Complete service repair manual for Hyster F006 (H135-155XL & H6.00-7.00XL Europe) Forklift Trucks, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Hyster F006 (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 F006 (H135-155XL & H6.00-7.00XL Europe) Service Manual.pdf
Total Pages: 1,303 + 1,406 pages
File Format: PDF
Language: English
F006 (H135-155XL)…2
1455747-0600SRM0705-(03-2006)-US-EN…4
toc…4
Perkins Diesel Engines…4
Safety Precautions Maintenance and Repair…5
General…12
General Safety Rules…12
Description…13
Engine Serial Number Codes…16
Engine Data…16
Engine Removal and Installation…18
Lift Engine…18
Cylinder Head Assembly Repair…18
Valve Cover…18
Remove…18
Install…19
Rocker Arm Assembly…19
Remove…19
Install…19
Disassemble…19
Inspect…20
Assemble…20
Valve Clearance Adjustments…20
Four-Cylinder Engines…21
Six-Cylinder Engines…21
Valve Springs…21
Cylinder Head Assembly…23
Remove…23
Install…25
Valves and Valve Springs…29
Remove…29
Inspect…29
Install…30
Valve Guides…30
Inspect…30
Remove…31
Install…31
Cylinder Head and Valve Seats…31
Inspect…31
Repair…31
New Valve Seats, Install…31
Piston and Connecting Rod Assemblies Repair…33
Rod Bearings…33
Remove…34
Install…34
Piston and Connecting Rod Assembly…35
Service Note…35
Remove…35
Install…36
Piston Rings…37
Remove…37
Inspect…37
Install…37
Piston and Connecting Rod…38
Disassemble…38
Inspect…39
How to Select Correct Replacements…39
Install…40
Piston Cooling Jets…40
Remove…40
Install…41
Crankshaft Assembly Repair…41
General…41
Crankshaft Pulley…42
Engine AR, Remove…42
Engines YG and YH, Remove…42
Inspect…43
Engine AR, Install…43
Engines YG and YH, Install…43
Rear Oil Seal…44
Replace…44
Main Bearings…45
Remove…45
Inspect…46
Install…46
Thrust Washers…46
Crankshaft Axial Movement, Check…46
Remove…47
Install…47
Crankshaft…48
Remove…48
Inspect…48
Install…48
Flywheel…50
Remove…50
Ring Gear, Replace…50
Install…50
Flywheel Housing…51
Remove…51
Install…51
Timing Case and Timing Gears Repair…52
General…52
Timing Case Cover…52
Remove…52
Install…53
Front Oil Seal…53
Remove…53
Install…53
Crankshaft Pulley Wear Sleeve…54
Install…54
Idler Gear and Hub…54
Remove…54
Install…55
Air Compressor Drive, Bendix…56
Disassemble…56
Assemble…57
Fuel Injection Pump Gear…57
Remove…58
Install…58
Camshaft Gear…59
Remove…59
Install…59
Crankshaft Gear…60
Remove…60
Install…60
Timing Case…60
Remove…60
Install…61
Camshaft and Tappets…62
Remove…62
Install…62
Cylinder Block Assembly Repair…63
Description…63
Cylinder Block…63
Disassemble…63
Inspect…64
Assemble…64
Cylinder Bore (Four-Cylinder Engines)…65
Cylinder Liner (Six-Cylinder Engines)…65
Inspect…65
Cylinder Liner Condition, Check…65
Remove…66
Service Liner, Install…67
Partially Finished Liner, Install…68
Engine Timing…69
Description…69
How to Set Number One Piston to TDC on Compression Stroke…70
How to Set Number One Piston to TDC on Compression Stroke (Alter…71
Valve Timing, Check…71
Fuel Injection Pump Timing, Check…72
Turbocharger – Engine YH Repair…73
General…73
Remove…73
Install…73
Impeller and Compressor Housing, Clean…74
Lubrication System Repair…75
General…75
Oil Filter, Replace…75
Filter Head…76
Remove and Install…76
Oil Sump…76
Remove…76
Install…77
Oil Pump…77
Remove…77
Inspect…77
Install…78
Relief Valve…78
Remove…78
Disassemble…79
Inspect…79
Assemble…79
Install…80
Idler Gear Shaft, Replace…80
Remove…80
Remove (Alternative)…80
Install…81
Install (Alternative)…81
Install (Alternative for Four-Cylinder Engines Only)…82
Fuel System Repair…82
Description…82
Fuel Injection Pump…83
Remove…83
Install…84
Check and Adjust…85
Fuel System Air Removal…85
Fuel Filter, Replace…86
Canister Type…87
Quick Release Canister Type…87
Fuel Injectors…88
Remove…88
Inspect…89
Install…89
Fuel Pump…90
Remove…90
Disassemble…90
Assemble…90
Install…91
Test…91
Cooling System Repair…92
General…92
Thermostat…92
Remove…92
Install…92
Test…93
Coolant Pump…93
Remove…93
Disassemble…93
Assemble…95
Install…97
Fan and Fan Drive…98
Remove…98
Install…98
Oil Cooler (Six-Cylinder Engines)…99
Remove…99
Disassemble and Assemble…99
Install…99
Oil Cooler Bypass Valve…99
Electrical Equipment Repair…100
Drive Belts…100
Adjustment…100
Remove…101
Install…101
Alternator…101
Remove…101
Install…101
Starter Motor…101
Remove…101
Install…101
Cold Start Aid…101
Air Compressor – Engines YG and YH…102
General…102
Repair…102
Remove…102
Install…102
Rotary Exhauster Replacement…104
Remove…104
Clean…104
Install…104
Engine Specifications…105
Cylinder Head Assembly…105
Piston and Connecting Rods…108
Crankshaft Assembly…111
Crankshaft Overhaul…113
Timing Case and Drive Assembly…115
Engine Block Assembly…116
Turbocharger…119
Lubrication System…119
Fuel System…120
Cooling System…122
Flywheel and Housing…122
Electrical Equipment…123
Torque Specifications…123
Cylinder Head Assembly…123
Piston and Connecting Rod Assemblies…123
Crankshaft Assembly…123
Timing Case and Drive Assembly…124
Turbocharger…124
Lubrication System…124
Fuel System…124
Cooling System…124
Flywheel…124
Auxiliary Equipment…124
Special Torque Specifications…125
Flywheel and Housing…125
Turbocharger…125
Electrical Equipment…125
Auxiliary Equipment…125
Special Tools*…126
Troubleshooting…131
tables…4
Table 1. Cylinder Head…105
Table 2. Valve Guides…105
Table 3. Inlet Valves…105
Table 4. Exhaust Valves…106
Table 5. Valve Springs…108
Table 6. Tappets…108
Table 7. Rocker Arm Shaft…108
Table 8. Rocker Arms and Bushings…108
Table 9. Pistons (Engine AR)…108
Table 10. Pistons (Engines YG and YH)…108
Table 11. Piston Rings (Engine AR)…109
Table 12. Piston Rings (Engines YG and YH)…109
Table 13. Piston Pins…110
Table 14. Connecting Rods…110
Table 15. Small End Bushings…110
Table 16. Connecting Rod Bearings (Engines AR and YG)…110
Table 17. Connecting Rod Bearings (Engine YH)…110
Table 18. Piston Cooling Jets…111
Table 19. Crankshaft…111
Table 20. Main Bearings…112
Table 21. Crankshaft Thrust Washers…112
Table 22. Crankshaft Heat Treatment…112
Table 23. Crankshaft Overhaul Specifications…113
Table 24. Maximum Variation (Run-out)…115
Table 25. Camshaft…115
Table 26. Camshaft Thrust Washer…115
Table 27. Camshaft Gear…115
Table 28. Gear for Fuel Injection Pump…116
Table 29. Crankshaft Gear…116
Table 30. Idler Gear and Hub…116
Table 31. Cylinder Block (Engine AR)…116
Table 32. Cylinder Bore Specifications…117
Table 33. Cylinder Block (Engines YG and YH)…118
Table 34. Cylinder Liners (Engines YG and YH)…118
Table 35. Cylinder Liner Specifications (Partially Finished)…118
Table 36. Oil Pump (Engine AR)…119
Table 37. Oil Pump (Engines YG and YH)…119
Table 38. Idler Gear for Oil Pump…120
Table 39. Relief Valve…120
Table 40. Oil Filter…120
Table 41. Lucas Fuel Injection Pump…120
Table 42. Fuel Injector Codes…121
Table 43. Fuel Pump (Engine AR)…122
Table 44. Fuel Pump (Engines YG and YH)…122
Table 45. Fuel Filter…122
Table 46. Coolant Pump…122
Table 47. Thermostat…122
Table 48. Fan Drive Housing…122
Table 49. Limits for Flywheel Run Out and Alignment (Total Indic…123
Table 50. Alternator…123
Table 51. Starter Motor…123
Table 52. Cold Start Aid…123
Table 53. List of Possible Causes…131
1473385-2200SRM0765-(11-2001)-US-EN…136
toc…136
Microprocessor Spark Timing System (MSTS)…136
Safety Precautions Maintenance and Repair…137
General…140
Description…141
What MSTS Does…141
How MSTS Begins Operation…141
Operation…142
Distributor…142
Ignition Coil…142
Ignition Module…142
When Engine Is Being Started…143
When Engine Is Running…144
Manifold Absolute Pressure (MAP) Sensor…145
Engine Coolant Temperature (ECT) Sensor…145
MSTS Module Corrections…146
Troubleshooting…147
General…147
Tools and Test Equipment…149
MSTS…150
Troubleshooting Procedure…150
Where to Start…150
Visual/Physical Inspection…150
Knowledge/Tools Required…150
Damage from Static Discharge (Static Electricity)…150
Troubleshooting Information…151
Malfunction Indicator Lamp (MIL)…151
Connecting CodeMate Tester…151
Reading Diagnostic Trouble Codes (DTC)…152
Clearing Diagnostic Trouble Codes (DTC's)…153
On-Board Diagnostic (OBD) System Check…153
Test Description…153
No Malfunction Indicator Lamp…155
Circuit Description…155
Test Description…155
No DTC-12, Malfunction Indicator Lamp ON…157
Circuit Description…157
Test Description…157
Starter Rotates Engine, Engine Does Not Run…158
Test Description…158
DTC-14 Engine Coolant Temperature (ECT) (Low Temperature Indicat…162
Circuit Description…162
Test Description…162
DTC-15 Engine Coolant Temperature Sensor (ECT) (High Temperature…164
Circuit Description…164
Test Description…164
DTC-34 Manifold Absolute Pressure (MAP) Sensor…166
Circuit Description…166
Test Description…166
DTC-41 Electronic Spark Timing (EST) Open Circuit…169
Circuit Description…169
Test Description…169
DTC-42 Electronic Spark Timing (EST) Grounded Circuit…171
Circuit Description…171
Test Description…171
DTC-51 MSTS Failure…173
Circuit Description…173
Distributor Repair…173
Remove…173
Disassemble…174
Inspect…174
Assemble…174
Install…175
Ignition Timing…175
Ignition Module Repair…176
Test For Fault…176
Replace…177
Sensing Coil Repair…177
Test For Fault…177
Replace…177
Ignition Coil Repair…178
Test For Fault…178
Remove…178
Install…178
MSTS Module Repair…179
Remove…179
Install…179
ECT Sensor Replacement…179
MAP Sensor Replacement…180
tables…136
Table 1. MSTS Module Connections…148
Table 2. Pressure Conversion Chart…149
Table 3. MSTS Diagnostic Codes…151
599805-0600SRM0104-(09-1993)-US-EN…184
897104-0100SRM0322-(02-2007)-US-EN…212
toc…212
Frame…212
Safety Precautions Maintenance and Repair…213
General…216
Description…216
Counterweight Repair…217
Remove…217
Install…217
Hood Repair…218
Remove…218
Install…218
Overhead Guard Repair…218
Remove…218
Install…218
Operator Restraint System Repair…219
Automatic Locking Retractor (ALR)…219
Emergency Locking Retractor (ELR)…219
Hydraulic Tank Repair…221
Remove…221
Inspect…221
Small Leaks Repair…221
Large Leaks Repair…221
Clean…221
Steam Method…222
Chemical Solution Method…222
Other Methods of Preparation for Repair…222
Install…222
Fuel Tank Repair…223
Remove…223
Repair…223
Install…223
Radiator Repair…223
Remove…223
Install…223
Engine Repair…224
Remove…224
Install…224
Throttle Pedal Adjustment…226
Perkins 1104C-44(RE) Diesel Engine…226
Safety Labels…227
Cab Repair…229
Cab, Replace…229
Window, Replace…229
Windshield Wipers and Heater…229
tables…212
Table 1. Material Specifications for Cab Windows…231
897106-1300SRM0324-(10-2003)-US-EN…234
toc…234
Two-Speed Powershift Transmission…234
Safety Precautions Maintenance and Repair…235
General…238
Mechanical Description…238
Torque Converter…238
Transmission Pump…239
Shaft Assemblies…239
Input Shaft…240
Forward Clutch Shaft…240
Clutch Assemblies…240
Countershaft…247
Output Shaft…247
Hydraulic Operation…248
Torque Converter…248
Seal Rings…249
Control Valve…249
System Pressure Regulator…252
Clutch Pressure Regulator…252
Torque Converter Regulator…253
Inching Spool…253
Direction Spool, Direction Control Lever…253
Direction Spool, MONOTROL Pedal…254
Range Spool…254
Drain Spool…255
Accumulator…255
Modulator Spool…255
Operation…255
Lubrication Circuit…256
MONOTROL Pedal…256
Oil Flow Diagrams…258
Neutral…258
Forward-Low…259
Forward-Low-Inching…260
Reverse-Low…261
897107-1300SRM0325-(10-2003)-US-EN…264
toc…264
Two-Speed Powershift Transmission…264
Safety Precautions Maintenance and Repair…265
General…268
Transmission Repair…268
Transmission and Torque Converter, Remove…268
Transmission, Disassemble…270
Reverse-Low Clutch, Disassemble…273
Reverse-High Clutch, Disassemble…276
Forward-Low Clutch, Disassemble…279
Forward-High Clutch, Disassemble…282
Clean and Inspect…284
Forward Low and High Clutches Assembly…285
Forward Clutches, Assemble…287
Reverse-Low Clutch, Assemble…293
Reverse Clutches, Assemble…295
Transmission, Assemble…302
Torque Converter, Install…309
Control Valve Repair…310
Remove…310
Disassemble…311
Assemble…312
Install…314
MONOTROL Pedal…314
Remove and Disassemble…314
Assemble and Install…314
