2929
Inspect…2929
Assemble and Install…2929
Spindles and Bearings Repair (All Units)…2931
Remove…2931
Clean…2931
Assemble and Install…2932
Tie Rods Repair (All Units)…2933
Remove…2933
Clean…2933
Install…2933
Steering Cylinder Repair…2936
Remove and Disassemble…2936
Clean and Inspect…2936
Assemble and Install…2936
Troubleshooting…2937
897109-1800SRM0327-(09-2003)-UK-EN…2942
toc…2942
Brake System…2942
Safety Precautions Maintenance and Repair…2943
General…2946
Description…2946
Operation…2947
Brake Booster and Master Cylinder…2947
Brake Booster…2947
Master Cylinder…2948
Service Brake Assembly…2949
Parking Brake…2950
Brake Shoe Assemblies Repair…2951
Remove and Disassemble…2951
Clean and Inspect…2952
Cleaning Procedures…2952
Inspect…2952
Assemble and Install…2953
Master Cylinder Repair…2954
Remove…2954
Disassemble…2954
Assemble…2956
Install…2956
Brake Booster Repair…2956
Remove…2956
Disassemble…2956
Clean and Inspect…2958
Assemble…2958
Install…2958
Brake System Air Removal…2958
Brake Pedal Adjustment…2959
Brake Shoes Adjustment…2960
Parking Brake Adjustment…2960
Parking Brake Switch Adjustment…2960
Brake Booster Relief Valve Check…2960
Troubleshooting…2961
897110-1900SRM0328-(09-2003)-UK-EN…2966
toc…2966
Hydraulic System…2966
Safety Precautions Maintenance and Repair…2967
General…2970
Description and Operation…2970
Hydraulic Pumps…2972
Main Control Valve…2972
Control Valve Lever…2973
Steering Control Unit…2973
Brake Valve…2973
Oil Clutch, H6.00-7.00XL (H135-155XL) (F006)…2974
Troubleshooting…2974
Lift, Lower, and Tilt Circuit…2975
Steering, Brake, and Oil Clutch System…2976
897111-4000SRM0329-(10-2003)-UK-EN…2980
toc…2980
Masts…2980
Safety Precautions Maintenance and Repair…2981
General…2984
Description and Operation…2984
General…2984
Safety Procedures When Working Near Mast…2985
Two-Stage Mast…2985
Three-Stage Mast…2987
Carriage Repair…2989
Remove…2989
Sideshift Carriage, Disassemble…2989
Sideshift Carriage, Assemble…2990
Install…2990
Two-Stage Mast Repair…2992
Remove…2992
Disassemble…2993
Clean and Inspect…2994
Assemble…2995
Install…2995
Three-Stage Mast Repair…2997
Remove…2997
Disassemble…2997
Clean and Inspect…2997
Assemble…2997
Install…2999
Mast Operation Check…2999
Lift and Tilt System Leaks Check…3000
Lift System…3000
Tilt System…3000
Tilt Cylinder Stroke and Backward Tilt Angle Adjustment…3001
Lift Chain Adjustments…3001
Mast Adjustments…3004
Carriage Adjustment…3004
Troubleshooting…3006
tables…2980
Table 1. Mast Parts Weight…2993
Table 2. Hook-Type Carriage Chain Adjustment…3002
Table 3. Pin-Type Carriage Chain Adjustment…3002
897113-8000SRM0331-(09-2003)-UK-EN…3010
toc…3010
Capacities and Specifications…3010
Safety Precautions Maintenance and Repair…3011
Lift Truck Weights…3014
Capacities…3014
Tire Sizes…3015
Tire Pressure…3015
Electrical System…3015
Wheel Nut Torque…3015
Engine Specifications…3016
Hydraulic System…3016
Mast Speeds…3017
Transmission Oil Pressures…3017
Torque Specifications…3018
Engine – GM 4.3L V-6…3018
Engine – Perkins 4.2482…3018
Engine – Perkins 1004.4…3018
Clutch…3018
Manual Transmission…3019
Powershift Transmission…3019
Speed Reducer…3019
Drive Axle…3019
Steering System…3019
Brake System…3019
Hydraulic System…3020
Tilt Cylinder…3020
Mast…3020
897123-8000SRM0341-(06-2007)-UK-EN…3024
toc…3024
Periodic Maintenance…3024
Safety Precautions Maintenance and Repair…3025
General…3030
Serial Number Data…3030
How to Move Disabled Truck…3030
How to Tow Lift Truck…3030
How to Put Lift Truck on Blocks…3031
How to Raise Drive Tires…3031
