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Hyster E004 (S3.50-5.0XM) Service Manual – PDF DOWNLOAD
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Hyster E004 (S3.50-5.0XM) Service Manual – PDF DOWNLOAD
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Description
Hyster E004 (S3.50-5.0XM) Service Manual – PDF DOWNLOAD
DESCRIPTION:
Hyster E004 (S3.50-5.0XM) Service Manual – PDF DOWNLOAD
SAFETY PRECAUTIONS MAINTENANCE AND REPAIR :
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly
fastened, and that the load being lifted is balanced. Make sure the crane, cables, and
chains have the capacity to support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair
on electric lift trucks.
• Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT
THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance
section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts
must meet or exceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before
using force to remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit whenmaking repairs,
or if the unit needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel
are flammable. Be sure to follow the necessary safety precautions when handling these
fuels and when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks
away from the area. Make sure the area is well ventilated.
TABLE OF CONTENTS:
Hyster E004 (S3.50-5.0XM) Service Manual – PDF DOWNLOAD
Alternator.............................................................................................. 1 toc................................................................................................. 1 Alternator with Regulator....................................................................... 1 Safety Precautions Maintenance and Repair....................................................... 2 General......................................................................................... 5 Description..................................................................................... 5 Alternator Repair............................................................................... 7 Alternator Type A........................................................................... 7 Remove and Disassemble.................................................................. 7 Clean................................................................................... 8 Assemble................................................................................ 9 Install................................................................................. 9 Alternator Type B........................................................................... 12 Remove and Disassemble.................................................................. 12 Clean................................................................................... 12 Assemble................................................................................ 13 Install................................................................................. 14 General Check and Adjustment.................................................................... 15 Low Output Check (Type A or Type B)............................................................. 15 High Output Check (Type A or Type B)............................................................ 17 Brushes Circuit Check........................................................................... 18 Delco Alternators........................................................................... 18 Motorola Alternators........................................................................ 19 Diodes Check.................................................................................... 20 Diode Bridge Check.............................................................................. 20 Delco and Leece-Neville Alternators......................................................... 20 Motorola Alternators........................................................................ 20 Rotor Field Winding Check....................................................................... 21 Stator Windings Check........................................................................... 22 Voltage Regulator Check......................................................................... 22 Troubleshooting................................................................................. 22 Brake system............................................................................................ 27 toc................................................................................................. 27 Brake System.................................................................................... 27 Safety Precautions Maintenance and Repair....................................................... 28 General......................................................................................... 31 Description and Operation....................................................................... 31 Brake Booster and Master Cylinder........................................................... 31 Service Brake Assembly...................................................................... 31 Parking Brake............................................................................... 31 Brake Shoe Assemblies Repair.................................................................... 32 Remove and Disassemble...................................................................... 32 Clean....................................................................................... 32 Inspect..................................................................................... 35 Assemble and Install........................................................................ 35 Brake Booster and Master Cylinder............................................................... 38 Remove...................................................................................... 38 Disassemble................................................................................. 38 Clean and Inspect........................................................................... 38 Assemble.................................................................................... 38 Install..................................................................................... 38 Brake Booster Filter, Replace............................................................... 38 Parking Brake Repair............................................................................ 40 Remove and Disassemble...................................................................... 40 Assemble and Install........................................................................ 40 Brake System Air Removal........................................................................ 42 Brake Pedal Adjustment.......................................................................... 42 Parking Brake Adjustment........................................................................ 42 Parking Brake Not Applied Switch Test........................................................... 43 Parking Brake Switch Test ( MONOTROL® Pedal Only)............................................... 43 Brake Shoes Adjustment.......................................................................... 44 Troubleshooting................................................................................. 44 Control valve........................................................................................... 49 toc................................................................................................. 49 Main Control Valve.............................................................................. 49 Safety Precautions Maintenance and Repair....................................................... 50 General......................................................................................... 53 Description..................................................................................... 53 Operation....................................................................................... 53 Lift Section................................................................................ 53 Tilt and Auxiliary Sections................................................................. 57 Reattaching the Clevis End of the Tilt Spool............................................ 58 Relief Valve................................................................................ 58 Main Control Valve Repair....................................................................... 58 Remove and Disassemble...................................................................... 58 Clean and Inspect........................................................................... 60 Assemble.................................................................................... 62 Install..................................................................................... 62 Pressure Relief Valve Check and Adjustment...................................................... 63 Main Relief Valve (Lift).................................................................... 63 Steering Relief Valve....................................................................... 63 Secondary Relief Valve (Tilt and Auxiliary)................................................. 66 Specifications.................................................................................. 67 Troubleshooting................................................................................. 67 Cooling system.......................................................................................... 73 toc................................................................................................. 73 Cooling System.................................................................................. 73 Safety Precautions Maintenance and Repair....................................................... 74 General......................................................................................... 77 Description..................................................................................... 78 Radiator.................................................................................... 78 Radiator Cap................................................................................ 78 Thermostat.................................................................................. 78 Water Pump.................................................................................. 79 Fan and Fan Shroud.......................................................................... 79 Cooling System Checks........................................................................... 79 Radiator.................................................................................... 79 Thermostat.................................................................................. 79 Water Pump.................................................................................. 80 Exhaust Leaks............................................................................... 80 Fan and Fan Shroud.......................................................................... 80 Radiator Cleaning............................................................................... 80 Drain....................................................................................... 80 Clean....................................................................................... 80 Fill........................................................................................ 81 Troubleshooting................................................................................. 82 Diagrams................................................................................................ 85 toc................................................................................................. 85 Diagrams........................................................................................ 85 Safety Precautions Maintenance and Repair....................................................... 86 General......................................................................................... 89 Drive axle.............................................................................................. 159 toc................................................................................................. 159 Drive Axle...................................................................................... 159 Safety Precautions Maintenance and Repair....................................................... 160 General......................................................................................... 163 Description..................................................................................... 163 Drive Axle Repairs.............................................................................. 163 Remove and Disassemble...................................................................... 163 Clean and Inspect........................................................................... 165 Brakes.................................................................................. 165 Drive Axle.............................................................................. 166 Assembly and Installation................................................................... 166 Torque Specifications........................................................................... 168 Troubleshooting................................................................................. 169 ECM diagnostics......................................................................................... 173 toc................................................................................................. 173 Electronic Control Module (ECM) Diagnostic Troubleshooting...................................... 173 Safety Precautions Maintenance and Repair....................................................... 174 General......................................................................................... 183 Description of ECM Based Diagnostics............................................................ 183 Definition of Terms......................................................................... 183 Diagnostics Overview of the Spectrum Fuel System............................................ 