Stall Test…317
Linkage Adjustments…318
Linkage for Inching Pedal H6.00-7.00XL (H135-155XL, H135-155XL 2…318
Linkage for Inching Pedal S6.00-7.00XL (S135-155XL, S135-155XL 2…321
Linkage for Range Lever – Early Model H6.00-7.00XL (H135-155XL) …324
Linkage for Direction Control Lever – Early Model H6.00-7.00XL (…324
Linkage for Range Lever – Later Model H6.00-7.00XL (H135-155XL, …326
Linkage for Direction Control Lever – Later Model H6.00-7.00XL (…328
Linkage for Range Lever S6.00-7.00XL (S135-155XL, S135-155XL 2 )…330
Linkage for Direction Control Lever S6.00-7.00XL (S135-155XL, S1…330
Oil Pressure Check…332
System Pressure Check Port…332
Torque Converter Check Port…332
Clutch Pressure Check Port…332
Inching Pressure…333
Solenoid Check Ports (MONOTROL Control Only)…333
Lubrication Pressure Check Ports…333
Specifications…334
Troubleshooting…334
Correct System Pressure: 1300 ±124 kPa ( 189 ±18 psi)…337
Correct Clutch Pressure: 924 ±69 kPa ( 134 ±10 psi)…338
Correct Solenoid Pressure (MONOTROL Only): 965 ±138 kPa ( 140 ±2…339
Torque Converter Pressure: 834 ±69 kPa ( 121 ±10 psi)…339
Lubrication Pressure: 83 ±21 kPa ( 12 ±3 psi)…339
tables…264
Table 1. Stall Speed Specifications…317
897108-1600SRM0326-(03-2007)-US-EN…342
toc…342
Steering Axle…342
Safety Precautions Maintenance and Repair…343
General…346
Description…346
Steering Axle Assembly Repair…351
Steering Axle H3.50-5.00XL (H70-110XL) (G005), S3.50-5.50XL (S70…351
Remove…351
Install…351
Steering Axle H6.00-7.00XL (H135-155XL, H135-155XL 2 ) (F006, G0…352
Remove…352
Install…352
Wheels and Hubs Repair (All Units)…353
Remove and Disassemble…353
Clean…353
Inspect…353
Assemble and Install…353
Spindles and Bearings Repair (All Units)…355
Remove…355
Clean…355
Assemble and Install…356
Tie Rods Repair (All Units)…357
Remove…357
Clean…357
Install…357
Steering Cylinder Repair…360
Remove and Disassemble…360
Clean and Inspect…360
Assemble and Install…360
Troubleshooting…361
897109-1800SRM0327-(09-2003)-US-EN…366
toc…366
Brake System…366
Safety Precautions Maintenance and Repair…367
General…370
Description…370
Operation…371
Brake Booster and Master Cylinder…371
Brake Booster…371
Master Cylinder…372
Service Brake Assembly…373
Parking Brake…374
Brake Shoe Assemblies Repair…375
Remove and Disassemble…375
Clean and Inspect…376
Cleaning Procedures…376
Inspect…376
Assemble and Install…377
Master Cylinder Repair…378
Remove…378
Disassemble…378
Assemble…380
Install…380
Brake Booster Repair…380
Remove…380
Disassemble…380
Clean and Inspect…382
Assemble…382
Install…382
Brake System Air Removal…382
Brake Pedal Adjustment…383
Brake Shoes Adjustment…384
Parking Brake Adjustment…384
Parking Brake Switch Adjustment…384
Brake Booster Relief Valve Check…384
Troubleshooting…385
897110-1900SRM0328-(09-2003)-US-EN…390
toc…390
Hydraulic System…390
Safety Precautions Maintenance and Repair…391
General…394
Description and Operation…394
Hydraulic Pumps…396
Main Control Valve…396
Control Valve Lever…397
Steering Control Unit…397
Brake Valve…397
Oil Clutch, H6.00-7.00XL (H135-155XL) (F006)…398
Troubleshooting…398
Lift, Lower, and Tilt Circuit…399
Steering, Brake, and Oil Clutch System…400
897111-4000SRM0329-(10-2003)-US-EN…404
toc…404
Masts…404
Safety Precautions Maintenance and Repair…405
General…408
Description and Operation…408
General…408
Safety Procedures When Working Near Mast…409
Two-Stage Mast…409
Three-Stage Mast…411
Carriage Repair…413
Remove…413
Sideshift Carriage, Disassemble…413
Sideshift Carriage, Assemble…414
Install…414
Two-Stage Mast Repair…416
Remove…416
Disassemble…417
Clean and Inspect…418
Assemble…419
Install…419
Three-Stage Mast Repair…421
Remove…421
Disassemble…421
Clean and Inspect…421
Assemble…421
Install…423
Mast Operation Check…423
Lift and Tilt System Leaks Check…424
Lift System…424
Tilt System…424
Tilt Cylinder Stroke and Backward Tilt Angle Adjustment…425
Lift Chain Adjustments…425
Mast Adjustments…428
Carriage Adjustment…428
Troubleshooting…430
tables…404
Table 1. Mast Parts Weight…417
Table 2. Hook-Type Carriage Chain Adjustment…426
Table 3. Pin-Type Carriage Chain Adjustment…426
897113-8000SRM0331-(09-2003)-US-EN…434
toc…434
Capacities and Specifications…434
Safety Precautions Maintenance and Repair…435
Lift Truck Weights…438
Capacities…438
Tire Sizes…439
Tire Pressure…439
Electrical System…439
Wheel Nut Torque…439
Engine Specifications…440
Hydraulic System…440
Mast Speeds…441
Transmission Oil Pressures…441
Torque Specifications…442
Engine – GM 4.3L V-6…442
Engine – Perkins 4.2482…442
Engine – Perkins 1004.4…442
Clutch…442
Manual Transmission…443
Powershift Transmission…443
Speed Reducer…443
Drive Axle…443
Steering System…443
Brake System…443
Hydraulic System…444
Tilt Cylinder…444
Mast…444
897114-8000SRM0332-(03-2003)-US-EN…448
toc…448
Diagrams…448
Safety Precautions Maintenance and Repair…449
897123-8000SRM0341-(06-2007)-US-EN…472
toc…472
Periodic Maintenance…472
Safety Precautions Maintenance and Repair…473
General…478
Serial Number Data…478
How to Move Disabled Truck…478
How to Tow Lift Truck…478
How to Put Lift Truck on Blocks…479
How to Raise Drive Tires…479
How to Raise Steering Tires…479
Maintenance Schedule…480
Maintenance Procedures Every 8 Hours or Daily…493
How to Make Checks With Engine Stopped…493
Hydraulic System Oil…493
Engine Oil…495
Drive Belts…495
Intake Manifold Rubber Cap…496
Cooling System…496
Air Filter…496
Fuel System…497
Primary Fuel Filter, Diesel Engine…497
Battery…497
Tires and Wheels…497
Forks…498
Adjust…498
Remove and Install…500
Forks, Mast, and Lift Chains, Inspect…501
Operator Restraint System…502
Automatic Locking Retractor (ALR)…502
Emergency Locking Retractor (ELR)…502
Safety Labels…503
How to Make Checks With Engine Running…504
Gauges, Lights, Horn, and Fuses…504
Oil Level, Powershift Transmission…505
Oil Level, Oil Clutch System, H3.50-5.00XL (H70-110XL)…506
Control Levers and Pedals…506
Lift System Operation…506
Inching/Brake Pedal…506
Service Brakes…506
Parking Brake…507
Steering System…507
Maintenance Procedures Every 250 Hours or 6 Weeks…507
Engine Oil and Filter, GM V-6 Engine…507
Lift Chains, Lubrication…507
Drive Shafts…507
Mast Lubrication…508
Crankcase Breather, GM V-6…509
Air Filter, GM V-6 EPA Compliant Engine …509
Maintenance Procedures Every 350 Hours or 2 Months…510
Engine Oil and Filter, Perkins 4.2482 Diesel Engine…510
Drive Belts…510
Perkins Diesel Engine…510
GM V-6 Engine (Early Models)…510
GM V-6 Engine (Late Models)…511
Brake Fluid…513
Lift Chains Wear Check…513
Forks Wear and Damage Check…513
Steering Axle Lubrication…513
Fuel System, Checks and Adjustments…514
Diesel Fuel System…514
LPG Carburetor (Early Models)…514
Gasoline Carburetor (Early Models)…515
Fuel Injection (Late Models)…515
Crankcase Breather, Perkins 4.2482 Diesel Engine…515
Hydraulic Tank Breather…515
Cooling System, Clean Debris from Radiator Core…515
Maintenance Procedures Every 500 Hours or 3 Months…516
Engine Oil and Filter, Perkins Diesel Engine…516
Crankcase Breather, Perkins Diesel Engine…516
PCV Valve, GM V-6…516
Maintenance Procedures Every 1000 Hours or 6 Months…516
Manifold Heat Valve, GM V-6 (Early Models)…516
Ignition System, GM V-6…516
Valve Clearance Adjustment…516
Fuel Filter, Replace (Diesel Engine)…517
Fuel System Air Removal (Perkins 1004-4 Diesel Engine)…517
Fuel Injection Pump With Vent Tube…517
Fuel Injection Pump With Vent Screw…518
Fuel System Air Removal (Perkins 4.2482 Diesel Engine)…520
Oil Level Check in Transmission…520
Manual Transmission, H3.50-5.00XL (H70-110XL)…520
Speed Reducer for Powershift Transmission, H3.50-5.00XL (H70-110…520
Manual Transmission, H6.00-7.00XL (H135-155XL)…520
Differential and Drive Axle for Powershift Transmission, H6.00-7…520
Differential, Speed Reducer, and Drive Axle for Manual Transmiss…521
Control Levers and Pedals, Lubricate…521
Crankcase Breather, Replace…521
Cooling System, GM V-6 EPA Compliant Engine…521
Spark Plug Replacement…521
Remove…521
Install…522
LPG Fuel Filter GM V-6 EPA Compliant Engine, Replace…522
Inspect Engine Electrical System, Connectors, and FCVS Connectio…523
Maintenance Procedures Every 2000 Hours or Yearly…523
Hydraulic System…523
Hydraulic Oil and Filter, H3.50-5.00XL (H70-110XL), Replace…523
Hydraulic Oil and Filter, H6.00-7.00XL (H135-155XL, H135-155XL 2…524
Oil Change and Oil Filter Replacement, Powershift Transmission, …524
Oil Change, Manual Transmission, H3.50-5.00XL (H70-110XL)…524
Oil Change, Manual Transmission, H6.00-7.00XL (H135-155XL)…524
Oil Change, Speed Reducer, Powershift Transmission, H3.50-5.00XL…524
Oil and Filter Change, Oil Clutch System, H3.50-5.00XL (H70-110X…525
Oil Change, Differential and Drive Axle, Powershift Transmission…525
Oil Change, Differential, Speed Reducer, and Drive Axle, Manual …525
Cooling System…525
PCV Valve, GM V-6…525
Service Brakes…526
LPG Filter, Replace…526
Gasoline Fuel Filter, Replace…527
Hood Latch Check, H3.50-5.00XL (H70-110XL)…527
Air Filter Element, GM V-6 EPA Compliant Engine…527
Oxygen Sensor GM V-6 EPA Compliant Engine…527
Inspect Low Pressure Regulator (LPR) for Oil Buildup and Leaks…528
Check Throttle Shaft for Sticking…529
Inspect Exhaust Manifold and Piping for Leaks…529
Test LPG/GAS Regulator Pressure…529
Safety Procedures When Working Near Mast…529
Lift Chain Adjustments…531
Fuel Injectors Repair…533
Lift and Tilt System Leak Check…534
Lift Cylinders, Leak Check…534
Tilt Cylinders, Leak Check…534
Welding Repairs…535
Overhead Guard Changes…535
Wheel and Tire Replacement…536
Remove Wheels From Lift Truck…536
Remove Wheels From Tire…536
Remove Tire From Two-Piece Wheel…538
Remove Tire From Three- and Four-Piece Wheels…540
Install Wheel in Tire…541
Install Three- or Four-Piece Wheel in Tire…542
Install Two-Piece Wheel in Tire…543
Add Air to Pneumatic Tires…544
Wheels, Install…544
Solid Rubber Tires Repair…545
Wheel, Tire Remove…545
Wheel, Tire Install…547
SIT Tire, Change for H3.50-5.00XL (G005), and H6.00-7.00XL (F006…549
Remove SIT Solid Tire From Wheel…549
Install SIT Solid Tire on Wheel…550
Adhesives and Sealants…551
Hydraulic Oil, Lubricant, and Coolant Specifications…552
tables…472
Table 1. Maintenance Schedule…482
Table 2. Hook-Type Carriage Chain Adjustment…532
Table 3. Pin-Type Carriage Chain Adjustment…532
897125-1300SRM0344-(03-1997)-US-EN…556
…556
…557
…558
…559
…560
…561
…562
…563
897128-0900SRM0347-(12-1992)-US-EN…564
…564
…565
…566
…567
…568
…569
…570
…571
…572
…573
…574
…575
…576
…577
…578
…579
897129-0900SRM0348-(09-2001)-US-EN…580
toc…580
LPG Fuel System…580
Safety Precautions Maintenance and Repair…581
General…584
Description and Operation…586
Fuel Tank…586
Fuel Filter and Fuel Valve Unit…587
Vaporizer…588
Carburetor…589
Governor…591
LPG Tank Repair…592
Remove…592
LPG Tanks with Fixed Mounting Bracket…592
LPG Tanks with EZ Lift Mounting Bracket…592
Install…593
LPG Tanks with Fixed Mounting Bracket…593
LPG Tanks with EZ Lift Mounting Bracket…594
Hydrostatic Relief Valve Repair…595
Remove and Install…595
Filter Unit Repair…595
Fuel Filter Element, Replace…595
Diaphragm and Fuel Valve, Replace…595
Hoses Replacement…597
Vaporizer Repair…597
Remove…597
Disassemble…597
Clean…597
Inspect…597
Assemble…599
Install…603
Carburetor Repair…603
Remove…603
Disassemble…603
Clean…603
Assemble…603
Install…603
Governor Repair…605
Filter Unit Check…607
Vaporizer Check…607
Pressure Reducer Valve…607
Vapor Valve…607
Carburetor Adjustment…607
Idle Mixture…607
Idle Speed…607
Power Mixture…608
Throttle Linkage Adjustment…608
Troubleshooting…610
897341-0600SRM0412-(08-1997)-US-EN…616
…616
…617
…618
…619
…620
…621
…622
…623
…624
…625
…626
…627
…628
…629
…630
…631
…632
…633
…634
…635
…636
…637
…638
…639
…640
…641
…642
…643
…644
…645
…646
…647
…648
…649
…650
…651
…652
…653
…654
…655
…656
…657
…658
…659
…660
…661
…662
…663
…664
…665
…666
…667
…668
…669
…670
…671
…672
…673
…674
…675
…676
…677
…678
…679
…680
…681
…682
…683
…684
…685
…686
…687
…688
…689
…690
…691
…692
…693
…694