How to Raise Steering Tires…3031
Maintenance Schedule…3032
Maintenance Procedures Every 8 Hours or Daily…3045
How to Make Checks With Engine Stopped…3045
Hydraulic System Oil…3045
Engine Oil…3047
Drive Belts…3047
Intake Manifold Rubber Cap…3048
Cooling System…3048
Air Filter…3048
Fuel System…3049
Primary Fuel Filter, Diesel Engine…3049
Battery…3049
Tires and Wheels…3049
Forks…3050
Adjust…3050
Remove and Install…3052
Forks, Mast, and Lift Chains, Inspect…3053
Operator Restraint System…3054
Automatic Locking Retractor (ALR)…3054
Emergency Locking Retractor (ELR)…3054
Safety Labels…3055
How to Make Checks With Engine Running…3056
Gauges, Lights, Horn, and Fuses…3056
Oil Level, Powershift Transmission…3057
Oil Level, Oil Clutch System, H3.50-5.00XL (H70-110XL)…3058
Control Levers and Pedals…3058
Lift System Operation…3058
Inching/Brake Pedal…3058
Service Brakes…3058
Parking Brake…3059
Steering System…3059
Maintenance Procedures Every 250 Hours or 6 Weeks…3059
Engine Oil and Filter, GM V-6 Engine…3059
Lift Chains, Lubrication…3059
Drive Shafts…3059
Mast Lubrication…3060
Crankcase Breather, GM V-6…3061
Air Filter, GM V-6 EPA Compliant Engine …3061
Maintenance Procedures Every 350 Hours or 2 Months…3062
Engine Oil and Filter, Perkins 4.2482 Diesel Engine…3062
Drive Belts…3062
Perkins Diesel Engine…3062
GM V-6 Engine (Early Models)…3062
GM V-6 Engine (Late Models)…3063
Brake Fluid…3065
Lift Chains Wear Check…3065
Forks Wear and Damage Check…3065
Steering Axle Lubrication…3065
Fuel System, Checks and Adjustments…3066
Diesel Fuel System…3066
LPG Carburetor (Early Models)…3066
Gasoline Carburetor (Early Models)…3067
Fuel Injection (Late Models)…3067
Crankcase Breather, Perkins 4.2482 Diesel Engine…3067
Hydraulic Tank Breather…3067
Cooling System, Clean Debris from Radiator Core…3067
Maintenance Procedures Every 500 Hours or 3 Months…3068
Engine Oil and Filter, Perkins Diesel Engine…3068
Crankcase Breather, Perkins Diesel Engine…3068
PCV Valve, GM V-6…3068
Maintenance Procedures Every 1000 Hours or 6 Months…3068
Manifold Heat Valve, GM V-6 (Early Models)…3068
Ignition System, GM V-6…3068
Valve Clearance Adjustment…3068
Fuel Filter, Replace (Diesel Engine)…3069
Fuel System Air Removal (Perkins 1004-4 Diesel Engine)…3069
Fuel Injection Pump With Vent Tube…3069
Fuel Injection Pump With Vent Screw…3070
Fuel System Air Removal (Perkins 4.2482 Diesel Engine)…3072
Oil Level Check in Transmission…3072
Manual Transmission, H3.50-5.00XL (H70-110XL)…3072
Speed Reducer for Powershift Transmission, H3.50-5.00XL (H70-110…3072
Manual Transmission, H6.00-7.00XL (H135-155XL)…3072
Differential and Drive Axle for Powershift Transmission, H6.00-7…3072
Differential, Speed Reducer, and Drive Axle for Manual Transmiss…3073
Control Levers and Pedals, Lubricate…3073
Crankcase Breather, Replace…3073
Cooling System, GM V-6 EPA Compliant Engine…3073
Spark Plug Replacement…3073
Remove…3073
Install…3074
LPG Fuel Filter GM V-6 EPA Compliant Engine, Replace…3074
Inspect Engine Electrical System, Connectors, and FCVS Connectio…3075
Maintenance Procedures Every 2000 Hours or Yearly…3075
Hydraulic System…3075
Hydraulic Oil and Filter, H3.50-5.00XL (H70-110XL), Replace…3075
Hydraulic Oil and Filter, H6.00-7.00XL (H135-155XL, H135-155XL 2…3076
Oil Change and Oil Filter Replacement, Powershift Transmission, …3076
Oil Change, Manual Transmission, H3.50-5.00XL (H70-110XL)…3076
Oil Change, Manual Transmission, H6.00-7.00XL (H135-155XL)…3076
Oil Change, Speed Reducer, Powershift Transmission, H3.50-5.00XL…3076