183 Malfunction Indicator Lamp (MIL)............................................................ 184 Spectrum Diagnostic Trouble Codes (DTC)..................................................... 184 Using a Laptop Computer to Diagnose the Spectrum System..................................... 184 Installing the Spectrum Diagnostic Software............................................. 185 Connecting a Laptop Computer to the Spectrum System..................................... 185 Diagnostic Communication Error.......................................................... 185 Diagnostic Trouble Codes.................................................................... 186 Checking Diagnostic Trouble Codes....................................................... 186 Clearing Diagnostic Trouble Codes....................................................... 186 DATA Stream................................................................................. 187 Reading Sensor and Actuator Values...................................................... 187 Graphing and Data Logging............................................................... 188 Ignition System Test........................................................................ 189 Disabling Ignition Outputs.............................................................. 189 Injector Test............................................................................... 190 Disabling Injectors..................................................................... 190 Throttle Test............................................................................... 190 Using a Diagnostic Jumper to Diagnose the ECI System.................................... 191 On-Board Diagnostics System Check/Malfunction Indicator Lamp.................................... 192 Circuit Description......................................................................... 192 Preliminary and Intermittent Checks............................................................. 195 GM 3.0L Wiring Schematics and Connectors........................................................ 197 GM 3.0L Diagnostic Trouble Codes................................................................ 211 DTC 111 - IAT High Voltage Motorola® TMAP................................................... 211 Circuit Description..................................................................... 211 Conditions for Setting the DTC.......................................................... 211 DTC 112 - IAT Low Voltage Motorola® TMAP.................................................... 214 Circuit Description..................................................................... 214 Conditions for Setting the DTC.......................................................... 214 DTC 113 - IAT Higher Than Expected 1 Motorola® TMAP......................................... 216 Circuit Description..................................................................... 216 Conditions for Setting the DTC.......................................................... 216 Diagnostic Aids......................................................................... 217 DTC 114 - IAT Higher Than Expected 2 Motorola® TMAP......................................... 218 Circuit Description..................................................................... 218 Conditions for Setting the DTC.......................................................... 218 Diagnostic Aids......................................................................... 218 DTC 115 - Oil Pressure Low.................................................................. 219 Circuit Description..................................................................... 219 Conditions for Setting the DTC.......................................................... 219 DTC 121 - ECT Voltage High.................................................................. 222 Circuit Description..................................................................... 222 Conditions for Setting the DTC.......................................................... 223 DTC 122 - ECT Voltage Low................................................................... 226 Circuit Description..................................................................... 226 Conditions for Setting the DTC.......................................................... 226 DTC 123 - ECT Higher Than Expected 1........................................................ 228 Circuit Description..................................................................... 228 Conditions for Setting the DTC.......................................................... 228 DTC 124 - ECT Higher Than Expected 2........................................................ 230 Circuit Description..................................................................... 230 Conditions for Setting the DTC.......................................................... 230 DTC 131 - MAP High Pressure Motorola® TMAP.................................................. 232 Circuit Description..................................................................... 232 Conditions for Setting the DTC.......................................................... 232 Diagnostic Aids......................................................................... 232 DTC 132 - MAP Low Voltage Motorola® TMAP.................................................... 235 Circuit Description..................................................................... 235 Conditions for Setting the DTC.......................................................... 235 DTC 134 - BP High Pressure Motorola® TMAP................................................... 239 Circuit Description..................................................................... 239 Conditions for Setting the DTC.......................................................... 239 DTC 135 - BP Low Pressure Motorola® TMAP.................................................... 240 Circuit Description..................................................................... 240 Conditions for Setting the DTC.......................................................... 240 DTC 142 - Crank Sync Noise.................................................................. 244 Circuit Description..................................................................... 244 Conditions for setting the DTC.......................................................... 244 DTC 143 - Never Crank Synced At Start....................................................... 248 Circuit Description..................................................................... 248 Conditions for Setting the DTC.......................................................... 248 DTC 144 - Camshaft Sensor Loss.............................................................. 251 Circuit Description..................................................................... 251 Conditions for Setting the DTC.......................................................... 251 DTC 145 - Camshaft Sensor Noise............................................................. 254 Circuit Description..................................................................... 254 Conditions for Setting the DTC.......................................................... 254 DTC 211 - Closed Loop Multiplier High (LPG)................................................. 257 Circuit Description..................................................................... 257 Conditions for Setting the DTC.......................................................... 257 Diagnostic Aids......................................................................... 257 DTC 212 - HO 2 S Open/Inactive.............................................................. 260 Circuit Description..................................................................... 260 Conditions for Setting the DTC.......................................................... 260 DTC 221 - Closed Loop Multiplier High (Gasoline)............................................ 262 Circuit Description..................................................................... 262 Conditions for Setting the DTC.......................................................... 262 Diagnostic Aids......................................................................... 263 DTC 222 - Closed Loop Multiplier Low (Gasoline)............................................. 266 Circuit Description..................................................................... 266 Conditions for Setting the DTC.......................................................... 266 Diagnostic Aids......................................................................... 266 DTC 224 - Closed Loop Multiplier Low (LPG).................................................. 268 Circuit Description..................................................................... 268 Conditions for Setting the DTC.......................................................... 268 Diagnostic Aids......................................................................... 268 DTC 241 - Adaptive Lean Fault (High Limit-Gasoline)......................................... 270 Circuit Description..................................................................... 270 Conditions for Setting the DTC.......................................................... 270 Diagnostic Aids......................................................................... 270 DTC 242 - Adaptive Rich Fault (Low Limit-Gasoline).......................................... 273 Circuit Description..................................................................... 273 Conditions for Setting the DTC.......................................................... 273 Diagnostic Aids......................................................................... 273 DTC 243 - Adaptive Learn High (LPG)......................................................... 276 Circuit Description..................................................................... 276 Conditions for Setting the DTC.......................................................... 276 Diagnostic Aids......................................................................... 276 DTC 244 - Adaptive Learn Low (LPG).......................................................... 279 Circuit Description..................................................................... 279 Conditions for Setting the DTC.......................................................... 279 Diagnostic Aids......................................................................... 279 DTC 261 - System Voltage High............................................................... 282 Circuit Description..................................................................... 282 Conditions for Setting the DTC.......................................................... 282 DTC 262 - System Voltage Low................................................................ 284 Circuit Description..................................................................... 284 Conditions for Setting the DTC.......................................................... 284 DTC 411 - Injector Driver 1 Open............................................................ 286 Circuit Description..................................................................... 286 Conditions for Setting the DTC.......................................................... 286 DTC 412 - Injector Driver 1 Shorted......................................................... 289 Circuit Description..................................................................... 289 Conditions for Setting the DTC.......................................................... 289 DTC 511 - COP Failure....................................................................... 292 Circuit Description..................................................................... 292 Conditions for Setting the DTC.......................................................... 292 DTC 512 - Invalid Interrupt................................................................. 294 Circuit Description..................................................................... 294 Conditions for Setting the DTC.......................................................... 294 DTC 513 - A/D Loss.......................................................................... 296 Circuit Description..................................................................... 296 Conditions for Setting the DTC.......................................................... 296 DTC 514 - RTI 1 Loss........................................................................ 298 Circuit Description..................................................................... 298 Conditions for Setting the DTC.......................................................... 298 DTC 515 - Flash Checksum Invalid............................................................ 300 Circuit Description..................................................................... 300 Conditions for Setting the DTC.......................................................... 300 DTC 516 - Ram Failure....................................................................... 302 Circuit Description..................................................................... 302 Conditions for Setting the DTC.......................................................... 302 DTC 531 - External 5V Ref Lower Than Expected............................................... 304 Circuit Description..................................................................... 304 Conditions for Setting the DTC.......................................................... 304 DTC 532 - External 5V Ref Higher Than Expected.............................................. 306 Circuit Description..................................................................... 306 Conditions for Setting the DTC.......................................................... 306 DTC 555 - RTI 2 Loss........................................................................ 308 Circuit Description..................................................................... 308 Conditions for Setting the DTC.......................................................... 308 DTC 556 - RTI 3 Loss........................................................................ 310 Circuit Description..................................................................... 