Complete service repair manual for Hyster F005 (H70-110XL & H3.50-5.00XL Europe) Forklift Trucks, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Hyster F005 (H70-110XL & H3.50-5.00XL 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 F005 (H70-110XL & H3.50-5.00XL Europe) Service Manual.pdf
Total Pages: 811 + 746 pages
File Format: PDF
Language: English
F005 (H3.50-5.00XL Europe)…………….2
100345…………….4
THE FRAME…………….4
GENERAL…………….4
DESCRIPTION…………….4
REPAIRS…………….4
COUNTERWEIGHT…………….4
Removal…………….4
COUNTERWEIGHT…………….5
Installation…………….5
HOOD…………….5
Removal…………….5
HOOD…………….5
Installation…………….5
OVERHEAD GUARD…………….6
Removal…………….6
Installation…………….6
OPERATOR RESTRAINT SYSTEM…………….6
RADIATOR…………….6
Removal…………….6
Installation…………….7
EXHAUST SYSTEM…………….7
Muffler Replacement…………….7
ENGINE…………….7
Removal…………….7
Installation…………….10
FUEL AND HYDRAULIC TANKS…………….11
Inspection…………….11
Repairs, Small Leaks…………….11
Repairs, Large Leaks…………….11
Cleaning…………….11
Other Methods Of Preparation For Repair…………….12
SAFETY LABELS…………….13
CAB…………….13
Cab Repalacement…………….13
Window Repalcement…………….13
Windshield Wipers, Heater and Fan…………….16
Material Specifications For Cab Windows…………….16
Cab Heater Hoses…………….16
1200334…………….17
INTRODUCTION…………….17
General…………….17
Description…………….17
REPAIRS…………….19
Removal and Disassembly…………….19
Cleaning and Inspection…………….20
Assembly and Installation…………….21
CHECKS AND ADJUSTMENTS…………….23
Adjusting the Clutch Pedal and Linkage…………….23
Adjusting the By-pass Valve for Cold Oil…………….23
TROUBLESHOOTING…………….24
1300335…………….26
INTRODUCTION…………….26
General…………….26
Description…………….26
Operation…………….26
REPAIRS…………….28
Removal…………….28
Disassembly…………….29
Cleaning…………….31
Inspection…………….32
Assembly…………….32
Installation…………….43
CHECKS AND ADJUSTMENTS…………….44
Adjusting The Shift Linkage H3.50-5.00XL (H70-110XL)…………….44
Adjusting The Shift Linkage S6.00-7.00XL (S135-155XL)…………….46
Adjusting The Clutch Pedal And Linkage…………….46
TROUBLESHOOTING…………….48
SPECIFICATIONS…………….50
1300336…………….51
DESCRIPTION…………….51
GENERAL…………….51
MECHANICAL DESCRIPTION…………….51
TORQUE CONVERTER…………….51
OIL LAMP…………….52
SHAFT AND CLUTCH ASSEMBLIES…………….52
Input Shaft…………….53
Forward Clutch Shaft…………….53
Clutch Assemblies…………….53
Output Gear…………….54
HYDRAULIC OPERATION…………….54
TORQUE CONVERTER…………….54
SHAFT ASSEMBLIES…………….55
CONTROL VALVE…………….57
General…………….57
System Regulator…………….57
Clutch Pressure Regulator…………….57
Torque Converter Regulator…………….58
Inching Spool…………….58
Direction Spool, Manual Control…………….58
Drain Spool…………….59
Accumulator…………….59
Modulation Spool…………….60
LUBRICATION CIRCUIT…………….61
MONOTROL PEDAL…………….61
OIL FLOW DIAGRAMS…………….61
Neutral…………….61
Forward…………….61
Forward-Inching…………….61
Reverse…………….62
1300337…………….67
REPAIRS …………….67
GENERAL…………….67
REMOVAL…………….67
TRANSMISSION, DISASSEMBLY…………….69
Input Shaft, Disassembly…………….70
Forward Shaft, Disassembly…………….72
Cleaning and Inspection…………….73
TRANSMISSION, ASSEMBLY…………….74
Forward Shaft, Assembly…………….74
Input Shaft, Assembly…………….76
Assembly…………….78
Installation…………….81
CONTROL VALVE…………….82
Removal…………….82
Disassembly…………….83
Assembly…………….83
Installation…………….85
THROTTLE PEDAL…………….85
MONOTROL PEDAL…………….85
Removal and Disassembly…………….85
Assembly and Installation…………….85
CHECKS AND ADJUSTMENTS…………….88
STALL TEST…………….88
ADJUST THE LINKAGE FOR THE INCHING PEDAL…………….89
Linkage For Models With An Inching Pedal And A Brake Pedal…………….89
Linkage For ModelsWith One Inching/Brake Pedal…………….91
ADJUST THE LINKAGE FOR THE DIRECTION CONTROL LEVER…………….92
Earlier Production…………….92
Later Production…………….93
CHECK THE OIL PRESSURE FOR THE TRANSMISSION…………….94
System Pressure Check Port…………….95
Torque Converter Check Port…………….95
Clutch Pressure Check Port…………….96
Inching Pressure…………….96
Solenoid Check Ports (Monotrol Control Only)…………….96
Lubrication Pressure Check Ports…………….96
TROUBLESHOOTING…………….97
1300346…………….100
INTRODUCTION…………….100
GENERAL…………….100
DESCRIPTION…………….100
REPAIRS…………….100
REMOVAL…………….100
DISASSEMBLY…………….100
CLEANING…………….103
INSPECTION…………….103
ASSEMBLY…………….103
Pinion Assembly…………….103
Differential…………….104
INSTALLATION…………….110
TROUBLESHOOTING…………….111
SPECIFICATIONS…………….112
1400361…………….113
INTRODUCTION…………….113
GENERAL…………….113
DESCRIPTION…………….113
REPAIRS…………….114
REMOVAL…………….114
Lift Trucks With A Manual Transmission…………….114
Lift Trucks With A Powershift Transmission…………….115
DISASSEMBLY…………….116
CLEANING…………….116
INSPECTION…………….116
ASSEMBLY…………….116
INSTALLATION…………….117
Lift Trucks With A Manual Transmission…………….117
Lift Trucks With A Powershift Transmission…………….118
TROUBLESHOOTING…………….119
SPECIFICATIONS…………….119
1600326…………….120
INTRODUCTION…………….120
GENERAL…………….120
DESCRIPTION…………….120
REPAIRS…………….121
STEERING AXLE, H3.50-5.00XL (H70-110XL) and S/E 3.50-5.50XL (S/E 70-120XL)…………….121
Removal…………….121
Installation…………….121
STEERING AXLE, H6.00-7.00XL (H135-155XL) H8.00-16.00XL (H165-360XL)…………….122
Removal…………….122
Installation…………….123
WHEELS AND HUBS, ALL UNITS…………….123
Removal and Disassembly…………….123
Cleaning…………….123
Assembly and Installation…………….123
SPINDLES AND BEARINGS, ALL UNITS…………….124
Removal…………….124
Cleaning…………….125
Assembly and Installation…………….125
TIE RODS, ALL UNITS…………….125
Removal…………….125
Cleaning…………….125
Installation…………….126
STEERING CYLINDER…………….127
Removal and Disassembly…………….127
Cleaning and Inspection…………….127
Assembly and Installation…………….127
TROUBLESHOOTING…………….128
160054…………….129
INTRODUCTION…………….129
GENERAL…………….129
DESCRIPTION…………….129
OPERATION…………….129
REPAIRS…………….129
STEERING WHEEL AND COLUMN ASSEMBLY…………….129
TYPE "A" STEERING COLUMN ASSEMBLY…………….131
Removal And Disassembly…………….131
Assembly And Installation…………….131
TYPE "A" STEERING COLUMN…………….132
TYPE "A" STEERING COLUMN…………….133
TYPE "B" STEERING COLUMN…………….134
Removal And Disassembly…………….134
Assembly And Installation…………….134
TYPE "B" STEERING COLUMN…………….135
Disassembly of Steering Control Unit…………….136
Cleaning of Steering Control Unit…………….136
Assembly of Steering Control Unit…………….138
CHECKS AND ADJUSTMENTS…………….141
REMOVE AIR FROM THE SYSTEM…………….141
TROUBLESHOOTING…………….142
1800338…………….143
INTRODUCTION…………….143
GENERAL…………….143
DESCRIPTION AND OPERATION…………….143
BRAKE BOOSTER AND MASTER CYLINDER…………….143
MASTER CYLINDER…………….143
SERVICE BRAKE ASSEMBLY…………….145
PARKING BRAKE…………….146
REPAIRS…………….146
BRAKE SHOE ASSEMBLIES…………….146
Removal and Disassembly…………….146
Cleaning and Inspection…………….147
Assembly and Installation…………….149
MASTER CYLINDER…………….152
S3.50-5.50XL (S70-120XL) and H3.50-5.00XL (H70-110XL…………….152
Removal …………….152
Disassembly…………….152
Assembly…………….153
Installation…………….153
MASTER CYLINDER, E3.50-5.50XL (E70-120XL)…………….153
Removal and Disassebly…………….153
Cleaning and Inspection…………….154
Assembly and Installation…………….154
BRAKE BOOSTER…………….154
Removal…………….154
Disassembly…………….154
Cleaning and Inspection…………….155
Assembly…………….155
Installation…………….156
CHECKS AND ADJUSTMENTS…………….156
REMOVE THE AIR FROM THE BRAKE SYSTEM…………….156
ADJUST THE BRAKE PEDAL…………….156
ADJUST THE BRAKE SHOES…………….157
ADJUST THE PARKING BRAKE…………….158
CHECK THE RELIEF VALVE ON THE PARKING BOOSTER…………….158
TROUBLESHOOTING…………….158
1900333…………….160
INTRODUCTION…………….160
GENERAL…………….160
DESCRIPTION AND OPERATION…………….160
Hydraulic Pump…………….160
Main Control Valve…………….161
Steering Control Unit…………….163
Brake Booster…………….163
REPAIRS…………….163
HYDRAULIC PUMP…………….163
Removal…………….163
Disassembly…………….164
Cleaning and Inspection…………….164
Assembly…………….164
Installation…………….165
Adjust the Flow Divider…………….165
SPECIFICATIONS…………….165
TROUBLESHOOTING…………….166
1900339…………….168
INTRODUCTION…………….168
GENERAL…………….168
DESCRIPTION…………….168
REPAIRS…………….170
REMOVAL AND DISASSEMBLY…………….170
CLEANING…………….170
INSPECTION…………….170
ASSEMBLY AND INSTALLATION…………….171
TROUBLESHOOTING…………….172
GENERAL…………….172
190097…………….173
INTRODUCTION…………….173
DESCRIPTION…………….173
OPERATION…………….173
Flow Control Valve…………….175
Relief Valve…………….175
REPAIRS…………….176
REMOVAL…………….176
DISASSEMBLY…………….176
CLEANING…………….178
INSPECTION…………….178
ASSEMBLY…………….179
INSTALLATION…………….180
CHECKS AND ADUSTMENTS…………….181
CHECK THE OUTPUT OF THE PUMP…………….181
CHECK FOR AIR IN THE HYDRAULIC SYSTEM…………….181
TROUBLESHOOTING…………….183
200077…………….186
INTRODUCTION…………….186
GENERAL…………….186
DESCRIPTION…………….186
OPERATION…………….187
Lift Section…………….188
Tilt Section…………….188
Relief Valve…………….190
SOLENOID VALVE FOR AUXILIARY FUNCTION…………….191
Operation…………….191
REPAIRS…………….191
MAIN CONTROL VALVE…………….191
Removal and Disassembly…………….191
Cleaning and Inspection…………….192
Assembly…………….192
Installation…………….192
SOLENOID VALVE FOR AUXILIARY FUNCTION…………….192
Removal and Disassembly…………….192
Assembly and Installation…………….194
CHECKS AND ADJUSTMENTS…………….194
PRESSURE RELIEF VALVES…………….194
Primary Relief Valve…………….194
Seconday Relief Valve…………….195
CONTROL LEVER ARRANGEMENT…………….195
TROUBLESHOOTING…………….198
SPECIFICATIONS…………….200
2100103…………….201
INTRODUCTION…………….204
GENERAL…………….204
DESCRIPTION…………….204
REPAIRS…………….204
REMOVAL…………….204
DISASSEMBLY…………….204
CLEANING…………….204
ASSEMBLY…………….204
Tilt Cylinders for the XM and XMS Models…………….204
Tilt Cylinders with O-Ring or Single Lip Seals…………….206
Tilt Cylinders for H700-800A and Early Model H700-920B…………….206
INSTALLATION…………….206
Tilt Cylinders with Chevron Packing…………….206
CHECKS AND ADJUSTMENTS…………….210
CHECK THE TILT CYLINDERS FOR LEAKS…………….210
ADJUST THE TILT CYLINDER STROKE AND THE MAST TILT ANGLE…………….210
TROUBLESHOOTING…………….213
2200106…………….216
INTRODUCTION…………….216
GENERAL…………….216
DESCRIPTION AND OPERATION…………….216
REPAIRS…………….218
REMOVAL…………….218
DISSASEMBLY…………….218
CLEANING…………….219
ASSEMBLY…………….219
INSTALLATION…………….219
CHECKS AND ADJUSTMENTS…………….220
GENERAL…………….220
TROUBLESHOOTING…………….222
2200107…………….224
HIGH ENERGY IGNITION (HEI)…………….224
DESCRIPTION…………….224
REPAIRS…………….226
DISTRIBUTOR…………….226
Removal…………….226
Disassembly…………….226
Assembly…………….231
INSTALLATION, IF THE CRANKSHAFT WAS NOT ROTATED WHEN DISTRIBUTOR WAS REMOVED…………….232
INSTALLATION, IF THE CRANKSHAFT WAS ROTATED WHEN THE DISTRIBUTOR WAS REMOVED…………….233
IGNITION COIL…………….233
Removal, Some 4 and 6 Cylinder Models…………….233
Installation, Some 4 and 6 Cylinder Models…………….234
Removal, V8, Some 4 and 6 Cylinder Models…………….234
Installation, V8, Some 4 and 6 Cylinder Models…………….235
ELECTRONIC MODULE…………….236
Removal…………….236
Installation…………….236
SENSING COIL…………….237
Removal…………….237
Installation…………….237
SPARK PLUGS…………….237
Removal…………….237
Installation…………….238
CHECKS AND ADJUSTMENTS…………….238
Visual Checks…………….238
Check The High Voltage Wires…………….238
Checking The Ignition Coil…………….238
Coil In Distributor Cap Design…………….238
Separate Coil Design…………….239
Checking The Sensing Coil…………….239
Check The Electronic Module…………….240
Ignition Timing Adjustment…………….240
Ignition System, GM V8-366 (6-litre)…………….241
Ignition Timing and Idle Speed Adjustment, GM V6-LPG (4.3-litre)…………….241
SPECIFICATIONS…………….241
TROUBLESHOOTING…………….242
2200143…………….243
INTRODUCTION…………….243
GENERAL…………….243
DESCRIPTION…………….243
GENERAL…………….243
STEERING COLUMN GAUGES, METERS AND INDICATORS…………….246
LED DISPLAY PANEL…………….246
Battery Discharge Indicators …………….246
Brush Wear Indicators…………….247