Oil and Filter Change, Oil Clutch System, H3.50-5.00XL (H70-110X…3077
Oil Change, Differential and Drive Axle, Powershift Transmission…3077
Oil Change, Differential, Speed Reducer, and Drive Axle, Manual …3077
Cooling System…3077
PCV Valve, GM V-6…3077
Service Brakes…3078
LPG Filter, Replace…3078
Gasoline Fuel Filter, Replace…3079
Hood Latch Check, H3.50-5.00XL (H70-110XL)…3079
Air Filter Element, GM V-6 EPA Compliant Engine…3079
Oxygen Sensor GM V-6 EPA Compliant Engine…3079
Inspect Low Pressure Regulator (LPR) for Oil Buildup and Leaks…3080
Check Throttle Shaft for Sticking…3081
Inspect Exhaust Manifold and Piping for Leaks…3081
Test LPG/GAS Regulator Pressure…3081
Safety Procedures When Working Near Mast…3081
Lift Chain Adjustments…3083
Fuel Injectors Repair…3085
Lift and Tilt System Leak Check…3086
Lift Cylinders, Leak Check…3086
Tilt Cylinders, Leak Check…3086
Welding Repairs…3087
Overhead Guard Changes…3087
Wheel and Tire Replacement…3088
Remove Wheels From Lift Truck…3088
Remove Wheels From Tire…3088
Remove Tire From Two-Piece Wheel…3090
Remove Tire From Three- and Four-Piece Wheels…3092
Install Wheel in Tire…3093
Install Three- or Four-Piece Wheel in Tire…3094
Install Two-Piece Wheel in Tire…3095
Add Air to Pneumatic Tires…3096
Wheels, Install…3096
Solid Rubber Tires Repair…3097
Wheel, Tire Remove…3097
Wheel, Tire Install…3099
SIT Tire, Change for H3.50-5.00XL (G005), and H6.00-7.00XL (F006…3101
Remove SIT Solid Tire From Wheel…3101
Install SIT Solid Tire on Wheel…3102
Adhesives and Sealants…3103
Hydraulic Oil, Lubricant, and Coolant Specifications…3104
tables…3024
Table 1. Maintenance Schedule…3034
Table 2. Hook-Type Carriage Chain Adjustment…3084
Table 3. Pin-Type Carriage Chain Adjustment…3084
897501-8000SRM0519-(06-2007)-UK-EN…3108
toc…3108
Diagrams…3108
Safety Precautions Maintenance and Repair…3109
897800-0600SRM0590-(08-2005)-UK-EN…3196
toc…3196
GM Engines…3196
Safety Precautions Maintenance and Repair…3197
General…3200
Description…3200
Engine Removal and Installation…3201
Cylinder Head Repair…3201
Remove and Disassemble…3201
Clean and Inspect…3201
Valve Guides and Seats, Repairs…3202
Valves, Repair…3202
Valve Seats, Repair…3203
Valve Springs…3203
Rocker Arm Studs (Early Models)…3205
Rocker Arm Studs (Late Models)…3205
Assemble and Install…3206
Cylinder Block Cleaning and Inspection…3209
Piston Bore Preparation…3209
Engine Mounts Installation…3210
Lubrication System Repair…3210
Oil Pump, Remove and Disassemble…3210
Clean and Inspect…3210
Oil Pump, Assemble and Install…3211
Oil Sump, Install…3211
Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters…3212
Timing Cover…3212
Remove…3212
Install…3214
Timing Sprockets…3214
Remove…3214
Install…3214
Camshaft…3215
Remove…3215
Inspect…3215
Install…3215
Balance Shaft…3216
Remove…3216
Install…3217
Hydraulic Valve Lifters…3217
Remove…3217
Disassemble…3218
Clean and Inspect…3218
Assemble…3218
Install…3219
Crankshaft Repair…3220
Remove…3220
Inspect and Repair…3220
How to Check Clearance Between Main Bearings and Their Journals…3221
Install…3222
Piston and Connecting Rod Assemblies Repair…3223
Connecting Rod Bearings, Replace…3223
Piston and Connecting Rod Assemblies, Remove…3224
Disassemble…3224
Piston, Clean and Inspect…3225
Cylinder Bores, Inspect and Repair…3225
Piston Rings…3226
Assemble…3227
Piston and Connecting Rod Assemblies, Install…3227
Flywheel and Flywheel Housing Repair…3228
Flywheel, Repair…3228
Flywheel, Install…3228