310 Conditions for Setting the DTC.......................................................... 310 DTC 611 - FPP High Voltage.................................................................. 312 Circuit Description..................................................................... 312 Conditions for Setting the DTC.......................................................... 312 DTC 612 - FPP Low Voltage................................................................... 316 Circuit Description..................................................................... 316 Conditions for Setting the DTC.......................................................... 316 DTC 631 - TPS1 Signal Voltage High.......................................................... 320 Circuit Description..................................................................... 320 Conditions for Setting the DTC.......................................................... 320 DTC 632 - TPS1 Signal Voltage Low........................................................... 323 Circuit Description..................................................................... 323 Conditions for Setting the DTC.......................................................... 323 DTC 638 - Throttle Unable To Close.......................................................... 326 Circuit Description..................................................................... 326 Conditions for Setting the DTC.......................................................... 326 Diagnostic Aids......................................................................... 327 DTC 651 - Maximum Govern Speed Override..................................................... 329 Circuit Description..................................................................... 329 Conditions for Setting the DTC.......................................................... 329 Diagnostic Aids......................................................................... 329 DTC 652 - Fuel Rev Limit.................................................................... 332 Circuit Description..................................................................... 332 Conditions for Setting the DTC.......................................................... 332 Diagnostic Aids......................................................................... 332 DTC 653 - Spark Rev Limit................................................................... 334 Circuit Description..................................................................... 334 Conditions for Setting the DTC.......................................................... 334 Diagnostic Aids......................................................................... 334 GM 4.3L Wiring Schematics and Connectors........................................................ 338 GM 4.3L Diagnostic Trouble Codes................................................................ 355 DTC 111 - IAT High Voltage Bosch® TMAP...................................................... 355 Circuit Description..................................................................... 355 Conditions for Setting the DTC.......................................................... 355 DTC 111 - IAT High Voltage Motorola® TMAP................................................... 358 Circuit Description..................................................................... 358 Conditions for Setting the DTC.......................................................... 358 DTC 112 - IAT Low Voltage Bosch® TMap....................................................... 360 Circuit Description..................................................................... 360 Conditions for Setting the DTC.......................................................... 361 DTC 112 - IAT Low Voltage Motorola® TMAP.................................................... 363 Circuit Description..................................................................... 363 Conditions for Setting the DTC.......................................................... 363 DTC 113 - IAT Higher Than Expected 1 Bosch® TMAP............................................ 366 Circuit Description..................................................................... 366 Conditions for Setting the DTC.......................................................... 366 Diagnostic Aids......................................................................... 366 DTC 113 - IAT Higher Than Expected 1 Motorola® TMAP......................................... 367 Circuit Description..................................................................... 367 Conditions for Setting the DTC.......................................................... 367 Diagnostic Aids......................................................................... 367 DTC 114 - IAT Higher Than Expected 2 Bosch® TMAP€........................................... 368 Circuit Description..................................................................... 368 Conditions for Setting the DTC.......................................................... 368 Diagnostic Aids......................................................................... 368 DTC 114 - IAT Higher Than Expected 2 Motorola® TMAP......................................... 369 Circuit Description..................................................................... 369 Conditions for Setting the DTC.......................................................... 369 Diagnostic Aids......................................................................... 369 DTC 115 - Oil Pressure Low.................................................................. 370 Circuit Description..................................................................... 370 Conditions for Setting the DTC.......................................................... 370 DTC 121 - ECT Voltage High.................................................................. 372 Circuit Description..................................................................... 372 Conditions for Setting the DTC.......................................................... 373 DTC 122 - ECT Voltage Low................................................................... 376 Circuit Description..................................................................... 376 Conditions for Setting the DTC.......................................................... 376 DTC 123 - ECT Higher Than Expected 1........................................................ 379 Circuit Description..................................................................... 379 Conditions for Setting the DTC.......................................................... 379 DTC 124 - ECT Higher Than Expected 2........................................................ 381 Circuit Description..................................................................... 381 Conditions for Setting the DTC.......................................................... 381 DTC 131 - MAP High Pressure Bosch® TMAP..................................................... 382 Circuit Description..................................................................... 382 Conditions for Setting the DTC.......................................................... 382 Diagnostic Aids......................................................................... 382 DTC 131 - MAP High Pressure Motorola® TMAP.................................................. 386 Circuit Description..................................................................... 386 Conditions for Setting the DTC.......................................................... 386 Diagnostic Aids......................................................................... 386 DTC 132 - MAP Low Voltage Bosch® TMAP....................................................... 389 Circuit Description..................................................................... 389 Conditions for Setting the DTC.......................................................... 389 DTC 132 - MAP Low Voltage Motorola® TMAP.................................................... 392 Circuit Description..................................................................... 392 Conditions for Setting the DTC.......................................................... 392 DTC 134 - BP High Pressure Bosch® TMAP...................................................... 397 Circuit Description..................................................................... 397 Conditions for Setting the DTC.......................................................... 397 DTC 134 - BP High Pressure Motorola® TMAP................................................... 399 Circuit Description..................................................................... 399 Conditions for Setting the DTC.......................................................... 399 DTC 135 - BP Low Pressure Bosch® TMAP....................................................... 401 Circuit Description..................................................................... 401 Conditions for Setting the DTC.......................................................... 401 DTC 135 - BP Low Pressure Motorola® TMAP.................................................... 405 Circuit Description..................................................................... 405 Conditions for Setting the DTC.......................................................... 405 DTC 142 - Crank Sync Noise.................................................................. 408 Circuit Description..................................................................... 408 Conditions for setting the DTC.......................................................... 408 DTC 143 - Never Crank Synced At Start....................................................... 412 Circuit Description..................................................................... 412 Conditions for Setting the DTC.......................................................... 412 DTC 144 - Camshaft Sensor Loss.............................................................. 415 Circuit Description..................................................................... 415 Conditions for Setting the DTC.......................................................... 415 DTC 145 - Camshaft Sensor Noise............................................................. 418 Circuit Description..................................................................... 418 Conditions for Setting the DTC.......................................................... 418 DTC 211 - Closed Loop Multiplier High (LPG)................................................. 421 Circuit Description..................................................................... 421 Conditions for Setting the DTC.......................................................... 421 Diagnostic Aids......................................................................... 422 DTC 212 - HO 2 S Open/Inactive.............................................................. 424 Circuit Description..................................................................... 424 Conditions for Setting the DTC.......................................................... 424 DTC 221 - Closed Loop Multiplier High (Gasoline)............................................ 427 Circuit Description..................................................................... 427 Conditions for Setting the DTC.......................................................... 427 Diagnostic Aids......................................................................... 427 DTC 222 - Closed Loop Multiplier Low (Gasoline)............................................. 430 Circuit Description..................................................................... 430 Conditions for Setting the DTC.......................................................... 430 Diagnostic Aids......................................................................... 430 DTC 224 - Closed Loop Multiplier Low (LPG).................................................. 432 Circuit Description..................................................................... 432 Conditions for Setting the DTC.......................................................... 432 Diagnostic Aids......................................................................... 433 DTC 241 - Adaptive Lean Fault (High Limit-Gasoline)......................................... 434 Circuit Description..................................................................... 434 Conditions for Setting the DTC.......................................................... 434 Diagnostic Aids......................................................................... 434 DTC 242 - Adaptive Rich Fault (Low Limit-Gasoline).......................................... 437 Circuit Description..................................................................... 437 Conditions for Setting the DTC.......................................................... 437 Diagnostic Aids......................................................................... 437 DTC 243 - Adaptive Learn High (LPG)......................................................... 440 Circuit Description..................................................................... 440 Conditions for Setting the DTC.......................................................... 440 Diagnostic Aids......................................................................... 440 DTC 244 - Adaptive Learn Low (LPG).......................................................... 443 Circuit Description..................................................................... 443 Conditions for Setting the DTC.......................................................... 443 Diagnostic Aids......................................................................... 443 DTC 261 - System Voltage High............................................................... 446 Circuit Description..................................................................... 446 Conditions for Setting the DTC.......................................................... 446 DTC 262 - System Voltage Low................................................................ 448 Circuit Description..................................................................... 448 Conditions for Setting the DTC.......................................................... 448 DTC 511 - COP Failure....................................................................... 