Motor Temperature Indicators…………….248
"LX" SERIES INSTRUMENT PANEL DISPLAY…………….249
Hourmeter Functions…………….250
Battery Indicator Function…………….250
Status Code Function…………….250
CHECKS AND ADJUSTMENTS…………….250
GENERAL…………….250
REPLACEMENT…………….251
GENERAL…………….251
METER REPLACEMENT…………….251
SENDER REPLACEMENT…………….252
Fuel Level Sender…………….252
Pressure And Temperature Sender…………….253
I.T.W. DISPLAY PANEL…………….253
Removal…………….253
SPECIFICATIONS…………….254
TROUBLESHOOTING…………….255
2200144…………….256
ELECTRICAL WARNING DEVICES…………….256
GENERAL…………….256
DESCRIPTION…………….256
Operator Controlled Horns…………….256
System Warning Lights, Buzzers and Bells…………….256
Reverse Warning Horns…………….257
Warning Lights…………….257
REPLACEMENT…………….258
General…………….258
Replacing Horns or Bells…………….258
Replacing Horn Relay or Buzzer…………….258
Replacing Warning Lights…………….258
Light Assemblies…………….259
Replacing Flashing Units…………….259
22002…………….260
INTRODUCTION…………….260
GENERAL…………….260
DESCRIPTION…………….260
REPAIRS…………….262
GENERAL…………….262
REMOVAL AND DISASSEMBLY (Type A)…………….262
CLEANING…………….262
ASSEMBLY (Type A)…………….263
REMOVAL AND DISAASSEMBLY (Type B)…………….265
CLEANING…………….267
ASSEMBLY (Type B)…………….267
INSTALLATION (Type A and Type B)…………….268
CHECKS AND ADJUSTMENTS…………….268
GENERAL…………….268
CHECK THE ALTERNATOR FOR LOW OUTPUT (Type A or Type B)…………….269
CHECK THE ALTERNATOR FOR HIGH OUTPUT (Type A or Type B)…………….270
CHECK THE CIRCUIT FOR THE BRUSHES…………….272
Delco Alternators…………….272
Motorola Alternators…………….272
CHECK THE DIODES…………….272
CHECK THE DIODE BRIDGE…………….272
Delco and Leece–Neville Alternators…………….272
Motorola Alternators…………….272
CHECK THE FIELD WINDING FOR THE ROTOR…………….273
CHECK THE WINDINGS IN THE STATOR…………….273
CHECK THE VOLTAGE REGULATOR…………….274
TROUBLESHOOTING…………….274
2200463…………….275
MICROPROCESSOR SPARK TIMING SYSTEM (MSTS)…………….275
GENERAL…………….275
DESCRIPTION…………….275
What MSTS Does…………….277
How MSTS Begins Operation…………….277
OPERATION…………….277
Pulse Generator…………….277
HEI Module…………….278
When the Engine Is Being Started…………….278
When the Engine Is Running…………….280
Manifold Absolute Pressure (MAP)…………….280
Coolant Temperature Sensor (CTS)…………….280
Electronic Control Module (ECM), Corrections…………….281
The Initial Timing Connector…………….281
Gasoline and LPG Conversions…………….282
TROUBLESHOOTING…………….284
GENERAL…………….284
TOOLS AND TEST EQUIPMENT…………….284
MSTS TROUBLESHOOTING…………….285
Test Description…………….285
IGNITION SYSTEM TROUBLESHOOTING…………….287
Test Description…………….287
ELECTRONIC SPARK TIMING (EST) TROUBLESHOOTING…………….290
Circuit Description…………….290
Test Description…………….290
MANIFOLD ABSOLUTE PRESSURE (MAP) TROUBLESHOOTING…………….293
Circuit Description…………….293
Test Description…………….293
COOLANT TEMPERATURE SENSOR (CTS) TROUBLESHOOTING…………….296
Circuit Description…………….296
Test Description…………….296
REPAIRS…………….298
DISTRIBUTOR…………….298
Removal…………….298
Disassembly…………….299
Inspection…………….299
Assembly…………….300
Installation…………….300
Igntion Timing…………….300
HEI MODULE…………….301
Test For A Fault…………….301
HEI Module Replacement…………….301
SENSING COIL…………….302
Test For A Fault…………….302
Sensing Coil Replacement…………….302
IGNITION COIL…………….302
Test For A Fault…………….302
ELECTRONIC CONTROL MODULE (ECM)…………….303
Removal…………….303
Installation…………….303
COOLANT TEMPERATURE SENSOR (CTS)…………….303
Removal…………….303
Installation…………….304
MANIFOLD ABSOLUTE PRESSURE (MAP)…………….304
Removal…………….304
Installation…………….304
PRESSURE CONVERSION CHART…………….305
2200468…………….306
ELECTRONIC ENGINE CONTROL, TROUBLESHOOTING AND REPAIR…………….306
GENERAL…………….306
Engine Data…………….306
LIGHT BULB CHECK…………….306
SYSTEM CHECK…………….308
TROUBLESHOOTING WITH THE FAULT MONITOR SYSTEM IN THE ECM…………….308
How To Clear A Code…………….309
Fault In The ECM…………….309
Fault In The PROM…………….310
CalPak Not Installed…………….310
Fuel Control…………….310
Idle Air Control (IAC)…………….310
Fuel Pump Circuit…………….310
Coolant Temperature Sensor (CTS)…………….311
Manifold Absolute Pressuer Sensor (MAP)…………….311
Throttle Position Sensodr (TPS)…………….311
Output Check, Throttle Position Sensor…………….311
Electronic Spark Timing…………….311
Engine Crank Signal…………….312
Distributor Reference Signal…………….312
TROUBLESHOOTING CHARTS…………….313
CHART A-1-No "Check Engine" Light…………….313
Circuit Description, "Check Engine" Light…………….313
CHART A-1-No "Check Engine" Light…………….314
CHART A-2-No ALDL Data Or No Code 12 From "Check Engine" Light. The "Check Engine" Light Is Continuosly Illuminated…………….315
Circuit Description, "Check Engine" Light…………….315
CHART A-2-No ALDL Data Or No Code 12 From "Check Engine" Light. The "Check Engine" Light Is Continuously Illuminated…………….316
CHART A-3-Starter Cranks The Engine, But Will Not Run…………….317
Circuit Description…………….318
CHART A-4-Fuel Injector Circuit…………….319
Circuit Description…………….319
CHART A-5-Fuel Pump Relay Circuit…………….321
Circuit Description…………….321
CHART A-6-Fuel System Pressure Test…………….323
Circuit Description…………….323
CHART A-7-MAP Output Check…………….325
Circuit Description…………….325
CHART A-8-Engine Crank Signal Check…………….327
Circuit Description…………….327
CHART A-9-Ignition System Troubleshooting…………….328
CHART A-9 Ignition System Troubleshooting Chart…………….329
CHART A-10-Idle Air Control (IAC) System…………….331
Circuit Description…………….331
FAULT CODES…………….333
CODE 14-Coolant Temperature Sensor Circuit (Indicates High Temperature)…………….333
Circuit Description…………….333
CODE 15-Coolant Temperature Sensor Circuit (Indicates Low Temperature…………….335
Circuit Description…………….335
CODE 21-Throttle Position Sensor Circuit (Signal Voltage High) …………….337
Circuit Description…………….337
CODE 22-Throttle Position Sensor Circuit (Signal Voltage Low) …………….339
Circuit Description…………….339
CODE 31-Engine Governor Circuit…………….341
Circuit Description…………….341
CODE 33-MAP Sensor Circuit, Signal Voltage High (Low Vacuum…………….343
Circuit Description…………….343
CODE 34-MAP Sensor Circuit, Signal Voltage Low (High Vacuum)…………….345
Circuit Description…………….345
CODE 42-Electronic Spark Timing (EST)…………….347
Circuit Description…………….347
CODE 54-Fuel Pump Circuit (Low Voltage)…………….349
Circuit Description…………….349
CODE 51-PROM In The ECM Has A Fault …………….351
CODE 52-Fuel CalPak Is Missing…………….351
CODE 55-ECM Has A Fault…………….351
TROUBLESHOOTING, POOR OPERATION…………….351
General…………….351
Make A Careful Visual Check…………….351
FAULT: Fuel Usage Too High…………….351
FAULT: Codes Or Performance That Is Not Regular…………….352
FAULT: "Dieseling"…………….352
FAULT: "Backfire"…………….352
FAULT: Rough Idle or Engine Stalls During Idle…………….352
FAULT: Smoke In The Exhaust Gases…………….353
FAULT: Engine is Difficult To Start…………….353
FAULT: Variation In Engine Power When The Throttle Is Held Steady…………….354
FAULT: Decreased Engine Power…………….354
FAULT: "Detontion"…………….354
FAULT: Engine Momentarily Does Not Increase Power When Throttle Changes…………….355
FAULT: One Cylinder In The Engine Does Not Operate Correctly. The Engine Does Not Idle Correctly…………….355
REPAIRS, FUEL SYSTEM COMPONENTS …………….357
General…………….357
Vacuum Ports…………….357
Throttle Body Injection (TBI) Unit…………….357
TBI Unit, Removal…………….357
TBI Unit, Cleaning and Inspection…………….358
TBI Unit, Installation…………….358
Cover For Fuel Meter Body, Replacement…………….358
Fuel Injectors…………….359
Fuel Injectors, Removal…………….359
Fuel Injectors, Installation…………….360
Pressure Regulator, Removal…………….360
Pressure Regulator, Inspection…………….360
Pressure Regulator, Installation …………….360
Fuel Meter Body, Removal…………….361
Fuel Meter Body, Installation…………….361
Throttle Position Sensor (TPS), Removal…………….361
Throttle Position Sensor (TPS), Installation…………….361
Idle Air Control (IAC) Valve, Removal…………….362
Cleaning and Inspection…………….362
Idle Air Control (IAC) Valve, Installation…………….362
Governor Throttle Drive Assembly, Removal…………….362
Governor Throttle Drive Assembly, Inspection…………….362
Cleaning and Lubrication…………….363
Governor Throttle Drive Assembly, Installation…………….363
Governor Drive Motor, Removal…………….364
Governor Drive Motor, Cleaning and Lubrication…………….364
Governor Drive Motor, Installation…………….365
Governor Drive Motor, Inspection…………….365
Throttle Body, Removal and Disassembly…………….365
Throttle Body, Inspection…………….365
Throttle Body, Assembly and Installation…………….365
Fuel Pump, Removal and Disassembly…………….366
Fuel Pump, Inspection…………….366
REPAIRS, ELECTRICAL COMPONENTS…………….366
General…………….366
Ignition Coil Test…………….366
Ignition Module Test…………….367
Distributor, Removal…………….367
Distributor, Disassembly…………….368
Distributor, Assembly…………….368
Distributor, Installation…………….369
Firing Order…………….370
Ignition Timing…………….370
Ignition Coil, Removal…………….371
Ignition Coil, Installation…………….371
Procedures For Spark Plugs, Spark Plug Wires And Boots …………….371
Troubleshooting of Spark Plugs…………….372
Coolant Temperature Sensor (CTS), Replacement …………….373
Manifold Absolute Pressure (MAP) Sensor, Replacement…………….373
Oil Pressure Switch, Replacement…………….374
Coolant Temperature Sender, Replacement…………….374
Wire Harness…………….374
Connectors And Terminals…………….374
Electronic Control Module (ECM)…………….378
ECM CONNECTOR A-B IDENTIFICATION…………….382
ECM CONNECTOR C-D IDENTIFICATION…………….383
SPECIAL TOOLS…………….384
2200473…………….387
INTRODUCTION…………….387
GENERAL…………….387
DESCRIPTION AND OPERATION…………….387
GENERAL…………….387
ECM (ELECTRONIC CONTROL MODULE)…………….387
ALDL Connector…………….389
How The ECM Begins Operation…………….389
ELECTRONIC ENGINE CONTROL…………….390
What The ECM Does…………….390
Pulse Generator, EST Distributor…………….391
EST Module(See FIGURE 9.)…………….392
When the Engine Is Being Started…………….392
When the Engine Is Running…………….394
Electronic Control Module (ECM) With EST Distrubutor, Corrrections…………….394
What The ECM Does…………….394
FUEL CONTROL…………….395
Throttle Body Injection…………….395
Fuel Injectors…………….396
Fuel Pressure Regulator…………….396
Throttle Position Sensor…………….396
Idle Air Control…………….396
Governor Motor And Throttle Drive Assembly…………….397
Vacuum Ports…………….399
Fuel Pump…………….399
ECM SENSORS AND CONTROLLERS…………….401
Manifold Absolute Pressure (MAP)…………….401
Coolant Temperature Sensor (CTS)…………….401
Initial Timing Connector (EST Distributor)…………….401
4000135…………….403
SAFETY PROCEDURES WHEN WORKING NEAR THE MAST…………….403
SAFETY PROCEDURES WHEN WORKING NEAR THE MAST…………….403
LIFT CYLINDERS…………….406
GENERAL…………….406
DESCRIPTION…………….406
Lowering Control Valve…………….406
Cylinders (General)…………….409
Cylinders (H520-620B,H700-800A)…………….411
Cylinders (H360-460B)…………….412
Cylinders (Two-Speed)…………….412
REPAIRS…………….413
REMOVAL OF THE LIFT CYLINDER WITHOUT REMOVING THE MAST…………….413
Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast…………….413
Standard and Full Free-Lift Masts with the Lift Cylinder to a Crosshead…………….417
Masts that have Two Cylinders, A Main Lift Cylinder and a Free-Lift Cylinder…………….415
DISASSEMBLY…………….415
ASSEMBLY…………….417
INSTALLATION OF THE LIFT CYLINDER IN THE MAST…………….417
Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast…………….417
Standard and Full-Free-Lift Masts with the Lift Cylinder Fastened to a Crosshead…………….417
CHEVRON PACKING…………….418
LIFT CYLINDERS FOR VISTA MASTS…………….421
DESCRIPTION…………….421
Lowering Control Valve…………….423
REMOVAL…………….424
DISASSEMBLY…………….424
ASSEMBLY…………….424
INSTALLATION…………….425
Main Lift Cylinders…………….425