…695
…696
…697
…698
…699
…700
…701
…702
…703
…704
…705
…706
…707
…708
…709
…710
…711
…712
…713
…714
…715
…716
…717
…718
…719
897412-2200SRM0463-(04-1993)-US-EN…720
…720
…721
…722
…723
…724
…725
…726
…727
…728
…729
…730
…731
…732
…733
…734
…735
…736
…737
…738
…739
…740
…741
…742
…743
…744
…745
…746
…747
…748
…749
…750
…751
…752
…753
…754
…755
897420-2200SRM0468-(05-1996)-US-EN…756
…756
…757
…758
…759
…760
…761
…762
…763
…764
…765
…766
…767
…768
…769
…770
…771
…772
…773
…774
…775
…776
…777
…778
…779
…780
…781
…782
…783
…784
…785
…786
…787
…788
…789
…790
…791
…792
…793
…794
…795
…796
…797
…798
…799
…800
…801
…802
…803
…804
…805
…806
…807
…808
…809
…810
…811
…812
…813
…814
…815
…816
…817
…818
…819
…820
…821
…822
…823
…824
…825
…826
…827
…828
…829
…830
…831
…832
…833
…834
…835
…836
…837
…838
…839
…840
…841
…842
…843
897435-2200SRM0473-(03-1994)-US-EN…844
…844
…845
…846
…847
…848
…849
…850
…851
…852
…853
…854
…855
…856
…857
…858
…859
…860
…861
…862
…863
…864
…865
897501-8000SRM0519-(06-2007)-US-EN…866
toc…866
Diagrams…866
Safety Precautions Maintenance and Repair…867
897800-0600SRM0590-(08-2005)-US-EN…954
toc…954
GM Engines…954
Safety Precautions Maintenance and Repair…955
General…958
Description…958
Engine Removal and Installation…959
Cylinder Head Repair…959
Remove and Disassemble…959
Clean and Inspect…959
Valve Guides and Seats, Repairs…960
Valves, Repair…960
Valve Seats, Repair…961
Valve Springs…961
Rocker Arm Studs (Early Models)…963
Rocker Arm Studs (Late Models)…963
Assemble and Install…964
Cylinder Block Cleaning and Inspection…967
Piston Bore Preparation…967
Engine Mounts Installation…968
Lubrication System Repair…968
Oil Pump, Remove and Disassemble…968
Clean and Inspect…968
Oil Pump, Assemble and Install…969
Oil Sump, Install…969
Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters…970
Timing Cover…970
Remove…970
Install…972
Timing Sprockets…972
Remove…972
Install…972
Camshaft…973
Remove…973
Inspect…973
Install…973
Balance Shaft…974
Remove…974
Install…975
Hydraulic Valve Lifters…975
Remove…975
Disassemble…976
Clean and Inspect…976
Assemble…976
Install…977
Crankshaft Repair…978
Remove…978
Inspect and Repair…978
How to Check Clearance Between Main Bearings and Their Journals…979
Install…980
Piston and Connecting Rod Assemblies Repair…981
Connecting Rod Bearings, Replace…981
Piston and Connecting Rod Assemblies, Remove…982
Disassemble…982
Piston, Clean and Inspect…983
Cylinder Bores, Inspect and Repair…983
Piston Rings…984
Assemble…985
Piston and Connecting Rod Assemblies, Install…985
Flywheel and Flywheel Housing Repair…986
Flywheel, Repair…986
Flywheel, Install…986
H3.50-5.00XL (H70-110XL), S3.50-5.50XL (S70-120XL), S6.00-7.00XL…986
H6.00-7.00XL (H135-155XL)…986
Flywheel Housing H3.50-5.00XL (H70-110XL), H3.50-5.50XM (H70-120…986
Engine Adapter H6.00-7.00XL (H135-155XL)…986
Coolant Pump Repair…987
Thermostat Replacement…987
Fan Mount Repair (Early Models)…987
Fan Mount Assembly Repair (Late Models)…987
Drive Belt Installation…989
Valve Clearance Adjustment (Early Models)…990
Valve Clearance Adjustment (New Models)…991
Compression Check…991
Engine Specifications…992
Engine Data…992
Cylinder Head…992
Hydraulic Valve Lifter…993
Camshaft…993
Pistons…993
Crankshaft…994
Connecting Rods…994
Balance Shaft…995
Cooling System…995
Lubrication System…995
Torque Specifications…995
Troubleshooting…996
tables…954
Table 1. Piston Rings Arrangement on Piston…985
897934-0700SRM0626-(11-2001)-US-EN…1002
toc…1002
Cooling System…1002
Safety Precautions Maintenance and Repair…1003
General…1006
Description…1007
Radiator…1007
Radiator Cap…1007
Thermostat…1007
Water Pump…1008
Fan and Fan Shroud…1008
Cooling System Checks…1008
Radiator…1008
Thermostat…1008
Water Pump…1009
Exhaust Leaks…1009
Fan and Fan Shroud…1009
Radiator Cleaning…1009
Drain…1009
Clean…1009
Fill…1010
Troubleshooting…1011
899783-2000SRM0090-(10-2003)-US-EN…1014
toc…1014
Main Control Valve…1014
Safety Precautions Maintenance and Repair…1015
General…1018
Description…1018
Operation…1021
Lift Spool…1021
Tilt Spool…1022
Tilt Backward…1022
Tilt Forward…1023
Single-Stage Relief Valve…1025
Two-Stage Relief Valve…1026
Main Control Valve Repair…1027
Remove and Disassemble…1027
Clean and Inspect…1027
Assemble…1027
Install…1028
Single-Stage Relief Valve Adjustment…1028
Two-Stage Relief Valve…1029
Auxiliary Control Valve Relief Valve Adjustment (H60-110E Only)…1029
Troubleshooting…1030
tables…1014
Table 1. Relief Pressures (Oil temperature at 55 to 66 C ( 131 t…1028
899784-2200SRM0002-(12-2004)-US-EN…1034
toc…1034
Alternator with Regulator…1034
Safety Precautions Maintenance and Repair…1035
General…1038
Description…1038
Alternator Repair…1040
Alternator Type A…1040
Remove and Disassemble…1040
Clean…1041
Assemble…1042
Install…1042
Alternator Type B…1045
Remove and Disassemble…1045
Clean…1045
Assemble…1046
Install…1047
General Check and Adjustment…1048
Low Output Check (Type A or Type B)…1048
High Output Check (Type A or Type B)…1050
Brushes Circuit Check…1051
Delco Alternators…1051
Motorola Alternators…1052
Diodes Check…1053
Diode Bridge Check…1053
Delco and Leece-Neville Alternators…1053
Motorola Alternators…1053
Rotor Field Winding Check…1054
Stator Windings Check…1055
Voltage Regulator Check…1055
Troubleshooting…1055
899788-2200SRM0107-(03-2002)-US-EN…1060
toc…1060
High Energy Ignition (HEI) System…1060
Safety Precautions Maintenance and Repair…1061
Description…1064
Distributor Repair…1066
Remove…1066
Disassemble…1066
Assemble…1071
Install, If Crankshaft WAS NOT Rotated when Distributor was Remo…1072
Install, If Crankshaft WAS Rotated when Distributor was Removed…1072
Ignition Coil Replacement…1073
Some Four- and Six-Cylinder Models…1073
Remove…1073
Install…1074
V8, Some Four- and Six-Cylinder Models…1074
Remove…1074
Install…1075
Electronic Module Replacement…1076
Remove…1076
Install…1076
Sensing Coil Replacement…1077
Remove…1077
Install…1077
Spark Plugs Replacement…1077
Remove…1077
Install…1078
Visual Check…1078
High Voltage Wires Check…1078
Ignition Coil Check…1079
Coil in Distributor Cap Design…1079
Separate Coil Design…1079
Sensing Coil, Check…1080
Electronic Module Check…1080
Ignition Timing Adjustment…1080
GM V8-366 (6-liter) Ignition System Check…1082
GM V6-LPG (4.3 liter) GM V6-LPG (4.3 liter) Ignition Timing and …1082
Specifications…1082
Troubleshooting…1083
910072-1400SRM0046-(07-2007)-US-EN…1088
toc…1088
Differential…1088
Safety Precautions Maintenance and Repair…1089
General…1092
Description…1092
Differential Repair…1093
Remove…1093
Differential Carrier From Axle Housing, Remove…1093
Differential and Ring Gear From Differential Carrier, Remove…1095
Drive Pinion and Pinion Carrier From Differential Carrier, Remov…1097
Disassemble…1098
Differential and Ring Gear Assembly, Disassemble…1098
Drive Pinion and Pinion Carrier, Disassemble…1100
Clean and Inspect…1103
Assemble…1104
Pinion, Bearings, and Pinion Carrier, Assemble…1104
Pinion Bearings, Adjust Preload…1104
Press Method…1104
Yoke or Flange Method…1105
Triple-Lip Seal, Install…1106
Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion)…1107
Differential and Ring Gear, Assemble…1109
Differential Gears Rotating Torque, Check…1111
Differential and Ring Gear Assembly, Install…1112
Differential Bearings, Preload Adjust…1114
Ring Gear, Runout Check…1115
Ring Gear Backlash, Adjust…1115
Gear Set, Tooth Contact Pattern Check…1117
Thrust Screw, Install and Adjust…1120
Install…1120
Differential Assembly Into Axle Housing, Install…1120
Specifications…1122
Troubleshooting…1127
tables…1088
Table 1. Ring Gear Backlash Adjustment Specifications…1117
Table 2. Ring and Pinion Tooth Contact Adjustment…1118
Table 3. General Specifications…1122
Table 4. Rivet Installation Pressure…1122
Table 5. Pinion Adjustment…1123
Table 6. Pinion Preload Pressure…1123
Table 7. Torque Specifications…1124
Table 8. Torque Specifications for Metric Hardware…1125
Table 9. Torque Specifications for Metric (Fine) Hardware…1126
910073-1400SRM0049-(09-2003)-US-EN…1130
toc…1130
Drive Axle…1130
Safety Precautions Maintenance and Repair…1131
General…1134
Description…1134
Drive Axle Repair…1135
Disassemble (Type 1 Shown)…1135
Clean…1138
Inspect…1138
Assemble (Type 1 Shown)…1139
Torque Specifications…1142
Troubleshooting…1143
910076-1600SRM0054-(10-2003)-US-EN…1146
toc…1146
Steering Control Unit…1146
Safety Precautions Maintenance and Repair…1147
General…1150
Description…1150
Operation…1150
Steering Wheel and Column Assembly Repair…1152
Steering Column Assembly Repair…1152
Type A Steering Column Assembly…1152
Remove and Disassemble…1152
Assemble and Install…1154
Type B Steering Column Assembly…1156
Remove and Disassemble…1156
Assemble and Install…1156
Steering Control Unit…1159
Disassemble…1159
Clean…1162
Assemble…1163
System Air Removal…1168
Troubleshooting…1168
910091-1900SRM0097-(07-2006)-US-EN…1172
toc…1172
Hydraulic Gear Pumps…1172
Safety Precautions Maintenance and Repair…1173
Description…1176
Operation…1177
Flow Control Valve…1177
Relief Valve…1178
Hydraulic Gear Pump Repair…1178
Remove…1178
Disassemble…1179
Clean…1179
Inspect…1180
Assemble…1183
Install…1185
Pump Output Check…1185
Method No. 1…1185
Method No. 2…1186
Hydraulic System Air Check…1187
Troubleshooting…1188
910092-1900SRM0098-(07-2003)-US-EN…1194
toc…1194
Hydraulic Vane Pumps…1194
Safety Precautions Maintenance and Repair…1195
General…1198
Description…1198
Operation…1199
Pump…1199
Relief Valve…1199
Hydraulic Vane Pumps Repair…1200
Remove…1200
Disassemble…1200
Assemble…1201
Install…1204
Relief Valve Relief Pressure Check…1204
Lift Trucks With Internal Combustion Engines…1204
Electric Lift Trucks…1204
Electric Lift Trucks With Adjustable Relief Valve…1205
Specifications…1206
Pressure Relief Valve…1206
Troubleshooting…1206
910102-2100SRM0103-(03-2007)-US-EN…1210
toc…1210
Tilt Cylinders…1210
Safety Precautions Maintenance and Repair…1211
General…1214
Description…1214
Tilt Cylinder Repair…1214
Remove…1214
Disassemble…1214
Clean…1214
Assemble…1214
Tilt Cylinders With O-Ring or Single-Lip Seals…1214
Tilt Cylinders for XM and XMS Models…1216
Tilt Cylinders for XL, XLS, and XL 3 Models…1217
Tilt Cylinders for H700-800A and Early Model H700-920B…1219
Install…1220
Tilt Cylinders Using Chevron Packing…1220
Install…1221
Tilt Cylinder Leak Check…1223
Tilt Cylinder Stroke and Mast Tilt Angle Adjustment…1225
Torque Specifications…1225
Piston Rod Nut…1225
Retainer…1226
Troubleshooting…1228
tables…1210
Table 1. Movement Rates (Maximum) for Tilt Cylinders…1224
910107-2200SRM0106-(12-2004)-US-EN…1232
toc…1232
Starter…1232
Safety Precautions Maintenance and Repair…1233
General…1236
Description and Operation…1236
Starter Repair…1238
Remove…1238
Disassemble…1238
Clean…1239
Assemble…1239
Install…1240
General Checks and Adjustments…1240
Troubleshooting…1243
910110-2200SRM0143-(02-2007)-US-EN…1248
toc…1248
Instrument Panel Indicators and Senders…1248
Safety Precautions Maintenance and Repair…1249
General…1252
Description…1253
Steering Column Gauges, Meters, and Indicators…1253
LED Display Panel…1253
Battery Discharge Indicators…1253
Brush Wear Indicators…1259
Motor Temperature Indicators…1259
LX Series Display Panel…1261
Hourmeter Functions…1262
Battery Indicator Function…1262
Status Code Function…1262
ZX Series Display Panels…1264
Display Panel…1264
Basic Display Panels…1264
Performance Display…1266
Brush Wear Indicators…1270
Adjustments – General…1270
Replacement – General Information…1270
Meter Replacement…1271
Sender Replacement…1272
Fuel Level Sender…1272
Pressure and Temperature Sender…1272
Seat Sensor, Operator Presence System (OPS)…1273
Remove…1273
Install…1273
Operator Presence System Module Replacement…1273
Remove…1274
Install…1275
ITW Display Panel Replacement…1276
Remove…1276
Column Mount Display Panel (EV-100/200ZX Motor Controllers) Repl…1276
Remove…1276
Display Panel Assembly, Replace…1276
Indicator LEDs…1277
Battery Indicators…1277