450 Circuit Description..................................................................... 450 Conditions for Setting the DTC.......................................................... 450 DTC 512 - Invalid Interrupt................................................................. 452 Circuit Description..................................................................... 452 Conditions for Setting the DTC.......................................................... 452 DTC 513 - A/D Loss.......................................................................... 454 Circuit Description..................................................................... 454 Conditions for Setting the DTC.......................................................... 454 DTC 514 - RTI 1 Loss........................................................................ 456 Circuit Description..................................................................... 456 Conditions for Setting the DTC.......................................................... 456 DTC 515 - Flash Checksum Invalid............................................................ 458 Circuit Description..................................................................... 458 Conditions for Setting the DTC.......................................................... 458 DTC 516 - Ram Failure....................................................................... 460 Circuit Description..................................................................... 460 Conditions for Setting the DTC.......................................................... 460 DTC 531 - External 5V Ref Lower Than Expected............................................... 462 Circuit Description..................................................................... 462 Conditions for Setting the DTC.......................................................... 462 DTC 532 - External 5V Ref Higher Than Expected.............................................. 464 Circuit Description..................................................................... 464 Conditions for Setting the DTC.......................................................... 464 DTC 555 - RTI 2 Loss........................................................................ 466 Circuit Description..................................................................... 466 Conditions for Setting the DTC.......................................................... 466 DTC 556 - RTI 3 Loss........................................................................ 468 Circuit Description..................................................................... 468 Conditions for Setting the DTC.......................................................... 468 DTC 611 - FPP High Voltage.................................................................. 470 Circuit Description..................................................................... 470 Conditions for Setting the DTC.......................................................... 470 DTC 612 - FPP Low Voltage................................................................... 474 Circuit Description..................................................................... 474 Conditions for Setting the DTC.......................................................... 474 DTC 631 - TPS1 Signal Voltage High.......................................................... 478 Circuit Description..................................................................... 478 Conditions for Setting the DTC.......................................................... 478 DTC 632 - TPS1 Signal Voltage Low........................................................... 481 Circuit Description..................................................................... 481 Conditions for Setting the DTC.......................................................... 481 DTC 638 - Throttle Unable To Close.......................................................... 484 Circuit Description..................................................................... 484 Conditions for Setting the DTC.......................................................... 484 Diagnostic Aids......................................................................... 485 DTC 651 - Maximum Govern Speed Override..................................................... 487 Circuit Description..................................................................... 487 Conditions for Setting the DTC.......................................................... 487 Diagnostic Aids......................................................................... 487 DTC 652 - Fuel Rev Limit.................................................................... 490 Circuit Description..................................................................... 490 Conditions for Setting the DTC.......................................................... 490 Diagnostic Aids......................................................................... 490 DTC 653 - Spark Rev Limit................................................................... 492 Circuit Description..................................................................... 492 Conditions for Setting the DTC.......................................................... 492 Diagnostic Aids......................................................................... 492 Wire Harness Repair............................................................................. 495 On Vehicle Service Wiring Harness Repair.................................................... 495 Connectors and Terminals.................................................................... 496 Twisted/Shielded Cable Repair........................................................... 496 Twisted Leads Repair.................................................................... 497 Micro-Pack.............................................................................. 498 Metri-Pack.............................................................................. 498 Remove.............................................................................. 498 Weather-Pack............................................................................ 500 Weather-Pack Terminal Repair........................................................ 501 tables.............................................................................................. 173 Table 1. OBD System Check....................................................................... 193 Table 2. Preliminary Checks..................................................................... 195 Table 3. Intermittent Checks.................................................................... 196 Table 4. Communication Port C002................................................................ 197 Table 5. Coil Connector C003.................................................................... 197 Table 6. Fuel System Interface C004............................................................. 197 Table 7. Oil Pressure Connector C005............................................................ 198 Table 8. Distributor Connector C006............................................................. 198 Table 9. Magnetic Pickup Connector C007......................................................... 198 Table 10. Heated Oxygen Sensor C008............................................................. 198 Table 11. Throttle Position Sensor Connector C009............................................... 199 Table 12. Foot Pedal Position Connector C010.................................................... 199 Table 13. Governor Motor Connector C011......................................................... 199 Table 14. TMAP Connector C012................................................................... 199 Table 15. Starter Solenoid C013................................................................. 200 Table 16. Engine Coolant Temperature C014....................................................... 200 Table 17. Battery Connector C015................................................................ 200 Table 18. Alternator Connection C016............................................................ 200 Table 19. Battery Connector C017................................................................ 200 Table 20. Alternator Connector C018............................................................. 201 Table 21. Instrument Panel Connector C019....................................................... 201 Table 22. Instrument Panel Connector C020....................................................... 201 Table 23. Instrument Panel Connector C021....................................................... 202 Table 24. Fuel Trim Valve Connector C022........................................................ 202 Table 25. Fuel Lockoff Connector C023........................................................... 202 Table 26. Pressure Trim Valve Connector C024.................................................... 203 Table 27. Throttle Body Injector Connector C025................................................. 203 Table 28. Relay and Fuse Center................................................................. 203 Table 29. DTC 111 - IAT Voltage High (Motorola® TMAP)........................................... 212 Table 30. DTC 112 - IAT Low Voltage (Motorola® TMAP)............................................ 215 Table 31. DTC 115 - Oil Pressure Low............................................................ 220 Table 32. Temperature Resistance................................................................ 222 Table 33. DTC 121 - ECT VOLTAGE HIGH............................................................ 223 Table 34. DTC 122 - ECT Voltage Low............................................................. 227 Table 35. DTC 123 - ECT Higher Than Expected 1.................................................. 229 Table 36. DTC 124 - ECT Higher Than Expected 2.................................................. 231 Table 37. DTC 131 - MAP HIGH PRESSURE (Motorola® TMAP).......................................... 233 Table 38. DTC 132 - MAP Low Voltage (Motorola® TMAP)............................................ 236 Table 39. DTC 134 - BP High Pressure (Motorola® TMAP)........................................... 239 Table 40. DTC 135 - BP Low Pressure (Motorola® TMAP)............................................ 241 Table 41. DTC 142 - Crank Sync Noise............................................................ 245 Table 42. DTC 143 - Never Crank Synced At Start................................................. 248 Table 43. DTC 144 - Camshaft Sensor Loss........................................................ 251 Table 44. DTC 145 - Camshaft Sensor Noise....................................................... 254 Table 45. DTC 211 - Closed Loop Multiplier High (LPG)........................................... 258 Table 46. DTC 212 - HO 2 S Open/Inactive........................................................ 261 Table 47. DTC 221 - Closed Loop Multiplier High (Gasoline)...................................... 264 Table 48. DTC 222 - Closed Loop Multiplier Low (Gasoline)....................................... 267 Table 49. DTC 224 - Closed Loop Multiplier Low (LPG)............................................ 269 Table 50. DTC 241 - Adaptive Lean Fault (High Limit-Gasoline)................................... 271 Table 51. DTC 242 - Adaptive Rich Fault (Low Limit-Gasoline).................................... 274 Table 52. DTC 243 - Adaptive Learn High (LPG)................................................... 277 Table 53. DTC 244 - Adaptive Learn Low (LPG).................................................... 280 Table 54. DTC 261 - System Voltage High......................................................... 283 Table 55. DTC 262 - System Voltage Low.......................................................... 284 Table 56. DTC 411 - Injector Driver 1 Open...................................................... 287 Table 57. DTC 412 - Injector Driver 1 Shorted................................................... 290 Table 58. DTC 511 - COP Failure................................................................. 293 Table 59. DTC 512 - Invalid Interrupt........................................................... 295 Table 60. DTC 513 - A/D Loss.................................................................... 297 Table 61. DTC 514 - RTI 1 Loss.................................................................. 299 Table 62. DTC 515 - Flash Checksum Invalid...................................................... 301 Table 63. DTC 516 - Ram Failure................................................................. 303 Table 64. DTC 531 - External 5V Ref Lower Than Expected......................................... 305 Table 65. DTC 532 - External 5 V Ref Higher Than Expected....................................... 307 Table 66. DTC 555 - RTI 2 Loss.................................................................. 309 Table 67. DTC 556 - RTI 3 Loss.................................................................. 311 Table 68. DTC 611 - FPP High Voltage............................................................ 313 Table 69. DTC 612 - FPP Low Voltage............................................................. 317 Table 70. DTC 631 - TPS1 Signal Voltage High.................................................... 321 Table 71. DTC 632 - TPS1 Signal Voltage Low..................................................... 324 Table 72. DTC 638 - Throttle Unable To Close.................................................... 327 Table 73. DTC 651 - Maximum Govern Speed Override............................................... 330 Table 74. DTC 652 - Fuel Rev Limit.............................................................. 333 Table 75. DTC 653 - Spark Rev Limit............................................................. 335 Table 76. Communication Port C002............................................................... 338 Table 77. Injector Connector C003............................................................... 338 Table 78. Injector Connector C004............................................................... 338 Table 79. Oil Pressure Connector C005........................................................... 339 Table 80. Throttle Position Sensor 1 Connector C006............................................. 