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Hyster B024 (S70XL-120XL S135-155XL) Service Manual – PDF DOWNLOAD
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Hyster B024 (S70XL-120XL S135-155XL) Service Manual – PDF DOWNLOAD
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Description
Hyster B024 (S70XL-120XL S135-155XL) Service Manual – PDF DOWNLOAD
FILE DETAILS:
Hyster B024 (S70XL-120XL S135-155XL) Service Manual – PDF DOWNLOAD
Language : English
Pages : 928
Downloadable : Yes
File Type : PDF
Size: 35 MB
TABLE OF CONTENTS:
Hyster B024 (S70XL-120XL S135-155XL) Service Manual – PDF DOWNLOAD
Alternator with Regulator..................................................................... 1 toc....................................................................................... 1 Alternator with Regulator............................................................. 1 General............................................................................... 3 Description........................................................................... 3 Alternator Repair..................................................................... 5 Alternator Type A................................................................. 5 Remove and Disassemble........................................................ 5 Clean......................................................................... 6 Assemble...................................................................... 7 Install....................................................................... 7 Alternator Type B................................................................. 10 Remove and Disassemble........................................................ 10 Clean......................................................................... 10 Assemble...................................................................... 11 Install....................................................................... 12 General Check and Adjustment.......................................................... 13 Low Output Check (Type A or Type B)................................................... 13 High Output Check (Type A or Type B).................................................. 15 Brushes Circuit Check................................................................. 16 Delco Alternators................................................................. 16 Motorola Alternators.............................................................. 17 Diodes Check.......................................................................... 18 Diode Bridge Check.................................................................... 18 Delco and Leece-Neville Alternators............................................... 18 Motorola Alternators.............................................................. 18 Rotor Field Winding Check............................................................. 19 Stator Windings Check................................................................. 20 Voltage Regulator Check............................................................... 20 Troubleshooting....................................................................... 20 Brake System.................................................................................. 24 toc....................................................................................... 24 Brake System.......................................................................... 24 General............................................................................... 27 Description and Operation............................................................. 27 Brake Booster and Master Cylinder................................................. 27 Master Cylinder................................................................... 27 Service Brake Assembly............................................................ 27 Parking Brake..................................................................... 30 Seat Brake........................................................................ 31 Brake Shoe Assemblies Repair.......................................................... 32 Remove and Disassemble............................................................ 32 Clean and Inspect................................................................. 34 Assemble and Install.............................................................. 34 Master Cylinder Repair................................................................ 39 Master Cylinder For Lift Truck Models S3.50-5.50XL (S70-120XL) (.................. 39 Remove........................................................................ 39 Disassemble................................................................... 39 Assemble...................................................................... 39 Install....................................................................... 39 Master Cylinder For Lift Truck Models E3.50-5.50XL (E70-120XL, E.................. 40 Remove and Disassemble........................................................ 40 Clean and Inspect............................................................. 41 Assemble and Install.......................................................... 42 Brake Booster Repair.................................................................. 42 Remove............................................................................ 42 Disassemble....................................................................... 42 Clean and Inspect................................................................. 42 Assemble.......................................................................... 43 Install........................................................................... 44 Brake System Air Removal.............................................................. 44 Brake Pedal Adjustment................................................................ 44 Brake Pedal for Lift Truck Models H3.50-5.00XL (H70-110XL) (F005.................. 44 Brake Shoes Adjustment................................................................ 46 Parking Brake Adjustment.............................................................. 46 Parking Brake Adjustment, Lift Truck Models S3.50-5.50XL (S70-12.................. 46 Parking Brake Lever and Switch Adjustment E3.50-5.50XL (E70-120X.................. 47 Seat Brake Assembly................................................................... 48 Remove............................................................................ 48 Clean and Inspect................................................................. 48 Install........................................................................... 48 Adjustments....................................................................... 50 Solenoid Adjustment........................................................... 50 Traction cutoff Switch Adjustment............................................. 50 Cable Adjustment.............................................................. 51 Brake Booster Relief Valve Check...................................................... 53 Troubleshooting....................................................................... 53 Cooling System................................................................................ 58 toc....................................................................................... 58 Cooling System........................................................................ 58 General............................................................................... 60 Description........................................................................... 61 Radiator.......................................................................... 61 Radiator Cap...................................................................... 61 Thermostat........................................................................ 61 Water Pump........................................................................ 62 Fan and Fan Shroud................................................................ 62 Cooling System Checks................................................................. 62 Radiator.......................................................................... 62 Thermostat........................................................................ 62 Water Pump........................................................................ 63 Exhaust Leaks..................................................................... 63 Fan and Fan Shroud................................................................ 63 Radiator Cleaning..................................................................... 63 Drain............................................................................. 63 Clean............................................................................. 63 Fill.............................................................................. 64 Troubleshooting....................................................................... 65 drive axle.................................................................................... 67 INTRODUCTION.............................................................................. 67 DESCRIPTION........................................................................... 67 GENERAL............................................................................... 67 REPAIRS................................................................................... 68 REMOVAL............................................................................... 68 CLEANING.............................................................................. 69 INSPECTION............................................................................ 69 ASSEMBLY.............................................................................. 69 TROUBLESHOOTING........................................................................... 70 frame and connected parts..................................................................... 71 INTRODUCTION.............................................................................. 71 GENERAL............................................................................... 71 DESCRIPTION........................................................................... 71 REPAIRS................................................................................... 71 COUNTERWEIGHT......................................................................... 72 Removal........................................................................... 72 Installation...................................................................... 73 MUFFLER............................................................................... 73 RADIATOR AND COOLANT SYSTEM........................................................... 74 Removal........................................................................... 74 Installation...................................................................... 74 OVERHEAD GUARD........................................................................ 75 Removal and Installation.......................................................... 75 OPERATOR RESTRAINT SYSTEM............................................................. 75 ENGINE REMOVAL AND INSTALLATION....................................................... 76 Removal........................................................................... 76 Installation...................................................................... 78 FUEL AND HYDRAULIC TANKS.............................................................. 80 Inspection........................................................................ 80 Repairs, Small Leaks.............................................................. 80 Repairs, Large Leaks.............................................................. 80 Cleaning.......................................................................... 80 Steam Method Of Cleaning.......................................................... 80 Chemical Method Of Cleaning....................................................... 81 Other Methods Of Preparation For Repair........................................... 81 SAFETY LABELS......................................................................... 81 GM Engines.................................................................................... 83 toc....................................................................................... 83 GM Engines............................................................................ 83 General............................................................................... 86 Description........................................................................... 86 Engine Removal and Installation....................................................... 87 Cylinder Head Repair.................................................................. 87 Remove and Disassemble............................................................ 87 Clean and Inspect................................................................. 87 Valve Guides and Seats, Repairs................................................... 88 Valves, Repair.................................................................... 88 Valve Seats, Repair............................................................... 89 Valve Springs..................................................................... 89 Rocker Arm Studs (Early Models)................................................... 91 Rocker Arm Studs (Late Models).................................................... 91 Assemble and Install.............................................................. 92 Cylinder Block Cleaning and Inspection................................................ 95 Piston Bore Preparation............................................................... 95 Engine Mounts Installation............................................................ 96 Lubrication System Repair............................................................. 96 Oil Pump, Remove and Disassemble.................................................. 96 Clean and Inspect................................................................. 96 Oil Pump, Assemble and Install.................................................... 97 Oil Sump, Install................................................................. 97 Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters........................... 98 Timing Cover...................................................................... 98 Remove........................................................................ 