Digital Display (Performance Display Panel Only)…1277
Status Code or Performance Level Switches and Indicator LEDs (Pe…1278
Basic Display Panel, Replace Parts…1278
Performance Display Panel, Replace Parts…1280
Dash Mount Display Panel (EV100/200ZX Motor Controllers) Replace…1280
Remove and Replace…1280
Specifications…1281
Meter Specifications…1281
Sender Specifications…1281
Troubleshooting…1282
Meter…1282
Troubleshooting for Operator Presence System…1283
tables…1248
Table 1. Troubleshooting Procedure for Operator Presence Module…1283
910119-4000SRM0135-(10-2003)-US-EN…1288
toc…1288
Lift Cylinders…1288
Safety Precautions Maintenance and Repair…1289
Safety Procedures When Working Near Mast…1292
General…1296
Description…1296
Lowering Control Valve…1296
Cylinders (General)…1299
Cylinders (H520-620B, H700-800A)…1299
Retainer, Install…1299
Cylinders (H360-460B)…1301
Cylinders (Two-Speed)…1303
Lift Cylinder Repair…1305
Lift Cylinder Removal Without Removing Mast…1305
Standard Masts With Main Lift Cylinder Fastened to Crossmember o…1305
Standard and Full Free-Lift Masts With Lift Cylinder Fastened to…1305
Masts That Have Two Cylinders, Main Lift Cylinder and Free-Lift …1305
Disassemble…1307
Assemble…1307
Lift Cylinder Installation in Mast…1309
Standard Masts With Main Lift Cylinder Fastened to Crossmember o…1309
Standard and Full Free-Lift Masts With Lift Cylinder Fastened to…1309
Chevron-Style Packing…1309
Chevron-Style Packing Installation on Piston…1310
Chevron-Style Packing Installation in Packing Gland…1312
Lift Cylinders for VISTA® Masts…1313
Description…1313
Lowering Control Valve…1313
Remove…1315
Disassemble…1316
Assemble…1317
Install…1318
Main Lift Cylinders…1318
Free-Lift Cylinder…1318
Lift System Leak Check…1319
Specifications…1320
Troubleshooting…1321
tables…1288
Table 1. Lift Trucks with Two-Speed Lift Cylinders…1304
Table 2. Cylinder Retainer Torque Specifications and Weight Guid…1320
910150-0600SRM0105-(06-1997)-US-EN…1324
…1324
…1325
…1326
…1327
…1328
…1329
…1330
…1331
…1332
…1333
…1334
…1335
…1336
…1337
…1338
…1339
…1340
…1341
…1342
…1343
…1344
…1345
…1346
…1347
…1348
…1349
…1350
…1351
…1352
…1353
…1354
…1355
…1356
…1357
…1358
…1359
…1360
…1361
…1362
…1363
910233-1300SRM0061-(02-1997)-US-EN…1364
…1364
…1365
…1366
…1367
…1368
…1369
…1370
…1371
…1372
…1373
…1374
…1375
…1376
…1377
…1378
…1379
…1380
…1381
…1382
…1383
…1384
…1385
…1386
…1387
910442-8000SRM0231-(12-2004)-US-EN…1388
toc…1388
Metric and Inch (SAE) Fasteners…1388
Safety Precautions Maintenance and Repair…1389
General…1392
Threaded Fasteners…1392
Nomenclature, Threads…1392
Strength Identification…1393
Cotter (Split) Pins…1393
Fastener Torque Tables…1398
Conversion Table…1400
tables…1388
Table 1. Bolts and Screws…1394
Table 2. Studs and Nuts…1395
Table 3. Torque Nuts…1396
Table 4. Torque Nuts With Nylon Insert…1397
Table 5. Torque Values for Metric Fasteners*…1398
Table 6. Torque Values for Inch Fasteners*…1399
Table 7. Conversion Table for Metric and English Units…1400
Table 8. Cotter Pin Dimensional Data…1401
Table 9. Cotter Pin Dimensional Data…1402
Table 10. Cotter Pin Dimensional Data…1403
Table 11. Cotter Pin Dimensional Data…1405
F006 (H6.00-7.00XL Europe)…1410
1455747-0600SRM0705-(03-2006)-UK-EN…1412
toc…1412
Perkins Diesel Engines…1412
Safety Precautions Maintenance and Repair…1413
General…1420
General Safety Rules…1420
Description…1421
Engine Serial Number Codes…1424
Engine Data…1424
Engine Removal and Installation…1426
Lift Engine…1426
Cylinder Head Assembly Repair…1426
Valve Cover…1426
Remove…1426
Install…1427
Rocker Arm Assembly…1427
Remove…1427
Install…1427
Disassemble…1427
Inspect…1428
Assemble…1428
Valve Clearance Adjustments…1428
Four-Cylinder Engines…1429
Six-Cylinder Engines…1429
Valve Springs…1429
Cylinder Head Assembly…1431
Remove…1431
Install…1433
Valves and Valve Springs…1437
Remove…1437
Inspect…1437
Install…1438
Valve Guides…1438
Inspect…1438
Remove…1439
Install…1439
Cylinder Head and Valve Seats…1439
Inspect…1439
Repair…1439
New Valve Seats, Install…1439
Piston and Connecting Rod Assemblies Repair…1441
Rod Bearings…1441
Remove…1442
Install…1442
Piston and Connecting Rod Assembly…1443
Service Note…1443
Remove…1443
Install…1444
Piston Rings…1445
Remove…1445
Inspect…1445
Install…1445
Piston and Connecting Rod…1446
Disassemble…1446
Inspect…1447
How to Select Correct Replacements…1447
Install…1448
Piston Cooling Jets…1448
Remove…1448
Install…1449
Crankshaft Assembly Repair…1449
General…1449
Crankshaft Pulley…1450
Engine AR, Remove…1450
Engines YG and YH, Remove…1450
Inspect…1451
Engine AR, Install…1451
Engines YG and YH, Install…1451
Rear Oil Seal…1452
Replace…1452
Main Bearings…1453
Remove…1453
Inspect…1454
Install…1454
Thrust Washers…1454
Crankshaft Axial Movement, Check…1454
Remove…1455
Install…1455
Crankshaft…1456
Remove…1456
Inspect…1456
Install…1456
Flywheel…1458
Remove…1458
Ring Gear, Replace…1458
Install…1458
Flywheel Housing…1459
Remove…1459
Install…1459
Timing Case and Timing Gears Repair…1460
General…1460
Timing Case Cover…1460
Remove…1460
Install…1461
Front Oil Seal…1461
Remove…1461
Install…1461
Crankshaft Pulley Wear Sleeve…1462
Install…1462
Idler Gear and Hub…1462
Remove…1462
Install…1463
Air Compressor Drive, Bendix…1464
Disassemble…1464
Assemble…1465
Fuel Injection Pump Gear…1465
Remove…1466
Install…1466
Camshaft Gear…1467
Remove…1467
Install…1467
Crankshaft Gear…1468
Remove…1468
Install…1468
Timing Case…1468
Remove…1468
Install…1469
Camshaft and Tappets…1470
Remove…1470
Install…1470
Cylinder Block Assembly Repair…1471
Description…1471
Cylinder Block…1471
Disassemble…1471
Inspect…1472
Assemble…1472
Cylinder Bore (Four-Cylinder Engines)…1473
Cylinder Liner (Six-Cylinder Engines)…1473
Inspect…1473
Cylinder Liner Condition, Check…1473
Remove…1474
Service Liner, Install…1475
Partially Finished Liner, Install…1476
Engine Timing…1477
Description…1477
How to Set Number One Piston to TDC on Compression Stroke…1478
How to Set Number One Piston to TDC on Compression Stroke (Alter…1479
Valve Timing, Check…1479
Fuel Injection Pump Timing, Check…1480
Turbocharger – Engine YH Repair…1481
General…1481
Remove…1481
Install…1481
Impeller and Compressor Housing, Clean…1482
Lubrication System Repair…1483
General…1483
Oil Filter, Replace…1483
Filter Head…1484
Remove and Install…1484
Oil Sump…1484
Remove…1484
Install…1485
Oil Pump…1485
Remove…1485
Inspect…1485
Install…1486
Relief Valve…1486
Remove…1486
Disassemble…1487
Inspect…1487
Assemble…1487
Install…1488
Idler Gear Shaft, Replace…1488
Remove…1488
Remove (Alternative)…1488
Install…1489
Install (Alternative)…1489
Install (Alternative for Four-Cylinder Engines Only)…1490
Fuel System Repair…1490
Description…1490
Fuel Injection Pump…1491
Remove…1491
Install…1492
Check and Adjust…1493
Fuel System Air Removal…1493
Fuel Filter, Replace…1494
Canister Type…1495
Quick Release Canister Type…1495
Fuel Injectors…1496
Remove…1496
Inspect…1497
Install…1497
Fuel Pump…1498
Remove…1498
Disassemble…1498
Assemble…1498
Install…1499
Test…1499
Cooling System Repair…1500
General…1500
Thermostat…1500
Remove…1500
Install…1500
Test…1501
Coolant Pump…1501
Remove…1501
Disassemble…1501
Assemble…1503
Install…1505
Fan and Fan Drive…1506
Remove…1506
Install…1506
Oil Cooler (Six-Cylinder Engines)…1507
Remove…1507
Disassemble and Assemble…1507
Install…1507
Oil Cooler Bypass Valve…1507
Electrical Equipment Repair…1508
Drive Belts…1508
Adjustment…1508
Remove…1509
Install…1509
Alternator…1509
Remove…1509
Install…1509
Starter Motor…1509
Remove…1509
Install…1509
Cold Start Aid…1509
Air Compressor – Engines YG and YH…1510
General…1510
Repair…1510
Remove…1510
Install…1510
Rotary Exhauster Replacement…1512
Remove…1512
Clean…1512
Install…1512
Engine Specifications…1513
Cylinder Head Assembly…1513
Piston and Connecting Rods…1516
Crankshaft Assembly…1519
Crankshaft Overhaul…1521
Timing Case and Drive Assembly…1523
Engine Block Assembly…1524
Turbocharger…1527
Lubrication System…1527
Fuel System…1528
Cooling System…1530
Flywheel and Housing…1530
Electrical Equipment…1531
Torque Specifications…1531
Cylinder Head Assembly…1531
Piston and Connecting Rod Assemblies…1531
Crankshaft Assembly…1531
Timing Case and Drive Assembly…1532
Turbocharger…1532
Lubrication System…1532
Fuel System…1532
Cooling System…1532
Flywheel…1532
Auxiliary Equipment…1532
Special Torque Specifications…1533
Flywheel and Housing…1533
Turbocharger…1533
Electrical Equipment…1533
Auxiliary Equipment…1533
Special Tools*…1534
Troubleshooting…1539
tables…1412
Table 1. Cylinder Head…1513
Table 2. Valve Guides…1513
Table 3. Inlet Valves…1513
Table 4. Exhaust Valves…1514
Table 5. Valve Springs…1516
Table 6. Tappets…1516
Table 7. Rocker Arm Shaft…1516
Table 8. Rocker Arms and Bushings…1516
Table 9. Pistons (Engine AR)…1516
Table 10. Pistons (Engines YG and YH)…1516
Table 11. Piston Rings (Engine AR)…1517
Table 12. Piston Rings (Engines YG and YH)…1517
Table 13. Piston Pins…1518
Table 14. Connecting Rods…1518
Table 15. Small End Bushings…1518
Table 16. Connecting Rod Bearings (Engines AR and YG)…1518
Table 17. Connecting Rod Bearings (Engine YH)…1518
Table 18. Piston Cooling Jets…1519
Table 19. Crankshaft…1519
Table 20. Main Bearings…1520
Table 21. Crankshaft Thrust Washers…1520
Table 22. Crankshaft Heat Treatment…1520
Table 23. Crankshaft Overhaul Specifications…1521
Table 24. Maximum Variation (Run-out)…1523
Table 25. Camshaft…1523
Table 26. Camshaft Thrust Washer…1523
Table 27. Camshaft Gear…1523
Table 28. Gear for Fuel Injection Pump…1524
Table 29. Crankshaft Gear…1524
Table 30. Idler Gear and Hub…1524
Table 31. Cylinder Block (Engine AR)…1524
Table 32. Cylinder Bore Specifications…1525
Table 33. Cylinder Block (Engines YG and YH)…1526
Table 34. Cylinder Liners (Engines YG and YH)…1526
Table 35. Cylinder Liner Specifications (Partially Finished)…1526
Table 36. Oil Pump (Engine AR)…1527
Table 37. Oil Pump (Engines YG and YH)…1527
Table 38. Idler Gear for Oil Pump…1528
Table 39. Relief Valve…1528
Table 40. Oil Filter…1528
Table 41. Lucas Fuel Injection Pump…1528
Table 42. Fuel Injector Codes…1529
Table 43. Fuel Pump (Engine AR)…1530
Table 44. Fuel Pump (Engines YG and YH)…1530
Table 45. Fuel Filter…1530
Table 46. Coolant Pump…1530
Table 47. Thermostat…1530
Table 48. Fan Drive Housing…1530
Table 49. Limits for Flywheel Run Out and Alignment (Total Indic…1531
Table 50. Alternator…1531
Table 51. Starter Motor…1531
Table 52. Cold Start Aid…1531
Table 53. List of Possible Causes…1539
1473385-2200SRM0765-(11-2001)-UK-EN…1544
toc…1544
Microprocessor Spark Timing System (MSTS)…1544
Safety Precautions Maintenance and Repair…1545
General…1548
Description…1549
What MSTS Does…1549
How MSTS Begins Operation…1549
Operation…1550
Distributor…1550
Ignition Coil…1550
Ignition Module…1550
When Engine Is Being Started…1551
When Engine Is Running…1552
Manifold Absolute Pressure (MAP) Sensor…1553
Engine Coolant Temperature (ECT) Sensor…1553
MSTS Module Corrections…1554
Troubleshooting…1555
General…1555
Tools and Test Equipment…1557
MSTS…1558
Troubleshooting Procedure…1558
Where to Start…1558
Visual/Physical Inspection…1558
Knowledge/Tools Required…1558
Damage from Static Discharge (Static Electricity)…1558
Troubleshooting Information…1559
Malfunction Indicator Lamp (MIL)…1559
Connecting CodeMate Tester…1559
Reading Diagnostic Trouble Codes (DTC)…1560
Clearing Diagnostic Trouble Codes (DTC's)…1561
On-Board Diagnostic (OBD) System Check…1561
Test Description…1561
No Malfunction Indicator Lamp…1563
Circuit Description…1563
Test Description…1563
No DTC-12, Malfunction Indicator Lamp ON…1565
Circuit Description…1565
Test Description…1565
Starter Rotates Engine, Engine Does Not Run…1566
Test Description…1566
DTC-14 Engine Coolant Temperature (ECT) (Low Temperature Indicat…1570
Circuit Description…1570
Test Description…1570
DTC-15 Engine Coolant Temperature Sensor (ECT) (High Temperature…1572
Circuit Description…1572
Test Description…1572
DTC-34 Manifold Absolute Pressure (MAP) Sensor…1574