339 Table 81. Foot Pedal Position Connector C006A................................................... 339 Table 82. Coil Connector C007................................................................... 339 Table 83. Module Connector C008................................................................. 340 Table 84. Crank Sensor Connector C009........................................................... 340 Table 85. EGO Sensor Connector C010............................................................. 340 Table 86. Cam Connector C011.................................................................... 341 Table 87. Throttle Connector C012............................................................... 341 Table 88. Bosch TMAP Connector C013 (Gasoline Fuel System Only)................................. 341 Table 89. Motorola TMAP Connector C013 (LPG Fuel System Only)................................... 342 Table 90. Starter Solenoid Connector C014....................................................... 342 Table 91. ECT Connector C015.................................................................... 342 Table 92. Starter Relay C016.................................................................... 342 Table 93. Power Relay C017...................................................................... 342 Table 94. Fuel Pump Relay C018.................................................................. 342 Table 95. Battery Connector C019................................................................ 343 Table 96. Alternator Connector C020............................................................. 343 Table 97. Alternator Connector C021............................................................. 343 Table 98. Instrument Panel Connector C022....................................................... 343 Table 99. Instrument Panel Connector C023....................................................... 344 Table 100. Instrument Panel Connector C024...................................................... 344 Table 101. Fuel Trim Valve Connector C025....................................................... 344 Table 102. Fuel Lockoff Connector C026.......................................................... 345 Table 103. Pressure Trim Valve Connector C027................................................... 345 Table 104. Injector 1 Connector C028............................................................ 345 Table 105. Injector 2 Connector C029............................................................ 346 Table 106. Injector 3 Connector C030............................................................ 346 Table 107. Injector 4 Connector C031............................................................ 346 Table 108. Injector 5 Connector C032............................................................ 347 Table 109. Injector 6 Connector C033............................................................ 347 Table 110. Relay and Fuse Center................................................................ 347 Table 111. DTC 111 - IAT Voltage High (Bosch® TMAP)............................................. 356 Table 112. DTC 111 - IAT Voltage High (Motorola® TMAP).......................................... 359 Table 113. DTC 112 - IAT Low Voltage (Bosch® TMAP).............................................. 361 Table 114. DTC 112 - IAT Low Voltage (Motorola® TMAP)........................................... 364 Table 115. DTC 115 - Oil Pressure Low........................................................... 370 Table 116. Temperature Resistance............................................................... 373 Table 117. DTC 121 - ECT VOLTAGE HIGH........................................................... 374 Table 118. DTC 122 - ECT Voltage Low............................................................ 377 Table 119. DTC 123 - ECT Higher Than Expected 1................................................. 380 Table 120. DTC 124 - ECT Higher Than Expected 2................................................. 382 Table 121. DTC 131 - MAP High Pressure (Bosch® TMAP)............................................ 383 Table 122. DTC 131 - MAP HIGH PRESSURE (Motorola® TMAP)......................................... 387 Table 123. DTC 132 - MAP Low Voltage (Bosch® TMAP).............................................. 390 Table 124. DTC 132 - MAP Low Voltage (Motorola® TMAP)........................................... 393 Table 125. DTC 134 - BP High Pressure (Bosch® TMAP)............................................. 398 Table 126. DTC 134 - BP High Pressure (Motorola® TMAP).......................................... 400 Table 127. DTC 135 - BP Low Pressure (Bosch® TMAP).............................................. 401 Table 128. DTC 135 - BP Low Pressure (Motorola® TMAP)........................................... 405 Table 129. DTC 142 - Crank Sync Noise........................................................... 409 Table 130. DTC 143 - Never Crank Synced At Start................................................ 412 Table 131. DTC 144 - Camshaft Sensor Loss....................................................... 415 Table 132. DTC 145 - Camshaft Sensor Noise...................................................... 418 Table 133. DTC 211 - Closed Loop Multiplier High (LPG).......................................... 422 Table 134. DTC 212 - HO 2 S Open/Inactive....................................................... 425 Table 135. DTC 221 - Closed Loop Multiplier High (Gasoline)..................................... 428 Table 136. DTC 222 - Closed Loop Multiplier Low (Gasoline)...................................... 431 Table 137. DTC 224 - Closed Loop Multiplier Low (LPG)........................................... 433 Table 138. DTC 241 - Adaptive Lean Fault (High Limit-Gasoline).................................. 435 Table 139. DTC 242 - Adaptive Rich Fault (Low Limit-Gasoline)................................... 438 Table 140. DTC 243 - Adaptive Learn High (LPG).................................................. 441 Table 141. DTC 244 - Adaptive Learn Low (LPG)................................................... 444 Table 142. DTC 261 - System Voltage High........................................................ 447 Table 143. DTC 262 - System Voltage Low......................................................... 448 Table 144. DTC 511 - COP Failure................................................................ 451 Table 145. DTC 512 - Invalid Interrupt.......................................................... 453 Table 146. DTC 513 - A/D Loss................................................................... 455 Table 147. DTC 514 - RTI 1 Loss................................................................. 457 Table 148. DTC 515 - Flash Checksum Invalid..................................................... 459 Table 149. DTC 516 - Ram Failure................................................................ 461 Table 150. DTC 531 - External 5V Ref Lower Than Expected........................................ 463 Table 151. DTC 532 - External 5 V Ref Higher Than Expected...................................... 465 Table 152. DTC 555 - RTI 2 Loss................................................................. 467 Table 153. DTC 556 - RTI 3 Loss................................................................. 469 Table 154. DTC 611 - FPP High Voltage........................................................... 471 Table 155. DTC 612 - FPP Low Voltage............................................................ 474 Table 156. DTC 631 - TPS1 Signal Voltage High................................................... 479 Table 157. DTC 632 - TPS1 Signal Voltage Low.................................................... 482 Table 158. DTC 638 - Throttle Unable To Close................................................... 485 Table 159. DTC 651 - Maximum Govern Speed Override.............................................. 488 Table 160. DTC 652 - Fuel Rev Limit............................................................. 491 Table 161. DTC 653 - Spark Rev Limit............................................................ 494 Frame................................................................................................... 505 toc................................................................................................. 505 Frame........................................................................................... 505 Safety Precautions Maintenance and Repair....................................................... 506 Description..................................................................................... 509 Counterweight Repair............................................................................ 510 Remove...................................................................................... 510 Install..................................................................................... 515 Exhaust System Repair........................................................................... 517 Muffler..................................................................................... 517 Remove.................................................................................. 517 Install................................................................................. 517 Exhaust Pipe - LPG/Gas Engine............................................................... 518 Remove.................................................................................. 518 Install................................................................................. 521 Exhaust Pipe - Diesel Engine................................................................ 521 Remove.................................................................................. 521 Install................................................................................. 522 Hood Repair..................................................................................... 522 Remove...................................................................................... 522 Install..................................................................................... 522 Overhead Guard Repair........................................................................... 523 Remove...................................................................................... 523 Install..................................................................................... 523 LED Backup and Brake Lights, Replace........................................................ 524 Remove.................................................................................. 524 Install................................................................................. 524 Operator Restraint System Repair................................................................ 524 Automatic Locking Retractor (ALR)........................................................... 525 Emergency Locking Retractor (ELR)........................................................... 525 Radiator and Coolant System..................................................................... 526 Remove...................................................................................... 526 Install..................................................................................... 526 Alternator Replacement.......................................................................... 528 Remove...................................................................................... 528 Install..................................................................................... 528 Engine Removal and Installation................................................................. 528 Remove...................................................................................... 528 Install..................................................................................... 532 Fuel and Hydraulic Tanks Repair................................................................. 534 Inspect..................................................................................... 534 Repairs, Small Leaks........................................................................ 534 Repairs, Large Leaks........................................................................ 534 Clean....................................................................................... 534 Steam Method of Cleaning................................................................ 534 Chemical Solution Method of Cleaning.................................................... 535 Other Methods of Preparation for Repair................................................. 535 Safety Labels................................................................................... 537 tables.............................................................................................. 505 Table 1. Weight of Counterweights............................................................... 515 Fuel system gas......................................................................................... 541 toc................................................................................................. 541 Electronic Controlled LPG/Gasoline Fuel System.................................................. 541 Safety Precautions Maintenance and Repair....................................................... 542 General......................................................................................... 547 Fuel System Warnings and Cautions........................................................... 547 Glossary........................................................................................ 548 Description and Operation of LPG Fuel System.................................................... 552 Propane Fuel System......................................................................... 552 LPG Fuel Tank............................................................................... 554 Service Line................................................................................ 554 Fuel Filter................................................................................. 554 Low Pressure Lock-Off (LPL)................................................................. 555 Low Pressure Regulator (LPR)................................................................ 