98 Install.......................................................................100 Timing Sprockets..................................................................100 Remove........................................................................100 Install.......................................................................100 Camshaft..........................................................................101 Remove........................................................................101 Inspect.......................................................................101 Install.......................................................................101 Balance Shaft.....................................................................102 Remove........................................................................102 Install.......................................................................103 Hydraulic Valve Lifters...........................................................103 Remove........................................................................103 Disassemble...................................................................104 Clean and Inspect.............................................................104 Assemble......................................................................104 Install.......................................................................105 Crankshaft Repair.....................................................................106 Remove............................................................................106 Inspect and Repair................................................................106 How to Check Clearance Between Main Bearings and Their Journals...................107 Install...........................................................................108 Piston and Connecting Rod Assemblies Repair...........................................109 Connecting Rod Bearings, Replace..................................................109 Piston and Connecting Rod Assemblies, Remove......................................110 Disassemble.......................................................................110 Piston, Clean and Inspect.........................................................111 Cylinder Bores, Inspect and Repair................................................111 Piston Rings......................................................................112 Assemble..........................................................................113 Piston and Connecting Rod Assemblies, Install.....................................113 Flywheel and Flywheel Housing Repair..................................................114 Flywheel, Repair..................................................................114 Flywheel, Install.................................................................114 H3.50-5.00XL (H70-110XL), S3.50-5.50XL (S70-120XL), S6.00-7.00XL..............114 H6.00-7.00XL (H135-155XL).....................................................114 Flywheel Housing H3.50-5.00XL (H70-110XL), H3.50-5.50XM (H70-120..................114 Engine Adapter H6.00-7.00XL (H135-155XL)..........................................114 Coolant Pump Repair...................................................................115 Thermostat Replacement................................................................115 Fan Mount Repair (Early Models).......................................................115 Fan Mount Assembly Repair (Late Models)...............................................115 Drive Belt Installation...............................................................117 Valve Clearance Adjustment (Early Models).............................................118 Valve Clearance Adjustment (New Models)...............................................119 Compression Check.....................................................................119 Engine Specifications.................................................................120 Engine Data.......................................................................120 Cylinder Head.....................................................................120 Hydraulic Valve Lifter............................................................121 Camshaft..........................................................................121 Pistons...........................................................................121 Crankshaft........................................................................122 Connecting Rods...................................................................122 Balance Shaft.....................................................................123 Cooling System....................................................................123 Lubrication System................................................................123 Torque Specifications.................................................................123 Troubleshooting.......................................................................124 tables.................................................................................... 83 Table 1. Piston Rings Arrangement on Piston...........................................113 High Energy Ignition (HEI) System.............................................................129 toc.......................................................................................129 High Energy Ignition (HEI) System.....................................................129 Description...........................................................................131 Distributor Repair....................................................................133 Remove............................................................................133 Disassemble.......................................................................133 Assemble..........................................................................138 Install, If Crankshaft WAS NOT Rotated when Distributor was Remo..................139 Install, If Crankshaft WAS Rotated when Distributor was Removed...................139 Ignition Coil Replacement.............................................................140 Some Four- and Six-Cylinder Models................................................140 Remove........................................................................140 Install.......................................................................141 V8, Some Four- and Six-Cylinder Models............................................141 Remove........................................................................141 Install.......................................................................142 Electronic Module Replacement.........................................................143 Remove............................................................................143 Install...........................................................................143 Sensing Coil Replacement..............................................................144 Remove............................................................................144 Install...........................................................................144 Spark Plugs Replacement...............................................................144 Remove............................................................................144 Install...........................................................................145 Visual Check..........................................................................145 High Voltage Wires Check..............................................................145 Ignition Coil Check...................................................................146 Coil in Distributor Cap Design....................................................146 Separate Coil Design..............................................................146 Sensing Coil, Check...............................................................147 Electronic Module Check...............................................................147 Ignition Timing Adjustment............................................................147 GM V8-366 (6-liter) Ignition System Check.............................................149 GM V6-LPG (4.3 liter) GM V6-LPG (4.3 liter) Ignition Timing and ......................149 Specifications........................................................................149 Troubleshooting.......................................................................150 Hydraulic Gear Pumps..........................................................................154 toc.......................................................................................154 Hydraulic Gear Pumps..................................................................154 Description...........................................................................156 Operation.............................................................................157 Flow Control Valve................................................................157 Relief Valve......................................................................158 Hydraulic Gear Pump Repair............................................................158 Remove............................................................................158 Disassemble.......................................................................159 Clean.............................................................................159 Inspect...........................................................................160 Assemble..........................................................................163 Install...........................................................................165 Pump Output Check.....................................................................165 Method No. 1......................................................................165 Method No. 2......................................................................166 Hydraulic System Air Check............................................................167 Troubleshooting.......................................................................168 Hydraulic Pump Drive Assembly.................................................................173 toc.......................................................................................173 Hydraulic Pump Drive Assembly.........................................................173 General...............................................................................175 Description...........................................................................175 Hydraulic Pump Drive Assembly Repair..................................................177 Remove and Disassemble............................................................177 Clean.............................................................................178 Inspect...........................................................................178 Assemble and Install..............................................................178 Troubleshooting.......................................................................179 hydraulic system..............................................................................182 INTRODUCTION..............................................................................182 GENERAL...............................................................................182 DESCRIPTION AND OPERATION.............................................................182 Hydraulic Pump....................................................................182 Main Control Valve................................................................183 Steering Control Unit.............................................................185 Brake Booster.....................................................................185 REPAIRS...................................................................................185 HYDRAULIC PUMP........................................................................185 Removal...........................................................................185 Disassembly.......................................................................186 Cleaning and Inspection...........................................................186 Assembly..........................................................................186 Installation......................................................................187 Adjust the Flow Divider...........................................................187 SPECIFICATIONS............................................................................187 TROUBLESHOOTING...........................................................................188 Instrument Panel Indicators and Senders.......................................................190 toc.......................................................................................190 Instrument Panel Indicators and Senders...............................................190 General...............................................................................193 Description...........................................................................194 Steering Column Gauges, Meters, and Indicators....................................194 LED Display Panel.................................................................194 Battery Discharge Indicators..................................................194 Brush Wear Indicators.........................................................200 Motor Temperature Indicators..................................................200 LX Series Display Panel...........................................................202 Hourmeter Functions...........................................................203 Battery Indicator Function....................................................203 Status Code Function..........................................................203 ZX Series Display Panels..........................................................205 Display Panel.................................................................205 Basic Display Panels..........................................................205 Performance Display...........................................................207 Brush Wear Indicators.........................................................211 Adjustments - General.................................................................211 Replacement - General Information.....................................................211 Meter Replacement.....................................................................212 Sender Replacement....................................................................213 Fuel Level Sender.................................................................213 Pressure and Temperature Sender...................................................213 Seat Sensor, Operator Presence System (OPS).......................................214 Remove........................................................................214 Install.......................................................................214 Operator Presence System Module Replacement.......................................214 Remove........................................................................215 Install.......................................................................216 ITW Display Panel Replacement.........................................................217 Remove............................................................................217 Column Mount Display Panel (EV-100/200ZX Motor Controllers) Repl......................217 Remove............................................................................217 Display Panel Assembly, Replace...................................................217 Indicator LEDs....................................................................218 Battery Indicators................................................................218 Digital Display (Performance Display Panel Only)..................................218 Status Code or Performance Level Switches and Indicator LEDs (Pe..................219 Basic Display Panel, Replace Parts................................................219 Performance Display Panel, Replace Parts..........................................221 Dash Mount Display Panel (EV100/200ZX Motor Controllers) Replace......................221 Remove and Replace................................................................221 Specifications........................................................................222 Meter Specifications..............................................................222 Sender Specifications.............................................................222 Troubleshooting.......................................................................223 Meter.............................................................................223 Troubleshooting for Operator Presence System..........................................224 tables....................................................................................190 Table 1. Troubleshooting Procedure for Operator Presence Module.......................224 Lift Cylinders................................................................................228 toc.......................................................................................228 Lift Cylinders........................................................................228 Safety Procedures When Working Near Mast..............................................230 General...............................................................................234 Description...........................................................................234 Lowering Control Valve............................................................234 Cylinders (General)...............................................................237 Cylinders (H520-620B, H700-800A)..................................................237 Retainer, Install.............................................................237 Cylinders (H360-460B).............................................................239 Cylinders (Two-Speed).............................................................241 Lift Cylinder Repair..................................................................243 Lift Cylinder Removal Without Removing Mast.......................................243 Standard Masts With Main Lift Cylinder Fastened to Crossmember o..............243 Standard and Full Free-Lift Masts With Lift Cylinder Fastened to..............243 Masts That Have Two Cylinders, Main Lift Cylinder and Free-Lift ..............243 Disassemble.......................................................................245 Assemble..........................................................................245 Lift Cylinder Installation in Mast................................................247 Standard Masts With Main Lift Cylinder Fastened to Crossmember o..............247 Standard and Full Free-Lift Masts With Lift Cylinder Fastened to..............247 Chevron-Style Packing.............................................................247 