Free-Lift Cylinders…………….425
CHECKS AND ADJUSTMENTS…………….426
CHECK FOR LEAKS IN LIFT SYSTEM…………….426
TROUBLESHOOTING…………….427
SPECIFICATIONS…………….428
4000340…………….429
VISTA® MASTS…………….429
GENERAL…………….429
DESCRIPTION AND OPERATION…………….429
CARRIAGES…………….429
TWO-STAGE MAST WITH LIMITED FREE-LIFT…………….429
TWO-STAGE MAST WITH FULL FREE-LIFT MAST…………….430
THREE-STAGE MAST WITH FULL FREE-LIFT…………….431
REPAIRS…………….433
SAFETY PROCEDURES WHEN WORKING NEAR THE MAST (1 OF 2)…………….433
SAFETY PROCEDURES WHEN WORKING NEAR THE MAST (2 OF 2)…………….434
FORKS…………….434
Forks, Removal And Installation…………….434
CARRIAGE…………….436
Removal…………….436
SIDE-SHIFT CARRIAGE (EARLIER DESIGNS)…………….437
Disassembly, Side Shift Carriage…………….437
Assembly, Side Shift Carriage…………….439
Installation…………….440
SIDE-SHIFT CARRIAGE (1993 AND LATER DESIGN)…………….440
Removal…………….440
Repairs…………….441
Installation…………….442
TABLE 1. WEIGHT OF MAST PARTS…………….442
TWO-STAGE MAST WITH LIMITED FREE-LIFT…………….443
Removal…………….443
Disassembly…………….443
Cleaning and Inspection…………….445
Assembly…………….445
Installation…………….446
TWO-STAGE MAST WITH FULL FREE-LIFT…………….446
Removal…………….446
Disassembly…………….446
Cleaning and Inspection…………….447
Assembly…………….447
Installation…………….447
THREE-STAGE MAST WITH FULL FREE LIFT…………….448
Removal…………….448
Disassembly…………….448
Cleaning and Inspection…………….449
Assembly…………….449
Installation…………….451
CHECKS AND ADJUSTMENTS…………….453
CHECK THE OPERATION OF THE MAST…………….453
CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM…………….453
Lift System…………….453
Tilt System…………….453
ADJUST THE TILT CYLINDER STROKE AND THE BACKWARD TILT ANGLE…………….454
LIFT CHAIN ADJUSTMENTS…………….454
MAST ADJUSTMENTS…………….455
CARRIAGE ADJUSTMENT…………….456
TROUBLESHOOTING…………….459
600105…………….461
INTRODUCTION…………….461
GENERAL…………….461
DESCRIPTION…………….461
ENGINE SERIAL NUMBER CODES…………….462
REMOVAL AND INSTALLATION…………….462
ENGINE…………….462
CYLINDER HEAD…………….462
Removal…………….462
Installation…………….463
Cylinder Head Repairs…………….464
OIL PUMP…………….466
Removal…………….466
Disassembly…………….466
Inspection…………….466
Assembly…………….467
Installation…………….467
RELIEF VALVE…………….468
TIMING GEAR CASE AND TIMING GEARS…………….468
Removal…………….468
Installation…………….469
PISTONS AND CONNECTING RODS…………….470
Removal…………….470
Disassembly…………….470
Inspection…………….471
Assembly…………….472
Installation…………….472
CRANKSHAFT AND MAIN BEARINGS…………….473
Removal…………….473
Inspection…………….473
Assembly…………….474
CAMSHAFT AND CAM FOLLOWERS…………….475
Removal…………….475
Inspection…………….476
Assembly…………….476
FLYWHEEL AND FLYWHEEL HOUSING…………….477
Removal…………….477
Repairs…………….477
Installation…………….477
STEERING PUMP DRIVE…………….477
Removal…………….477
Installation…………….478
PCV VALVE…………….478
FUEL SYSTEM…………….478
FUEL PUMP…………….478
Removal…………….478
Disassembly…………….478
Assembly…………….478
Installation…………….479
FUEL INJECTION PUMP…………….479
Removal…………….479
Repairs…………….479
Installation…………….479
FUEL INJECTORS…………….479
Removal…………….479
Repairs…………….480
Installation…………….480
COLD START AID…………….480
Description…………….480
Removal…………….480
Installation…………….480
COOLING SYSTEM…………….481
THERMOSTAT…………….481
Removal…………….481
Inspection…………….481
Installation…………….481
WATER PUMP…………….481
Removal…………….481
Disassembly…………….481
Assembly…………….481
Installation…………….481
CHECKS AND ADJUSTMENTS…………….481
CHECKING THE INJECTORS…………….481
Repairs…………….482
Installation…………….482
REMOVING AIR FROM THE FUEL SYSTEM…………….482
CHECKING THE TIMING MARKS…………….483
Method A…………….483
Method B…………….484
CHECKING THE TIMING ANGLE OF THE FUEL INJECTION PUMP WITH THE SPECIAL TOOL…………….485
VALVE CLEARANCE ADJUSTMENT…………….486
ADJUSTING THE THROTTLE LINKAGE…………….486
TROUBLESHOOTING…………….488
SPECIFICATIONS…………….489
TORQUE SPECIFICATIONS…………….492
600412…………….493
PERKINS DIESEL ENGINES, SERIES 1000…………….493
1.1 GENERAL…………….493
GENERAL SAFETY RULES…………….493
Viton Seals…………….493
1.2 DESCRIPTION…………….496
1.3 Engine Serial Number Codes…………….496
1.4 Engine Data…………….496
1.5 1004–4 ENGINE…………….497
1.6 1004–4T ENGINE…………….497
1.7 1006–6 ENGINE…………….497
1.8 1006–6T ENGINE…………….497
1.9 REMOVAL AND INSTALLATION…………….497
CYLINDER HEAD ASSEMBLY…………….498
1.10 VALVE COVER…………….498
1.11 Removal…………….498
1.12 Installation…………….498
1.13 ROCKER ARM ASSEMBLY…………….498
1.14 Removal…………….498
1.15 Installation…………….498
1.16 Disassembly…………….499
1.17 Inspection…………….499
1.18 Assembly…………….499
1.19 VALVE CLEARANCE ADJUSTMENTS…………….499
1.20 Four Cylinder Engines…………….500
1.21 Six Cylinder Engines…………….500
1.22 VALVE SPRINGS…………….500
1.23 CYLINDER HEAD ASSEMBLY…………….502
1.24 Removal…………….502
1.25 Installation…………….503
1.26 VALVES AND VALVE SPRINGS…………….506
1.27 Removal…………….506
1.28 Inspection…………….507
1.29 Installation…………….507
1.30 VALVE GUIDES…………….507
1.31 Inspection…………….507
1.32 Removal…………….508
1.33 Installation…………….508
1.34 CYLINDER HEAD AND VALVE SEATS…………….508
1.35 Inspection…………….508
1.36 Repair…………….509
1.37 Installation Of New Valve Seats…………….509
PISTON AND CONNECTING ROD ASSEMBLIES…………….510
1.38 ROD BEARINGS…………….510
1.39 Removal…………….510
1.40 Installation…………….511
1.41 PISTON AND CONNECTING ROD ASSEMBLY…………….511
1.42 Service Note…………….511
1.43 Removal…………….511
1.44 Installation…………….512
1.45 PISTON RINGS…………….513
1.46 Removal…………….513
1.47 Inspection…………….513
1.48 Installation…………….514
1.49 PISTON AND CONNECTING ROD…………….515
1.50 Disassembly…………….515
1.51 Inspection…………….515
1.52 Installation…………….515
1.53 PISTON COOLING JETS…………….516
1.54 Removal…………….516
1.55 Installation…………….516
CRANKSHAFT ASSEMBLY…………….517
1.56 GENERAL…………….517
1.57 CRANKSHAFT PULLEY…………….517
1.58 Removal, Engines AA and AB…………….517
1.59 Installation, Engines AA and AB…………….517
1.60 Removal, Engines YA and YB…………….517
1.61 Installation, Engines YA and YB…………….517
1.62 REAR OIL SEAL…………….518
1.63 Replacement…………….518
1.64 MAIN BEARINGS…………….519
1.65 Removal…………….519
1.66 Installation…………….519
1.67 THRUST WASHERS…………….520
1.68 Check The Axial Movement Of The Crankshaft…………….520
1.69 Removal…………….521
1.70 Installation…………….521
1.71 CRANKSHAFT…………….521
1.72 Removal…………….521
1.73 Inspection…………….522
1.74 Installation…………….522
TIMING CASE AND TIMING GEARS…………….524
1.75 GENERAL…………….524
1.76 TIMING CASE COVER…………….524
1.77 Removal…………….524
1.78 Installation…………….524
1.79 FRONT OIL SEAL…………….525
1.80 Removal…………….525
1.81 Installation…………….525
1.82 IDLER GEAR AND HUB…………….525
1.83 Removal…………….525
1.84 Installation…………….526
1.85 GEAR FOR THE FUEL INJECTION PUMP OR THE CAMSHAFT GEAR…………….527
1.86 Removal…………….527
1.87 Installation…………….527
1.88 CRANKSHAFT GEAR…………….528
1.89 Removal…………….528
1.90 Installation…………….528
1.91 TIMING CASE…………….528
1.92 Removal…………….528
1.93 Installation…………….528
1.94 CAMSHAFT AND TAPPETS…………….529
1.95 Removal…………….530
1.96 Installation…………….530
ENGINE BLOCK ASSEMBLY…………….531
1.97 DESCRIPTION…………….531
1.98 ENGINE BLOCK…………….531
1.99 Disassembly…………….531
1.100 Inspection…………….532
1.101 Assembly…………….532
1.102 CYLINDER LINER…………….532
1.103 Inspection…………….532
1.104 Hone…………….533
1.105 Removal…………….533
1.106 Installation…………….534
TURBOCHARGER, ENGINES AB AND YB…………….535
1.107 GENERAL…………….535
1.108 Removal…………….535
1.109 Installation…………….536
1.110 Clean The Impeller And Compressor Housing…………….536
LUBRICATION SYSTEM…………….537
1.111 GENERAL…………….537
1.112 OIL FILTER, REPLACEMENT…………….537
1.113 OIL SUMP…………….538
1.114 Removal…………….538
1.115 Installation…………….538
1.116 OIL PUMP…………….538
1.117 Removal…………….538
1.118 Inspection…………….539
1.119 Installation…………….539
1.120 RELIEF VALVE…………….540
1.121 Removal…………….540
1.122 Disassembly…………….540
1.123 Inspection…………….541
1.124 Installation…………….541
FUEL SYSTEM…………….541
1.125 DESCRIPTION…………….541
1.126 CAV FUEL INJECTION PUMP…………….542
1.127 Removal…………….542
1.128 Installation…………….542
1.129 CAV FUEL INJECTION PUMP, CHECKS AND ADJUSTMENTS…………….543
1.130 Timing Gear Marks…………….543
1.131 How To Set Number 1 Piston To TDC On The Compression Stroke…………….544
1.132 Check The Valve Timing…………….544
1.133 Check The Timing Of The Fuel Injection Pump…………….545
1.134 Check The Timing Mark Of The Fuel Injection Pump…………….545
1.135 Check The Engine Timing Mark…………….546
1.136 REMOVE AIR FROM THE FUEL SYSTEM…………….547
1.137 Fuel Injection Pump With Vent Tube…………….547
1.138 Fuel Injection Pump With Vent Screw…………….548
1.139 FUEL FILTER (REPLACEMENT)…………….549
1.140 FUEL INJECTORS…………….549
1.141 Removal…………….549
1.142 Inspection…………….550
1.143 Installation…………….551
1.144 FUEL PUMP…………….551
1.145 Removal…………….551
1.146 Disassembly…………….551
1.147 Assembly…………….552
1.148 Installation…………….552
1.149 Test…………….553
COOLING SYSTEM…………….553
1.150 GENERAL…………….553
1.151 THERMOSTAT…………….553
1.152 Replacement…………….553
1.153 COOLANT PUMP…………….554
1.154 Removal…………….554
1.155 Disassembly…………….554
1.156 Assembly…………….555
1.157 Installation…………….555
1.158 FAN AND FAN DRIVE…………….555
1.159 Removal…………….555
1.160 Disassembly…………….555
1.161 Assembly…………….556
1.162 Installation…………….556
1.163 OIL COOLER…………….556
1.164 Removal, Engine AB…………….556
1.165 Removal, Engines YA and YB…………….556
1.166 Disassembly And Assembly…………….557
1.167 Installation, Engine AB…………….557
1.168 Installation, Engines YA and YB…………….558
1.169 By–Pass Valve, Oil Cooler…………….558
FLYWHEEL AND FLYWHEEL HOUSING…………….558
1.170 GENERAL…………….558
1.171 FLYWHEEL…………….558
1.172 Removal…………….558
1.173 Ring Gear (Replacement)…………….558
1.174 Installation…………….558
1.175 FLYWHEEL HOUSING…………….559
1.176 Removal…………….559
1.177 Installation…………….559
ELECTRICAL EQUIPMENT…………….560
1.178 DRIVE BELTS…………….560
1.179 ALTERNATOR…………….561
1.180 STARTER MOTOR…………….561
1.181 Removal…………….561
1.182 Installation…………….561
1.183 COLD START AID…………….561
AIR COMPRESSOR, ENGINES YA AND YB…………….561
1.184 GENERAL…………….561
1.185 Air Compressor, Removal, WABCO…………….561
1.186 Compressor Drive, Inspection…………….562
1.187 Air Compressor, Installation, WABCO…………….562
1.188 Compressor Drive, Disassembly, WABCO…………….562
1.189 Compressor Drive, Assembly, WABCO…………….563
1.190 Air Compressor, Removal, BENDIX…………….563
1.191 Air Compressor, Installation, BENDIX…………….564
1.192 Compressor Drive, Disassembly, BENDIX…………….565
1.193 Compressor Drive, Assembly, BENDIX…………….565
ENGINE SPECIFICATIONS…………….567
1.194 CYLINDER HEAD ASSEMBLY…………….567
1.195 Cylinder Head…………….567
1.196 Valve Guides…………….567
1.197 Inlet Valves…………….568
1.198 Exhaust Valves…………….568
1.199 Double Valve Springs To Outer…………….568
1.200 Double Valve Springs To Inner…………….568
1.201 Single Valve Springs…………….568
1.202 Tappets…………….568
1.203 Rocker Arm Shaft…………….568
1.204 Rocker Arms And Bushings…………….569
1.205 PISTON AND CONNECTING RODS…………….569
1.206 Pistons, Engines AA And YA…………….569
1.207 Pistons, Engines AB And YB…………….569
1.208 Piston Rings, Engines AA And YA…………….569
1.209 Piston Rings, Engines AB And YB…………….569
1.210 Connecting Rods, Engines AB And YB…………….570
1.211 Connecting Rods, Engines AB And YB…………….570
1.212 Piston Pins, Engines AA And YA…………….570
1.213 Piston Pins, Engines AB and YB…………….570
1.214 Small End Bushings, Engines AA And YA…………….570
1.215 Small End Bushings, Engines AB And YB…………….570
1.216 Connecting Rod Bearings, Engines AA And YA…………….571
1.217 Connecting Rod Bearings, Engines AB And YB…………….571
1.218 Piston Cooling Jets, Engines AB And YB…………….571
1.219 CRANKSHAFT ASSEMBLY…………….571
1.220 Crankshaft…………….571
1.221 Crankshaft Heat Treatment…………….571