555 Air Fuel Mixer.............................................................................. 555 Throttle Control Device..................................................................... 556 Drive By Cable.......................................................................... 556 Three-Way Catalytic (TWC) Muffler........................................................... 557 Electronic Control Module (ECM)............................................................. 557 Heated Exhaust Gas Oxygen (HEGO) Sensor..................................................... 560 Description and Operation of Gasoline Fuel System............................................... 560 Gasoline Fuel System Throttle Body Injection (TBI), 3.0L Engine ............................ 560 Gasoline Multi-Point Fuel Injection (MPFI) System, 4.3L Only................................ 562 Gasoline Fuel Storage Tank.................................................................. 562 Gasoline Fuel Pump.......................................................................... 562 Fuel Filter................................................................................. 562 Fuel Pressure Regulator, 3.0L Only.......................................................... 564 Fuel Rail and Pressure Regulator, 4.3L Only................................................. 564 Fuel Injector............................................................................... 564 Throttle Control Device..................................................................... 564 Drive By Cable.......................................................................... 564 Three-Way Catalytic Muffler................................................................. 565 Electronic Control Module (ECM)............................................................. 566 Heated Exhaust Gas Oxygen (HEGO) Sensor..................................................... 567 LPG Fuel System Repair.......................................................................... 568 Propane Fuel System Pressure Relief......................................................... 568 Propane Fuel System Leak Test............................................................... 568 Propane Fuel Filter Replacement............................................................. 568 Remove.................................................................................. 568 Install................................................................................. 569 Low Pressure Lock-Off (LPL) Replacement..................................................... 569 Remove.................................................................................. 569 Install................................................................................. 569 Pressure Trim Valve (PTV) Replacement....................................................... 571 Remove.................................................................................. 571 Install................................................................................. 571 Low Pressure Regulator...................................................................... 571 Remove.................................................................................. 571 Install................................................................................. 571 Fuel Trim Valve (FTV) Solenoid Replacement.................................................. 572 Remove.................................................................................. 572 Install................................................................................. 572 Temperature Manifold Absolute Pressure (TMAP)............................................... 575 Remove.................................................................................. 575 Install................................................................................. 575 Throttle Body Replacement................................................................... 575 Remove.................................................................................. 575 Install................................................................................. 576 Mixer Replacement........................................................................... 576 Remove.................................................................................. 576 Install................................................................................. 576 Coolant Hose Replacement.................................................................... 576 Remove.................................................................................. 576 Install................................................................................. 577 Vapor Hose Replacement...................................................................... 577 Remove.................................................................................. 577 Install................................................................................. 577 Balance Line Hose Replacement............................................................... 577 Remove.................................................................................. 577 Install................................................................................. 577 PTV Hose Replacement........................................................................ 577 Remove.................................................................................. 577 Install................................................................................. 577 FTV Hose Replacement........................................................................ 578 Remove.................................................................................. 578 Install................................................................................. 578 Throttle Position Sensor (TPS) Replacement.................................................. 578 Foot Pedal Position (FPP) Sensor Replacement................................................ 580 Electronic Control Module (ECM) Replacement................................................. 583 Remove.................................................................................. 583 Install................................................................................. 583 Heated Exhaust Gas Oxygen (HEGO) Sensor Replacement......................................... 584 Remove.................................................................................. 584 Install................................................................................. 584 Three-Way Catalytic Muffler (TWC) Replacement............................................... 584 Remove.................................................................................. 584 Install................................................................................. 584 Restricted Exhaust System Diagnosis......................................................... 584 Exhaust System Description.............................................................. 584 Tools Required...................................................................... 584 Diagnostic Tool..................................................................... 584 Check at Heated Exhaust Gas Oxygen Sensor (HEGO)........................................ 585 Gasoline Fuel System Repair..................................................................... 585 Gasoline MPFI and TBI Fuel System Pressure Relief........................................... 585 Gasoline Fuel System Leak Test.............................................................. 586 Throttle Body Injector (TBI) Assembly Replacement, 3.0L Only................................ 586 Remove.................................................................................. 586 Install................................................................................. 586 Throttle Body Assembly Replacement, 3.0L Only............................................... 588 Remove.................................................................................. 588 Install................................................................................. 588 Throttle Body Assembly Replacement, 4.3L Only............................................... 588 Remove.................................................................................. 588 Install................................................................................. 589 Fuel Rail Replacement, Gasoline 4.3L Only................................................... 591 Remove.................................................................................. 591 Install................................................................................. 591 Injector Replacement, Gasoline 4.3L Only.................................................... 591 Remove.................................................................................. 591 Install................................................................................. 591 Injector Replacement, Gasoline 3.0L Only.................................................... 592 Remove.................................................................................. 592 Install................................................................................. 592 Temperature Manifold Absolute Pressure (TMAP) Replacement................................... 592 Remove.................................................................................. 592 Install................................................................................. 592 Throttle Position Sensor (TPS) Replacement.................................................. 592 Foot Pedal Position (FPP) Sensor Replacement................................................ 595 Electronic Control Module (ECM) Replacement................................................. 598 Remove.................................................................................. 598 Install................................................................................. 598 Heated Exhaust Gas Oxygen (HEGO) Sensor Replacement......................................... 598 Remove.................................................................................. 598 Install................................................................................. 599 Three-Way Catalytic Muffler (TWC) Replacement............................................... 599 Remove.................................................................................. 599 Install................................................................................. 599 Restricted Exhaust System Diagnosis......................................................... 599 Exhaust System Description.............................................................. 599 Tools Required...................................................................... 599 Diagnostic Tool..................................................................... 599 Check at Heated Exhaust Gas Oxygen Sensor (HEGO)........................................ 599 LPG System Diagnosis............................................................................ 600 Fuel System Description..................................................................... 600 Diagnostic Aids............................................................................. 601 Tools Required.......................................................................... 601 Duty Cycle Monitoring Tool.............................................................. 601 Diagnostic Tool......................................................................... 601 Pressure Gauges......................................................................... 601 Test Description........................................................................ 601 Gasoline System Diagnosis....................................................................... 609 Fuel System Description, 3.0L Only.......................................................... 609 Fuel System Description, 4.3L Only.......................................................... 609 Diagnostic Aids............................................................................. 610 Tools Required.......................................................................... 610 Diagnostic Tool......................................................................... 610 Test Description........................................................................ 610 LPG Symptom Diagnosis........................................................................... 617 Gasoline Symptom Diagnosis...................................................................... 631 Wire Harness Repair............................................................................. 641 On Vehicle Service Wiring Harness Repair.................................................... 641 Connectors and Terminals.................................................................... 642 Twisted/Shielded Cable Repair........................................................... 642 Twisted Leads Repair.................................................................... 643 Micro-Pack.............................................................................. 644 Metri-Pack.............................................................................. 645 Remove.............................................................................. 645 Weather-Pack............................................................................ 646 Weather-Pack Terminal Repair........................................................ 647 tables.............................................................................................. 541 Table 1. TPS Replacement Procedure.............................................................. 578 Table 2. FPP Replacement Procedure.............................................................. 581 Table 3. TPS Replacement Procedure.............................................................. 593 Table 4. FPP Replacement Procedure.............................................................. 596 Table 5. LPG Fuel System Diagnosis.............................................................. 601 Table 6. Fuel Control Diagnosis................................................................. 