Chevron-Style Packing Installation on Piston..................................248 Chevron-Style Packing Installation in Packing Gland...........................250 Lift Cylinders for VISTA® Masts.......................................................251 Description.......................................................................251 Lowering Control Valve........................................................251 Remove............................................................................253 Disassemble.......................................................................254 Assemble..........................................................................255 Install...........................................................................256 Main Lift Cylinders...........................................................256 Free-Lift Cylinder............................................................256 Lift System Leak Check................................................................257 Specifications........................................................................258 Troubleshooting.......................................................................259 tables....................................................................................228 Table 1. Lift Trucks with Two-Speed Lift Cylinders....................................242 Table 2. Cylinder Retainer Torque Specifications and Weight Guid......................258 LPG Fuel System...............................................................................261 toc.......................................................................................261 LPG Fuel System.......................................................................261 General...............................................................................264 Description and Operation.............................................................266 Fuel Tank.........................................................................266 Fuel Filter and Fuel Valve Unit...................................................267 Vaporizer.........................................................................268 Carburetor........................................................................269 Governor..........................................................................271 LPG Tank Repair.......................................................................272 Remove............................................................................272 LPG Tanks with Fixed Mounting Bracket.........................................272 LPG Tanks with EZ Lift Mounting Bracket.......................................272 Install...........................................................................273 LPG Tanks with Fixed Mounting Bracket.........................................273 LPG Tanks with EZ Lift Mounting Bracket.......................................274 Hydrostatic Relief Valve Repair.......................................................275 Remove and Install................................................................275 Filter Unit Repair....................................................................275 Fuel Filter Element, Replace......................................................275 Diaphragm and Fuel Valve, Replace.................................................275 Hoses Replacement.....................................................................277 Vaporizer Repair......................................................................277 Remove............................................................................277 Disassemble.......................................................................277 Clean.............................................................................277 Inspect...........................................................................277 Assemble..........................................................................279 Install...........................................................................282 Carburetor Repair.....................................................................283 Remove............................................................................283 Disassemble.......................................................................283 Clean.............................................................................283 Assemble..........................................................................283 Install...........................................................................283 Governor Repair.......................................................................284 Filter Unit Check.....................................................................286 Vaporizer Check.......................................................................286 Pressure Reducer Valve............................................................286 Vapor Valve.......................................................................286 Carburetor Adjustment.................................................................286 Idle Mixture......................................................................286 Idle Speed........................................................................286 Power Mixture.....................................................................287 Throttle Linkage Adjustment...........................................................287 Troubleshooting.......................................................................289 Manual hydraulic Control Valve................................................................295 toc.......................................................................................295 Manual hydraulic Control Valve........................................................295 General...............................................................................297 Description...........................................................................297 Operation.............................................................................298 Lift Section......................................................................298 Tilt Section......................................................................300 Tilt Backward.................................................................300 Tilt Forward..................................................................302 Relief Valve..................................................................302 Solenoid Valve for Auxiliary Function.............................................302 Main Control Valve Repair.............................................................304 Remove and Disassemble............................................................304 Clean and Inspect.................................................................305 Assemble..........................................................................305 Install...........................................................................305 Solenoid Valve for Auxiliary Function Repair..........................................306 Remove and Disassemble............................................................306 Assemble and Install..............................................................306 Troubleshooting...................................................................308 Pressure Relief Valve Check and Adjustment............................................308 Primary Relief Valve..............................................................308 Secondary Relief Valve............................................................309 Control Lever Arrangement and Adjustment..............................................310 Specifications........................................................................312 Troubleshooting.......................................................................313 Masts.........................................................................................316 toc.......................................................................................316 Vista ® Masts.........................................................................316 General...............................................................................319 Description and Operation.............................................................319 Carriages.........................................................................319 Two-Stage Mast With Limited Free-Lift.............................................319 Two-Stage Mast With Full Free-Lift Mast...........................................320 Three-Stage Mast With Full Free-Lift..............................................321 Safety Procedures When Working Near Mast..............................................323 Forks Replacement.....................................................................325 Remove and Install................................................................325 Hook Fork.....................................................................325 Remove....................................................................325 Install...................................................................325 Pin Fork......................................................................326 Remove....................................................................326 Install...................................................................326 Carriage Repair.......................................................................326 Remove............................................................................326 Sideshift Carriage Repair.............................................................328 Sideshift Carriage (Earlier Designs)..............................................328 Disassemble...................................................................328 Assemble......................................................................329 Install.......................................................................332 Sideshift Carriage (1993 and Later Design)........................................332 Remove........................................................................332 Repairs.......................................................................332 Install.......................................................................332 Weight of Mast Parts..................................................................335 Two-Stage Mast With Limited Free-Lift Repair..........................................335 Remove............................................................................335 Disassemble.......................................................................335 Clean and Inspect.................................................................337 Assemble..........................................................................337 Install...........................................................................339 Two-Stage Mast With Full Free-Lift Repair.............................................339 Remove............................................................................339 Disassemble.......................................................................339 Clean and Inspect.................................................................341 Assemble..........................................................................341 Install...........................................................................341 Three-Stage Mast With Full Free-Lift..................................................342 Remove............................................................................342 Disassemble.......................................................................342 Clean and Inspect.................................................................342 Assemble..........................................................................342 Install...........................................................................344 Mast Operation Check..................................................................346 Lift and Tilt System Leak Check.......................................................347 Lift System.......................................................................347 Tilt System.......................................................................347 Tilt Cylinder Stroke and Backward Tilt Angle Adjustment...............................348 Lift Chain Adjustments................................................................348 Mast Adjustments......................................................................349 Carriage Adjustment...................................................................351 Troubleshooting.......................................................................352 Metric and Inch (SAE) Fasteners...............................................................356 toc.......................................................................................356 Metric and Inch (SAE) Fasteners.......................................................356 General...............................................................................358 Threaded Fasteners................................................................358 Nomenclature, Threads.............................................................358 Strength Identification...........................................................359 Cotter (Split) Pins...............................................................359 Fastener Torque Tables............................................................364 Conversion Table..................................................................366 tables....................................................................................356 Table 1. Bolts and Screws.............................................................360 Table 2. Studs and Nuts...............................................................361 Table 3. Torque Nuts..................................................................362 Table 4. Torque Nuts With Nylon Insert................................................363 Table 5. Torque Values for Metric Fasteners*..........................................364 Table 6. Torque Values for Inch Fasteners*............................................365 Table 7. Conversion Table for Metric and English Units................................366 Table 8. Cotter Pin Dimensional Data..................................................367 Table 9. Cotter Pin Dimensional Data..................................................368 Table 10. Cotter Pin Dimensional Data.................................................369 Table 11. Cotter Pin Dimensional Data.................................................371 Microprocessor Spark Timing System (MSTS).....................................................375 toc.......................................................................................375 Microprocessor Spark Timing System (MSTS).............................................375 General...............................................................................378 Description...........................................................................379 What MSTS Does....................................................................379 How MSTS Begins Operation.........................................................379 Operation.............................................................................380 Distributor.......................................................................380 Ignition Coil.....................................................................380 Ignition Module...................................................................380 When Engine Is Being Started......................................................381 When Engine Is Running............................................................382 Manifold Absolute Pressure (MAP) Sensor...........................................383 Engine Coolant Temperature (ECT) Sensor...........................................383 MSTS Module Corrections...........................................................384 Troubleshooting.......................................................................385 General...........................................................................385 Tools and Test Equipment..........................................................387 MSTS..............................................................................388 Troubleshooting Procedure.........................................................388 Where to Start................................................................388 Visual/Physical Inspection....................................................388 Knowledge/Tools Required......................................................388 Damage from Static Discharge (Static Electricity).............................388 Troubleshooting Information.......................................................389 