1.222 Crankshaft Overhaul…………….571
1.223 Main Bearings…………….573
1.224 Crankshaft Thrust Washers…………….573
1.225 TIMING CASE AND DRIVE ASSEMBLY…………….573
1.226 Camshaft…………….573
1.227 Camshaft Thrust Washer…………….573
1.228 Camshaft Gear…………….574
1.229 Gear For Fuel Injection Pump…………….574
1.230 Crankshaft Gear…………….574
1.231 Idler Gear And Hub…………….574
1.232 ENGINE BLOCK ASSEMBLY…………….574
1.233 Engine Block…………….574
1.234 Cylinder Liners…………….574
1.235 TURBOCHARGER…………….575
1.236 LUBRICATION SYSTEM…………….575
1.237 Oil Pump, Engines AA And AB…………….575
1.238 Oil Pump, Engines YA And YB…………….575
1.239 Relief Valve…………….575
1.240 Oil Filter…………….575
1.241 FUEL SYSTEM…………….575
1.242 Cav Fuel Injection Pump…………….575
1.243 FUEL INJECTORS…………….576
1.244 Fuel Pump, Engines AA And AB…………….577
1.245 Fuel Pump, Engines YA And YB…………….577
1.246 Fuel Filter…………….577
1.247 COOLING SYSTEM…………….577
1.248 Coolant Pump…………….577
1.249 Thermostat…………….578
1.250 Fan Drive Housing…………….578
1.251 FLYWHEEL AND HOUSING…………….578
1.252 Limits for flywheel ''run out'' and alignment (total indicator reading)……………..578
1.253 ELECTRICAL EQUIPMENT…………….578
1.254 Alternator…………….578
1.255 Starter Motor…………….578
1.256 Cold Start Aid…………….578
TORQUE SPECIFICATIONS…………….579
SPECIAL TOOLS…………….580
600590…………….584
GM 4.3 LITRE V-6…………….584
INTRODUCTION…………….584
DESCRIPTION…………….584
ENGINE, REMOVAL AND INSTALLATION…………….585
CYLINDER HEAD…………….585
Removal And Disassembly…………….585
Cleaning And Inspection…………….585
Repairs, Valve Guides and Seats…………….585
Repairs, Valves…………….586
Repairs, Valve Seats…………….586
Valve Springs…………….587
Studs For The Rocker Arms (Early Models)…………….588
Studs For The Rocker Arms (Late Models)…………….589
Assembly And Installation…………….589
CYLINDER BLOCK, CLEANING AND INSPECTION…………….591
PISTON BORE PREPARATION…………….591
ENGINE MOUNTS…………….591
LUBRICATION SYSTEM…………….591
Oil Pump, Removal and Disassembly…………….591
Cleaning and Inspection…………….592
Oil Pump, Assembly and Installation…………….592
Oil Sump, Installation…………….592
TIMING COVER, TIMING SPROCKETS, CAMSHAFT AND VALVE LIFTERS…………….593
Timing Cover, Removal…………….593
Installation…………….594
Timing Sprockets, Removal…………….595
Timing Sprockets, Installation…………….595
Camshaft, Removal…………….595
Camshaft, Inspection…………….595
Camshaft, Installation…………….595
Balance Shaft, Removal…………….596
Balance Shaft, Installation…………….597
Hydraulic Valve Lifters, Removal…………….598
Hydraulic Valve Lifters, Disassembly…………….598
Hydraulic Valve Lifters, Cleaning And Inspection…………….598
Hydraulic Valve Lifters, Assembly…………….599
Hydraulic Valve Lifters, Installation…………….599
CRANKSHAFT…………….600
Removal…………….600
Inspection and Repair…………….600
How To Check The Clearance Between The Main Bearings And Their Journals…………….601
Installation…………….602
PISTON AND CONNECTING ROD ASSEMBLIES…………….603
Connecting Rod Bearings, Replacement…………….603
Piston And Connecting Rod Assemblies, Removal…………….604
Disassembly…………….604
Piston, Cleaning And Inspection…………….604
Cylinder Bores, Inspection And Repair…………….605
Piston Rings…………….606
Assembly…………….606
Piston And Connecting Rod Assemblies, Installation…………….607
FLYWHEEL AND FLYWHEEL HOUSING…………….607
Flywheel Repairs…………….607
Flywheel, Installation…………….607
Flywheel Housing…………….608
Engine Adapter…………….608
COOLANT PUMP…………….608
THERMOSTAT…………….608
FAN MOUNT, EARLY MODELS…………….608
FAN MOUNT ASSEMBLY, LATE MODELS…………….609
DRIVE BELT, INSTALLATION…………….610
CHECKS AND ADJUSTMENTS…………….612
VALVE CLEARANCE ADJUSTMENT, EARLY MODELS…………….612
VALVE CLEARANCE ADJUSTMENT, NEW MODELS…………….612
CHECK THE COMPRESSION…………….612
ENGINE SPECIFICATIONS…………….613
Engine Data…………….613
Cylinder head…………….613
Hydraulic Valve Lifter…………….613
Camshaft…………….613
Pistons…………….613
Crankshaft…………….614
Connecting Rods…………….614
Connecting Rods…………….614
Balance Shaft…………….614
Cooling System…………….614
Lubrication System…………….614
TORQUE SPECIFICATIONS…………….615
TROUBLESHOOTING…………….616
700626…………….619
COOLING SYSTEM…………….619
INTRODUCTION…………….619
DESCRIPTION…………….619
RADIATOR…………….619
RADIATOR CAP…………….619
THERMOSTAT…………….619
WATER PUMP…………….620
FAN AND FAN SHROUD …………….620
REPAIRS…………….620
COOLING SYSTEM CHECKS…………….620
Exhaust Leaks…………….620
RADIATOR…………….620
Checks…………….620
Cleaning The Radiator…………….620
Drain The Cooling System…………….622
Fill The Cooling System…………….622
WATER PUMP…………….622
Checks…………….622
THERMOSTAT…………….623
Checks…………….623
FAN AND FAN SHROUD …………….623
TROUBLESHOOTING…………….624
8000231…………….625
INTRODUCTION…………….625
NOMENCLATURE, THREADS…………….625
STRENGTH IDENTIFICATION…………….626
TABLE 1. BOLTS AND SCREWS…………….626
TABLE 2. STUDS AND NUTS…………….627
TABLE 3. TORQUE NUTS…………….628
TABLE 4. TORQUE NUTS WITH NYLON INSERT…………….629
TABLE 5. TORQUE VALUES FOR INCH FASTENERS…………….630
TABLE 6. TORQUE VALUES FOR METRIC FASTENERS…………….631
8000341…………….634
PERIODIC MAINTENANCE…………….634
GENERAL…………….634
SERIAL NUMBER DATA…………….634
HOW TO MOVE A DISABLED LIFT TRUCK…………….634
How To Tow the Lift Truck…………….634
HOW TO PUT A LIFT TRUCK ON BLOCKS…………….635
How To Raise the Drive Tires…………….635
How To Raise the Steering Tires…………….635
MAINTENANCE SCHEDULE…………….637
MAINTENANCE PROCEDURES…………….640
EVERY 8 HOURS OR DAILY…………….640
HOW TO MAKE THE CHECKS WITH THE ENGINE STOPPED…………….640
Hydraulic System Oil…………….640
Engine Oil…………….642
Drive Belts…………….642
Cooling System…………….642
Air Filter…………….642
Fuel System…………….643
Primary Fuel Filter, Diesel Engine…………….643
Battery…………….643
Tires and Wheels…………….643
Forks…………….644
Forks, Adjustment…………….644
Forks, Removal And Installation…………….644
Inspection of Forks, Mast, And Lift Chains…………….645
Operator Restraint System…………….647
Safety Labels…………….648
HOW TO MAKE THE CHECKS WITH THE ENGINE RUNNING…………….648
Gauges, Lights, Horn, and Fuses…………….648
Oil Level, Powershift Transmission…………….648
Oil Level, Oil Clutch System, H3.50-5.00XL (H70-110XL)…………….649
Control Levers and Pedals…………….649
Lift System Operation…………….649
Inching/Brake Pedal…………….650
Service Brakes…………….650
Parking Brake…………….650
Steering System…………….650
EVRY 150 HOURS OR MONTHLY…………….650
THRUST SCREW FOR THE DIFFERENTIAL, H6.00-7.00XL (H135-155XL)…………….650
LIFT CHAINS, LUBRICATION…………….650
DRIVE SHAFTS…………….651
EVERY 350 HOURS OR TWO MONTHS…………….651
ENGINE OIL AND FILTER…………….651
DRIVE BELTS…………….652
Perkins Diesel Engine…………….652
GM V-6 Engine (Early Models)…………….652
GM V-6 Engine (Later Models)…………….653
HYDRAULIC TANK BREATHER, CLEAN AND CHECK…………….654
BRAKE FLUID…………….654
LIFT CHAINS, CHECK FOR WEAR…………….654
FORKS, CHECK FOR WEAR AND DAMAGE…………….655
MAST, LUBRICATION…………….655
CONTROL LEVERS AND PEDALS, LUBRICATION…………….655
STEERING AXLE, LUBRICATION…………….656
FUEL SYSTEM, CHECKS AND ADJUSTMENTS…………….656
Diesel Fuel System…………….656
LPG Carburetor (Early Models)…………….656
Gasoline Carburetor (Early Models)…………….657
Fuel Injection (Late Models)…………….657
EVERY 1000 HOURS OR SIX MONTHS…………….657
PCV VALVE, GM V-6…………….657
MANIFOLD HEAT VALVE, GM V-6 (EARLY MODELS)…………….657
CRANKCASE BREATHER, GM-V6…………….657
IGNITION SYSTEM (GM V-6)…………….657
VALVE CLEARANCE ADJUSTMENT…………….658
FUEL FILTER (REPLACEMENT), DIESEL ENGINE…………….658
REMOVE AIR FROM THE FUEL SYSTEM: PERKINS 1004-4 DIESEL ENGINE…………….658
Fuel Injection Pump With A Vent Tube…………….658
Fuel Injection Pump With A Vent Screw…………….659
REMOVE AIR FROM THE FUEL SYSTEM: PERKINS 4.2482 DIESEL ENGINE…………….660
CHECK THE OIL LEVEL IN THE TRANSMISSION…………….660
Manual Transmission, H3.50-5.00XL (H70-110XL)…………….660
Speed Reducer For The Powershift Transmission, H3.50-5.00XL (H70-110XL)…………….661
Manual Transmission, H6.00-7.00XL (H135-155XL)…………….661
Differential And Drive Axle For The Powershift Transmission, H6.00-7.00XL (H135-155XL…………….661
Differential, Speed Reducer, And Drive Axle For The Manual Transmission, H6.00-7.00XL (H135-155XL)…………….661
EVERY 2000 HOURS OR YEARLY…………….661
HYDRAULIC SYSTEM…………….661
Replace the Hydraulic Oil and Filter, H3.50-5.00XL (H70-110XL)…………….661
Replace the Hydraulic Oil and Filter, H6.00-7.00XL (H135-155XL)…………….662
CHANGE THE OIL AND REPLACE THE OIL FILTER, POWERSHIFT TRANSMISSION, ALL UNITS…………….662
CHANGE THE OIL, MANUAL TRANSMISSION, H3.50-5.00XL (H70-110XL)…………….662
CHANGE THE OIL, MANUAL TRANSMISSION, H6.00-7.00XL (H135-155XL)…………….662
CHANGE THE OIL, SPEED REDUCER, POWERSHIFT TRANSMISSION, H3.50-5.00XL (H70-110XL)…………….663
CHANGE THE OIL AND FILTER, OIL CLUTCH SYSTEM, H3.50-5.00XL (H70-110XL)…………….663
CHANGE THE OIL, DIFFERENTIAL AND DRIVE AXLE FOR THE POWERSHIFT TRANSMISSION, H6.00-7.00XL (H135-155XL)…………….663
CHANGE THE OIL, DIFFERENTIAL, SPEED REDUCER, AND DRIVE AXLE FOR MANUAL TRANSMISSION, H6.00-7.00XL (H135-155XL)…………….663
COOLING SYSTEM…………….664
WHEEL BEARINGS…………….664
Steering Wheels, lubrication…………….664
Drive Wheels, Lubrication…………….664
PCV VALVE, GM V-6…………….664
SERVICE BRAKES…………….664
LPG FILTER, REPLACEMENT…………….665
GASOLINE FUEL FILTER, REPLACEMENT…………….665
CHECK THE HOOD LATCH, H3.50-5.00XL (H70-110XL)…………….665
GENERAL PROCEDURES…………….666
SAFETY PROCEDURES WHEN WORKING NEAR THE MAST…………….666
LIFT CHAIN ADJUSTMENTS…………….668
FUEL INJECTORS…………….668
CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM…………….669
Check the Lift Cylinder for Leaks…………….669
Check the Tilt Cylinder for Leaks…………….669
WELDING REPAIRS…………….669
CHANGES TO THE OVERHEAD GUARD…………….670
WHEELS AND TIRES…………….671
Remove The Wheels From The Lift Truck…………….671
Remove The Wheel From The Tire…………….671
Install The Wheel In The Tire…………….673
Pneumatic Tires, Add Air To The Tires…………….674
Install the Wheels…………….674
SOLID RUBBER TIRES…………….675
Remove The Tire From The Wheel…………….675
Install The Tire On The Wheel…………….676
REFERENCE TABLE…………….677
8000342…………….678
8000343…………….686
FIGURE 1. ELECTRICAL SCHEMATIC (GASOLINE/LPG, EARLY PRODUCTION)…………….686
FIGURE 2. ELECTRICAL SCHEMATIC (GASOLINE/LPG, LATER PRODUCTION)…………….688
FIGURE 3. ELECTRICAL SCHEMATIC (DIESEL, PERKINS 4.2482)…………….690
FIGURE 4. ELECTRICAL SCHEMATIC (DIESEL, PERKINS 1004-4, EARLY PRODUCTION)…………….692
FIGURE 5. ELECTRICAL SCHEMATIC (DIESEL, PERKINS 1004-4, LATER PRODUCTION)…………….694
FIGURE 6. HYDRAULIC SCHEMATIC…………….696
FIGURE 7. HYDRAULIC SCHEMATIC, POWERSHIFT TRANSMISSION WITH MANUAL CONTROL…………….697
FIGURE 8. HYDRAULIC SCHEMATIC, POWERSHIFT TRANSMISSION WITH MONTROL PEDAL…………….698
FIGURE 9. WIRING DIAGRAM, BACK-UP ALARM…………….699
8000494…………….700
900347…………….714
WEBER CARBURETOR WITH GOVERNOR…………….714
GENERAL…………….714
DESCRIPTION…………….714
Carburetor…………….714
Governor…………….714
OPERATION…………….715
Carburetor, Float System…………….715
Carburetor, Idle System…………….715
Carburetor, Main Metering System…………….715
Carburetor, Power System…………….716
Carburetor, Accelerator Pump System…………….716
Carburetor, Choke System…………….717
GOVERNOR…………….718
REPAIRS…………….719
CARBURETOR…………….719
Removal…………….719
Disassembly…………….719
Cleaning…………….719
Assembly…………….719
Installation…………….720
GOVERNOR…………….720
CHECKS AND ADJUSTMENTS…………….721
GENERAL…………….721
CHOKE SYSTEM…………….721
ELECTRIC CHOKE…………….721
IDLE MIXTURE ADJUSTMENT…………….722
IDLE SPEED ADJUSTMENT…………….722
THROTTLE LINKAGE ADJUSTMENT…………….723
TROUBLESHOOTING…………….724
900348…………….725
INTRODUCTION…………….725
GENERAL…………….725
DESCRIPTION AND OPERATION…………….725
Fuel Tank…………….726
Fuel Filter and Fuel Valve Unit…………….726
Vaporizer…………….727
Carburetor…………….728
Governor…………….729
REPAIRS…………….731
LPG TANK…………….731
Removal…………….731