H3.50-5.00XL (H70-110XL), S3.50-5.50XL (S70-120XL), S6.00-7.00XL…3228
H6.00-7.00XL (H135-155XL)…3228
Flywheel Housing H3.50-5.00XL (H70-110XL), H3.50-5.50XM (H70-120…3228
Engine Adapter H6.00-7.00XL (H135-155XL)…3228
Coolant Pump Repair…3229
Thermostat Replacement…3229
Fan Mount Repair (Early Models)…3229
Fan Mount Assembly Repair (Late Models)…3229
Drive Belt Installation…3231
Valve Clearance Adjustment (Early Models)…3232
Valve Clearance Adjustment (New Models)…3233
Compression Check…3233
Engine Specifications…3234
Engine Data…3234
Cylinder Head…3234
Hydraulic Valve Lifter…3235
Camshaft…3235
Pistons…3235
Crankshaft…3236
Connecting Rods…3236
Balance Shaft…3237
Cooling System…3237
Lubrication System…3237
Torque Specifications…3237
Troubleshooting…3238
tables…3196
Table 1. Piston Rings Arrangement on Piston…3227
897934-0700SRM0626-(11-2001)-UK-EN…3244
toc…3244
Cooling System…3244
Safety Precautions Maintenance and Repair…3245
General…3248
Description…3249
Radiator…3249
Radiator Cap…3249
Thermostat…3249
Water Pump…3250
Fan and Fan Shroud…3250
Cooling System Checks…3250
Radiator…3250
Thermostat…3250
Water Pump…3251
Exhaust Leaks…3251
Fan and Fan Shroud…3251
Radiator Cleaning…3251
Drain…3251
Clean…3251
Fill…3252
Troubleshooting…3253
899783-2000SRM0090-(10-2003)-UK-EN…3256
toc…3256
Main Control Valve…3256
Safety Precautions Maintenance and Repair…3257
General…3260
Description…3260
Operation…3263
Lift Spool…3263
Tilt Spool…3264
Tilt Backward…3264
Tilt Forward…3265
Single-Stage Relief Valve…3267
Two-Stage Relief Valve…3268
Main Control Valve Repair…3269
Remove and Disassemble…3269
Clean and Inspect…3269
Assemble…3269
Install…3270
Single-Stage Relief Valve Adjustment…3270
Two-Stage Relief Valve…3271
Auxiliary Control Valve Relief Valve Adjustment (H60-110E Only)…3271
Troubleshooting…3272
tables…3256
Table 1. Relief Pressures (Oil temperature at 55 to 66 C ( 131 t…3270
899784-2200SRM0002-(10-2003)-UK-EN…3276
toc…3276
Alternator with Regulator…3276
Safety Precautions Maintenance and Repair…3277
General…3280
Description…3280
Alternator Repair…3282
Alternator Type A…3282
Remove and Disassemble…3282
Clean…3283
Assemble…3284
Install…3284
Alternator Type B…3287
Remove and Disassemble…3287
Clean…3287
Assemble…3288
Install…3289
General Check and Adjustment…3290
Low Output Check (Type A or Type B)…3290
High Output Check (Type A or Type B)…3292
Brushes Circuit Check…3293
Delco Alternators…3293
Motorola Alternators…3294
Diodes Check…3295
Diode Bridge Check…3295
Delco and Leece-Neville Alternators…3295
Motorola Alternators…3295
Rotor Field Winding Check…3296
Stator Windings Check…3297
Voltage Regulator Check…3297
Troubleshooting…3297
910072-1400SRM0046-(07-2007)-UK-EN…3302
toc…3302
Differential…3302
Safety Precautions Maintenance and Repair…3303
General…3306
Description…3306
Differential Repair…3307
Remove…3307
Differential Carrier From Axle Housing, Remove…3307
Differential and Ring Gear From Differential Carrier, Remove…3309
Drive Pinion and Pinion Carrier From Differential Carrier, Remov…3311
Disassemble…3312
Differential and Ring Gear Assembly, Disassemble…3312
Drive Pinion and Pinion Carrier, Disassemble…3314
Clean and Inspect…3317
Assemble…3318
Pinion, Bearings, and Pinion Carrier, Assemble…3318
Pinion Bearings, Adjust Preload…3318
Press Method…3318
Yoke or Flange Method…3319
Triple-Lip Seal, Install…3320
Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion)…3321
Differential and Ring Gear, Assemble…3323
Differential Gears Rotating Torque, Check…3325