Malfunction Indicator Lamp (MIL)..............................................389 Connecting CodeMate Tester....................................................389 Reading Diagnostic Trouble Codes (DTC)........................................390 Clearing Diagnostic Trouble Codes (DTC's).....................................391 On-Board Diagnostic (OBD) System Check............................................391 Test Description..............................................................391 No Malfunction Indicator Lamp.........................................................393 Circuit Description...............................................................393 Test Description..................................................................393 No DTC-12, Malfunction Indicator Lamp ON..............................................395 Circuit Description...............................................................395 Test Description..................................................................395 Starter Rotates Engine, Engine Does Not Run...........................................396 Test Description..................................................................396 DTC-14 Engine Coolant Temperature (ECT) (Low Temperature Indicat......................400 Circuit Description...............................................................400 Test Description..................................................................400 DTC-15 Engine Coolant Temperature Sensor (ECT) (High Temperature......................402 Circuit Description...............................................................402 Test Description..................................................................402 DTC-34 Manifold Absolute Pressure (MAP) Sensor........................................404 Circuit Description...............................................................404 Test Description..................................................................404 DTC-41 Electronic Spark Timing (EST) Open Circuit.....................................407 Circuit Description...............................................................407 Test Description..................................................................407 DTC-42 Electronic Spark Timing (EST) Grounded Circuit.................................409 Circuit Description...............................................................409 Test Description..................................................................409 DTC-51 MSTS Failure...................................................................411 Circuit Description...............................................................411 Distributor Repair....................................................................411 Remove............................................................................411 Disassemble.......................................................................412 Inspect...........................................................................412 Assemble..........................................................................412 Install...........................................................................413 Ignition Timing...................................................................413 Ignition Module Repair................................................................414 Test For Fault....................................................................414 Replace...........................................................................415 Sensing Coil Repair...................................................................415 Test For Fault....................................................................415 Replace...........................................................................415 Ignition Coil Repair..................................................................416 Test For Fault....................................................................416 Remove............................................................................416 Install...........................................................................416 MSTS Module Repair....................................................................417 Remove............................................................................417 Install...........................................................................417 ECT Sensor Replacement................................................................417 MAP Sensor Replacement................................................................418 tables....................................................................................375 Table 1. MSTS Module Connections......................................................386 Table 2. Pressure Conversion Chart....................................................387 Table 3. MSTS Diagnostic Codes........................................................389 Periodic Maintenance..........................................................................421 toc.......................................................................................421 Periodic Maintenance..................................................................421 General...............................................................................425 Serial Number Data................................................................425 How to Move Disabled Lift Truck...................................................425 How to Tow Lift Truck.........................................................425 How to Put Lift Truck on Blocks...................................................426 How to Raise Drive Tires......................................................426 How to Raise Steering Tires...................................................426 Maintenance Schedule..................................................................427 Safety Procedures When Working Near Mast..............................................435 Maintenance Procedures Every 8 Hours or Daily.........................................438 How to Make Checks With Engine Stopped............................................438 Hydraulic System..............................................................438 Engine Oil....................................................................438 Drive Belts...................................................................438 Intake Manifold Rubber Cap....................................................438 Cooling System................................................................438 Air Filter....................................................................439 Fuel System...................................................................441 Primary Fuel Filter, Diesel Engine............................................441 Battery.......................................................................441 Tires and Wheels..............................................................441 Forks.........................................................................442 Adjust....................................................................442 Remove....................................................................442 Install...................................................................444 Forks, Mast, and Lift Chains, Inspect.........................................444 Operator Restraint System.....................................................445 Automatic Locking Retractor (ALR).........................................445 Emergency Locking Retractor (ELR).........................................445 Safety Labels.................................................................447 How to Make Checks With Engine Running............................................447 Gauges, Lights, Horn, and Fuses...............................................447 Oil Level, Powershift Transmission............................................448 Oil Level, Oil Clutch System, S6.00-7.00XL (S135-155XL).......................448 Control Levers and Pedals.....................................................448 Lift System Operation.........................................................449 Inching/Brake Pedal...........................................................449 Service Brakes................................................................450 Parking Brake.................................................................450 Steering System...............................................................450 Maintenance Procedures Every 250 Hours or 6 Weeks.....................................451 Engine Oil and Filter, GM V-6.....................................................451 Mast, Lubrication.................................................................451 Lift Chains, Lubrication..........................................................451 Crankcase Breather, GM V-6 Engine.................................................451 Drive Shafts, S6.00-7.00XL (S135-155XL)...........................................452 Air Filter GM V-6 EPA Compliant Engine............................................452 Maintenance Procedures Every 350 Hours or 2 Months....................................453 Drive Belts.......................................................................453 Perkins Diesel Engine.........................................................453 GM V-6 Engine, Early Models...................................................453 GM V-6 Engine, Late Models....................................................453 Forks, Wear and Damage Check......................................................455 Lift Chains, Wear Check...........................................................455 Hydraulic Tank Breather, Clean and Check..........................................456 Brake Fluid.......................................................................456 Fuel System, Checks and Adjustments...............................................456 Diesel Fuel System............................................................456 LPG Carburetor................................................................457 Gasoline Carburetor (Early Models)............................................457 Fuel Injection (Late Model GM V-6)............................................458 Steering Axle, Lubrication........................................................458 Cooling System, Clean Debris from Radiator Core...................................458 Air Filter........................................................................458 Maintenance Procedures Every 500 Hours or 3 Months....................................459 Engine Oil and Filter, Perkins Diesel Engine......................................459 Crankcase Breather, Perkins Diesel Engine.........................................459 PCV Valve, GM V-6.................................................................459 Maintenance Procedures Every 1000 Hours or 6 Months...................................459 Manifold Heat Valve, GM V-6.......................................................459 Crankcase Breather, GM V-6........................................................459 Ignition System, GM V-6...........................................................459 Valve Clearance, Check and Adjust.................................................460 Fuel Filter, Diesel Engine, Replace...............................................460 Fuel System Air Removal, Perkins (1004.42 Diesel Engine)..........................460 Fuel Injection Pump With Vent Tube............................................460 Fuel Injection Pump With Vent Screw...........................................461 Differential and Drive Axle, Oil Level Check......................................463 Differential S3.50-5.50XL (S70-120XL).........................................463 Differential and Drive Axle for Powershift Transmission S6.00-7...............463 Differential, Speed Reducer, and Drive Axle for Manual Transmiss..............463 Control Levers and Pedals, Lubrication............................................463 Cooling System GM V-6 EPA Compliant Engine........................................463 LPG Fuel Filter GM V-6 EPA Compliant Engine, Replace..............................464 Inspect Engine Electrical System, Connectors, and FCVS Connectio..................464 Spark Plug Replacement............................................................465 Remove........................................................................465 Install.......................................................................465 Maintenance Procedures Every 2000 Hours or Yearly.....................................466 Hydraulic System..................................................................466 Hydraulic Oil and Filter S3.50-5.50XL (S70-120XL), Replace....................466 Hydraulic Oil and Filter S6.00-7.00XL (S135-155XL), Replace...................466 Powershift Transmission (All Units), Oil Change and Oil Filter, ..................466 Manual Transmission and Differential S6.00-7.00XL (S135-155XL), ..............467 Oil Clutch System S6.00-7.00XL (S135-155XL), Oil and Filter Chan..................467 Differential and Drive Axle for Powershift Transmission (All Uni..................467 Cooling System....................................................................468 PCV Valve, GM V-6.................................................................468 Service Brakes....................................................................468 LPG Filter, Replace (Pre-2004)....................................................468 Oxygen Sensor GM V-6 EPA Compliant Engine.........................................469 Gasoline Fuel Filter, Replace.....................................................469 Air Filter Element, GM V-6 EPA Compliant Engine...................................469 Test LPG/GAS Regulator Pressure...................................................469 Inspect Low Pressure Regulator (LPR) for Oil Buildup and Leaks....................469 Check Throttle Shaft for Sticking.................................................470 Inspect Exhaust Manifold and Piping for Leaks.....................................470 Hood Latch Check......................................................................471 Lift Chain Adjustments................................................................471 Fuel Injectors Repair.................................................................473 Lift and Tilt System Leak Check.......................................................474 Lift Cylinders, Leak Check........................................................474 Tilt Cylinders, Leak Check........................................................474 Welding Repairs.......................................................................475 Overhead Guard Changes................................................................475 Wheel and Tire Replacement............................................................476 Solid Rubber Tire, Change.........................................................476 Wheels, Install...............................................................477 Adhesives and Sealants................................................................477 Hydraulic Oil, Lubricant, and Coolant Specifications..................................478 tables....................................................................................421 Table 1. Maintenance Schedule.........................................................427 Table 2. Hook-Type Carriage Chain Adjustment..........................................472 Table 3. Pin-Type Carriage Chain Adjustment...........................................472 Perkins Diesel Engines........................................................................480 toc.......................................................................................480 Perkins Diesel Engines................................................................480 General...............................................................................487 General Safety Rules..............................................................487 Description...........................................................................488 Engine Serial Number Codes........................................................491 Engine Data.......................................................................491 Engine Removal and Installation.......................................................493 Lift Engine.......................................................................493 Cylinder Head Assembly Repair.........................................................493 Valve Cover.......................................................................493 Remove........................................................................493 Install.......................................................................494 Rocker Arm