605 Table 7. Gasoline Fuel System Diagnosis, 3.0L Only.............................................. 611 Table 8. Gasoline Fuel System Diagnosis, 4.3L Only.............................................. 614 Table 9. Preliminary Checks..................................................................... 617 Table 10. Intermittent ......................................................................... 619 Table 11. No Start.............................................................................. 620 Table 12. Hard Start............................................................................ 622 Table 13. Cuts Out or Misses.................................................................... 623 Table 14. Hesitation, Sag, or Stumble........................................................... 624 Table 15. Backfire.............................................................................. 625 Table 16. Lack of Power, Sluggishness, or Sponginess............................................ 626 Table 17. Poor Fuel Economy..................................................................... 627 Table 18. Rough, Unstable, Incorrect Idle, or Stalling.......................................... 628 Table 19. Surges or Chuggles.................................................................... 630 Table 20. Preliminary Checks.................................................................... 631 Table 21. Intermittent.......................................................................... 632 Table 22. No Start.............................................................................. 633 Table 23. Hard Start............................................................................ 634 Table 24. Cuts Out or Misses.................................................................... 635 Table 25. Hesitation, Sag, or Stumble........................................................... 636 Table 26. Backfire.............................................................................. 637 Table 27. Lack of Power, Sluggishness, or Sponginess............................................ 638 Table 28. Poor Fuel Economy..................................................................... 639 Table 29. Rough, Unstable, Incorrect Idle, or Stalling.......................................... 640 Table 30. Surges or Chuggles.................................................................... 641 GM engines.............................................................................................. 651 Hydraulic pump.......................................................................................... 705 toc................................................................................................. 705 Hydraulic Gear Pumps............................................................................ 705 Safety Precautions Maintenance and Repair....................................................... 706 Description..................................................................................... 709 Operation....................................................................................... 710 Flow Control Valve.......................................................................... 710 Relief Valve................................................................................ 710 Hydraulic Gear Pump Repair...................................................................... 711 Remove...................................................................................... 711 Disassemble................................................................................. 712 Clean....................................................................................... 712 Inspect..................................................................................... 713 Assemble.................................................................................... 716 Install..................................................................................... 718 Pump Output Check............................................................................... 718 Method No. 1................................................................................ 718 Method No. 2................................................................................ 719 Hydraulic System Air Check...................................................................... 720 Troubleshooting................................................................................. 721 Hydraulic system........................................................................................ 727 toc................................................................................................. 727 Hydraulic System................................................................................ 727 Safety Precautions Maintenance and Repair....................................................... 728 General......................................................................................... 731 Description..................................................................................... 731 Operation....................................................................................... 733 Hydraulic Pump H3.50-5.50XM (H70-120XM)..................................................... 733 Hydraulic Pump S3.50-5.50XM (S70-120XM)..................................................... 733 Main Control Valve.......................................................................... 733 Steering Control Unit....................................................................... 734 Specifications.................................................................................. 734 Hydraulic System Capacity (Powershift)...................................................... 734 Hydraulic System Capacity (Hydrostatic)..................................................... 734 Hydraulic Tank Capacity (Powershift and Hydrostatic)........................................ 735 Hydraulic Tank Capacity..................................................................... 735 Relief Pressures @ 2200 RPM, 50 to 80 C ( 120 to 180 F)..................................... 735 Hydraulic Pump Flow to Valve................................................................ 735 Steering Priority Flow...................................................................... 735 Troubleshooting................................................................................. 735 Lift, Lower and Tilt Circuit................................................................ 736 Steering Circuit............................................................................ 737 Ignition system......................................................................................... 741 Instrunment panel....................................................................................... 781 toc................................................................................................. 781 Instrument Panel Indicators and Senders......................................................... 781 Safety Precautions Maintenance and Repair....................................................... 782 General......................................................................................... 785 Description..................................................................................... 785 Instruments and Senders..................................................................... 785 Password Function........................................................................... 792 Supervisor Password Function............................................................ 792 Entering Operator Passwords......................................................... 792 Deleting Operator Passwords......................................................... 793 Retrieve the Most Recent Operator Password Used to Enable the Tr.................... 793 Display All Operator Passwords Programmed Into the System........................... 793 Enable and Disable Operator Passwords Function...................................... 793 Allow Supervisor Password to Enable the Truck to Start.............................. 793 Operator Passwords Function............................................................. 793 Component Replacement - General Information..................................................... 794 Sender Replacement.............................................................................. 794 Fuel Level Sender........................................................................... 794 Pressure and Temperature Sender............................................................. 795 Seat Sensor, Operator Presence System (OPS)................................................. 796 Remove.................................................................................. 796 Install................................................................................. 796 Operator Presence System Module Replacement................................................. 797 Remove.................................................................................. 797 Install................................................................................. 798 Display Panel Replacement....................................................................... 799 Specifications.................................................................................. 800 Troubleshooting................................................................................. 802 Troubleshooting For Operator Presence System H3.50-5.50XM (H70-1................................ 803 Troubleshooting For Operator Presence System S70-120XM (E004, F0................................ 805 tables.............................................................................................. 781 Table 1. Instrument Panel Description........................................................... 786 Table 2. Sender Description..................................................................... 791 Table 3. Meter and Sender Specifications........................................................ 800 Table 4. Troubleshooting Procedure for the Operator Presence Mod................................ 803 Table 5. Troubleshooting Procedure for the Operator Presence Mod................................ 805 Lift cylinder........................................................................................... 811 toc................................................................................................. 811 Lift Cylinders.................................................................................. 811 Safety Precautions Maintenance and Repair....................................................... 812 Safety Procedures When Working Near Mast........................................................ 815 General......................................................................................... 817 Description..................................................................................... 817 Lowering Control Valve (Velocity Fuse)...................................................... 817 Lift Cylinder Repair............................................................................ 820 Remove...................................................................................... 820 Disassemble................................................................................. 821 Assemble.................................................................................... 821 Install..................................................................................... 822 Lift System Leak Check.......................................................................... 822 Troubleshooting................................................................................. 823 Masts................................................................................................... 827 toc................................................................................................. 827 Masts........................................................................................... 827 Safety Precautions Maintenance and Repair....................................................... 828 General......................................................................................... 831 Description and Operation....................................................................... 831 Carriages................................................................................... 831 Two-Stage Mast With Limited Free-Lift....................................................... 831 Two-Stage Mast With Full Free-Lift.......................................................... 832 Three-Stage Mast With Full Free-Lift........................................................ 833 Safety Procedures When Working Near Mast........................................................ 835 Fork Replacement................................................................................ 837 Remove...................................................................................... 838 Install..................................................................................... 838 Carriage Repair................................................................................. 839 Remove...................................................................................... 839 Sideshift Carriage Repair....................................................................... 841 Remove...................................................................................... 841 Disassemble................................................................................. 842 Assemble.................................................................................... 842 Install..................................................................................... 842 Two-Stage Mast With Limited Free-Lift Repair.................................................... 843 Remove, H3.50-5.50XM (H70-120XM) Model Lift Trucks.......................................... 843 Remove, S3.50-5.50XM (S70-120XM), E3.50-5.50XL 3 (E70-120XL 3 ) ............................ 845 Disassemble................................................................................. 848 Clean and Inspect........................................................................... 