Circuit Description…1574
Test Description…1574
DTC-41 Electronic Spark Timing (EST) Open Circuit…1577
Circuit Description…1577
Test Description…1577
DTC-42 Electronic Spark Timing (EST) Grounded Circuit…1579
Circuit Description…1579
Test Description…1579
DTC-51 MSTS Failure…1581
Circuit Description…1581
Distributor Repair…1581
Remove…1581
Disassemble…1582
Inspect…1582
Assemble…1582
Install…1583
Ignition Timing…1583
Ignition Module Repair…1584
Test For Fault…1584
Replace…1585
Sensing Coil Repair…1585
Test For Fault…1585
Replace…1585
Ignition Coil Repair…1586
Test For Fault…1586
Remove…1586
Install…1586
MSTS Module Repair…1587
Remove…1587
Install…1587
ECT Sensor Replacement…1587
MAP Sensor Replacement…1588
tables…1544
Table 1. MSTS Module Connections…1556
Table 2. Pressure Conversion Chart…1557
Table 3. MSTS Diagnostic Codes…1559
897104-0100SRM0322-(02-2007)-UK-EN…1592
toc…1592
Frame…1592
Safety Precautions Maintenance and Repair…1593
General…1596
Description…1596
Counterweight Repair…1597
Remove…1597
Install…1597
Hood Repair…1598
Remove…1598
Install…1598
Overhead Guard Repair…1598
Remove…1598
Install…1598
Operator Restraint System Repair…1599
Automatic Locking Retractor (ALR)…1599
Emergency Locking Retractor (ELR)…1599
Hydraulic Tank Repair…1601
Remove…1601
Inspect…1601
Small Leaks Repair…1601
Large Leaks Repair…1601
Clean…1601
Steam Method…1602
Chemical Solution Method…1602
Other Methods of Preparation for Repair…1602
Install…1602
Fuel Tank Repair…1603
Remove…1603
Repair…1603
Install…1603
Radiator Repair…1603
Remove…1603
Install…1603
Engine Repair…1604
Remove…1604
Install…1604
Throttle Pedal Adjustment…1606
Perkins 1104C-44(RE) Diesel Engine…1606
Safety Labels…1607
Cab Repair…1609
Cab, Replace…1609
Window, Replace…1609
Windshield Wipers and Heater…1609
tables…1592
Table 1. Material Specifications for Cab Windows…1611
897106-1300SRM0324-(10-2003)-UK-EN…1614
toc…1614
Two-Speed Powershift Transmission…1614
Safety Precautions Maintenance and Repair…1615
General…1618
Mechanical Description…1618
Torque Converter…1618
Transmission Pump…1619
Shaft Assemblies…1619
Input Shaft…1620
Forward Clutch Shaft…1620
Clutch Assemblies…1620
Countershaft…1627
Output Shaft…1627
Hydraulic Operation…1628
Torque Converter…1628
Seal Rings…1629
Control Valve…1629
System Pressure Regulator…1632
Clutch Pressure Regulator…1632
Torque Converter Regulator…1633
Inching Spool…1633
Direction Spool, Direction Control Lever…1633
Direction Spool, MONOTROL Pedal…1634
Range Spool…1634
Drain Spool…1635
Accumulator…1635
Modulator Spool…1635
Operation…1635
Lubrication Circuit…1636
MONOTROL Pedal…1636
Oil Flow Diagrams…1638
Neutral…1638
Forward-Low…1639
Forward-Low-Inching…1640
Reverse-Low…1641
897107-1300SRM0325-(10-2003)-UK-EN…1644
toc…1644
Two-Speed Powershift Transmission…1644
Safety Precautions Maintenance and Repair…1645
General…1648
Transmission Repair…1648
Transmission and Torque Converter, Remove…1648
Transmission, Disassemble…1650
Reverse-Low Clutch, Disassemble…1653
Reverse-High Clutch, Disassemble…1656
Forward-Low Clutch, Disassemble…1659
Forward-High Clutch, Disassemble…1662
Clean and Inspect…1664
Forward Low and High Clutches Assembly…1665
Forward Clutches, Assemble…1667
Reverse-Low Clutch, Assemble…1673
Reverse Clutches, Assemble…1675
Transmission, Assemble…1682
Torque Converter, Install…1689
Control Valve Repair…1690
Remove…1690
Disassemble…1691
Assemble…1692
Install…1694
MONOTROL Pedal…1694
Remove and Disassemble…1694
Assemble and Install…1694
Stall Test…1697
Linkage Adjustments…1698
Linkage for Inching Pedal H6.00-7.00XL (H135-155XL, H135-155XL 2…1698
Linkage for Inching Pedal S6.00-7.00XL (S135-155XL, S135-155XL 2…1701
Linkage for Range Lever – Early Model H6.00-7.00XL (H135-155XL) …1704
Linkage for Direction Control Lever – Early Model H6.00-7.00XL (…1704
Linkage for Range Lever – Later Model H6.00-7.00XL (H135-155XL, …1706
Linkage for Direction Control Lever – Later Model H6.00-7.00XL (…1708
Linkage for Range Lever S6.00-7.00XL (S135-155XL, S135-155XL 2 )…1710
Linkage for Direction Control Lever S6.00-7.00XL (S135-155XL, S1…1710
Oil Pressure Check…1712
System Pressure Check Port…1712
Torque Converter Check Port…1712
Clutch Pressure Check Port…1712
Inching Pressure…1713
Solenoid Check Ports (MONOTROL Control Only)…1713
Lubrication Pressure Check Ports…1713
Specifications…1714
Troubleshooting…1714
Correct System Pressure: 1300 ±124 kPa ( 189 ±18 psi)…1717
Correct Clutch Pressure: 924 ±69 kPa ( 134 ±10 psi)…1718
Correct Solenoid Pressure (MONOTROL Only): 965 ±138 kPa ( 140 ±2…1719
Torque Converter Pressure: 834 ±69 kPa ( 121 ±10 psi)…1719
Lubrication Pressure: 83 ±21 kPa ( 12 ±3 psi)…1719
tables…1644
Table 1. Stall Speed Specifications…1697
897108-1600SRM0326-(03-2007)-UK-EN…1722
toc…1722
Steering Axle…1722
Safety Precautions Maintenance and Repair…1723
General…1726
Description…1726
Steering Axle Assembly Repair…1731
Steering Axle H3.50-5.00XL (H70-110XL) (G005), S3.50-5.50XL (S70…1731
Remove…1731
Install…1731
Steering Axle H6.00-7.00XL (H135-155XL, H135-155XL 2 ) (F006, G0…1732
Remove…1732
Install…1732
Wheels and Hubs Repair (All Units)…1733
Remove and Disassemble…1733
Clean…1733
Inspect…1733
Assemble and Install…1733
Spindles and Bearings Repair (All Units)…1735
Remove…1735
Clean…1735
Assemble and Install…1736
Tie Rods Repair (All Units)…1737
Remove…1737
Clean…1737
Install…1737
Steering Cylinder Repair…1740
Remove and Disassemble…1740
Clean and Inspect…1740
Assemble and Install…1740
Troubleshooting…1741
897109-1800SRM0327-(09-2003)-UK-EN…1746
toc…1746
Brake System…1746
Safety Precautions Maintenance and Repair…1747
General…1750
Description…1750
Operation…1751
Brake Booster and Master Cylinder…1751
Brake Booster…1751
Master Cylinder…1752
Service Brake Assembly…1753
Parking Brake…1754
Brake Shoe Assemblies Repair…1755
Remove and Disassemble…1755
Clean and Inspect…1756
Cleaning Procedures…1756
Inspect…1756
Assemble and Install…1757
Master Cylinder Repair…1758
Remove…1758
Disassemble…1758
Assemble…1760
Install…1760
Brake Booster Repair…1760
Remove…1760
Disassemble…1760
Clean and Inspect…1762
Assemble…1762
Install…1762
Brake System Air Removal…1762
Brake Pedal Adjustment…1763
Brake Shoes Adjustment…1764
Parking Brake Adjustment…1764
Parking Brake Switch Adjustment…1764
Brake Booster Relief Valve Check…1764
Troubleshooting…1765
897110-1900SRM0328-(09-2003)-UK-EN…1770
toc…1770
Hydraulic System…1770
Safety Precautions Maintenance and Repair…1771
General…1774
Description and Operation…1774
Hydraulic Pumps…1776
Main Control Valve…1776
Control Valve Lever…1777
Steering Control Unit…1777
Brake Valve…1777
Oil Clutch, H6.00-7.00XL (H135-155XL) (F006)…1778
Troubleshooting…1778
Lift, Lower, and Tilt Circuit…1779
Steering, Brake, and Oil Clutch System…1780
897111-4000SRM0329-(10-2003)-UK-EN…1784
toc…1784
Masts…1784
Safety Precautions Maintenance and Repair…1785
General…1788
Description and Operation…1788
General…1788
Safety Procedures When Working Near Mast…1789
Two-Stage Mast…1789
Three-Stage Mast…1791
Carriage Repair…1793
Remove…1793
Sideshift Carriage, Disassemble…1793
Sideshift Carriage, Assemble…1794
Install…1794
Two-Stage Mast Repair…1796
Remove…1796
Disassemble…1797
Clean and Inspect…1798
Assemble…1799
Install…1799
Three-Stage Mast Repair…1801
Remove…1801
Disassemble…1801
Clean and Inspect…1801
Assemble…1801
Install…1803
Mast Operation Check…1803
Lift and Tilt System Leaks Check…1804
Lift System…1804
Tilt System…1804
Tilt Cylinder Stroke and Backward Tilt Angle Adjustment…1805
Lift Chain Adjustments…1805
Mast Adjustments…1808
Carriage Adjustment…1808
Troubleshooting…1810
tables…1784
Table 1. Mast Parts Weight…1797
Table 2. Hook-Type Carriage Chain Adjustment…1806
Table 3. Pin-Type Carriage Chain Adjustment…1806
897113-8000SRM0331-(09-2003)-UK-EN…1814
toc…1814
Capacities and Specifications…1814
Safety Precautions Maintenance and Repair…1815
Lift Truck Weights…1818
Capacities…1818
Tire Sizes…1819
Tire Pressure…1819
Electrical System…1819
Wheel Nut Torque…1819
Engine Specifications…1820
Hydraulic System…1820
Mast Speeds…1821
Transmission Oil Pressures…1821
Torque Specifications…1822
Engine – GM 4.3L V-6…1822
Engine – Perkins 4.2482…1822
Engine – Perkins 1004.4…1822
Clutch…1822
Manual Transmission…1823
Powershift Transmission…1823
Speed Reducer…1823
Drive Axle…1823
Steering System…1823
Brake System…1823
Hydraulic System…1824
Tilt Cylinder…1824
Mast…1824
897114-8000SRM0332-(09-1997)-UK-EN…1828
ELECTRICAL SCHEMATIC (GASOLINE & LPG)…1828
ELECTRICAL SCHEMATIC (DIESEL, PERKINS 4.2482)…1830
ELECTRICAL SCHEMATIC (DIESEL, PERKINS 1004.4)…1832
HYDRAULIC SCHEMATIC…1834
HYDRAULIC SCHEMATIC, POWERSHIFT TRANSMISSION WITH MANUAL CONTROL…1835
HYDRAULIC SCHEMATIC, POWERSHIFT TRANSMISSION WITH MONOTROL PEDAL…1836
897123-8000SRM0341-(06-2007)-UK-EN…1837
toc…1837
Periodic Maintenance…1837
Safety Precautions Maintenance and Repair…1838
General…1843
Serial Number Data…1843
How to Move Disabled Truck…1843
How to Tow Lift Truck…1843
How to Put Lift Truck on Blocks…1844
How to Raise Drive Tires…1844
How to Raise Steering Tires…1844
Maintenance Schedule…1845
Maintenance Procedures Every 8 Hours or Daily…1858
How to Make Checks With Engine Stopped…1858
Hydraulic System Oil…1858
Engine Oil…1860
Drive Belts…1860
Intake Manifold Rubber Cap…1861
Cooling System…1861
Air Filter…1861
Fuel System…1862
Primary Fuel Filter, Diesel Engine…1862
Battery…1862
Tires and Wheels…1862
Forks…1863
Adjust…1863
Remove and Install…1865
Forks, Mast, and Lift Chains, Inspect…1866
Operator Restraint System…1867
Automatic Locking Retractor (ALR)…1867
Emergency Locking Retractor (ELR)…1867
Safety Labels…1868
How to Make Checks With Engine Running…1869
Gauges, Lights, Horn, and Fuses…1869
Oil Level, Powershift Transmission…1870
Oil Level, Oil Clutch System, H3.50-5.00XL (H70-110XL)…1871
Control Levers and Pedals…1871
Lift System Operation…1871
Inching/Brake Pedal…1871
Service Brakes…1871
Parking Brake…1872
Steering System…1872
Maintenance Procedures Every 250 Hours or 6 Weeks…1872
Engine Oil and Filter, GM V-6 Engine…1872
Lift Chains, Lubrication…1872
Drive Shafts…1872
Mast Lubrication…1873
Crankcase Breather, GM V-6…1874
Air Filter, GM V-6 EPA Compliant Engine …1874
Maintenance Procedures Every 350 Hours or 2 Months…1875
Engine Oil and Filter, Perkins 4.2482 Diesel Engine…1875
Drive Belts…1875
Perkins Diesel Engine…1875
GM V-6 Engine (Early Models)…1875
GM V-6 Engine (Late Models)…1876
Brake Fluid…1878
Lift Chains Wear Check…1878
Forks Wear and Damage Check…1878
Steering Axle Lubrication…1878
Fuel System, Checks and Adjustments…1879
Diesel Fuel System…1879
LPG Carburetor (Early Models)…1879
Gasoline Carburetor (Early Models)…1880
Fuel Injection (Late Models)…1880
Crankcase Breather, Perkins 4.2482 Diesel Engine…1880
Hydraulic Tank Breather…1880
Cooling System, Clean Debris from Radiator Core…1880
Maintenance Procedures Every 500 Hours or 3 Months…1881
Engine Oil and Filter, Perkins Diesel Engine…1881
Crankcase Breather, Perkins Diesel Engine…1881
PCV Valve, GM V-6…1881
Maintenance Procedures Every 1000 Hours or 6 Months…1881
Manifold Heat Valve, GM V-6 (Early Models)…1881
Ignition System, GM V-6…1881
Valve Clearance Adjustment…1881
Fuel Filter, Replace (Diesel Engine)…1882
Fuel System Air Removal (Perkins 1004-4 Diesel Engine)…1882
Fuel Injection Pump With Vent Tube…1882
Fuel Injection Pump With Vent Screw…1883
Fuel System Air Removal (Perkins 4.2482 Diesel Engine)…1885
Oil Level Check in Transmission…1885
Manual Transmission, H3.50-5.00XL (H70-110XL)…1885
Speed Reducer for Powershift Transmission, H3.50-5.00XL (H70-110…1885
Manual Transmission, H6.00-7.00XL (H135-155XL)…1885
Differential and Drive Axle for Powershift Transmission, H6.00-7…1885
Differential, Speed Reducer, and Drive Axle for Manual Transmiss…1886
Control Levers and Pedals, Lubricate…1886
Crankcase Breather, Replace…1886
Cooling System, GM V-6 EPA Compliant Engine…1886
Spark Plug Replacement…1886