Assembly...............................................................494 Remove........................................................................494 Install.......................................................................494 Disassemble...................................................................494 Inspect.......................................................................495 Assemble......................................................................495 Valve Clearance Adjustments.......................................................495 Four-Cylinder Engines.........................................................496 Six-Cylinder Engines..........................................................496 Valve Springs.....................................................................496 Cylinder Head Assembly............................................................498 Remove........................................................................498 Install.......................................................................500 Valves and Valve Springs..........................................................504 Remove........................................................................504 Inspect.......................................................................504 Install.......................................................................505 Valve Guides......................................................................505 Inspect.......................................................................505 Remove........................................................................506 Install.......................................................................506 Cylinder Head and Valve Seats.....................................................506 Inspect.......................................................................506 Repair........................................................................506 New Valve Seats, Install......................................................506 Piston and Connecting Rod Assemblies Repair...........................................508 Rod Bearings......................................................................508 Remove........................................................................509 Install.......................................................................509 Piston and Connecting Rod Assembly................................................510 Service Note..................................................................510 Remove........................................................................510 Install.......................................................................511 Piston Rings......................................................................512 Remove........................................................................512 Inspect.......................................................................512 Install.......................................................................512 Piston and Connecting Rod.........................................................513 Disassemble...................................................................513 Inspect.......................................................................514 How to Select Correct Replacements............................................514 Install.......................................................................515 Piston Cooling Jets...............................................................515 Remove........................................................................515 Install.......................................................................516 Crankshaft Assembly Repair............................................................516 General...........................................................................516 Crankshaft Pulley.................................................................517 Engine AR, Remove.............................................................517 Engines YG and YH, Remove.....................................................517 Inspect.......................................................................518 Engine AR, Install............................................................518 Engines YG and YH, Install....................................................518 Rear Oil Seal.....................................................................519 Replace.......................................................................519 Main Bearings.....................................................................520 Remove........................................................................520 Inspect.......................................................................521 Install.......................................................................521 Thrust Washers....................................................................521 Crankshaft Axial Movement, Check..............................................521 Remove........................................................................522 Install.......................................................................522 Crankshaft........................................................................523 Remove........................................................................523 Inspect.......................................................................523 Install.......................................................................523 Flywheel..........................................................................525 Remove........................................................................525 Ring Gear, Replace............................................................525 Install.......................................................................525 Flywheel Housing..................................................................526 Remove........................................................................526 Install.......................................................................526 Timing Case and Timing Gears Repair...................................................527 General...........................................................................527 Timing Case Cover.................................................................527 Remove........................................................................527 Install.......................................................................528 Front Oil Seal....................................................................528 Remove........................................................................528 Install.......................................................................528 Crankshaft Pulley Wear Sleeve.....................................................529 Install.......................................................................529 Idler Gear and Hub................................................................529 Remove........................................................................529 Install.......................................................................530 Air Compressor Drive, Bendix......................................................531 Disassemble...................................................................531 Assemble......................................................................532 Fuel Injection Pump Gear..........................................................532 Remove........................................................................533 Install.......................................................................533 Camshaft Gear.....................................................................534 Remove........................................................................534 Install.......................................................................534 Crankshaft Gear...................................................................535 Remove........................................................................535 Install.......................................................................535 Timing Case.......................................................................535 Remove........................................................................535 Install.......................................................................536 Camshaft and Tappets..............................................................537 Remove........................................................................537 Install.......................................................................537 Cylinder Block Assembly Repair........................................................538 Description.......................................................................538 Cylinder Block....................................................................538 Disassemble...................................................................538 Inspect.......................................................................539 Assemble......................................................................539 Cylinder Bore (Four-Cylinder Engines).............................................540 Cylinder Liner (Six-Cylinder Engines).............................................540 Inspect.......................................................................540 Cylinder Liner Condition, Check...............................................540 Remove........................................................................541 Service Liner, Install........................................................542 Partially Finished Liner, Install.............................................543 Engine Timing.........................................................................544 Description.......................................................................544 How to Set Number One Piston to TDC on Compression Stroke.....................545 How to Set Number One Piston to TDC on Compression Stroke (Alter..............546 Valve Timing, Check...........................................................546 Fuel Injection Pump Timing, Check.............................................547 Turbocharger - Engine YH Repair.......................................................548 General...........................................................................548 Remove........................................................................548 Install.......................................................................548 Impeller and Compressor Housing, Clean........................................549 Lubrication System Repair.............................................................550 General...........................................................................550 Oil Filter, Replace...............................................................550 Filter Head.......................................................................551 Remove and Install............................................................551 Oil Sump..........................................................................551 Remove........................................................................551 Install.......................................................................552 Oil Pump..........................................................................552 Remove........................................................................552 Inspect.......................................................................552 Install.......................................................................553 Relief Valve......................................................................553 Remove........................................................................553 Disassemble...................................................................554 Inspect.......................................................................554 Assemble......................................................................554 Install.......................................................................555 Idler Gear Shaft, Replace.........................................................555 Remove........................................................................555 Remove (Alternative)..........................................................555 Install.......................................................................556 Install (Alternative).........................................................556 Install (Alternative for Four-Cylinder Engines Only)..........................557 Fuel System Repair....................................................................557 Description.......................................................................557 Fuel Injection Pump...............................................................558 Remove........................................................................558 Install.......................................................................559 Check and Adjust..............................................................560 Fuel System Air Removal...........................................................560 Fuel Filter, Replace..............................................................561 Canister Type.................................................................562 Quick Release Canister Type...................................................562 Fuel Injectors....................................................................563 Remove........................................................................563 Inspect.......................................................................564 Install.......................................................................564 Fuel Pump.........................................................................565 Remove........................................................................565 Disassemble...................................................................565 Assemble......................................................................565 Install.......................................................................566 Test..........................................................................566 Cooling System Repair.................................................................567 General...........................................................................567 Thermostat........................................................................567 Remove........................................................................567 Install.......................................................................567 Test..........................................................................568 Coolant Pump......................................................................568 Remove........................................................................568 Disassemble...................................................................568 Assemble......................................................................570 Install.......................................................................572 Fan and Fan Drive.................................................................573 Remove........................................................................573 Install.......................................................................573 Oil Cooler (Six-Cylinder Engines).................................................574 Remove........................................................................574 Disassemble and Assemble......................................................574 Install.......................................................................574 Oil Cooler Bypass Valve.......................................................574 Electrical Equipment Repair...........................................................575 Drive Belts.......................................................................575 Adjustment....................................................................575 Remove........................................................................576 Install.......................................................................576 Alternator........................................................................576 Remove........................................................................576 Install.......................................................................576 Starter Motor.....................................................................576 Remove........................................................................576 Install.......................................................................576 Cold Start Aid....................................................................576 Air Compressor - Engines YG and YH....................................................577 