Installation…………….731
HYDROSTATIC RELIEF VALVE…………….731
Removal and Installation…………….731
FILTER UNIT…………….733
Replacement Of The Fuel Filter Element…………….733
Replacement of the Diaphragm and Fuel Valve …………….733
REPLACEMENT OF THE HOSES…………….733
VAPORIZER…………….733
Removal…………….733
Vaporizer Disassembly…………….735
Cleaning…………….735
Inspection…………….735
Vaporizer Assembly…………….735
Installation…………….737
CARBURETOR…………….737
Removal…………….737
Disassembly…………….737
Cleaning…………….738
Assembly…………….738
Installation…………….738
GOVERNOR…………….738
CHECKS AND ADJUSTMENTS…………….739
CHECK THE FILTER UNIT…………….739
CHECK THE VAPORIZER…………….739
Pressure Reducer Valve…………….739
Vapor Valve…………….739
ADJUST THE CARBURETOR…………….740
Idle Mixture…………….740
Idle Speed …………….740
Power Mixture…………….740
ADJUST THE THROTTLE LINKAGE…………….740
TROUBLESHOOTING…………….741
F005 (H70-110XL)…………….744
100345…………….746
THE FRAME…………….746
GENERAL…………….746
DESCRIPTION…………….746
REPAIRS…………….746
COUNTERWEIGHT…………….746
Removal…………….746
COUNTERWEIGHT…………….747
Installation…………….747
HOOD…………….747
Removal…………….747
HOOD…………….747
Installation…………….747
OVERHEAD GUARD…………….748
Removal…………….748
Installation…………….748
OPERATOR RESTRAINT SYSTEM…………….748
RADIATOR…………….748
Removal…………….748
Installation…………….749
EXHAUST SYSTEM…………….749
Muffler Replacement…………….749
ENGINE…………….749
Removal…………….749
Installation…………….752
FUEL AND HYDRAULIC TANKS…………….753
Inspection…………….753
Repairs, Small Leaks…………….753
Repairs, Large Leaks…………….753
Cleaning…………….753
Other Methods Of Preparation For Repair…………….754
SAFETY LABELS…………….755
CAB…………….755
Cab Repalacement…………….755
Window Repalcement…………….755
Windshield Wipers, Heater and Fan…………….758
Material Specifications For Cab Windows…………….758
Cab Heater Hoses…………….758
1200334…………….759
INTRODUCTION…………….759
General…………….759
Description…………….759
REPAIRS…………….761
Removal and Disassembly…………….761
Cleaning and Inspection…………….762
Assembly and Installation…………….763
CHECKS AND ADJUSTMENTS…………….765
Adjusting the Clutch Pedal and Linkage…………….765
Adjusting the By-pass Valve for Cold Oil…………….765
TROUBLESHOOTING…………….766
1300335…………….768
INTRODUCTION…………….768
General…………….768
Description…………….768
Operation…………….768
REPAIRS…………….770
Removal…………….770
Disassembly…………….771
Cleaning…………….773
Inspection…………….774
Assembly…………….774
Installation…………….785
CHECKS AND ADJUSTMENTS…………….786
Adjusting The Shift Linkage H3.50-5.00XL (H70-110XL)…………….786
Adjusting The Shift Linkage S6.00-7.00XL (S135-155XL)…………….788
Adjusting The Clutch Pedal And Linkage…………….788
TROUBLESHOOTING…………….790
SPECIFICATIONS…………….792
1300336…………….793
DESCRIPTION…………….793
GENERAL…………….793
MECHANICAL DESCRIPTION…………….793
TORQUE CONVERTER…………….793
OIL LAMP…………….794
SHAFT AND CLUTCH ASSEMBLIES…………….794
Input Shaft…………….795
Forward Clutch Shaft…………….795
Clutch Assemblies…………….795
Output Gear…………….796
HYDRAULIC OPERATION…………….796
TORQUE CONVERTER…………….796
SHAFT ASSEMBLIES…………….797
CONTROL VALVE…………….799
General…………….799
System Regulator…………….799
Clutch Pressure Regulator…………….799
Torque Converter Regulator…………….800
Inching Spool…………….800
Direction Spool, Manual Control…………….800
Drain Spool…………….801
Accumulator…………….801
Modulation Spool…………….802
LUBRICATION CIRCUIT…………….803
MONOTROL PEDAL…………….803
OIL FLOW DIAGRAMS…………….803
Neutral…………….803
Forward…………….803
Forward-Inching…………….803
Reverse…………….804
1300337…………….809
REPAIRS …………….809
GENERAL…………….809
REMOVAL…………….809
TRANSMISSION, DISASSEMBLY…………….811
Input Shaft, Disassembly…………….812
Forward Shaft, Disassembly…………….814
Cleaning and Inspection…………….815
TRANSMISSION, ASSEMBLY…………….816
Forward Shaft, Assembly…………….816
Input Shaft, Assembly…………….818
Assembly…………….820
Installation…………….823
CONTROL VALVE…………….824
Removal…………….824
Disassembly…………….825
Assembly…………….825
Installation…………….827
THROTTLE PEDAL…………….827
MONOTROL PEDAL…………….827
Removal and Disassembly…………….827
Assembly and Installation…………….827
CHECKS AND ADJUSTMENTS…………….830
STALL TEST…………….830
ADJUST THE LINKAGE FOR THE INCHING PEDAL…………….831
Linkage For Models With An Inching Pedal And A Brake Pedal…………….831
Linkage For ModelsWith One Inching/Brake Pedal…………….833
ADJUST THE LINKAGE FOR THE DIRECTION CONTROL LEVER…………….834
Earlier Production…………….834
Later Production…………….835
CHECK THE OIL PRESSURE FOR THE TRANSMISSION…………….836
System Pressure Check Port…………….837
Torque Converter Check Port…………….837
Clutch Pressure Check Port…………….838
Inching Pressure…………….838
Solenoid Check Ports (Monotrol Control Only)…………….838
Lubrication Pressure Check Ports…………….838
TROUBLESHOOTING…………….839
1300346…………….842
INTRODUCTION…………….842
GENERAL…………….842
DESCRIPTION…………….842
REPAIRS…………….842
REMOVAL…………….842
DISASSEMBLY…………….842
CLEANING…………….845
INSPECTION…………….845
ASSEMBLY…………….845
Pinion Assembly…………….845
Differential…………….846
INSTALLATION…………….852
TROUBLESHOOTING…………….853
SPECIFICATIONS…………….854
1400361…………….855
INTRODUCTION…………….855
GENERAL…………….855
DESCRIPTION…………….855
REPAIRS…………….856
REMOVAL…………….856
Lift Trucks With A Manual Transmission…………….856
Lift Trucks With A Powershift Transmission…………….857
DISASSEMBLY…………….858
CLEANING…………….858
INSPECTION…………….858
ASSEMBLY…………….858
INSTALLATION…………….859
Lift Trucks With A Manual Transmission…………….859
Lift Trucks With A Powershift Transmission…………….860
TROUBLESHOOTING…………….861
SPECIFICATIONS…………….861
1600326…………….862
General…………….864
Description…………….864
Steering Axle Assembly Repair…………….864
Steering Axle H3.50-5.00XL (H70-110XL) and S/E3.50-5.50XL (S/E70-120XL)…………….864
Remove…………….864
Install…………….865
Steering Axle H6.00-7.00XL (H135-155XL), H8.00-16.00XL (H165-360XL), and H8.00-16.00XM (H170-360HD)…………….866
Remove…………….866
Install…………….867
Wheels and Hubs Repair (All Units)…………….868
Remove and Disassemble…………….868
Clean…………….868
Assembly and Install…………….868
Spindles and Bearings Repair (All Units)…………….870
Remove…………….870
Clean…………….870
Assemble and Install…………….870
Tie Rods Repair (All Units)…………….871
Remove…………….871
Clean…………….871
Install…………….871
Steering Cylinder Repair…………….873
Remove and Disassemble…………….873
Clean and Inspect…………….873
Assemble and Install…………….873
Troubleshooting…………….874
160054…………….877
INTRODUCTION…………….877
GENERAL…………….877
DESCRIPTION…………….877
OPERATION…………….877
REPAIRS…………….877
STEERING WHEEL AND COLUMN ASSEMBLY…………….877
TYPE "A" STEERING COLUMN ASSEMBLY…………….879
Removal And Disassembly…………….879
Assembly And Installation…………….879
TYPE "A" STEERING COLUMN…………….880
TYPE "A" STEERING COLUMN…………….881
TYPE "B" STEERING COLUMN…………….882
Removal And Disassembly…………….882
Assembly And Installation…………….882
TYPE "B" STEERING COLUMN…………….883
Disassembly of Steering Control Unit…………….884
Cleaning of Steering Control Unit…………….884
Assembly of Steering Control Unit…………….886
CHECKS AND ADJUSTMENTS…………….889
REMOVE AIR FROM THE SYSTEM…………….889
TROUBLESHOOTING…………….890
1800338…………….891
…………….891
…………….892
…………….893
…………….894
…………….895
…………….896
…………….897
…………….898
…………….899
…………….900
…………….901
…………….902
…………….903
…………….904
…………….905
…………….906
…………….907
…………….908
…………….909
…………….910
…………….911
…………….912
…………….913
…………….914
1900333…………….915
INTRODUCTION…………….915
GENERAL…………….915
DESCRIPTION AND OPERATION…………….915
Hydraulic Pump…………….915
Main Control Valve…………….916
Steering Control Unit…………….918
Brake Booster…………….918
REPAIRS…………….918
HYDRAULIC PUMP…………….918
Removal…………….918
Disassembly…………….919
Cleaning and Inspection…………….919
Assembly…………….919
Installation…………….920
Adjust the Flow Divider…………….920
SPECIFICATIONS…………….920
TROUBLESHOOTING…………….921
1900339…………….923
INTRODUCTION…………….923
GENERAL…………….923
DESCRIPTION…………….923
REPAIRS…………….925
REMOVAL AND DISASSEMBLY…………….925
CLEANING…………….925
INSPECTION…………….925
ASSEMBLY AND INSTALLATION…………….926
TROUBLESHOOTING…………….927
GENERAL…………….927
190097…………….928
INTRODUCTION…………….928
DESCRIPTION…………….928
OPERATION…………….928
Flow Control Valve…………….930
Relief Valve…………….930
REPAIRS…………….931
REMOVAL…………….931
DISASSEMBLY…………….931
CLEANING…………….933
INSPECTION…………….933
ASSEMBLY…………….934
INSTALLATION…………….935
CHECKS AND ADUSTMENTS…………….936
CHECK THE OUTPUT OF THE PUMP…………….936
CHECK FOR AIR IN THE HYDRAULIC SYSTEM…………….936
TROUBLESHOOTING…………….938
200077…………….941
INTRODUCTION…………….941
GENERAL…………….941
DESCRIPTION…………….941
OPERATION…………….942
Lift Section…………….943
Tilt Section…………….943
Relief Valve…………….945
SOLENOID VALVE FOR AUXILIARY FUNCTION…………….946
Operation…………….946
REPAIRS…………….946
MAIN CONTROL VALVE…………….946
Removal and Disassembly…………….946
Cleaning and Inspection…………….947
Assembly…………….947
Installation…………….947
SOLENOID VALVE FOR AUXILIARY FUNCTION…………….947
Removal and Disassembly…………….947
Assembly and Installation…………….949
CHECKS AND ADJUSTMENTS…………….949
PRESSURE RELIEF VALVES…………….949
Primary Relief Valve…………….949
Seconday Relief Valve…………….950
CONTROL LEVER ARRANGEMENT…………….950
TROUBLESHOOTING…………….953
SPECIFICATIONS…………….955
2100103…………….956
General…………….958
Description…………….958
Tilt Cylinder…………….958
Remove…………….958
Disassemble…………….958
Clean…………….958
Assemble…………….958
Tilt Cylinders with O-Ring or Single-Lip Seals…………….958
Tilt Cylinders for XM and XMS Models…………….960
Tilt Cylinders for H700-800A and Early Model H700-920B…………….961
Install…………….962
Tilt Cylinders Using Chevron Packing…………….963
Install…………….964
Tilt Cylinder Leak Check…………….966
Tilt Cylinder Stroke and Mast Tilt Angle Adjustment…………….967
Torque Specifications…………….967
Piston Rod Nut…………….967
Retainer…………….969
Troubleshooting…………….970
2200106…………….973
General…………….975
Description and Operation…………….975
Starter Repair…………….977
Remove…………….977
Disassemble…………….977
Clean…………….978
Assemble…………….978
Install…………….979
General Checks and Adjustments…………….979
Troubleshooting…………….982
2200107…………….986
toc…………….986
High Energy Ignition (HEI) System…………….986
Safety Precautions Maintenance and Repair…………….987
Description…………….990
Distributor Repair…………….992
Remove…………….992
Disassemble…………….992
Assemble…………….997
Install, If Crankshaft WAS NOT Rotated when Distributor was Remo…………….998
Install, If Crankshaft WAS Rotated when Distributor was Removed…………….998
Ignition Coil Replacement…………….999
Some Four- and Six-Cylinder Models…………….999
Remove…………….999
Install…………….1000
V8, Some Four- and Six-Cylinder Models…………….1000
Remove…………….1000
Install…………….1001
Electronic Module Replacement…………….1002
Remove…………….1002
Install…………….1002
Sensing Coil Replacement…………….1003
Remove…………….1003
Install…………….1003
Spark Plugs Replacement…………….1003
Remove…………….1003
Install…………….1004
Visual Check…………….1004
High Voltage Wires Check…………….1004
Ignition Coil Check…………….1005
Coil in Distributor Cap Design…………….1005
Separate Coil Design…………….1005
Sensing Coil, Check…………….1006
Electronic Module Check…………….1006
Ignition Timing Adjustment…………….1006
GM V8-366 (6-liter) Ignition System Check…………….1008
GM V6-LPG (4.3 liter) GM V6-LPG (4.3 liter) Ignition Timing and …………….1008
Specifications…………….1008
Troubleshooting…………….1009
2200143…………….1014
INTRODUCTION…………….1014
GENERAL…………….1014
DESCRIPTION…………….1014
GENERAL…………….1014
STEERING COLUMN GAUGES, METERS AND INDICATORS…………….1017
LED DISPLAY PANEL…………….1017
Battery Discharge Indicators…………….1017
Brush Wear Indicators…………….1018
Motor Temperature Indicators…………….1019
"LX" SERIES DISPLAY PANEL…………….1020
Hourmeter Functions…………….1021
Battery Indicator Function…………….1021
Status Code Function…………….1021
"ZX" SERIES DISPLAY PANELS…………….1021