Remove…1886
Install…1887
LPG Fuel Filter GM V-6 EPA Compliant Engine, Replace…1887
Inspect Engine Electrical System, Connectors, and FCVS Connectio…1888
Maintenance Procedures Every 2000 Hours or Yearly…1888
Hydraulic System…1888
Hydraulic Oil and Filter, H3.50-5.00XL (H70-110XL), Replace…1888
Hydraulic Oil and Filter, H6.00-7.00XL (H135-155XL, H135-155XL 2…1889
Oil Change and Oil Filter Replacement, Powershift Transmission, …1889
Oil Change, Manual Transmission, H3.50-5.00XL (H70-110XL)…1889
Oil Change, Manual Transmission, H6.00-7.00XL (H135-155XL)…1889
Oil Change, Speed Reducer, Powershift Transmission, H3.50-5.00XL…1889
Oil and Filter Change, Oil Clutch System, H3.50-5.00XL (H70-110X…1890
Oil Change, Differential and Drive Axle, Powershift Transmission…1890
Oil Change, Differential, Speed Reducer, and Drive Axle, Manual …1890
Cooling System…1890
PCV Valve, GM V-6…1890
Service Brakes…1891
LPG Filter, Replace…1891
Gasoline Fuel Filter, Replace…1892
Hood Latch Check, H3.50-5.00XL (H70-110XL)…1892
Air Filter Element, GM V-6 EPA Compliant Engine…1892
Oxygen Sensor GM V-6 EPA Compliant Engine…1892
Inspect Low Pressure Regulator (LPR) for Oil Buildup and Leaks…1893
Check Throttle Shaft for Sticking…1894
Inspect Exhaust Manifold and Piping for Leaks…1894
Test LPG/GAS Regulator Pressure…1894
Safety Procedures When Working Near Mast…1894
Lift Chain Adjustments…1896
Fuel Injectors Repair…1898
Lift and Tilt System Leak Check…1899
Lift Cylinders, Leak Check…1899
Tilt Cylinders, Leak Check…1899
Welding Repairs…1900
Overhead Guard Changes…1900
Wheel and Tire Replacement…1901
Remove Wheels From Lift Truck…1901
Remove Wheels From Tire…1901
Remove Tire From Two-Piece Wheel…1903
Remove Tire From Three- and Four-Piece Wheels…1905
Install Wheel in Tire…1906
Install Three- or Four-Piece Wheel in Tire…1907
Install Two-Piece Wheel in Tire…1908
Add Air to Pneumatic Tires…1909
Wheels, Install…1909
Solid Rubber Tires Repair…1910
Wheel, Tire Remove…1910
Wheel, Tire Install…1912
SIT Tire, Change for H3.50-5.00XL (G005), and H6.00-7.00XL (F006…1914
Remove SIT Solid Tire From Wheel…1914
Install SIT Solid Tire on Wheel…1915
Adhesives and Sealants…1916
Hydraulic Oil, Lubricant, and Coolant Specifications…1917
tables…1837
Table 1. Maintenance Schedule…1847
Table 2. Hook-Type Carriage Chain Adjustment…1897
Table 3. Pin-Type Carriage Chain Adjustment…1897
897125-1300SRM0344-(07-1993)-UK-EN…1921
INTRODUCTION…1921
GENERAL…1921
DESCRIPTION…1921
OPERATION…1922
REPAIRS…1922
REMOVAL…1922
DISASSEMBLY…1922
CLEANING AND INSPECTION…1923
ASSEMBLY…1923
INSTALLATION…1925
CHECKS AND ADJUSTMENTS…1925
ADJUST THE DIRECTION CONTROL LINKAGE…1925
897129-0900SRM0348-(09-2001)-UK-EN…1926
toc…1926
LPG Fuel System…1926
Safety Precautions Maintenance and Repair…1927
General…1930
Description and Operation…1932
Fuel Tank…1932
Fuel Filter and Fuel Valve Unit…1933
Vaporizer…1934
Carburetor…1935
Governor…1937
LPG Tank Repair…1938
Remove…1938
LPG Tanks with Fixed Mounting Bracket…1938
LPG Tanks with EZ Lift Mounting Bracket…1938
Install…1939
LPG Tanks with Fixed Mounting Bracket…1939
LPG Tanks with EZ Lift Mounting Bracket…1940
Hydrostatic Relief Valve Repair…1941
Remove and Install…1941
Filter Unit Repair…1941
Fuel Filter Element, Replace…1941
Diaphragm and Fuel Valve, Replace…1941
Hoses Replacement…1943
Vaporizer Repair…1943
Remove…1943
Disassemble…1943
Clean…1943
Inspect…1943
Assemble…1945
Install…1948
Carburetor Repair…1949
Remove…1949
Disassemble…1949
Clean…1949
Assemble…1949
Install…1949
Governor Repair…1950
Filter Unit Check…1952
Vaporizer Check…1952
Pressure Reducer Valve…1952
Vapor Valve…1952
Carburetor Adjustment…1952
Idle Mixture…1952
Idle Speed…1952
Power Mixture…1953
Throttle Linkage Adjustment…1953
Troubleshooting…1955
897341-0600SRM0412-(08-1997)-UK-EN…1962
PERKINS DIESEL ENGINES, SERIES 1000…1962
1.1 GENERAL…1962
GENERAL SAFETY RULES…1962
Viton Seals…1962
1.2 DESCRIPTION…1965
1.3 Engine Serial Number Codes…1965
1.4 Engine Data…1965
1.5 1004–4 ENGINE…1966
1.6 1004–4T ENGINE…1966
1.7 1006–6 ENGINE…1966
1.8 1006–6T ENGINE…1966
1.9 REMOVAL AND INSTALLATION…1966
CYLINDER HEAD ASSEMBLY…1967
1.10 VALVE COVER…1967
1.11 Removal…1967
1.12 Installation…1967
1.13 ROCKER ARM ASSEMBLY…1967
1.14 Removal…1967
1.15 Installation…1967
1.16 Disassembly…1968
1.17 Inspection…1968
1.18 Assembly…1968
1.19 VALVE CLEARANCE ADJUSTMENTS…1968
1.20 Four Cylinder Engines…1969
1.21 Six Cylinder Engines…1969
1.22 VALVE SPRINGS…1969
1.23 CYLINDER HEAD ASSEMBLY…1971
1.24 Removal…1971
1.25 Installation…1972
1.26 VALVES AND VALVE SPRINGS…1975
1.27 Removal…1975
1.28 Inspection…1976
1.29 Installation…1976
1.30 VALVE GUIDES…1976
1.31 Inspection…1976
1.32 Removal…1977
1.33 Installation…1977
1.34 CYLINDER HEAD AND VALVE SEATS…1977
1.35 Inspection…1977
1.36 Repair…1978
1.37 Installation Of New Valve Seats…1978
PISTON AND CONNECTING ROD ASSEMBLIES…1979
1.38 ROD BEARINGS…1979
1.39 Removal…1979
1.40 Installation…1980
1.41 PISTON AND CONNECTING ROD ASSEMBLY…1980
1.42 Service Note…1980
1.43 Removal…1980
1.44 Installation…1981
1.45 PISTON RINGS…1982
1.46 Removal…1982
1.47 Inspection…1982
1.48 Installation…1983
1.49 PISTON AND CONNECTING ROD…1984
1.50 Disassembly…1984
1.51 Inspection…1984
1.52 Installation…1984
1.53 PISTON COOLING JETS…1985
1.54 Removal…1985
1.55 Installation…1985
CRANKSHAFT ASSEMBLY…1986
1.56 GENERAL…1986
1.57 CRANKSHAFT PULLEY…1986
1.58 Removal, Engines AA and AB…1986
1.59 Installation, Engines AA and AB…1986
1.60 Removal, Engines YA and YB…1986
1.61 Installation, Engines YA and YB…1986
1.62 REAR OIL SEAL…1987
1.63 Replacement…1987
1.64 MAIN BEARINGS…1988
1.65 Removal…1988
1.66 Installation…1988
1.67 THRUST WASHERS…1989
1.68 Check The Axial Movement Of The Crankshaft…1989
1.69 Removal…1990
1.70 Installation…1990
1.71 CRANKSHAFT…1990
1.72 Removal…1990
1.73 Inspection…1991
1.74 Installation…1991
TIMING CASE AND TIMING GEARS…1993
1.75 GENERAL…1993
1.76 TIMING CASE COVER…1993
1.77 Removal…1993
1.78 Installation…1993
1.79 FRONT OIL SEAL…1994
1.80 Removal…1994
1.81 Installation…1994
1.82 IDLER GEAR AND HUB…1994
1.83 Removal…1994
1.84 Installation…1995
1.85 GEAR FOR THE FUEL INJECTION PUMP OR THE CAMSHAFT GEAR…1996
1.86 Removal…1996
1.87 Installation…1996
1.88 CRANKSHAFT GEAR…1997
1.89 Removal…1997
1.90 Installation…1997
1.91 TIMING CASE…1997
1.92 Removal…1997
1.93 Installation…1997
1.94 CAMSHAFT AND TAPPETS…1998
1.95 Removal…1999
1.96 Installation…1999
ENGINE BLOCK ASSEMBLY…2000
1.97 DESCRIPTION…2000
1.98 ENGINE BLOCK…2000
1.99 Disassembly…2000
1.100 Inspection…2001
1.101 Assembly…2001
1.102 CYLINDER LINER…2001
1.103 Inspection…2001
1.104 Hone…2002
1.105 Removal…2002
1.106 Installation…2003
TURBOCHARGER, ENGINES AB AND YB…2004
1.107 GENERAL…2004
1.108 Removal…2004
1.109 Installation…2005
1.110 Clean The Impeller And Compressor Housing…2005
LUBRICATION SYSTEM…2006
1.111 GENERAL…2006
1.112 OIL FILTER, REPLACEMENT…2006
1.113 OIL SUMP…2007
1.114 Removal…2007
1.115 Installation…2007
1.116 OIL PUMP…2007
1.117 Removal…2007
1.118 Inspection…2008
1.119 Installation…2008
1.120 RELIEF VALVE…2009
1.121 Removal…2009
1.122 Disassembly…2009
1.123 Inspection…2010
1.124 Installation…2010
FUEL SYSTEM…2010
1.125 DESCRIPTION…2010
1.126 CAV FUEL INJECTION PUMP…2011
1.127 Removal…2011
1.128 Installation…2011
1.129 CAV FUEL INJECTION PUMP, CHECKS AND ADJUSTMENTS…2012
1.130 Timing Gear Marks…2012
1.131 How To Set Number 1 Piston To TDC On The Compression Stroke…2013
1.132 Check The Valve Timing…2013
1.133 Check The Timing Of The Fuel Injection Pump…2014
1.134 Check The Timing Mark Of The Fuel Injection Pump…2014
1.135 Check The Engine Timing Mark…2015
1.136 REMOVE AIR FROM THE FUEL SYSTEM…2016
1.137 Fuel Injection Pump With Vent Tube…2016
1.138 Fuel Injection Pump With Vent Screw…2017
1.139 FUEL FILTER (REPLACEMENT)…2018
1.140 FUEL INJECTORS…2018
1.141 Removal…2018
1.142 Inspection…2019
1.143 Installation…2020
1.144 FUEL PUMP…2020
1.145 Removal…2020
1.146 Disassembly…2020
1.147 Assembly…2021
1.148 Installation…2021
1.149 Test…2022
COOLING SYSTEM…2022
1.150 GENERAL…2022
1.151 THERMOSTAT…2022
1.152 Replacement…2022
1.153 COOLANT PUMP…2023
1.154 Removal…2023
1.155 Disassembly…2023
1.156 Assembly…2024
1.157 Installation…2024
1.158 FAN AND FAN DRIVE…2024
1.159 Removal…2024
1.160 Disassembly…2024
1.161 Assembly…2025
1.162 Installation…2025
1.163 OIL COOLER…2025
1.164 Removal, Engine AB…2025
1.165 Removal, Engines YA and YB…2025
1.166 Disassembly And Assembly…2026
1.167 Installation, Engine AB…2026
1.168 Installation, Engines YA and YB…2027
1.169 By–Pass Valve, Oil Cooler…2027
FLYWHEEL AND FLYWHEEL HOUSING…2027
1.170 GENERAL…2027
1.171 FLYWHEEL…2027
1.172 Removal…2027
1.173 Ring Gear (Replacement)…2027
1.174 Installation…2027
1.175 FLYWHEEL HOUSING…2028
1.176 Removal…2028
1.177 Installation…2028
ELECTRICAL EQUIPMENT…2029
1.178 DRIVE BELTS…2029
1.179 ALTERNATOR…2030
1.180 STARTER MOTOR…2030
1.181 Removal…2030
1.182 Installation…2030
1.183 COLD START AID…2030
AIR COMPRESSOR, ENGINES YA AND YB…2030
1.184 GENERAL…2030
1.185 Air Compressor, Removal, WABCO…2030
1.186 Compressor Drive, Inspection…2031
1.187 Air Compressor, Installation, WABCO…2031
1.188 Compressor Drive, Disassembly, WABCO…2031
1.189 Compressor Drive, Assembly, WABCO…2032
1.190 Air Compressor, Removal, BENDIX…2032
1.191 Air Compressor, Installation, BENDIX…2033
1.192 Compressor Drive, Disassembly, BENDIX…2034
1.193 Compressor Drive, Assembly, BENDIX…2034
ENGINE SPECIFICATIONS…2036
1.194 CYLINDER HEAD ASSEMBLY…2036
1.195 Cylinder Head…2036
1.196 Valve Guides…2036
1.197 Inlet Valves…2037
1.198 Exhaust Valves…2037
1.199 Double Valve Springs To Outer…2037
1.200 Double Valve Springs To Inner…2037
1.201 Single Valve Springs…2037
1.202 Tappets…2037
1.203 Rocker Arm Shaft…2037
1.204 Rocker Arms And Bushings…2038
1.205 PISTON AND CONNECTING RODS…2038
1.206 Pistons, Engines AA And YA…2038
1.207 Pistons, Engines AB And YB…2038
1.208 Piston Rings, Engines AA And YA…2038
1.209 Piston Rings, Engines AB And YB…2038
1.210 Connecting Rods, Engines AB And YB…2039
1.211 Connecting Rods, Engines AB And YB…2039
1.212 Piston Pins, Engines AA And YA…2039
1.213 Piston Pins, Engines AB and YB…2039
1.214 Small End Bushings, Engines AA And YA…2039
1.215 Small End Bushings, Engines AB And YB…2039
1.216 Connecting Rod Bearings, Engines AA And YA…2040
1.217 Connecting Rod Bearings, Engines AB And YB…2040
1.218 Piston Cooling Jets, Engines AB And YB…2040
1.219 CRANKSHAFT ASSEMBLY…2040
1.220 Crankshaft…2040
1.221 Crankshaft Heat Treatment…2040
1.222 Crankshaft Overhaul…2040
1.223 Main Bearings…2042
1.224 Crankshaft Thrust Washers…2042
1.225 TIMING CASE AND DRIVE ASSEMBLY…2042
1.226 Camshaft…2042
1.227 Camshaft Thrust Washer…2042
1.228 Camshaft Gear…2043
1.229 Gear For Fuel Injection Pump…2043
1.230 Crankshaft Gear…2043
1.231 Idler Gear And Hub…2043
1.232 ENGINE BLOCK ASSEMBLY…2043
1.233 Engine Block…2043
1.234 Cylinder Liners…2043
1.235 TURBOCHARGER…2044
1.236 LUBRICATION SYSTEM…2044
1.237 Oil Pump, Engines AA And AB…2044
1.238 Oil Pump, Engines YA And YB…2044
1.239 Relief Valve…2044
1.240 Oil Filter…2044
1.241 FUEL SYSTEM…2044
1.242 Cav Fuel Injection Pump…2044
1.243 FUEL INJECTORS…2045
1.244 Fuel Pump, Engines AA And AB…2046
1.245 Fuel Pump, Engines YA And YB…2046
1.246 Fuel Filter…2046
1.247 COOLING SYSTEM…2046
1.248 Coolant Pump…2046
1.249 Thermostat…2047
1.250 Fan Drive Housing…2047
1.251 FLYWHEEL AND HOUSING…2047
1.252 Limits for flywheel ''run out'' and alignment (total indicator reading)…2047
1.253 ELECTRICAL EQUIPMENT…2047
1.254 Alternator…2047
1.255 Starter Motor…2047
1.256 Cold Start Aid…2047
TORQUE SPECIFICATIONS…2048
SPECIAL TOOLS…2049
897412-2200SRM0463-(04-1993)-UK-EN…2053
MICROPROCESSOR SPARK TIMING SYSTEM (MSTS)…2053
GENERAL…2053
DESCRIPTION…2053
What MSTS Does…2055
How MSTS Begins Operation…2055
OPERATION…2055
Pulse Generator…2055
HEI Module…2056
When the Engine Is Being Started…2056
When the Engine Is Running…2058
Manifold Absolute Pressure (MAP)…2058