General...........................................................................577 Repair............................................................................577 Remove........................................................................577 Install.......................................................................577 Rotary Exhauster Replacement..........................................................579 Remove............................................................................579 Clean.............................................................................579 Install...........................................................................579 Engine Specifications.................................................................580 Cylinder Head Assembly............................................................580 Piston and Connecting Rods........................................................583 Crankshaft Assembly...............................................................586 Crankshaft Overhaul...........................................................588 Timing Case and Drive Assembly....................................................590 Engine Block Assembly.............................................................591 Turbocharger......................................................................594 Lubrication System................................................................594 Fuel System.......................................................................595 Cooling System....................................................................597 Flywheel and Housing..............................................................597 Electrical Equipment..............................................................598 Torque Specifications.................................................................598 Cylinder Head Assembly............................................................598 Piston and Connecting Rod Assemblies..............................................598 Crankshaft Assembly...............................................................598 Timing Case and Drive Assembly....................................................599 Turbocharger......................................................................599 Lubrication System................................................................599 Fuel System.......................................................................599 Cooling System....................................................................599 Flywheel..........................................................................599 Auxiliary Equipment...............................................................599 Special Torque Specifications.........................................................600 Flywheel and Housing..............................................................600 Turbocharger......................................................................600 Electrical Equipment..............................................................600 Auxiliary Equipment...............................................................600 Special Tools*........................................................................601 Troubleshooting.......................................................................606 tables....................................................................................480 Table 1. Cylinder Head................................................................580 Table 2. Valve Guides.................................................................580 Table 3. Inlet Valves.................................................................580 Table 4. Exhaust Valves...............................................................581 Table 5. Valve Springs................................................................583 Table 6. Tappets......................................................................583 Table 7. Rocker Arm Shaft.............................................................583 Table 8. Rocker Arms and Bushings.....................................................583 Table 9. Pistons (Engine AR)..........................................................583 Table 10. Pistons (Engines YG and YH).................................................583 Table 11. Piston Rings (Engine AR)....................................................584 Table 12. Piston Rings (Engines YG and YH)............................................584 Table 13. Piston Pins.................................................................585 Table 14. Connecting Rods.............................................................585 Table 15. Small End Bushings..........................................................585 Table 16. Connecting Rod Bearings (Engines AR and YG).................................585 Table 17. Connecting Rod Bearings (Engine YH).........................................585 Table 18. Piston Cooling Jets.........................................................586 Table 19. Crankshaft..................................................................586 Table 20. Main Bearings...............................................................587 Table 21. Crankshaft Thrust Washers...................................................587 Table 22. Crankshaft Heat Treatment...................................................587 Table 23. Crankshaft Overhaul Specifications..........................................588 Table 24. Maximum Variation (Run-out).................................................590 Table 25. Camshaft....................................................................590 Table 26. Camshaft Thrust Washer......................................................590 Table 27. Camshaft Gear...............................................................590 Table 28. Gear for Fuel Injection Pump................................................591 Table 29. Crankshaft Gear.............................................................591 Table 30. Idler Gear and Hub..........................................................591 Table 31. Cylinder Block (Engine AR)..................................................591 Table 32. Cylinder Bore Specifications................................................592 Table 33. Cylinder Block (Engines YG and YH)..........................................593 Table 34. Cylinder Liners (Engines YG and YH).........................................593 Table 35. Cylinder Liner Specifications (Partially Finished)..........................593 Table 36. Oil Pump (Engine AR)........................................................594 Table 37. Oil Pump (Engines YG and YH)................................................594 Table 38. Idler Gear for Oil Pump.....................................................595 Table 39. Relief Valve................................................................595 Table 40. Oil Filter..................................................................595 Table 41. Lucas Fuel Injection Pump...................................................595 Table 42. Fuel Injector Codes.........................................................596 Table 43. Fuel Pump (Engine AR).......................................................597 Table 44. Fuel Pump (Engines YG and YH)...............................................597 Table 45. Fuel Filter.................................................................597 Table 46. Coolant Pump................................................................597 Table 47. Thermostat..................................................................597 Table 48. Fan Drive Housing...........................................................597 Table 49. Limits for Flywheel Run Out and Alignment (Total Indic......................598 Table 50. Alternator..................................................................598 Table 51. Starter Motor...............................................................598 Table 52. Cold Start Aid..............................................................598 Table 53. List of Possible Causes.....................................................606 SCHEMATIC (2).................................................................................610 SCHEMATIC.....................................................................................624 ELECTRICAL SCHEMATIC (GASOLINE/LPG).......................................................624 ELECTRICAL SCHEMATIC (DIESEL).............................................................626 HYDRAULIC SCHEMATIC.......................................................................628 HYDRAULIC SCHEMATIC, TRANSMISSION WITH MANUAL CONTROL.....................................629 HYDRAULIC SCHEMATIC, TRANSMISSION WITH MONTROL CONTROL....................................630 ELECTRICAL SCHEMATIC FOR THE LIGHT CIRCUIT................................................631 Series 1000 Perkins diesel engine.............................................................632 PERKINS DIESEL ENGINES, SERIES 1000.......................................................632 1.1 GENERAL...........................................................................632 GENERAL SAFETY RULES..................................................................632 Viton Seals.......................................................................632 1.2 DESCRIPTION.......................................................................635 1.3 Engine Serial Number Codes....................................................635 1.4 Engine Data...................................................................635 1.5 1004–4 ENGINE.................................................................636 1.6 1004–4T ENGINE................................................................636 1.7 1006–6 ENGINE.................................................................636 1.8 1006–6T ENGINE................................................................636 1.9 REMOVAL AND INSTALLATION..........................................................636 CYLINDER HEAD ASSEMBLY....................................................................637 1.10 VALVE COVER......................................................................637 1.11 Removal......................................................................637 1.12 Installation.................................................................637 1.13 ROCKER ARM ASSEMBLY..............................................................637 1.14 Removal......................................................................637 1.15 Installation.................................................................637 1.16 Disassembly..................................................................638 1.17 Inspection...................................................................638 1.18 Assembly.....................................................................638 1.19 VALVE CLEARANCE ADJUSTMENTS......................................................638 1.20 Four Cylinder Engines........................................................639 1.21 Six Cylinder Engines.........................................................639 1.22 VALVE SPRINGS....................................................................639 1.23 CYLINDER HEAD ASSEMBLY...........................................................641 1.24 Removal......................................................................641 1.25 Installation.................................................................642 1.26 VALVES AND VALVE SPRINGS.........................................................645 1.27 Removal......................................................................645 1.28 Inspection...................................................................646 1.29 Installation.................................................................646 1.30 VALVE GUIDES.....................................................................646 1.31 Inspection...................................................................646 1.32 Removal......................................................................647 1.33 Installation.................................................................647 1.34 CYLINDER HEAD AND VALVE SEATS....................................................647 1.35 Inspection...................................................................647 1.36 Repair.......................................................................648 1.37 Installation Of New Valve Seats..............................................648 PISTON AND CONNECTING ROD ASSEMBLIES......................................................649 1.38 ROD BEARINGS.....................................................................649 1.39 Removal......................................................................649 1.40 Installation.................................................................650 1.41 PISTON AND CONNECTING ROD ASSEMBLY...............................................650 1.42 Service Note.................................................................650 1.43 Removal......................................................................650 1.44 Installation.................................................................651 1.45 PISTON RINGS.....................................................................652 1.46 Removal......................................................................652 1.47 Inspection...................................................................652 1.48 Installation.................................................................653 1.49 PISTON AND CONNECTING ROD........................................................654 1.50 Disassembly..................................................................654 1.51 Inspection...................................................................654 1.52 Installation.................................................................654 1.53 PISTON COOLING JETS..............................................................655 1.54 Removal......................................................................655 1.55 Installation.................................................................655 CRANKSHAFT ASSEMBLY.......................................................................656 1.56 GENERAL..........................................................................656 1.57 CRANKSHAFT PULLEY................................................................656 1.58 Removal, Engines AA and AB...................................................656 1.59 Installation, Engines AA and AB..............................................656 1.60 Removal, Engines YA and YB...................................................656 1.61 Installation, Engines YA and YB..............................................656 1.62 REAR OIL SEAL....................................................................657 1.63 Replacement..................................................................657 1.64 MAIN BEARINGS....................................................................658 1.65 Removal......................................................................658 1.66 Installation.................................................................658 1.67 THRUST WASHERS...................................................................659 1.68 Check The Axial Movement Of The Crankshaft...................................659 1.69 Removal......................................................................660 1.70 Installation.................................................................660 1.71 CRANKSHAFT.......................................................................660 1.72 Removal......................................................................660 1.73 Inspection...................................................................661 1.74 Installation.................................................................661 TIMING CASE AND TIMING GEARS..............................................................663 1.75 GENERAL..........................................................................663 1.76 TIMING CASE COVER................................................................663 1.77 Removal......................................................................663 1.78 Installation.................................................................663 1.79 FRONT OIL SEAL...................................................................664 1.80 Removal......................................................................664 1.81 Installation.................................................................664 1.82 IDLER GEAR AND HUB...............................................................664 1.83 Removal......................................................................664 1.84 Installation.................................................................665 1.85 GEAR FOR THE FUEL INJECTION PUMP