Display Panel…………….1022
Basic Display Panels…………….1022
Performance Display…………….1024
Brush Wear Indicators…………….1027
CHECKS AND ADJUSTMENTS…………….1027
GENERAL…………….1027
REPLACEMENT…………….1028
GENERAL…………….1028
METER REPLACEMENT…………….1028
SENDER REPLACEMENT…………….1029
Fuel Level Sender…………….1029
Pressure And Temperature Sender…………….1029
I.T.W. DISPLAY PANEL…………….1030
Removal…………….1030
DISPLAY PANELS FOR THE EV – 100/200ZX MOTOR CONTROLLERS, COLUMN MOUNT…………….1031
Removal…………….1031
Replacing Display Panel Assembly…………….1031
Indicator LEDs…………….1031
Battery Indicators…………….1031
Digital Display (Performance Disply Panel Only)…………….1031
Status Code Or Performance Level Switches And Indicator LEDs (Performance Display Panel Only)…………….1031
Replacing Parts Of The Basic Display Panel…………….1032
Replacing Parts Of The Performance Display Panel…………….1034
DISPLAY PANELS FOR THE EV-100/200ZX MOTOR CONTROLLERS, DASH MOUNT…………….1034
Removal And Replacement…………….1034
SPECIFICATIONS…………….1035
TROUBLESHOOTING…………….1036
2200144…………….1037
ELECTRICAL WARNING DEVICES…………….1037
GENERAL…………….1037
DESCRIPTION…………….1037
Operator Controlled Horns…………….1037
System Warning Lights, Buzzers and Bells…………….1037
Reverse Warning Horns…………….1038
Warning Lights…………….1038
REPLACEMENT…………….1039
General…………….1039
Replacing Horns or Bells…………….1039
Replacing Horn Relay or Buzzer…………….1039
Replacing Warning Lights…………….1039
Light Assemblies…………….1040
Replacing Flashing Units…………….1040
22002…………….1041
General…………….1043
Description…………….1043
Alternator Repair…………….1045
Alternator Type A…………….1045
Remove and Disassemble…………….1045
Clean…………….1046
Assemble…………….1046
Install…………….1047
Alternator Type B…………….1050
Remove and Disassemble…………….1050
Clean…………….1050
Assemble…………….1051
Install…………….1052
General Check and Adjustment…………….1053
Low Output Check (Type A or Type B)…………….1053
High Output Check (Type A or Type B)…………….1055
Brushes Circuit Check…………….1056
Delco Alternators…………….1056
Motorola Alternators…………….1057
Diodes Check…………….1058
Diodes Bridge Check…………….1058
Delco and Leece-Neville Alternators…………….1058
Motorola Alternators…………….1058
Rotor Field Winding Check…………….1059
Stator Windings Check…………….1060
Voltage Regulator Check…………….1060
Troubleshooting…………….1061
2200463…………….1063
…………….1063
…………….1064
…………….1065
…………….1066
…………….1067
…………….1068
…………….1069
…………….1070
…………….1071
…………….1072
…………….1073
…………….1074
…………….1075
…………….1076
…………….1077
…………….1078
…………….1079
…………….1080
…………….1081
…………….1082
…………….1083
…………….1084
…………….1085
…………….1086
…………….1087
…………….1088
…………….1089
…………….1090
…………….1091
…………….1092
…………….1093
…………….1094
…………….1095
…………….1096
…………….1097
…………….1098
2200468…………….1099
ELECTRONIC ENGINE CONTROL, TROUBLESHOOTING AND REPAIR…………….1099
GENERAL…………….1099
Engine Data…………….1099
LIGHT BULB CHECK…………….1099
SYSTEM CHECK…………….1101
TROUBLESHOOTING WITH THE FAULT MONITOR SYSTEM IN THE ECM…………….1101
How To Clear A Code…………….1102
Fault In The ECM…………….1102
Fault In The PROM…………….1103
CalPak Not Installed…………….1103
Fuel Control…………….1103
Idle Air Control (IAC)…………….1103
Fuel Pump Circuit…………….1103
Coolant Temperature Sensor (CTS)…………….1104
Manifold Absolute Pressuer Sensor (MAP)…………….1104
Throttle Position Sensodr (TPS)…………….1104
Output Check, Throttle Position Sensor…………….1104
Electronic Spark Timing…………….1104
Engine Crank Signal…………….1105
Distributor Reference Signal…………….1105
TROUBLESHOOTING CHARTS…………….1106
CHART A-1-No "Check Engine" Light…………….1106
Circuit Description, "Check Engine" Light…………….1106
CHART A-1-No "Check Engine" Light…………….1107
CHART A-2-No ALDL Data Or No Code 12 From "Check Engine" Light. The "Check Engine" Light Is Continuosly Illuminated…………….1108
Circuit Description, "Check Engine" Light…………….1108
CHART A-2-No ALDL Data Or No Code 12 From "Check Engine" Light. The "Check Engine" Light Is Continuously Illuminated…………….1109
CHART A-3-Starter Cranks The Engine, But Will Not Run…………….1110
Circuit Description…………….1111
CHART A-4-Fuel Injector Circuit…………….1112
Circuit Description…………….1112
CHART A-5-Fuel Pump Relay Circuit…………….1114
Circuit Description…………….1114
CHART A-6-Fuel System Pressure Test…………….1116
Circuit Description…………….1116
CHART A-7-MAP Output Check…………….1118
Circuit Description…………….1118
CHART A-8-Engine Crank Signal Check…………….1120
Circuit Description…………….1120
CHART A-9-Ignition System Troubleshooting…………….1121
CHART A-9 Ignition System Troubleshooting Chart…………….1122
CHART A-10-Idle Air Control (IAC) System…………….1124
Circuit Description…………….1124
FAULT CODES…………….1126
CODE 14-Coolant Temperature Sensor Circuit (Indicates High Temperature)…………….1126
Circuit Description…………….1126
CODE 15-Coolant Temperature Sensor Circuit (Indicates Low Temperature…………….1128
Circuit Description…………….1128
CODE 21-Throttle Position Sensor Circuit (Signal Voltage High) …………….1130
Circuit Description…………….1130
CODE 22-Throttle Position Sensor Circuit (Signal Voltage Low) …………….1132
Circuit Description…………….1132
CODE 31-Engine Governor Circuit…………….1134
Circuit Description…………….1134
CODE 33-MAP Sensor Circuit, Signal Voltage High (Low Vacuum…………….1136
Circuit Description…………….1136
CODE 34-MAP Sensor Circuit, Signal Voltage Low (High Vacuum)…………….1138
Circuit Description…………….1138
CODE 42-Electronic Spark Timing (EST)…………….1140
Circuit Description…………….1140
CODE 54-Fuel Pump Circuit (Low Voltage)…………….1142
Circuit Description…………….1142
CODE 51-PROM In The ECM Has A Fault …………….1144
CODE 52-Fuel CalPak Is Missing…………….1144
CODE 55-ECM Has A Fault…………….1144
TROUBLESHOOTING, POOR OPERATION…………….1144
General…………….1144
Make A Careful Visual Check…………….1144
FAULT: Fuel Usage Too High…………….1144
FAULT: Codes Or Performance That Is Not Regular…………….1145
FAULT: "Dieseling"…………….1145
FAULT: "Backfire"…………….1145
FAULT: Rough Idle or Engine Stalls During Idle…………….1145
FAULT: Smoke In The Exhaust Gases…………….1146
FAULT: Engine is Difficult To Start…………….1146
FAULT: Variation In Engine Power When The Throttle Is Held Steady…………….1147
FAULT: Decreased Engine Power…………….1147
FAULT: "Detontion"…………….1147
FAULT: Engine Momentarily Does Not Increase Power When Throttle Changes…………….1148
FAULT: One Cylinder In The Engine Does Not Operate Correctly. The Engine Does Not Idle Correctly…………….1148
REPAIRS, FUEL SYSTEM COMPONENTS …………….1150
General…………….1150
Vacuum Ports…………….1150
Throttle Body Injection (TBI) Unit…………….1150
TBI Unit, Removal…………….1150
TBI Unit, Cleaning and Inspection…………….1151
TBI Unit, Installation…………….1151
Cover For Fuel Meter Body, Replacement…………….1151
Fuel Injectors…………….1152
Fuel Injectors, Removal…………….1152
Fuel Injectors, Installation…………….1153
Pressure Regulator, Removal…………….1153
Pressure Regulator, Inspection…………….1153
Pressure Regulator, Installation …………….1153
Fuel Meter Body, Removal…………….1154
Fuel Meter Body, Installation…………….1154
Throttle Position Sensor (TPS), Removal…………….1154
Throttle Position Sensor (TPS), Installation…………….1154
Idle Air Control (IAC) Valve, Removal…………….1155
Cleaning and Inspection…………….1155
Idle Air Control (IAC) Valve, Installation…………….1155
Governor Throttle Drive Assembly, Removal…………….1155
Governor Throttle Drive Assembly, Inspection…………….1155
Cleaning and Lubrication…………….1156
Governor Throttle Drive Assembly, Installation…………….1156
Governor Drive Motor, Removal…………….1157
Governor Drive Motor, Cleaning and Lubrication…………….1157
Governor Drive Motor, Installation…………….1158
Governor Drive Motor, Inspection…………….1158
Throttle Body, Removal and Disassembly…………….1158
Throttle Body, Inspection…………….1158
Throttle Body, Assembly and Installation…………….1158
Fuel Pump, Removal and Disassembly…………….1159
Fuel Pump, Inspection…………….1159
REPAIRS, ELECTRICAL COMPONENTS…………….1159
General…………….1159
Ignition Coil Test…………….1159
Ignition Module Test…………….1160
Distributor, Removal…………….1160
Distributor, Disassembly…………….1161
Distributor, Assembly…………….1161
Distributor, Installation…………….1162
Firing Order…………….1163
Ignition Timing…………….1163
Ignition Coil, Removal…………….1164
Ignition Coil, Installation…………….1164
Procedures For Spark Plugs, Spark Plug Wires And Boots …………….1164
Troubleshooting of Spark Plugs…………….1165
Coolant Temperature Sensor (CTS), Replacement …………….1166
Manifold Absolute Pressure (MAP) Sensor, Replacement…………….1166
Oil Pressure Switch, Replacement…………….1167
Coolant Temperature Sender, Replacement…………….1167
Wire Harness…………….1167
Connectors And Terminals…………….1167
Electronic Control Module (ECM)…………….1171
ECM CONNECTOR A-B IDENTIFICATION…………….1175
ECM CONNECTOR C-D IDENTIFICATION…………….1176
SPECIAL TOOLS…………….1177
2200473…………….1180
…………….1180
…………….1181
…………….1182
…………….1183
…………….1184
…………….1185
…………….1186
…………….1187
…………….1188
…………….1189
…………….1190
…………….1191
…………….1192
…………….1193
…………….1194
…………….1195
…………….1196
…………….1197
…………….1198
…………….1199
…………….1200
…………….1201
4000135…………….1202
Safety Procedures When Working Near Mast…………….1204
General…………….1209
Description…………….1209
Lowering Control Valve…………….1209
Cylinders (General)…………….1212
Cylinders (H520-620B, H700-800A)…………….1212
Retainer, Install…………….1212
Cylinders (H360-460B)…………….1214
Cylinders (Two-Speed)…………….1217
Lift Cylinder Repair…………….1218
Lift Cylinder Removal Without Removing Mast…………….1218
Standard Masts With Main Lift Cylinders Fastened to Crossmember of Inner Mast…………….1218
Standard and Full Free-Lift Masts With Lift Cylinder Fastened to Crosshead…………….1219
Masts That Have Two Cylinders, Main Lift Cylinder and Free-Lift Cylinder…………….1220
Disasemble…………….1220
Assemble…………….1220
Lift Cylinder Installation in Mast…………….1222
Standard Masts With Main Lift Cylinder Fastened to Crossmember of Inner Mast…………….1222
Standard and Full Free-Lift Masts With Lift Cylinder Fastened to Crosshead…………….1222
Chevron-Style Packing…………….1222
Chevron-Style Packing Installation on Piston…………….1223
Chevron-Style Packing Installation in Packing Gland…………….1225
Lift Cylinders for Vista Masts…………….1226
Description…………….1226
Lowering Control Valve…………….1226
Remove…………….1228
Disassemble…………….1229
Assemble…………….1230
Install…………….1231
Main Lift Cylinders…………….1231
Free-Lift Cylinder…………….1231
Lift System Leak Check…………….1231
Specifications…………….1232
Troubleshooting…………….1233
4000340…………….1236
VISTA® MASTS…………….1236
GENERAL…………….1236
DESCRIPTION AND OPERATION…………….1236
CARRIAGES…………….1236
TWO-STAGE MAST WITH LIMITED FREE-LIFT…………….1236
TWO-STAGE MAST WITH FULL FREE-LIFT MAST…………….1237
THREE-STAGE MAST WITH FULL FREE-LIFT…………….1238
REPAIRS…………….1240
SAFETY PROCEDURES WHEN WORKING NEAR THE MAST (1 of 2)…………….1240
SAFETY PROCEDURES WHEN WORKING NEAR THE MAST (2 of 2)…………….1241
FORKS…………….1241
Forks, Removal And Installation…………….1241
CARRIAGE…………….1243
Removal…………….1243
SIDE-SHIFT CARRIAGE (EARLIER DESIGNS)…………….1244
Disassembly, Side Shift Carriage…………….1244
Assembly, Side Shift Carriage…………….1244
Installation…………….1247
SIDE-SHIFT CARRIAGE (1993 AND LATER DESIGNS)…………….1247
Removal…………….1247
Repairs…………….1248
Installation…………….1249
WEIGHT OF MAST PARTS…………….1250
TWO-STAGE MAST WITH LIMITED FREE LIFT…………….1250
Removal…………….1250
Disassembly…………….1250
Cleaning and Inspection…………….1252
Assembly…………….1252
Installation…………….1253
TWO-STAGE MAST WITH FULL FREE-LIFT…………….1253
Removal…………….1253
Disassembly…………….1253
Cleaning and Inspection…………….1254
Assembly…………….1254
Installation…………….1255
THREE-STAGE MAST WITH FULL FREE LIFT…………….1256