Coolant Temperature Sensor (CTS)…2058
Electronic Control Module (ECM), Corrections…2059
The Initial Timing Connector…2059
Gasoline and LPG Conversions…2060
TROUBLESHOOTING…2062
GENERAL…2062
TOOLS AND TEST EQUIPMENT…2062
MSTS TROUBLESHOOTING…2063
Test Description…2063
IGNITION SYSTEM TROUBLESHOOTING…2065
Test Description…2065
ELECTRONIC SPARK TIMING (EST) TROUBLESHOOTING…2068
Circuit Description…2068
Test Description…2068
MANIFOLD ABSOLUTE PRESSURE (MAP) TROUBLESHOOTING…2071
Circuit Description…2071
Test Description…2071
COOLANT TEMPERATURE SENSOR (CTS) TROUBLESHOOTING…2074
Circuit Description…2074
Test Description…2074
REPAIRS…2076
DISTRIBUTOR…2076
Removal…2076
Disassembly…2077
Inspection…2077
Assembly…2078
Installation…2078
Igntion Timing…2078
HEI MODULE…2079
Test For A Fault…2079
HEI Module Replacement…2079
SENSING COIL…2080
Test For A Fault…2080
Sensing Coil Replacement…2080
IGNITION COIL…2080
Test For A Fault…2080
ELECTRONIC CONTROL MODULE (ECM)…2081
Removal…2081
Installation…2081
COOLANT TEMPERATURE SENSOR (CTS)…2081
Removal…2081
Installation…2082
MANIFOLD ABSOLUTE PRESSURE (MAP)…2082
Removal…2082
Installation…2082
PRESSURE CONVERSION CHART…2083
897420-2200SRM0468-(05-1996)-UK-EN…2084
ELECTRONIC ENGINE CONTROL, TROUBLESHOOTING AND REPAIR…2084
GENERAL…2084
Engine Data…2084
LIGHT BULB CHECK…2084
SYSTEM CHECK…2086
TROUBLESHOOTING WITH THE FAULT MONITOR SYSTEM IN THE ECM…2086
How To Clear A Code…2087
Fault In The ECM…2087
Fault In The PROM…2088
CalPak Not Installed…2088
Fuel Control…2088
Idle Air Control (IAC)…2088
Fuel Pump Circuit…2088
Coolant Temperature Sensor (CTS)…2089
Manifold Absolute Pressuer Sensor (MAP)…2089
Throttle Position Sensodr (TPS)…2089
Output Check, Throttle Position Sensor…2089
Electronic Spark Timing…2089
Engine Crank Signal…2090
Distributor Reference Signal…2090
TROUBLESHOOTING CHARTS…2091
CHART A-1-No "Check Engine" Light…2091
Circuit Description, "Check Engine" Light…2091
CHART A-1-No "Check Engine" Light…2092
CHART A-2-No ALDL Data Or No Code 12 From "Check Engine" Light. The "Check Engine" Light Is Continuosly Illuminated…2093
Circuit Description, "Check Engine" Light…2093
CHART A-2-No ALDL Data Or No Code 12 From "Check Engine" Light. The "Check Engine" Light Is Continuously Illuminated…2094
CHART A-3-Starter Cranks The Engine, But Will Not Run…2095
Circuit Description…2096
CHART A-4-Fuel Injector Circuit…2097
Circuit Description…2097
CHART A-5-Fuel Pump Relay Circuit…2099
Circuit Description…2099
CHART A-6-Fuel System Pressure Test…2101
Circuit Description…2101
CHART A-7-MAP Output Check…2103
Circuit Description…2103
CHART A-8-Engine Crank Signal Check…2105
Circuit Description…2105
CHART A-9-Ignition System Troubleshooting…2106
CHART A-9 Ignition System Troubleshooting Chart…2107
CHART A-10-Idle Air Control (IAC) System…2109
Circuit Description…2109
FAULT CODES…2111
CODE 14-Coolant Temperature Sensor Circuit (Indicates High Temperature)…2111
Circuit Description…2111
CODE 15-Coolant Temperature Sensor Circuit (Indicates Low Temperature…2113
Circuit Description…2113
CODE 21-Throttle Position Sensor Circuit (Signal Voltage High) …2115
Circuit Description…2115
CODE 22-Throttle Position Sensor Circuit (Signal Voltage Low) …2117
Circuit Description…2117
CODE 31-Engine Governor Circuit…2119
Circuit Description…2119
CODE 33-MAP Sensor Circuit, Signal Voltage High (Low Vacuum…2121
Circuit Description…2121
CODE 34-MAP Sensor Circuit, Signal Voltage Low (High Vacuum)…2123
Circuit Description…2123
CODE 42-Electronic Spark Timing (EST)…2125
Circuit Description…2125
CODE 54-Fuel Pump Circuit (Low Voltage)…2127
Circuit Description…2127
CODE 51-PROM In The ECM Has A Fault …2129
CODE 52-Fuel CalPak Is Missing…2129
CODE 55-ECM Has A Fault…2129
TROUBLESHOOTING, POOR OPERATION…2129
General…2129
Make A Careful Visual Check…2129
FAULT: Fuel Usage Too High…2129
FAULT: Codes Or Performance That Is Not Regular…2130
FAULT: "Dieseling"…2130
FAULT: "Backfire"…2130
FAULT: Rough Idle or Engine Stalls During Idle…2130
FAULT: Smoke In The Exhaust Gases…2131
FAULT: Engine is Difficult To Start…2131
FAULT: Variation In Engine Power When The Throttle Is Held Steady…2132
FAULT: Decreased Engine Power…2132
FAULT: "Detontion"…2132
FAULT: Engine Momentarily Does Not Increase Power When Throttle Changes…2133
FAULT: One Cylinder In The Engine Does Not Operate Correctly. The Engine Does Not Idle Correctly…2133
REPAIRS, FUEL SYSTEM COMPONENTS …2135
General…2135
Vacuum Ports…2135
Throttle Body Injection (TBI) Unit…2135
TBI Unit, Removal…2135
TBI Unit, Cleaning and Inspection…2136
TBI Unit, Installation…2136
Cover For Fuel Meter Body, Replacement…2136
Fuel Injectors…2137
Fuel Injectors, Removal…2137
Fuel Injectors, Installation…2138
Pressure Regulator, Removal…2138
Pressure Regulator, Inspection…2138
Pressure Regulator, Installation …2138
Fuel Meter Body, Removal…2139
Fuel Meter Body, Installation…2139
Throttle Position Sensor (TPS), Removal…2139
Throttle Position Sensor (TPS), Installation…2139
Idle Air Control (IAC) Valve, Removal…2140
Cleaning and Inspection…2140
Idle Air Control (IAC) Valve, Installation…2140
Governor Throttle Drive Assembly, Removal…2140
Governor Throttle Drive Assembly, Inspection…2140
Cleaning and Lubrication…2141
Governor Throttle Drive Assembly, Installation…2141
Governor Drive Motor, Removal…2142
Governor Drive Motor, Cleaning and Lubrication…2142
Governor Drive Motor, Installation…2143
Governor Drive Motor, Inspection…2143
Throttle Body, Removal and Disassembly…2143
Throttle Body, Inspection…2143
Throttle Body, Assembly and Installation…2143
Fuel Pump, Removal and Disassembly…2144
Fuel Pump, Inspection…2144
REPAIRS, ELECTRICAL COMPONENTS…2144
General…2144
Ignition Coil Test…2144
Ignition Module Test…2145
Distributor, Removal…2145
Distributor, Disassembly…2146
Distributor, Assembly…2146
Distributor, Installation…2147
Firing Order…2148
Ignition Timing…2148
Ignition Coil, Removal…2149
Ignition Coil, Installation…2149
Procedures For Spark Plugs, Spark Plug Wires And Boots …2149
Troubleshooting of Spark Plugs…2150
Coolant Temperature Sensor (CTS), Replacement …2151
Manifold Absolute Pressure (MAP) Sensor, Replacement…2151
Oil Pressure Switch, Replacement…2152
Coolant Temperature Sender, Replacement…2152
Wire Harness…2152
Connectors And Terminals…2152
Electronic Control Module (ECM)…2156
ECM CONNECTOR A-B IDENTIFICATION…2160
ECM CONNECTOR C-D IDENTIFICATION…2161
SPECIAL TOOLS…2162
897435-2200SRM0473-(03-1994)-UK-EN…2165
INTRODUCTION…2165
GENERAL…2165
DESCRIPTION AND OPERATION…2165
GENERAL…2165
ECM (ELECTRONIC CONTROL MODULE)…2165
ALDL Connector…2167
How The ECM Begins Operation…2167
ELECTRONIC ENGINE CONTROL…2168
What The ECM Does…2168
Pulse Generator, EST Distributor…2169
EST Module(See FIGURE 9.)…2170
When the Engine Is Being Started…2170
When the Engine Is Running…2172
Electronic Control Module (ECM) With EST Distrubutor, Corrrections…2172
What The ECM Does…2172
FUEL CONTROL…2173
Throttle Body Injection…2173
Fuel Injectors…2174
Fuel Pressure Regulator…2174
Throttle Position Sensor…2174
Idle Air Control…2174
Governor Motor And Throttle Drive Assembly…2175
Vacuum Ports…2177
Fuel Pump…2177
ECM SENSORS AND CONTROLLERS…2179
Manifold Absolute Pressure (MAP)…2179
Coolant Temperature Sensor (CTS)…2179
Initial Timing Connector (EST Distributor)…2179
897501-8000SRM0519-(06-2007)-UK-EN…2181
toc…2181
Diagrams…2181
Safety Precautions Maintenance and Repair…2182
897800-0600SRM0590-(08-2005)-UK-EN…2269
toc…2269
GM Engines…2269
Safety Precautions Maintenance and Repair…2270
General…2273
Description…2273
Engine Removal and Installation…2274
Cylinder Head Repair…2274
Remove and Disassemble…2274
Clean and Inspect…2274
Valve Guides and Seats, Repairs…2275
Valves, Repair…2275
Valve Seats, Repair…2276
Valve Springs…2276
Rocker Arm Studs (Early Models)…2278
Rocker Arm Studs (Late Models)…2278
Assemble and Install…2279
Cylinder Block Cleaning and Inspection…2282
Piston Bore Preparation…2282
Engine Mounts Installation…2283
Lubrication System Repair…2283
Oil Pump, Remove and Disassemble…2283
Clean and Inspect…2283
Oil Pump, Assemble and Install…2284
Oil Sump, Install…2284
Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters…2285
Timing Cover…2285
Remove…2285
Install…2287
Timing Sprockets…2287
Remove…2287
Install…2287
Camshaft…2288
Remove…2288
Inspect…2288
Install…2288
Balance Shaft…2289
Remove…2289
Install…2290
Hydraulic Valve Lifters…2290
Remove…2290
Disassemble…2291
Clean and Inspect…2291
Assemble…2291
Install…2292
Crankshaft Repair…2293
Remove…2293
Inspect and Repair…2293
How to Check Clearance Between Main Bearings and Their Journals…2294
Install…2295
Piston and Connecting Rod Assemblies Repair…2296
Connecting Rod Bearings, Replace…2296
Piston and Connecting Rod Assemblies, Remove…2297
Disassemble…2297
Piston, Clean and Inspect…2298
Cylinder Bores, Inspect and Repair…2298
Piston Rings…2299
Assemble…2300
Piston and Connecting Rod Assemblies, Install…2300
Flywheel and Flywheel Housing Repair…2301
Flywheel, Repair…2301
Flywheel, Install…2301
H3.50-5.00XL (H70-110XL), S3.50-5.50XL (S70-120XL), S6.00-7.00XL…2301
H6.00-7.00XL (H135-155XL)…2301
Flywheel Housing H3.50-5.00XL (H70-110XL), H3.50-5.50XM (H70-120…2301
Engine Adapter H6.00-7.00XL (H135-155XL)…2301
Coolant Pump Repair…2302
Thermostat Replacement…2302
Fan Mount Repair (Early Models)…2302
Fan Mount Assembly Repair (Late Models)…2302
Drive Belt Installation…2304
Valve Clearance Adjustment (Early Models)…2305
Valve Clearance Adjustment (New Models)…2306
Compression Check…2306
Engine Specifications…2307
Engine Data…2307
Cylinder Head…2307
Hydraulic Valve Lifter…2308
Camshaft…2308
Pistons…2308
Crankshaft…2309
Connecting Rods…2309
Balance Shaft…2310
Cooling System…2310
Lubrication System…2310
Torque Specifications…2310
Troubleshooting…2311
tables…2269
Table 1. Piston Rings Arrangement on Piston…2300
897934-0700SRM0626-(11-2001)-UK-EN…2317
toc…2317
Cooling System…2317
Safety Precautions Maintenance and Repair…2318
General…2321
Description…2322
Radiator…2322
Radiator Cap…2322
Thermostat…2322
Water Pump…2323
Fan and Fan Shroud…2323
Cooling System Checks…2323
Radiator…2323
Thermostat…2323
Water Pump…2324
Exhaust Leaks…2324
Fan and Fan Shroud…2324
Radiator Cleaning…2324
Drain…2324
Clean…2324
Fill…2325
Troubleshooting…2326
899783-2000SRM0090-(10-2003)-UK-EN…2329
toc…2329
Main Control Valve…2329
Safety Precautions Maintenance and Repair…2330
General…2333
Description…2333
Operation…2336
Lift Spool…2336
Tilt Spool…2337
Tilt Backward…2337
Tilt Forward…2338
Single-Stage Relief Valve…2340
Two-Stage Relief Valve…2341
Main Control Valve Repair…2342
Remove and Disassemble…2342
Clean and Inspect…2342
Assemble…2342
Install…2343
Single-Stage Relief Valve Adjustment…2343
Two-Stage Relief Valve…2344
Auxiliary Control Valve Relief Valve Adjustment (H60-110E Only)…2344
Troubleshooting…2345
tables…2329
Table 1. Relief Pressures (Oil temperature at 55 to 66 C ( 131 t…2343
899784-2200SRM0002-(10-2003)-UK-EN…2349
toc…2349
Alternator with Regulator…2349
Safety Precautions Maintenance and Repair…2350
General…2353
Description…2353
Alternator Repair…2355
Alternator Type A…2355
Remove and Disassemble…2355
Clean…2356
Assemble…2357
Install…2357
Alternator Type B…2360
Remove and Disassemble…2360
Clean…2360
Assemble…2361
Install…2362
General Check and Adjustment…2363
Low Output Check (Type A or Type B)…2363
High Output Check (Type A or Type B)…2365
Brushes Circuit Check…2366
Delco Alternators…2366
Motorola Alternators…2367
Diodes Check…2368
Diode Bridge Check…2368
Delco and Leece-Neville Alternators…2368
Motorola Alternators…2368
Rotor Field Winding Check…2369
Stator Windings Check…2370
Voltage Regulator Check…2370
Troubleshooting…2370
899788-2200SRM0107-(03-2002)-UK-EN…2375
toc…2375
High Energy Ignition (HEI) System…2375
Safety Precautions Maintenance and Repair…2376
Description…2379
Distributor Repair…2381
Remove…2381
Disassemble…2381
Assemble…2386