Differential and Ring Gear Assembly, Install…3326
Differential Bearings, Preload Adjust…3328
Ring Gear, Runout Check…3329
Ring Gear Backlash, Adjust…3329
Gear Set, Tooth Contact Pattern Check…3331
Thrust Screw, Install and Adjust…3334
Install…3334
Differential Assembly Into Axle Housing, Install…3334
Specifications…3336
Troubleshooting…3341
tables…3302
Table 1. Ring Gear Backlash Adjustment Specifications…3331
Table 2. Ring and Pinion Tooth Contact Adjustment…3332
Table 3. General Specifications…3336
Table 4. Rivet Installation Pressure…3336
Table 5. Pinion Adjustment…3337
Table 6. Pinion Preload Pressure…3337
Table 7. Torque Specifications…3338
Table 8. Torque Specifications for Metric Hardware…3339
Table 9. Torque Specifications for Metric (Fine) Hardware…3340
910073-1400SRM0049-(09-2003)-UK-EN…3344
toc…3344
Drive Axle…3344
Safety Precautions Maintenance and Repair…3345
General…3348
Description…3348
Drive Axle Repair…3349
Disassemble (Type 1 Shown)…3349
Clean…3352
Inspect…3352
Assemble (Type 1 Shown)…3353
Torque Specifications…3356
Troubleshooting…3357
910076-1600SRM0054-(10-2003)-UK-EN…3360
toc…3360
Steering Control Unit…3360
Safety Precautions Maintenance and Repair…3361
General…3364
Description…3364
Operation…3364
Steering Wheel and Column Assembly Repair…3366
Steering Column Assembly Repair…3366
Type A Steering Column Assembly…3366
Remove and Disassemble…3366
Assemble and Install…3368
Type B Steering Column Assembly…3370
Remove and Disassemble…3370
Assemble and Install…3370
Steering Control Unit…3373
Disassemble…3373
Clean…3376
Assemble…3377
System Air Removal…3382
Troubleshooting…3382
910091-1900SRM0097-(07-2006)-UK-EN…3386
toc…3386
Hydraulic Gear Pumps…3386
Safety Precautions Maintenance and Repair…3387
Description…3390
Operation…3391
Flow Control Valve…3391
Relief Valve…3392
Hydraulic Gear Pump Repair…3392
Remove…3392
Disassemble…3393
Clean…3393
Inspect…3394
Assemble…3397
Install…3399
Pump Output Check…3399
Method No. 1…3399
Method No. 2…3400
Hydraulic System Air Check…3401
Troubleshooting…3402
910102-2100SRM0103-(03-2007)-UK-EN…3408
toc…3408
Tilt Cylinders…3408
Safety Precautions Maintenance and Repair…3409
General…3412
Description…3412
Tilt Cylinder Repair…3412
Remove…3412
Disassemble…3412
Clean…3412
Assemble…3412
Tilt Cylinders With O-Ring or Single-Lip Seals…3412
Tilt Cylinders for XM and XMS Models…3414
Tilt Cylinders for XL, XLS, and XL 3 Models…3415
Tilt Cylinders for H700-800A and Early Model H700-920B…3417
Install…3418
Tilt Cylinders Using Chevron Packing…3418
Install…3419
Tilt Cylinder Leak Check…3421
Tilt Cylinder Stroke and Mast Tilt Angle Adjustment…3423
Torque Specifications…3423
Piston Rod Nut…3423
Retainer…3424
Troubleshooting…3426
tables…3408
Table 1. Movement Rates (Maximum) for Tilt Cylinders…3422
910107-2200SRM0106-(02-2001)-UK-EN…3430
toc…3430
Starter…3430
Safety Precautions Maintenance and Repair…3431
General…3434
Description and Operation…3434
Starter Repair…3436
Remove…3436
Disassemble…3436
Clean…3437
Assemble…3437
Install…3438
General Checks and Adjustments…3438
Troubleshooting…3441
910110-2200SRM0143-(02-2007)-UK-EN…3446
toc…3446
Instrument Panel Indicators and Senders…3446
Safety Precautions Maintenance and Repair…3447
General…3450
Description…3451
Steering Column Gauges, Meters, and Indicators…3451
LED Display Panel…3451
Battery Discharge Indicators…3451
Brush Wear Indicators…3457
Motor Temperature Indicators…3457
LX Series Display Panel…3459
Hourmeter Functions…3460
Battery Indicator Function…3460
Status Code Function…3460