OR THE CAMSHAFT GEAR............................666 1.86 Removal......................................................................666 1.87 Installation.................................................................666 1.88 CRANKSHAFT GEAR..................................................................667 1.89 Removal......................................................................667 1.90 Installation.................................................................667 1.91 TIMING CASE......................................................................667 1.92 Removal......................................................................667 1.93 Installation.................................................................667 1.94 CAMSHAFT AND TAPPETS.............................................................668 1.95 Removal......................................................................669 1.96 Installation.................................................................669 ENGINE BLOCK ASSEMBLY.....................................................................670 1.97 DESCRIPTION......................................................................670 1.98 ENGINE BLOCK.....................................................................670 1.99 Disassembly..................................................................670 1.100 Inspection..................................................................671 1.101 Assembly....................................................................671 1.102 CYLINDER LINER..................................................................671 1.103 Inspection..................................................................671 1.104 Hone........................................................................672 1.105 Removal.....................................................................672 1.106 Installation................................................................673 TURBOCHARGER, ENGINES AB AND YB...........................................................674 1.107 GENERAL.........................................................................674 1.108 Removal.....................................................................674 1.109 Installation................................................................675 1.110 Clean The Impeller And Compressor Housing...................................675 LUBRICATION SYSTEM........................................................................676 1.111 GENERAL.........................................................................676 1.112 OIL FILTER, REPLACEMENT.........................................................676 1.113 OIL SUMP........................................................................677 1.114 Removal.....................................................................677 1.115 Installation................................................................677 1.116 OIL PUMP........................................................................677 1.117 Removal.....................................................................677 1.118 Inspection..................................................................678 1.119 Installation................................................................678 1.120 RELIEF VALVE....................................................................679 1.121 Removal.....................................................................679 1.122 Disassembly.................................................................679 1.123 Inspection..................................................................680 1.124 Installation................................................................680 FUEL SYSTEM...............................................................................680 1.125 DESCRIPTION.....................................................................680 1.126 CAV FUEL INJECTION PUMP.........................................................681 1.127 Removal.....................................................................681 1.128 Installation................................................................681 1.129 CAV FUEL INJECTION PUMP, CHECKS AND ADJUSTMENTS.................................682 1.130 Timing Gear Marks...........................................................682 1.131 How To Set Number 1 Piston To TDC On The Compression Stroke.................683 1.132 Check The Valve Timing......................................................683 1.133 Check The Timing Of The Fuel Injection Pump.................................684 1.134 Check The Timing Mark Of The Fuel Injection Pump............................684 1.135 Check The Engine Timing Mark................................................685 1.136 REMOVE AIR FROM THE FUEL SYSTEM.................................................686 1.137 Fuel Injection Pump With Vent Tube..........................................686 1.138 Fuel Injection Pump With Vent Screw.........................................687 1.139 FUEL FILTER (REPLACEMENT).......................................................688 1.140 FUEL INJECTORS..................................................................688 1.141 Removal.....................................................................688 1.142 Inspection..................................................................689 1.143 Installation................................................................690 1.144 FUEL PUMP.......................................................................690 1.145 Removal.....................................................................690 1.146 Disassembly.................................................................690 1.147 Assembly....................................................................691 1.148 Installation................................................................691 1.149 Test........................................................................692 COOLING SYSTEM............................................................................692 1.150 GENERAL.........................................................................692 1.151 THERMOSTAT......................................................................692 1.152 Replacement.................................................................692 1.153 COOLANT PUMP....................................................................693 1.154 Removal.....................................................................693 1.155 Disassembly.................................................................693 1.156 Assembly....................................................................694 1.157 Installation................................................................694 1.158 FAN AND FAN DRIVE...............................................................694 1.159 Removal.....................................................................694 1.160 Disassembly.................................................................694 1.161 Assembly....................................................................695 1.162 Installation................................................................695 1.163 OIL COOLER......................................................................695 1.164 Removal, Engine AB..........................................................695 1.165 Removal, Engines YA and YB..................................................695 1.166 Disassembly And Assembly....................................................696 1.167 Installation, Engine AB.....................................................696 1.168 Installation, Engines YA and YB.............................................697 1.169 By–Pass Valve, Oil Cooler...................................................697 FLYWHEEL AND FLYWHEEL HOUSING.............................................................697 1.170 GENERAL.........................................................................697 1.171 FLYWHEEL........................................................................697 1.172 Removal.....................................................................697 1.173 Ring Gear (Replacement).....................................................697 1.174 Installation................................................................697 1.175 FLYWHEEL HOUSING................................................................698 1.176 Removal.....................................................................698 1.177 Installation................................................................698 ELECTRICAL EQUIPMENT......................................................................699 1.178 DRIVE BELTS.....................................................................699 1.179 ALTERNATOR......................................................................700 1.180 STARTER MOTOR...................................................................700 1.181 Removal.....................................................................700 1.182 Installation................................................................700 1.183 COLD START AID..................................................................700 AIR COMPRESSOR, ENGINES YA AND YB.........................................................700 1.184 GENERAL.........................................................................700 1.185 Air Compressor, Removal, WABCO..............................................700 1.186 Compressor Drive, Inspection................................................701 1.187 Air Compressor, Installation, WABCO.........................................701 1.188 Compressor Drive, Disassembly, WABCO........................................701 1.189 Compressor Drive, Assembly, WABCO...........................................702 1.190 Air Compressor, Removal, BENDIX.............................................702 1.191 Air Compressor, Installation, BENDIX........................................703 1.192 Compressor Drive, Disassembly, BENDIX.......................................704 1.193 Compressor Drive, Assembly, BENDIX..........................................704 ENGINE SPECIFICATIONS.....................................................................706 1.194 CYLINDER HEAD ASSEMBLY..........................................................706 1.195 Cylinder Head...............................................................706 1.196 Valve Guides................................................................706 1.197 Inlet Valves................................................................707 1.198 Exhaust Valves..............................................................707 1.199 Double Valve Springs To Outer...............................................707 1.200 Double Valve Springs To Inner...............................................707 1.201 Single Valve Springs........................................................707 1.202 Tappets.....................................................................707 1.203 Rocker Arm Shaft............................................................707 1.204 Rocker Arms And Bushings....................................................708 1.205 PISTON AND CONNECTING RODS......................................................708 1.206 Pistons, Engines AA And YA..................................................708 1.207 Pistons, Engines AB And YB..................................................708 1.208 Piston Rings, Engines AA And YA.............................................708 1.209 Piston Rings, Engines AB And YB.............................................708 1.210 Connecting Rods, Engines AB And YB..........................................709 1.211 Connecting Rods, Engines AB And YB..........................................709 1.212 Piston Pins, Engines AA And YA..............................................709 1.213 Piston Pins, Engines AB and YB..............................................709 1.214 Small End Bushings, Engines AA And YA.......................................709 1.215 Small End Bushings, Engines AB And YB.......................................709 1.216 Connecting Rod Bearings, Engines AA And YA..................................710 1.217 Connecting Rod Bearings, Engines AB And YB..................................710 1.218 Piston Cooling Jets, Engines AB And YB......................................710 1.219 CRANKSHAFT ASSEMBLY.............................................................710 1.220 Crankshaft..................................................................710 1.221 Crankshaft Heat Treatment...................................................710 1.222 Crankshaft Overhaul.........................................................710 1.223 Main Bearings...............................................................712 1.224 Crankshaft Thrust Washers...................................................712 1.225 TIMING CASE AND DRIVE ASSEMBLY..................................................712 1.226 Camshaft....................................................................712 1.227 Camshaft Thrust Washer......................................................712 1.228 Camshaft Gear...............................................................713 1.229 Gear For Fuel Injection Pump................................................713 1.230 Crankshaft Gear.............................................................713 1.231 Idler Gear And Hub..........................................................713 1.232 ENGINE BLOCK ASSEMBLY...........................................................713 1.233 Engine Block................................................................713 1.234 Cylinder Liners.............................................................713 1.235 TURBOCHARGER....................................................................714 1.236 LUBRICATION SYSTEM..............................................................714 1.237 Oil Pump, Engines AA And AB.................................................714 1.238 Oil Pump, Engines YA And YB.................................................714 1.239 Relief Valve................................................................714 1.240 Oil Filter..................................................................714 1.241 FUEL SYSTEM.....................................................................714 1.242 Cav Fuel Injection Pump.....................................................714 1.243 FUEL INJECTORS..............................................................715 1.244 Fuel Pump, Engines AA And AB................................................716 1.245 Fuel Pump, Engines YA And YB................................................716 1.246 Fuel Filter.................................................................716 1.247 COOLING SYSTEM..................................................................716 1.248 Coolant Pump................................................................716 1.249 Thermostat..................................................................717 1.250 Fan Drive Housing...........................................................717 1.251 FLYWHEEL AND HOUSING............................................................717 1.252 Limits for flywheel ''run out'' and alignment (total indicator reading).....717 1.253 ELECTRICAL EQUIPMENT............................................................717 1.254 Alternator..................................................................717 1.255 Starter Motor...............................................................717 1.256 Cold Start Aid..............................................................717 TORQUE SPECIFICATIONS.....................................................................718 SPECIAL TOOLS.............................................................................719 Single-Speed Powershift Transmission (2)......................................................723 toc.......................................................................................723 Single-Speed Powershift Transmission..................................................723 General...............................................................................725 Mechanical Description................................................................725 General...........................................................................725 Torque Converter..................................................................725 Oil Pump..........................................................................725 Shaft Assemblies..................................................................725 Input Shaft...................................................................725 Reverse Clutch Shaft..........................................................725 Countershaft..................................................................726 Ring Gear, Pinion, and Differential...........................................726 