Install, If Crankshaft WAS NOT Rotated when Distributor was Remo…2387
Install, If Crankshaft WAS Rotated when Distributor was Removed…2387
Ignition Coil Replacement…2388
Some Four- and Six-Cylinder Models…2388
Remove…2388
Install…2389
V8, Some Four- and Six-Cylinder Models…2389
Remove…2389
Install…2390
Electronic Module Replacement…2391
Remove…2391
Install…2391
Sensing Coil Replacement…2392
Remove…2392
Install…2392
Spark Plugs Replacement…2392
Remove…2392
Install…2393
Visual Check…2393
High Voltage Wires Check…2393
Ignition Coil Check…2394
Coil in Distributor Cap Design…2394
Separate Coil Design…2394
Sensing Coil, Check…2395
Electronic Module Check…2395
Ignition Timing Adjustment…2395
GM V8-366 (6-liter) Ignition System Check…2397
GM V6-LPG (4.3 liter) GM V6-LPG (4.3 liter) Ignition Timing and …2397
Specifications…2397
Troubleshooting…2398
910072-1400SRM0046-(07-2007)-UK-EN…2403
toc…2403
Differential…2403
Safety Precautions Maintenance and Repair…2404
General…2407
Description…2407
Differential Repair…2408
Remove…2408
Differential Carrier From Axle Housing, Remove…2408
Differential and Ring Gear From Differential Carrier, Remove…2410
Drive Pinion and Pinion Carrier From Differential Carrier, Remov…2412
Disassemble…2413
Differential and Ring Gear Assembly, Disassemble…2413
Drive Pinion and Pinion Carrier, Disassemble…2415
Clean and Inspect…2418
Assemble…2419
Pinion, Bearings, and Pinion Carrier, Assemble…2419
Pinion Bearings, Adjust Preload…2419
Press Method…2419
Yoke or Flange Method…2420
Triple-Lip Seal, Install…2421
Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion)…2422
Differential and Ring Gear, Assemble…2424
Differential Gears Rotating Torque, Check…2426
Differential and Ring Gear Assembly, Install…2427
Differential Bearings, Preload Adjust…2429
Ring Gear, Runout Check…2430
Ring Gear Backlash, Adjust…2430
Gear Set, Tooth Contact Pattern Check…2432
Thrust Screw, Install and Adjust…2435
Install…2435
Differential Assembly Into Axle Housing, Install…2435
Specifications…2437
Troubleshooting…2442
tables…2403
Table 1. Ring Gear Backlash Adjustment Specifications…2432
Table 2. Ring and Pinion Tooth Contact Adjustment…2433
Table 3. General Specifications…2437
Table 4. Rivet Installation Pressure…2437
Table 5. Pinion Adjustment…2438
Table 6. Pinion Preload Pressure…2438
Table 7. Torque Specifications…2439
Table 8. Torque Specifications for Metric Hardware…2440
Table 9. Torque Specifications for Metric (Fine) Hardware…2441
910073-1400SRM0049-(09-2003)-UK-EN…2445
toc…2445
Drive Axle…2445
Safety Precautions Maintenance and Repair…2446
General…2449
Description…2449
Drive Axle Repair…2450
Disassemble (Type 1 Shown)…2450
Clean…2453
Inspect…2453
Assemble (Type 1 Shown)…2454
Torque Specifications…2457
Troubleshooting…2458
910076-1600SRM0054-(10-2003)-UK-EN…2461
toc…2461
Steering Control Unit…2461
Safety Precautions Maintenance and Repair…2462
General…2465
Description…2465
Operation…2465
Steering Wheel and Column Assembly Repair…2467
Steering Column Assembly Repair…2467
Type A Steering Column Assembly…2467
Remove and Disassemble…2467
Assemble and Install…2469
Type B Steering Column Assembly…2471
Remove and Disassemble…2471
Assemble and Install…2471
Steering Control Unit…2474
Disassemble…2474
Clean…2477
Assemble…2478
System Air Removal…2483
Troubleshooting…2483
910091-1900SRM0097-(07-2006)-UK-EN…2487
toc…2487
Hydraulic Gear Pumps…2487
Safety Precautions Maintenance and Repair…2488
Description…2491
Operation…2492
Flow Control Valve…2492
Relief Valve…2493
Hydraulic Gear Pump Repair…2493
Remove…2493
Disassemble…2494
Clean…2494
Inspect…2495
Assemble…2498
Install…2500
Pump Output Check…2500
Method No. 1…2500
Method No. 2…2501
Hydraulic System Air Check…2502
Troubleshooting…2503
910092-1900SRM0098-(07-2003)-UK-EN…2509
toc…2509
Hydraulic Vane Pumps…2509
Safety Precautions Maintenance and Repair…2510
General…2513
Description…2513
Operation…2514
Pump…2514
Relief Valve…2514
Hydraulic Vane Pumps Repair…2515
Remove…2515
Disassemble…2515
Assemble…2516
Install…2519
Relief Valve Relief Pressure Check…2519
Lift Trucks With Internal Combustion Engines…2519
Electric Lift Trucks…2519
Electric Lift Trucks With Adjustable Relief Valve…2520
Specifications…2521
Pressure Relief Valve…2521
Troubleshooting…2521
910102-2100SRM0103-(03-2007)-UK-EN…2525
toc…2525
Tilt Cylinders…2525
Safety Precautions Maintenance and Repair…2526
General…2529
Description…2529
Tilt Cylinder Repair…2529
Remove…2529
Disassemble…2529
Clean…2529
Assemble…2529
Tilt Cylinders With O-Ring or Single-Lip Seals…2529
Tilt Cylinders for XM and XMS Models…2531
Tilt Cylinders for XL, XLS, and XL 3 Models…2532
Tilt Cylinders for H700-800A and Early Model H700-920B…2534
Install…2535
Tilt Cylinders Using Chevron Packing…2535
Install…2536
Tilt Cylinder Leak Check…2538
Tilt Cylinder Stroke and Mast Tilt Angle Adjustment…2540
Torque Specifications…2540
Piston Rod Nut…2540
Retainer…2541
Troubleshooting…2543
tables…2525
Table 1. Movement Rates (Maximum) for Tilt Cylinders…2539
910107-2200SRM0106-(02-2001)-UK-EN…2547
toc…2547
Starter…2547
Safety Precautions Maintenance and Repair…2548
General…2551
Description and Operation…2551
Starter Repair…2553
Remove…2553
Disassemble…2553
Clean…2554
Assemble…2554
Install…2555
General Checks and Adjustments…2555
Troubleshooting…2558
910110-2200SRM0143-(02-2007)-UK-EN…2563
toc…2563
Instrument Panel Indicators and Senders…2563
Safety Precautions Maintenance and Repair…2564
General…2567
Description…2568
Steering Column Gauges, Meters, and Indicators…2568
LED Display Panel…2568
Battery Discharge Indicators…2568
Brush Wear Indicators…2574
Motor Temperature Indicators…2574
LX Series Display Panel…2576
Hourmeter Functions…2577
Battery Indicator Function…2577
Status Code Function…2577
ZX Series Display Panels…2579
Display Panel…2579
Basic Display Panels…2579
Performance Display…2581
Brush Wear Indicators…2585
Adjustments – General…2585
Replacement – General Information…2585
Meter Replacement…2586
Sender Replacement…2587
Fuel Level Sender…2587
Pressure and Temperature Sender…2587
Seat Sensor, Operator Presence System (OPS)…2588
Remove…2588
Install…2588
Operator Presence System Module Replacement…2588
Remove…2589
Install…2590
ITW Display Panel Replacement…2591
Remove…2591
Column Mount Display Panel (EV-100/200ZX Motor Controllers) Repl…2591
Remove…2591
Display Panel Assembly, Replace…2591
Indicator LEDs…2592
Battery Indicators…2592
Digital Display (Performance Display Panel Only)…2592
Status Code or Performance Level Switches and Indicator LEDs (Pe…2593
Basic Display Panel, Replace Parts…2593
Performance Display Panel, Replace Parts…2595
Dash Mount Display Panel (EV100/200ZX Motor Controllers) Replace…2595
Remove and Replace…2595
Specifications…2596
Meter Specifications…2596
Sender Specifications…2596
Troubleshooting…2597
Meter…2597
Troubleshooting for Operator Presence System…2598
tables…2563
Table 1. Troubleshooting Procedure for Operator Presence Module…2598
910111-2200SRM0144-(05-1997)-UK-EN…2603
ELECTRICAL WARNING DEVICES…2603
GENERAL…2603
DESCRIPTION…2603
Operator Controlled Horns…2603
System Warning Lights, Buzzers and Bells…2603
Reverse Warning Horns…2604
Warning Lights…2604
REPLACEMENT…2605
General…2605
Replacing Horns or Bells…2605
Replacing Horn Relay or Buzzer…2605
Replacing Warning Lights…2605
Light Assemblies…2606
Replacing Flashing Units…2606
910119-4000SRM0135-(10-2003)-UK-EN…2607
toc…2607
Lift Cylinders…2607
Safety Precautions Maintenance and Repair…2608
Safety Procedures When Working Near Mast…2611
General…2615
Description…2615
Lowering Control Valve…2615
Cylinders (General)…2618
Cylinders (H520-620B, H700-800A)…2618
Retainer, Install…2618
Cylinders (H360-460B)…2620
Cylinders (Two-Speed)…2622
Lift Cylinder Repair…2624
Lift Cylinder Removal Without Removing Mast…2624
Standard Masts With Main Lift Cylinder Fastened to Crossmember o…2624
Standard and Full Free-Lift Masts With Lift Cylinder Fastened to…2624
Masts That Have Two Cylinders, Main Lift Cylinder and Free-Lift …2624
Disassemble…2626
Assemble…2626
Lift Cylinder Installation in Mast…2628
Standard Masts With Main Lift Cylinder Fastened to Crossmember o…2628
Standard and Full Free-Lift Masts With Lift Cylinder Fastened to…2628
Chevron-Style Packing…2628
Chevron-Style Packing Installation on Piston…2629
Chevron-Style Packing Installation in Packing Gland…2631
Lift Cylinders for VISTA® Masts…2632
Description…2632
Lowering Control Valve…2632
Remove…2634
Disassemble…2635
Assemble…2636
Install…2637
Main Lift Cylinders…2637
Free-Lift Cylinder…2637
Lift System Leak Check…2638
Specifications…2639
Troubleshooting…2640
tables…2607
Table 1. Lift Trucks with Two-Speed Lift Cylinders…2623
Table 2. Cylinder Retainer Torque Specifications and Weight Guid…2639
910150-0600SRM0105-(06-1997)-UK-EN…2643
INTRODUCTION…2643
GENERAL…2643
DESCRIPTION…2643
ENGINE SERIAL NUMBER CODES…2644
REMOVAL AND INSTALLATION…2644
ENGINE…2644
CYLINDER HEAD…2644
Removal…2644
Installation…2645
Cylinder Head Repairs…2646
OIL PUMP…2648
Removal…2648
Disassembly…2648
Inspection…2648
Assembly…2649
Installation…2649
RELIEF VALVE…2650
TIMING GEAR CASE AND TIMING GEARS…2650
Removal…2650
Installation…2651
PISTONS AND CONNECTING RODS…2652
Removal…2652
Disassembly…2652
Inspection…2653
Assembly…2654
Installation…2654
CRANKSHAFT AND MAIN BEARINGS…2655
Removal…2655
Inspection…2655
Assembly…2656
CAMSHAFT AND CAM FOLLOWERS…2657
Removal…2657
Inspection…2658
Assembly…2658
FLYWHEEL AND FLYWHEEL HOUSING…2659
Removal…2659
Repairs…2659
Installation…2659
STEERING PUMP DRIVE…2659
Removal…2659
Installation…2660
PCV VALVE…2660
FUEL SYSTEM…2660
FUEL PUMP…2660
Removal…2660
Disassembly…2660
Assembly…2660
Installation…2661
FUEL INJECTION PUMP…2661
Removal…2661
Repairs…2661
Installation…2661
FUEL INJECTORS…2661
Removal…2661
Repairs…2662
Installation…2662
COLD START AID…2662
Description…2662
Removal…2662
Installation…2662
COOLING SYSTEM…2663
THERMOSTAT…2663
Removal…2663
Inspection…2663
Installation…2663
WATER PUMP…2663
Removal…2663
Disassembly…2663
Assembly…2663
Installation…2663
CHECKS AND ADJUSTMENTS…2663
CHECKING THE INJECTORS…2663
Repairs…2664
Installation…2664
REMOVING AIR FROM THE FUEL SYSTEM…2664
CHECKING THE TIMING MARKS…2665
Method A…2665
Method B…2666
CHECKING THE TIMING ANGLE OF THE FUEL INJECTION PUMP WITH THE SPECIAL TOOL…2667
VALVE CLEARANCE ADJUSTMENT…2668
ADJUSTING THE THROTTLE LINKAGE…2668
TROUBLESHOOTING…2670
SPECIFICATIONS…2671
TORQUE SPECIFICATIONS…2674
910233-1300SRM0061-(02-1997)-UK-EN…2675
INTRODUCTION…2675
GENERAL…2675
DESCRIPTION…2675
Oil Clutch Assembly, H6.00-7.00XL (H135-155XL)…2675
Manual Transmission…2677
REPAIRS…2677
OIL CLUTCH ASSEMBLY…2677
Removal and Disassembly…2677
Cleaning…2677
Inspection…2677
Assembly and Installation…2678
TRANSMISSION…2678
Removal, H6.00-7.00XL (H135-155XL)…2678
Disassembly…2679
Cleaning…2681
Inspection…2681
Assembly…2682
Installation, H6.00-7.00XL (H135-155XL)…2686
CHECKS AND ADJUSTMENTS…2687
ADJUSTING THE CLUTCH PEDAL LINKAGE, H6.00-7.00XL (H135-155XL)…2687
TROUBLESHOOTING-OIL CLUTCH ASSEMBLY…2688
TROUBLESHOOTING-MANUAL TRANSMISSION…2690
910442-8000SRM0231-(12-2004)-UK-EN…2692
toc…2692
Metric and Inch (SAE) Fasteners…2692
Safety Precautions Maintenance and Repair…2693
General…2696
Threaded Fasteners…2696
Nomenclature, Threads…2696
Strength Identification…2697
Cotter (Split) Pins…2697
Fastener Torque Tables…2702
Conversion Table…2704
tables…2692
Table 1. Bolts and Screws…2698
Table 2. Studs and Nuts…2699
Table 3. Torque Nuts…2700
Table 4. Torque Nuts With Nylon Insert…2701
Table 5. Torque Values for Metric Fasteners*…2702
Table 6. Torque Values for Inch Fasteners*…2703
Table 7. Conversion Table for Metric and English Units…2704
Table 8. Cotter Pin Dimensional Data…2705
Table 9. Cotter Pin Dimensional Data…2706
Table 10. Cotter Pin Dimensional Data…2707
Table 11. Cotter Pin Dimensional Data…2709
Hyster Forklift Trucks F006 (H135-155XL & H6.00-7.00XL Europe) Repair Service Manuals