Removal…………….1256
Disassembly…………….1256
Cleaning and Inspection…………….1256
Assembly…………….1256
Installation…………….1258
CHECKS AND ADJUSTMENTS…………….1260
CHECK THE OPERATION OF THE MAST…………….1260
CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM…………….1260
Lift System…………….1260
Tilt System…………….1260
ADJUST THE TILT CYLINDER STROKE AND THE BACKWARD TILT ANGLE…………….1261
LIFT CHAIN ADJUSTMENTS…………….1261
MAST ADJUSTMENTS…………….1262
CARRIAGE ADJUSTMENT…………….1263
TROUBLESHOOTING…………….1264
600105…………….1267
INTRODUCTION…………….1267
GENERAL…………….1267
DESCRIPTION…………….1267
ENGINE SERIAL NUMBER CODES…………….1268
REMOVAL AND INSTALLATION…………….1268
ENGINE…………….1268
CYLINDER HEAD…………….1268
Removal…………….1268
Installation…………….1269
Cylinder Head Repairs…………….1270
OIL PUMP…………….1272
Removal…………….1272
Disassembly…………….1272
Inspection…………….1272
Assembly…………….1273
Installation…………….1273
RELIEF VALVE…………….1274
TIMING GEAR CASE AND TIMING GEARS…………….1274
Removal…………….1274
Installation…………….1275
PISTONS AND CONNECTING RODS…………….1276
Removal…………….1276
Disassembly…………….1276
Inspection…………….1277
Assembly…………….1278
Installation…………….1278
CRANKSHAFT AND MAIN BEARINGS…………….1279
Removal…………….1279
Inspection…………….1279
Assembly…………….1280
CAMSHAFT AND CAM FOLLOWERS…………….1281
Removal…………….1281
Inspection…………….1282
Assembly…………….1282
FLYWHEEL AND FLYWHEEL HOUSING…………….1283
Removal…………….1283
Repairs…………….1283
Installation…………….1283
STEERING PUMP DRIVE…………….1283
Removal…………….1283
Installation…………….1284
PCV VALVE…………….1284
FUEL SYSTEM…………….1284
FUEL PUMP…………….1284
Removal…………….1284
Disassembly…………….1284
Assembly…………….1284
Installation…………….1285
FUEL INJECTION PUMP…………….1285
Removal…………….1285
Repairs…………….1285
Installation…………….1285
FUEL INJECTORS…………….1285
Removal…………….1285
Repairs…………….1286
Installation…………….1286
COLD START AID…………….1286
Description…………….1286
Removal…………….1286
Installation…………….1286
COOLING SYSTEM…………….1287
THERMOSTAT…………….1287
Removal…………….1287
Inspection…………….1287
Installation…………….1287
WATER PUMP…………….1287
Removal…………….1287
Disassembly…………….1287
Assembly…………….1287
Installation…………….1287
CHECKS AND ADJUSTMENTS…………….1287
CHECKING THE INJECTORS…………….1287
Repairs…………….1288
Installation…………….1288
REMOVING AIR FROM THE FUEL SYSTEM…………….1288
CHECKING THE TIMING MARKS…………….1289
Method A…………….1289
Method B…………….1290
CHECKING THE TIMING ANGLE OF THE FUEL INJECTION PUMP WITH THE SPECIAL TOOL…………….1291
VALVE CLEARANCE ADJUSTMENT…………….1292
ADJUSTING THE THROTTLE LINKAGE…………….1292
TROUBLESHOOTING…………….1294
SPECIFICATIONS…………….1295
TORQUE SPECIFICATIONS…………….1298
600412…………….1299
PERKINS DIESEL ENGINES, SERIES 1000…………….1299
1.1 GENERAL…………….1299
GENERAL SAFETY RULES…………….1299
Viton Seals…………….1299
1.2 DESCRIPTION…………….1302
1.3 Engine Serial Number Codes…………….1302
1.4 Engine Data…………….1302
1.5 1004–4 ENGINE…………….1303
1.6 1004–4T ENGINE…………….1303
1.7 1006–6 ENGINE…………….1303
1.8 1006–6T ENGINE…………….1303
1.9 REMOVAL AND INSTALLATION…………….1303
CYLINDER HEAD ASSEMBLY…………….1304
1.10 VALVE COVER…………….1304
1.11 Removal…………….1304
1.12 Installation…………….1304
1.13 ROCKER ARM ASSEMBLY…………….1304
1.14 Removal…………….1304
1.15 Installation…………….1304
1.16 Disassembly…………….1305
1.17 Inspection…………….1305
1.18 Assembly…………….1305
1.19 VALVE CLEARANCE ADJUSTMENTS…………….1305
1.20 Four Cylinder Engines…………….1306
1.21 Six Cylinder Engines…………….1306
1.22 VALVE SPRINGS…………….1306
1.23 CYLINDER HEAD ASSEMBLY…………….1308
1.24 Removal…………….1308
1.25 Installation…………….1309
1.26 VALVES AND VALVE SPRINGS…………….1312
1.27 Removal…………….1312
1.28 Inspection…………….1313
1.29 Installation…………….1313
1.30 VALVE GUIDES…………….1313
1.31 Inspection…………….1313
1.32 Removal…………….1314
1.33 Installation…………….1314
1.34 CYLINDER HEAD AND VALVE SEATS…………….1314
1.35 Inspection…………….1314
1.36 Repair…………….1315
1.37 Installation Of New Valve Seats…………….1315
PISTON AND CONNECTING ROD ASSEMBLIES…………….1316
1.38 ROD BEARINGS…………….1316
1.39 Removal…………….1316
1.40 Installation…………….1317
1.41 PISTON AND CONNECTING ROD ASSEMBLY…………….1317
1.42 Service Note…………….1317
1.43 Removal…………….1317
1.44 Installation…………….1318
1.45 PISTON RINGS…………….1319
1.46 Removal…………….1319
1.47 Inspection…………….1319
1.48 Installation…………….1320
1.49 PISTON AND CONNECTING ROD…………….1321
1.50 Disassembly…………….1321
1.51 Inspection…………….1321
1.52 Installation…………….1321
1.53 PISTON COOLING JETS…………….1322
1.54 Removal…………….1322
1.55 Installation…………….1322
CRANKSHAFT ASSEMBLY…………….1323
1.56 GENERAL…………….1323
1.57 CRANKSHAFT PULLEY…………….1323
1.58 Removal, Engines AA and AB…………….1323
1.59 Installation, Engines AA and AB…………….1323
1.60 Removal, Engines YA and YB…………….1323
1.61 Installation, Engines YA and YB…………….1323
1.62 REAR OIL SEAL…………….1324
1.63 Replacement…………….1324
1.64 MAIN BEARINGS…………….1325
1.65 Removal…………….1325
1.66 Installation…………….1325
1.67 THRUST WASHERS…………….1326
1.68 Check The Axial Movement Of The Crankshaft…………….1326
1.69 Removal…………….1327
1.70 Installation…………….1327
1.71 CRANKSHAFT…………….1327
1.72 Removal…………….1327
1.73 Inspection…………….1328
1.74 Installation…………….1328
TIMING CASE AND TIMING GEARS…………….1330
1.75 GENERAL…………….1330
1.76 TIMING CASE COVER…………….1330
1.77 Removal…………….1330
1.78 Installation…………….1330
1.79 FRONT OIL SEAL…………….1331
1.80 Removal…………….1331
1.81 Installation…………….1331
1.82 IDLER GEAR AND HUB…………….1331
1.83 Removal…………….1331
1.84 Installation…………….1332
1.85 GEAR FOR THE FUEL INJECTION PUMP OR THE CAMSHAFT GEAR…………….1333
1.86 Removal…………….1333
1.87 Installation…………….1333
1.88 CRANKSHAFT GEAR…………….1334
1.89 Removal…………….1334
1.90 Installation…………….1334
1.91 TIMING CASE…………….1334
1.92 Removal…………….1334
1.93 Installation…………….1334
1.94 CAMSHAFT AND TAPPETS…………….1335
1.95 Removal…………….1336
1.96 Installation…………….1336
ENGINE BLOCK ASSEMBLY…………….1337
1.97 DESCRIPTION…………….1337
1.98 ENGINE BLOCK…………….1337
1.99 Disassembly…………….1337
1.100 Inspection…………….1338
1.101 Assembly…………….1338
1.102 CYLINDER LINER…………….1338
1.103 Inspection…………….1338
1.104 Hone…………….1339
1.105 Removal…………….1339
1.106 Installation…………….1340
TURBOCHARGER, ENGINES AB AND YB…………….1341
1.107 GENERAL…………….1341
1.108 Removal…………….1341
1.109 Installation…………….1342
1.110 Clean The Impeller And Compressor Housing…………….1342
LUBRICATION SYSTEM…………….1343
1.111 GENERAL…………….1343
1.112 OIL FILTER, REPLACEMENT…………….1343
1.113 OIL SUMP…………….1344
1.114 Removal…………….1344
1.115 Installation…………….1344
1.116 OIL PUMP…………….1344
1.117 Removal…………….1344
1.118 Inspection…………….1345
1.119 Installation…………….1345
1.120 RELIEF VALVE…………….1346
1.121 Removal…………….1346
1.122 Disassembly…………….1346
1.123 Inspection…………….1347
1.124 Installation…………….1347
FUEL SYSTEM…………….1347
1.125 DESCRIPTION…………….1347
1.126 CAV FUEL INJECTION PUMP…………….1348
1.127 Removal…………….1348
1.128 Installation…………….1348
1.129 CAV FUEL INJECTION PUMP, CHECKS AND ADJUSTMENTS…………….1349
1.130 Timing Gear Marks…………….1349
1.131 How To Set Number 1 Piston To TDC On The Compression Stroke…………….1350
1.132 Check The Valve Timing…………….1350
1.133 Check The Timing Of The Fuel Injection Pump…………….1351
1.134 Check The Timing Mark Of The Fuel Injection Pump…………….1351
1.135 Check The Engine Timing Mark…………….1352
1.136 REMOVE AIR FROM THE FUEL SYSTEM…………….1353
1.137 Fuel Injection Pump With Vent Tube…………….1353
1.138 Fuel Injection Pump With Vent Screw…………….1354
1.139 FUEL FILTER (REPLACEMENT)…………….1355
1.140 FUEL INJECTORS…………….1355
1.141 Removal…………….1355
1.142 Inspection…………….1356
1.143 Installation…………….1357
1.144 FUEL PUMP…………….1357
1.145 Removal…………….1357
1.146 Disassembly…………….1357
1.147 Assembly…………….1358
1.148 Installation…………….1358
1.149 Test…………….1359
COOLING SYSTEM…………….1359
1.150 GENERAL…………….1359
1.151 THERMOSTAT…………….1359
1.152 Replacement…………….1359
1.153 COOLANT PUMP…………….1360
1.154 Removal…………….1360
1.155 Disassembly…………….1360
1.156 Assembly…………….1361
1.157 Installation…………….1361
1.158 FAN AND FAN DRIVE…………….1361
1.159 Removal…………….1361
1.160 Disassembly…………….1361
1.161 Assembly…………….1362
1.162 Installation…………….1362
1.163 OIL COOLER…………….1362
1.164 Removal, Engine AB…………….1362
1.165 Removal, Engines YA and YB…………….1362
1.166 Disassembly And Assembly…………….1363
1.167 Installation, Engine AB…………….1363
1.168 Installation, Engines YA and YB…………….1364
1.169 By–Pass Valve, Oil Cooler…………….1364
FLYWHEEL AND FLYWHEEL HOUSING…………….1364
1.170 GENERAL…………….1364
1.171 FLYWHEEL…………….1364
1.172 Removal…………….1364
1.173 Ring Gear (Replacement)…………….1364
1.174 Installation…………….1364
1.175 FLYWHEEL HOUSING…………….1365
1.176 Removal…………….1365
1.177 Installation…………….1365
ELECTRICAL EQUIPMENT…………….1366
1.178 DRIVE BELTS…………….1366
1.179 ALTERNATOR…………….1367
1.180 STARTER MOTOR…………….1367
1.181 Removal…………….1367
1.182 Installation…………….1367
1.183 COLD START AID…………….1367
AIR COMPRESSOR, ENGINES YA AND YB…………….1367
1.184 GENERAL…………….1367
1.185 Air Compressor, Removal, WABCO…………….1367
1.186 Compressor Drive, Inspection…………….1368
1.187 Air Compressor, Installation, WABCO…………….1368
1.188 Compressor Drive, Disassembly, WABCO…………….1368
1.189 Compressor Drive, Assembly, WABCO…………….1369
1.190 Air Compressor, Removal, BENDIX…………….1369
1.191 Air Compressor, Installation, BENDIX…………….1370
1.192 Compressor Drive, Disassembly, BENDIX…………….1371
1.193 Compressor Drive, Assembly, BENDIX…………….1371
ENGINE SPECIFICATIONS…………….1373
1.194 CYLINDER HEAD ASSEMBLY…………….1373
1.195 Cylinder Head…………….1373
1.196 Valve Guides…………….1373
1.197 Inlet Valves…………….1374
1.198 Exhaust Valves…………….1374
1.199 Double Valve Springs To Outer…………….1374
1.200 Double Valve Springs To Inner…………….1374
1.201 Single Valve Springs…………….1374
1.202 Tappets…………….1374
1.203 Rocker Arm Shaft…………….1374
1.204 Rocker Arms And Bushings…………….1375
1.205 PISTON AND CONNECTING RODS…………….1375
1.206 Pistons, Engines AA And YA…………….1375
1.207 Pistons, Engines AB And YB…………….1375
1.208 Piston Rings, Engines AA And YA…………….1375
1.209 Piston Rings, Engines AB And YB…………….1375
1.210 Connecting Rods, Engines AB And YB…………….1376
1.211 Connecting Rods, Engines AB And YB…………….1376
1.212 Piston Pins, Engines AA And YA…………….1376
1.213 Piston Pins, Engines AB and YB…………….1376
1.214 Small End Bushings, Engines AA And YA…………….1376
1.215 Small End Bushings, Engines AB And YB…………….1376
1.216 Connecting Rod Bearings, Engines AA And YA…………….1377
1.217 Connecting Rod Bearings, Engines AB And YB…………….1377
1.218 Piston Cooling Jets, Engines AB And YB…………….1377
1.219 CRANKSHAFT ASSEMBLY…………….1377
1.220 Crankshaft…………….1377
1.221 Crankshaft Heat Treatment…………….1377
1.222 Crankshaft Overhaul…………….1377
1.223 Main Bearings…………….1379
1.224 Crankshaft Thrust Washers…………….1379
1.225 TIMING CASE AND DRIVE ASSEMBLY…………….1379
1.226 Camshaft…………….1379
1.227 Camshaft Thrust Washer…………….1379
1.228 Camshaft Gear…………….1380
1.229 Gear For Fuel Injection Pump…………….1380
1.230 Crankshaft Gear…………….1380
1.231 Idler Gear And Hub…………….1380
1.232 ENGINE BLOCK ASSEMBLY…………….1380
1.233 Engine Block…………….1380
1.234 Cylinder Liners…………….1380
1.235 TURBOCHARGER…………….1381
1.236 LUBRICATION SYSTEM…………….1381
1.237 Oil Pump, Engines AA And AB…………….1381
1.238 Oil Pump, Engines YA And YB…………….1381
1.239 Relief Valve…………….1381
1.240 Oil Filter…………….1381
1.241 FUEL SYSTEM…………….1381
1.242 Cav Fuel Injection Pump…………….1381
1.243 FUEL INJECTORS…………….1382
1.244 Fuel Pump, Engines AA And AB…………….1383
1.245 Fuel Pump, Engines YA And YB…………….1383
1.246 Fuel Filter…………….1383
1.247 COOLING SYSTEM…………….1383
1.248 Coolant Pump…………….1383