ZX Series Display Panels…3462
Display Panel…3462
Basic Display Panels…3462
Performance Display…3464
Brush Wear Indicators…3468
Adjustments – General…3468
Replacement – General Information…3468
Meter Replacement…3469
Sender Replacement…3470
Fuel Level Sender…3470
Pressure and Temperature Sender…3470
Seat Sensor, Operator Presence System (OPS)…3471
Remove…3471
Install…3471
Operator Presence System Module Replacement…3471
Remove…3472
Install…3473
ITW Display Panel Replacement…3474
Remove…3474
Column Mount Display Panel (EV-100/200ZX Motor Controllers) Repl…3474
Remove…3474
Display Panel Assembly, Replace…3474
Indicator LEDs…3475
Battery Indicators…3475
Digital Display (Performance Display Panel Only)…3475
Status Code or Performance Level Switches and Indicator LEDs (Pe…3476
Basic Display Panel, Replace Parts…3476
Performance Display Panel, Replace Parts…3478
Dash Mount Display Panel (EV100/200ZX Motor Controllers) Replace…3478
Remove and Replace…3478
Specifications…3479
Meter Specifications…3479
Sender Specifications…3479
Troubleshooting…3480
Meter…3480
Troubleshooting for Operator Presence System…3481
tables…3446
Table 1. Troubleshooting Procedure for Operator Presence Module…3481
910119-4000SRM0135-(10-2003)-UK-EN…3486
toc…3486
Lift Cylinders…3486
Safety Precautions Maintenance and Repair…3487
Safety Procedures When Working Near Mast…3490
General…3494
Description…3494
Lowering Control Valve…3494
Cylinders (General)…3497
Cylinders (H520-620B, H700-800A)…3497
Retainer, Install…3497
Cylinders (H360-460B)…3499
Cylinders (Two-Speed)…3501
Lift Cylinder Repair…3503
Lift Cylinder Removal Without Removing Mast…3503
Standard Masts With Main Lift Cylinder Fastened to Crossmember o…3503
Standard and Full Free-Lift Masts With Lift Cylinder Fastened to…3503
Masts That Have Two Cylinders, Main Lift Cylinder and Free-Lift …3503
Disassemble…3505
Assemble…3505
Lift Cylinder Installation in Mast…3507
Standard Masts With Main Lift Cylinder Fastened to Crossmember o…3507
Standard and Full Free-Lift Masts With Lift Cylinder Fastened to…3507
Chevron-Style Packing…3507
Chevron-Style Packing Installation on Piston…3508
Chevron-Style Packing Installation in Packing Gland…3510
Lift Cylinders for VISTA® Masts…3511
Description…3511
Lowering Control Valve…3511
Remove…3513
Disassemble…3514
Assemble…3515
Install…3516
Main Lift Cylinders…3516
Free-Lift Cylinder…3516
Lift System Leak Check…3517
Specifications…3518
Troubleshooting…3519
tables…3486
Table 1. Lift Trucks with Two-Speed Lift Cylinders…3502
Table 2. Cylinder Retainer Torque Specifications and Weight Guid…3518
910442-8000SRM0231-(12-2004)-UK-EN…3522
toc…3522
Metric and Inch (SAE) Fasteners…3522
Safety Precautions Maintenance and Repair…3523
General…3526
Threaded Fasteners…3526
Nomenclature, Threads…3526
Strength Identification…3527
Cotter (Split) Pins…3527
Fastener Torque Tables…3532
Conversion Table…3534
tables…3522
Table 1. Bolts and Screws…3528
Table 2. Studs and Nuts…3529
Table 3. Torque Nuts…3530
Table 4. Torque Nuts With Nylon Insert…3531
Table 5. Torque Values for Metric Fasteners*…3532
Table 6. Torque Values for Inch Fasteners*…3533
Table 7. Conversion Table for Metric and English Units…3534
Table 8. Cotter Pin Dimensional Data…3535
Table 9. Cotter Pin Dimensional Data…3536
Table 10. Cotter Pin Dimensional Data…3537
Table 11. Cotter Pin Dimensional Data…3539

Hyster Forklift Trucks G006 (H135-155XL & H6.00-7.00XL Europe) Repair Service Manual

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