Clutch Assemblies.............................................................727 Hydraulic Operation...................................................................728 Torque Converter..................................................................728 Shaft Assemblies..................................................................729 Control Valve.....................................................................729 General.......................................................................729 System Regulator..............................................................729 Clutch Pressure Regulator.....................................................729 Torque Converter Regulator....................................................729 Inching Spool.................................................................729 Direction Spool, Manual Control...............................................731 Direction Spool, MONOTROL Pedal...............................................731 Modulation Spool..............................................................731 Accumulator...................................................................731 Drain Spool...................................................................731 MONOTROL Pedal....................................................................731 Control Valve.....................................................................733 General.......................................................................733 Regulator for Clutch Pressure.................................................733 Inching Spool Assembly........................................................733 Direction Spool...............................................................736 Direction Spool, Manual Control...............................................737 Modulator Circuit.............................................................737 Regulator for Torque Convertor................................................737 Lubrication Circuit...............................................................737 Direction Control Lever...........................................................737 MONOTROL Pedal....................................................................738 Start Circuit, MONOTROL Pedal.................................................738 Creep Speed Switch............................................................739 Oil Flow Diagrams.................................................................739 Neutral.......................................................................739 Forward.......................................................................739 Forward-Inching...............................................................739 Reverse.......................................................................739 Single-Speed Powershift Transmission..........................................................754 toc.......................................................................................754 Single-Speed Powershift Transmission..................................................754 General...............................................................................757 Transmission Repair...................................................................757 Remove............................................................................757 Disassemble.......................................................................758 Transmission, Disassemble.....................................................758 Input Shaft, Disassemble......................................................759 Reverse Clutch, Disassemble...................................................761 Output Shaft (Pinion) and Differential, Remove and Disassemble................764 Clean and Inspect.................................................................766 Assemble..........................................................................766 Input Shaft, Assemble.........................................................767 Reverse Clutch, Assemble......................................................775 Output Shaft (Pinion) and Differential, Assemble and Install..................780 Transmission, Assemble........................................................787 Control Valve, Install........................................................790 Install...........................................................................790 Control Valve Repair..................................................................791 Remove, Early Model S3.50-5.50XL (S70-120XL) Lift Trucks..........................791 Disassemble, Early Model S3.50-5.50XL (S70-120XL) Lift Trucks.....................791 Assemble, Early Model S3.50-5.50XL (S70-120XL) Lift Trucks........................792 Install, Early Model S3.50-5.50XL (S70-120XL) Lift Trucks.........................792 Remove and Disassemble, Later Model S3.50-5.50XL (S70-120XL) Tru..................792 Inspect, Later Model S3.50-5.50XL (S70-120XL) Trucks and S3.50-5..................795 Assemble and Install, Later Model S3.50-5.50XL (S70-120XL) Truck..................795 MONOTROL® Pedal Repair................................................................797 Remove and Disassemble, S3.50-5.50XL (S70-120XL) Model Lift Truc..................797 Assemble and Install, S3.50-5.50XL (S70-120XL) Model Lift Trucks..................798 Remove and Disassemble, S3.50-5.50XM (S70-120XM) Model Lift Truc..................800 Assemble and Install, S3.50-5.50XM (S70-120XM) Model Lift Trucks..................800 Direction Control Lever Repair........................................................802 Remove and Disassemble............................................................802 Assemble and Install..............................................................802 Stall Test............................................................................803 Linkages Adjustment...................................................................804 Linkage for Inching/Brake Pedal, S3.50-5.50XL (S70-120XL) (D004)..................804 Linkage for Direction Control Lever...............................................806 Linkage for Inching/Brake Pedal, S3.50-5.50XM (S70-120XM) (E004,..................806 Brake Shoe Adjustment.........................................................806 Inching/Brake Pedal Height Adjustment.........................................806 Single Pedal Height Adjustment............................................806 Two Pedal Height Adjustment...............................................806 Inching/Brake Linkage Adjustment..............................................808 Oil Pressures Check...................................................................810 System Pressure Check Port........................................................810 Torque Converter Check Port.......................................................810 Clutch Pressure Check Port........................................................811 Inching Pressure..................................................................811 Solenoid Check Ports ( MONOTROL Control Only).....................................813 Lubrication Pressure Check Ports..................................................813 System Pressure Check Port........................................................813 Torque Converter Check Port.......................................................813 Reverse Clutch Pressure Check Port................................................813 Forward Clutch Pressure Check Port................................................813 Lubrication Pressure Check Port...................................................813 Modulator Pressure Check Port.....................................................813 Troubleshooting.......................................................................814 tables....................................................................................754 Table 1. Ring and Pinion Tooth Contact Adjustment.....................................785 Table 2. Stall Speed Specifications...................................................803 Table 3. Transmission Oil Pressure Check, Early Model S3.50-5.50......................811 Table 4. Transmission Oil Pressure Check, Later Model S3.50-5.50......................812 Starter.......................................................................................820 toc.......................................................................................820 Starter...............................................................................820 General...............................................................................822 Description and Operation.............................................................822 Starter Repair........................................................................824 Remove............................................................................824 Disassemble.......................................................................824 Clean.............................................................................825 Assemble..........................................................................825 Install...........................................................................826 General Checks and Adjustments........................................................826 Troubleshooting.......................................................................829 Steering Axle.................................................................................833 toc.......................................................................................833 Steering Axle.........................................................................833 General...............................................................................835 Description...........................................................................835 Steering Axle Assembly Repair.........................................................840 Steering Axle H3.50-5.00XL (H70-110XL) (G005), S3.50-5.50XL (S70..................840 Remove........................................................................840 Install.......................................................................840 Steering Axle H6.00-7.00XL (H135-155XL, H135-155XL 2 ) (F006, G0..................841 Remove........................................................................841 Install.......................................................................841 Wheels and Hubs Repair (All Units)....................................................842 Remove and Disassemble............................................................842 Clean.............................................................................842 Inspect...........................................................................842 Assemble and Install..............................................................842 Spindles and Bearings Repair (All Units)..............................................844 Remove............................................................................844 Clean.............................................................................844 Assemble and Install..............................................................845 Tie Rods Repair (All Units)...........................................................846 Remove............................................................................846 Clean.............................................................................846 Install...........................................................................846 Steering Cylinder Repair..............................................................849 Remove and Disassemble............................................................849 Clean and Inspect.................................................................849 Assemble and Install..............................................................849 Troubleshooting.......................................................................850 Steering Control Unit (2).....................................................................854 STEERING CONTROL UNIT.....................................................................855 GENERAL...............................................................................855 DESCRIPTION...........................................................................855 Control Valve Section.............................................................855 Metering Section..................................................................855 DISASSEMBLY AND INSPECTION............................................................857 ASSEMBLY..............................................................................867 TROUBLESHOOTING...........................................................................881 Steering Control Unit.........................................................................882 toc.......................................................................................882 Steering Control Unit.................................................................882 General...............................................................................884 Description...........................................................................884 Operation.............................................................................884 Steering Wheel and Column Assembly Repair.............................................886 Steering Column Assembly Repair.......................................................886 Type A Steering Column Assembly...................................................886 Remove and Disassemble........................................................886 Assemble and Install..........................................................888 Type B Steering Column Assembly...................................................890 Remove and Disassemble........................................................890 Assemble and Install..........................................................890 Steering Control Unit.........................................................893 Disassemble...............................................................893 Clean.....................................................................896 Assemble..................................................................897 System Air Removal....................................................................902 Troubleshooting.......................................................................902 Tilt Cylinders................................................................................905 toc.......................................................................................905 Tilt Cylinders........................................................................905 General...............................................................................907 Description...........................................................................907 Tilt Cylinder Repair..................................................................907 Remove............................................................................907 Disassemble.......................................................................907 Clean.............................................................................907 Assemble..........................................................................907 Tilt Cylinders With O-Ring or Single-Lip Seals................................907 Tilt Cylinders for XM and XMS Models..........................................909 Tilt Cylinders for XL, XLS, and XL 3 Models...................................910 Tilt Cylinders for H700-800A and Early Model H700-920B........................912 Install...........................................................................913 Tilt Cylinders Using Chevron Packing..........................................913 Install...................................................................914 Tilt Cylinder Leak Check..............................................................916 Tilt Cylinder Stroke and Mast Tilt Angle Adjustment...................................918 Torque Specifications.................................................................918 Piston Rod Nut....................................................................918 Retainer..........................................................................919 Troubleshooting.......................................................................921 tables....................................................................................905 Table 1. Movement Rates (Maximum) for Tilt Cylinders..................................917 Weight........................................................................................924
HYSTER B024 (S70XL-120XL S135-155XL) SERVICE MANUAL – PDF DOWNLOAD:
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