1.249 Thermostat…………….1384
1.250 Fan Drive Housing…………….1384
1.251 FLYWHEEL AND HOUSING…………….1384
1.252 Limits for flywheel ''run out'' and alignment (total indicator reading)……………..1384
1.253 ELECTRICAL EQUIPMENT…………….1384
1.254 Alternator…………….1384
1.255 Starter Motor…………….1384
1.256 Cold Start Aid…………….1384
TORQUE SPECIFICATIONS…………….1385
SPECIAL TOOLS…………….1386
600590…………….1390
GM 4.3 LITRE V-6…………….1390
INTRODUCTION…………….1390
DESCRIPTION…………….1390
ENGINE, REMOVAL AND INSTALLATION …………….1391
CYLINDER HEAD…………….1391
Removal And Disassembly…………….1391
Cleaning And Inspection…………….1391
Repairs, Valve Guides and Seats…………….1391
Repairs, Valves …………….1392
Repairs, Valve Seats…………….1392
Valve Springs…………….1393
Studs For The Rocker Arms (Early Models)…………….1394
Studs For The Rocker Arms (Late Models)…………….1395
Assembly And Installation…………….1395
CYLINDER BLOCK, CLEANING AND INSPECTION…………….1397
PISTON BORE PREPARATION…………….1397
ENGINE MOUNTS…………….1397
LUBRICATION SYSTEM…………….1397
Oil Pump, Removal and Disassembly…………….1397
Cleaning and Inspection…………….1398
Oil Pump, Assembly and Installation…………….1398
Oil Sump, Installation…………….1398
TIMING COVER, TIMING SPROCKETS, CAMSHAFT AND VALVE LIFTERS…………….1399
Timing Cover, Removal…………….1399
Installation…………….1400
Timing Sprockets, Removal…………….1401
Timing Sprockets, Installation…………….1401
Camshaft, Removal…………….1401
Camshaft, Inspection…………….1401
Camshaft, Installation…………….1401
Balance Shaft, Removal…………….1402
Balance Shaft, Installation…………….1403
Hydraulic Valve Lifters, Removal…………….1404
Hydraulic Valve Lifters, Disassembly…………….1404
Hydraulic Valve Lifters, Cleaning And Inspection…………….1404
Hydraulic Valve Lifters, Assembly…………….1405
Hydraulic Valve Lifters, Installation…………….1405
CRANKSHAFT…………….1406
Removal…………….1406
Inspection and Repair…………….1406
How To Check The Clearance Between The Main Bearings And Their Journals…………….1407
Installation…………….1408
PISTON AND CONNECTING ROD ASSEMBLIES…………….1409
Connecting Rod Bearings, Replacement…………….1409
Piston And Connecting Rod Assemblies, Removal…………….1410
Disassembly…………….1410
Piston, Cleaning And Inspection…………….1410
Cylinder Bores, Inspection And Repair…………….1411
Piston Rings…………….1412
Assembly…………….1412
Piston And Connecting Rod Assemblies, Installation…………….1413
FLYWHEEL AND FLYWHEEL HOUSING…………….1413
Flywheel Repairs…………….1413
Flywheel, Installation …………….1413
Flywheel Housing…………….1414
Engine Adapter…………….1414
COOLANT PUMP…………….1414
THERMOSTAT…………….1414
FAN MOUNT, EARLY MODELS…………….1414
FAN MOUNT ASSEMBLY, LATE MODELS…………….1415
DRIVE BELT, INSTALLATION…………….1416
CHECKS AND ADJUSTMENTS…………….1418
VALVE CLEARANCE ADJUSTMENT, EARLY MODELS…………….1418
VALVE CLEARANCE ADJUSTMENT, NEW MODELS…………….1418
CHECK THE COMPRESSION…………….1418
ENGINE SPECIFICATIONS…………….1419
Engine Data…………….1419
Engine Data…………….1419
Cylinder head…………….1419
Hydraulic Valve Lifter…………….1419
Camshaft…………….1419
Pistons…………….1419
Crankshaft…………….1420
Connecting Rods…………….1420
Connecting Rods…………….1420
Balance Shaft…………….1420
Cooling System…………….1420
Lubrication System…………….1420
TORQUE SPECIFICATIONS…………….1421
TROUBLESHOOTING…………….1422
700626…………….1425
General…………….1427
Description…………….1428
Radiator…………….1428
Radiator Cap…………….1428
Thermostat…………….1428
Water Pump…………….1429
Fan and Fan Shroud…………….1429
Cooling System Checks…………….1429
Radiator…………….1429
Thermostat…………….1429
Water Pump…………….1430
Exhaust Leaks…………….1430
Fan and Fan Shroud…………….1430
Radiator Cleaning…………….1430
Drain…………….1430
Clean…………….1430
Fill…………….1431
Troubleshooting…………….1432
8000231…………….1434
General…………….1436
Nomenclature, Threads…………….1436
Strength Identification…………….1437
Fastener Torque Tables…………….1441
Conversion Table…………….1443
8000341…………….1445
PERIODIC MAINTENANCE…………….1445
GENERAL…………….1445
SERIAL NUMBER DATA…………….1445
HOW TO MOVE A DISABLED LIFT TRUCK …………….1445
How To Tow the Lift Truck…………….1445
HOW TO PUT A LIFT TRUCK ON BLOCKS…………….1446
How To Raise the Drive Tires…………….1446
How To Raise the Steering Tires…………….1446
MAINTENANCE SCHEDULE…………….1448
MAINTENANCE PROCEDURES EVERY 8 HOURS OR DAILY…………….1451
HOW TO MAKE CHECKS WITH THE ENGINE STOPPED…………….1451
Hydraulic System Oil…………….1451
Engine Oil…………….1453
Drive Belts…………….1453
Cooling System…………….1453
Air Filter…………….1453
Fuel System…………….1454
Primary Fuel Filter, Diesel Engine…………….1454
Battery…………….1454
Tires and Wheels…………….1454
Forks…………….1455
Forks, Adjustment…………….1455
Forks, Removal And Installation…………….1455
Inspection Of Forks, Mast, and Lift Chains…………….1456
Operator Restraint System…………….1458
Safety Labels…………….1459
HOW TO MAKE THE CHECKS WITH THE ENGINE RUNNING…………….1459
Gauges, Lights, Horns, and Fuses…………….1459
Oil Level, Powershift Transmission…………….1459
Oil Level, Oil Clutch System, H3.50-5.00Xl (H70-110XL)…………….1460
Control Levers and Pedals…………….1460
Lift System Operation…………….1460
Inching/Brake Pedal…………….1461
Service Brakes…………….1461
Parking Brake…………….1461
Steering System…………….1461
EVERY 150 HOURS OR MONTHLY…………….1461
THRUST SCREW FOR THE DIFFERENTIAL, H6.00-7.00XL (H135-155XL)…………….1461
LIFT CHAINS, LUBRICATION…………….1461
DRIVE SHAFTS…………….1462
EVERY 350 HOURS OR TWO MONTHS…………….1462
ENGINE OIL AND FILTER…………….1462
DRIVE BELTS…………….1463
Perkins Diesel Engine…………….1463
GM V-6 Engine (Early Models)…………….1463
GM V-6 Engine (Late Models)…………….1464
HYDRAULIC TANK BREATHER, CLEAN AND CHECK…………….1465
BRAKE FLUID…………….1465
LIFT CHAINS, CHECK FOR WEAR…………….1465
FORKS, CHECK FOR WEAR AND DAMAGE…………….1466
MAST, LUBRICATION…………….1466
CONTROL LEVERS AND PEDALS, LUBRICATION…………….1466
STEERING AXLE, LUBRICATION…………….1467
FUEL SYSTEM, CHECKS AND ADJUSTMENT…………….1467
Diesel Fuel System…………….1467
LPG Carburetor (Early Models)…………….1467
Gasoline Carburetor (Early Models)…………….1468
Fuel Injection (Late Models)…………….1468
EVERY 1000 HOURS OR SIX MONTHS…………….1468
PCV VALVE, GM V-6…………….1468
MANIFOLD HEAT VALVE, GM V-6 (EARLY MODELS)…………….1468
CRANKCASE BREATHER, GM-V6…………….1468
IGNITION SYSTEM (GM V-6)…………….1468
VALVE CLEARANCE ADJUSTMENT…………….1469
FUEL FILTER (REPLACEMENT), DIESEL ENGINE…………….1469
REMOVE AIR FROM THE FUEL SYSTEM: PERKINS 1004-4 DIESEL ENGINE…………….1469
Fuel Injection Pump With A Vent Tube…………….1469
Fuel Injection Pump With A Vent Screw…………….1470
REMOVE THE AIR FROM THE FUEL SYSTEM: PERKINS 4.2482 DIESEL ENGINE…………….1471
CHECK THE OIL LEVEL IN THE TRANSMISSION…………….1471
Manual Transmission, H3.50-5.00XL (H70-110Xl)…………….1471
Speed Reducer For The Powershift Transmission, H3.50-5.00XL (H70-110XL)…………….1472
Manual Transmission, H6.00-7.00XL (H135-155XL)…………….1472
Differential And Drive Axle For The Powershift Transmission, H6.00-7.00Xl (H135-155XL)…………….1472
Differential, Speed Reducer, And Drive Axle For The Manual Transmission, H6.00-7.00Xl (H135-155XL) …………….1472
EVERY 2000 HOURS OR YEARLY…………….1472
HYDRAULIC SYSTEM…………….1472
Replace the Hydraulic Oil and Filter, H3.50-5.00XL (H70-110XL) …………….1472
Replace the Hydraulic Oil and Filter, H6.00-7.00XL (H135-155XL) …………….1473
CHANGE THE OIL AND REPLACE THE OIL FILTER, POWERSHIFT TRANSMISSION, ALL UNITS …………….1473
CHANGE THE OIL, MANUAL TRANSMISSION, H3.50-5.00XL (H70-110XL)…………….1473
CHANGE THE OIL, MANUAL TRANSMISSION, H6.00-7.00XL (H135-155XL)…………….1473
CHANGE THE OIL, SPEED REDUCER, POWERSHIFT TRANSMISSION, H3.50-5.00XL (H70-110XL)…………….1474
CHANGE THE OIL AND FILTER, OIL CLUTCH SYSTEM, H3.50-5.00XL (H70-110XL)…………….1474
CHANGE THE OIL, DIFFERENTIAL AND DRIVE AXLE FOR THE POWERSHIFT TRANSMISSION, H6.00-7.00XL (H135-155XL)…………….1474
CHANGE THE OIL, DIFFERENTIAL, SPEED REDUCER, AND DRIVE AXLE FOR MANUAL TRANSMISSION, H6.00-7.00XL (H135-155XL)…………….1474
COOLING SYSTEM…………….1475
WHEEL BEARINGS…………….1475
Steering Wheel, lubrication…………….1475
Drive Wheels, Lubrication…………….1475
PCV VALVE, GM V-6…………….1475
SERVICE BRAKES…………….1475
LPG FILTER, REPLACEMENT…………….1476
GASOLINE FUEL FILTER, REPLACEMENT…………….1476
CHECK THE HOOD LATCH, H3.50-5.00XL (H70-110XL)…………….1476
GENERAL PROCEDURES…………….1477
SAFETY PROCEDURES WHEN WORKING NEAR THE MAST…………….1477
LIFT CHAIN ADJUSTMENTS…………….1479
FUEL INJECTORS…………….1479
CHECKS FOR LEAKS IN THE LIFT AND TILT SYSTEM …………….1480
Check the Lift Cylinders for Leaks…………….1480
Check the Tilt Cylinders for Leaks…………….1480
WELDING REPAIRS…………….1480
CHANGES TO THE OVERHEAD GUARD…………….1481
WHEELS AND TIRES…………….1482
Remove The Wheels From The Lift Truck…………….1482
Remove The Wheel From The Tire…………….1482
Install The Wheel In The Tire…………….1484
Pneumatic Tires, Add Air To The Tires…………….1485
Install the Wheels …………….1485
SOLID RUBBER TIRES…………….1486
Remove The Tire From The Wheel…………….1486
Install The Tire On The Wheel…………….1487
REFERENCE TABLE…………….1488
8000342…………….1490
8000343…………….1498
FIGURE 1. ELECTRICAL SCHEMATIC (GASOLINE/LPG, EARLY PRODUCTION)…………….1498
FIGURE 2. ELECTRICAL SCHEMATIC (GASOLINE/LPG, LATER PRODUCTION)…………….1500
FIGURE 3. ELECTRICAL SCHEMATIC (DIESEL, PERKINS 4.2482)…………….1502
FIGURE 4. ELECTRICAL SCHEMATIC (DIESEL, PERKINS 1004-4, EARLY PRODUCTION)…………….1504
FIGURE 5. ELECTRICAL SCHEMATIC (DIESEL, PERKINS 1004-4, LATER PRODUCTION)…………….1506
FIGURE 6. HYDRAULIC SCHEMATIC…………….1508
FIGURE 7. HYDRAULIC SCHEMATIC, POWERSHIFT TRANSMISSION WITH MANUAL CONTROL…………….1509
FIGURE 8. HYDRAULIC SCHEMATIC, POWERSHIFT TRANSMISSION WITH MONTROL PEDAL…………….1510
FIGURE 9. WIRING DIAGRAM, BACK-UP ALARM…………….1511
8000494…………….1512
900347…………….1526
WEBER CARBURETOR WITH GOVERNOR…………….1526
GENERAL…………….1526
DESCRIPTION…………….1526
Carburetor…………….1526
Governor…………….1526
OPERATION…………….1527
Carburetor, Float System…………….1527
Carburetor, Idle System…………….1527
Carburetor, Main Metering System…………….1527
Carburetor, Power System…………….1528
Carburetor, Accelerator Pump System…………….1528
Carburetor, Choke System…………….1529
GOVERNOR…………….1530
REPAIRS…………….1531
CARBURETOR…………….1531
Removal…………….1531
Disassembly…………….1531
Cleaning…………….1531
Assembly…………….1531
Installation…………….1532
GOVERNOR…………….1532
CHECKS AND ADJUSTMENTS…………….1533
GENERAL…………….1533
CHOKE SYSTEM…………….1533
ELECTRIC CHOKE…………….1533
IDLE MIXTURE ADJUSTMENT…………….1534
IDLE SPEED ADJUSTMENT…………….1534
THROTTLE LINKAGE ADJUSTMENT…………….1535
TROUBLESHOOTING…………….1536
900348…………….1537
INTRODUCTION…………….1537
GENERAL…………….1537
DESCRIPTION AND OPERATION…………….1537
Fuel Tank…………….1538
Fuel Filter and Fuel Valve Unit…………….1538
Vaporizer…………….1539
Carburetor…………….1540
Governor…………….1541
REPAIRS…………….1543
LPG TANK…………….1543
Removal…………….1543
Installation…………….1543
HYDROSTATIC RELIEF VALVE…………….1543
Removal and Installation…………….1543
FILTER UNIT…………….1545
Replacement Of The Fuel Filter Element…………….1545
Replacement of the Diaphragm and Fuel Valve …………….1545
REPLACEMENT OF THE HOSES…………….1545
VAPORIZER…………….1545
Removal…………….1545
Vaporizer Disassembly…………….1547
Cleaning…………….1547
Inspection…………….1547
Vaporizer Assembly…………….1547
Installation…………….1549
CARBURETOR…………….1549
Removal…………….1549
Disassembly…………….1549
Cleaning…………….1550
Assembly…………….1550
Installation…………….1550
GOVERNOR…………….1550
CHECKS AND ADJUSTMENTS…………….1551
CHECK THE FILTER UNIT…………….1551
CHECK THE VAPORIZER…………….1551
Pressure Reducer Valve…………….1551
Vapor Valve…………….1551
ADJUST THE CARBURETOR…………….1552
Idle Mixture…………….1552
Idle Speed …………….1552
Power Mixture…………….1552
ADJUST THE THROTTLE LINKAGE…………….1552
TROUBLESHOOTING…………….1553
Hyster Forklift Trucks F005 (H70-110XL & H3.50-5.00XL Europe) Repair Service Manuals