848 Assemble.................................................................................... 849 Install, H3.50-5.50XM (H70-120XM) Lift Truck Models......................................... 850 Install, S3.50-5.50XM (S70-120XM), E3.50-5.50XL 3 (E70-120XL 3 )............................ 852 Two-Stage Mast With Full Free-Lift Repair....................................................... 854 Remove...................................................................................... 854 Disassemble................................................................................. 854 Clean and Inspect........................................................................... 856 Assemble.................................................................................... 856 Install..................................................................................... 856 Three-Stage Mast With Full Free-Lift Repair..................................................... 858 Remove...................................................................................... 858 Disassemble................................................................................. 858 Clean and Inspect........................................................................... 862 Assemble.................................................................................... 862 Install..................................................................................... 863 Mast Operation Check............................................................................ 869 Lift and Tilt System Leak Check................................................................. 870 Lift System................................................................................. 870 Tilt System................................................................................. 871 Tilt Cylinder Stroke and Backward Tilt Angle Adjustment......................................... 872 Lift Chain Adjustments.......................................................................... 874 Mast Adjustments................................................................................ 876 Carriage Adjustment............................................................................. 878 Troubleshooting................................................................................. 879 tables.............................................................................................. 827 Table 1. Tilt Cylinder Leak Check Specifications, S3.50-5.50XM (................................ 871 Table 2. Hook-Type Carriage Chain Adjustment.................................................... 874 Table 3. Pin-Type Carriage Chain Adjustment..................................................... 875 Parts................................................................................................... 885 Frame............................................................................................... 903 GENERAL TRUCK................................................................................... 906 FLOOR PLATES AND COVERS......................................................................... 908 HOOD............................................................................................ 912 BATTERY TRAY LATCH.............................................................................. 915 COUNTERWEIGHT................................................................................... 918 OVERHEAD GUARD.................................................................................. 920 NON-SUSPENSION SEAT............................................................................. 922 NON-SUSPENSION SEAT............................................................................. 924 FULL SUSPENSION SEAT SHEET 1 OF 2 (→ S/N F004V03917C) ......................................... 926 FULL SUSPENSION SEAT SHEET 2 OF 2 (→ S/N F004V03917C) ......................................... 930 FULL SUSPENSION SEAT............................................................................ 932 FULL SUSPENSION SWIVEL SEAT SHEET 1 OF 2 (→ S/N F004V03917C) .................................. 934 FULL SUSPENSION SWIVEL SEAT SHEET 2 OF 2 (→ S/N F004V03917C) .................................. 938 FULL SUSPENSION SWIVEL SEAT..................................................................... 942 LABELS.......................................................................................... 944 FORK STANDARD TAPER HOOK TYPE (S70-80XM)........................................................ 946 FORK STANDARD TAPER HOOK TYPE (S100-120XM)...................................................... 947 FORK POLISHED WITH FULL BOTTOM TAPER HOOK TYPE.................................................. 948 LOAD BACKREST EXTENSION......................................................................... 950 ENGINES............................................................................................. 953 ASSEMBLED ENGINE GASOLINE, 4.3L EPA COMPLIANT - SHEET 1 OF 2 ................................... 958 ASSEMBLED ENGINE GASOLINE, 4.3L EPA COMPLIANT - SHEET 2 OF 2 ................................... 960 ASSEMBLED ENGINE LPG, 4.3L EPA COMPLIANT - SHEET 1 OF 2 ........................................ 964 ASSEMBLED ENGINE LPG, 4.3L EPA COMPLIANT - SHEET 2 OF 2 ........................................ 966 COIL ASSEMBLY................................................................................... 969 VALVE COVER AND INLET MANIFOLD GASOLINE AND LPG................................................. 970 CYLINDER HEAD GASOLINE AND LPG.................................................................. 974 CYLINDER BLOCK GASOLINE AND LPG................................................................. 976 INTAKE MANIFOLD AND FUEL RAIL GASOLINE - 4.3L EPA COMPLIANT .................................... 978 CAMSHAFT AND OIL PAN GASOLINE AND LPG........................................................... 980 OIL PUMP GASOLINE AND LPG....................................................................... 984 DRIP SHIELD GASOLINE AND LPG.................................................................... 986 COOLING GASOLINE AND LPG........................................................................ 988 FAN DRIVE AND ALTERNATOR MOUNTING GASOLINE AND LPG.............................................. 992 VALVE COVER AND ROCKER ARM SHAFT DIESEL......................................................... 994 CYLINDER HEAD DIESEL............................................................................ 996 CYLINDER BLOCK DIESEL........................................................................... 998 MANIFOLDS DIESEL................................................................................1000 CRANKSHAFT AND PISTON DIESEL....................................................................1002 OIL PAN AND PUMP DIESEL.........................................................................1004 OIL FILTER DIESEL...............................................................................1007 COOLING DIESEL..................................................................................1008 COOLANT PUMP DIESEL.............................................................................1010 TIMING GEAR DIESEL..............................................................................1012 ENGINE MOUNTS...................................................................................1014 FLYWHEEL HOUSING GASOLINE, LPG AND DIESEL.......................................................1016 EXHAUST GASOLINE AND LPG (STANDARD, OVERHEAD AND SAFETY), DIESEL (OVERHEAD) - EPA COMPLIANT ....1018 EXHAUST WRAPS PAPER INDUSTRY OPTION.............................................................1020 EXHAUST DIESEL - STANDARD ......................................................................1022 EXHAUSTER ROTARY - DIESEL ......................................................................1024 EXHAUST GASOLINE AND LPG - NON-EPA COMPLIANT ...................................................1026 FUEL SYSTEM.........................................................................................1029 AIR INTAKE AND FILTER SYSTEM GASOLINE, LPG AND DIESEL...........................................1032 AIR FILTER......................................................................................1034 FUEL SUPPLY SYSTEM GASOLINE.....................................................................1036 THROTTLE BODY ASSEMBLY GASOLINE - 4.3L EPA COMPLIANT ENGINE ....................................1038 ENGINE FUEL SYSTEM LPG - 4.3L EPA COMPLIANT ENGINE .............................................1040 FUEL FILTERING SYSTEM LPG - 4.3L EPA COMPLIANT ENGINE ..........................................1042 THROTTLE BODY AND MIXER LPG - 4.3L EPA COMPLIANT ENGINE ........................................1044 REGULATING SYSTEM LPG - 4.3L EPA COMPLIANT ENGINE ..............................................1046 LPG TANK BRACKET FIXED - STANDARD (→ S/N F004V02383B) ........................................1048 LPG TANK BRACKET FIXED - STANDARD (S/N F004V02384B →) ........................................1050 LPG TANK BRACKET EZXCHANGE BRACKET - STANDARD AND BOX CAR SPECIAL (→ S/N F004V02383B) ........1052 LPG TANK BRACKET EZXCHANGE BRACKET - STANDARD AND BOX CAR SPECIAL (S/N F004V02384B →) ........1056 LPG TANK BRACKET FIXED - BOX CAR SPECIAL .......................................................1059 LPG TANK BRACKET EZXCHANGE BRACKET - 80 BOX CAR SPECIAL ........................................1060 LPG TANK BRACKET EZXCHANGE BRACKET - 80 BOX CAR SPECIAL (1/2005 →) ...........................1062 LPG TANK BRACKET FIXED - STANDARD WITH NYLON STRAP .............................................1065 LPG TANK BRACKET FIXED - BOX CAR SPECIAL WITH NYLON STRAP ......................................1067 LPG TANK BRACKET EZXCHANGE BRACKET - 80 BOX CAR SPECIAL WITH NYLON STRAP .......................1068 FUEL SUPPLY SYSTEM DIESEL.......................................................................1072 FUEL SYSTEM LOW PRESSURE - DIESEL ..............................................................1074 HIGH PRESSURE FUEL INJECTION DIESEL.............................................................1076 WATER SEPARATOR DIESEL..........................................................................1078 LIFT PUMP DIESEL................................................................................1080 FUEL FILTER DIESEL..............................................................................1081 THROTTLE LINKAGE GASOLINE, LPG, AND DIESEL......................................................1082 ACCELERATOR PEDAL AND BRACKET ASSEMBLY WITH FORWARD AND REVERSE LEVER...........................1084 ACCELERATOR PEDAL AND BRACKET ASSEMBLY MONOTROL.................................................1086 MONOTROL PEDAL..................................................................................1088 ELECTRICAL SYSTEM...................................................................................1091 INSTRUMENT PANEL................................................................................1094 ELECTRICAL SYSTEM DASH PANEL....................................................................1096 ELECTRICAL SYSTEM GASOLINE AND LPG..............................................................1100 ELECTRICAL SYSTEM LPS...........................................................................1104 ELECTRICAL SYSTEM DIESEL........................................................................1106 ELECTRICAL SYSTEM CHASSIS.......................................................................1110 WIRE HARNESS DASH (→ S/N F004V01696B) .........................................................1112 WIRE HARNESS DASH (S/N F004V01697B ↔ S/N F004V03148C) .........................................1114 WIRE HARNESS DASH (S/N F004V03149C →) .........................................................1116 WIRE HARNESS POWER DISTRIBUTION GROUP...........................................................1120 WIRE HARNESS CHASSIS (→ S/N F004V03917C) ......................................................1124 WIRE HARNESS CHASSIS (S/N F004V03918C →) ......................................................1126 WIRE HARNESS FUEL INJECTOR - GASOLINE GM 4.3L ..................................................1129 WIRE HARNESS ENGINE, GASOLINE GM 4.3L - SHEET 1 0F 2 ...........................................1132 WIRE HARNESS ENGINE, GASOLINE GM 4.3L - SHEET 2 OF 2 ...........................................1134 WIRE HARNESS - ENGINE LPG GM 4.3L - SHEET 1 0F 2 ...............................................1136 WIRE HARNESS - ENGINE LPG GM 4.3L - SHEET 2 OF 2 ...............................................1140 WIRE HARNESS LPG REGULATOR......................................................................1142 WIRE HARNESS ENGINE - DIESEL ...................................................................1144 WIRE HARNESS INTERFACE..........................................................................1148 WIRE HARNESS SEALED ALTERNATOR..................................................................1150 DISTRIBUTOR GASOLINE AND LPG....................................................................1152 SEALED ALTERNATOR...............................................................................1154 ALTERNATOR MOUNTING DIESEL......................................................................1156 STARTER GASOLINE AND LPG........................................................................1158 STARTER DIESEL..................................................................................1160 STARTER DIESEL - OPTIONAL ......................................................................1162 TRANSMISSION........................................................................................1165 TRANSMISSION....................................................................................1168 TRANSMISSION CONTROL VALVE SHEET 1 OF 2.........................................................1172 TRANSMISSION CONTROL VALVE SHEET 2 OF 2.........................................................1174 CLUTCH PACKS....................................................................................1176 CLUTCH PACKS....................................................................................1178 TORQUE CONVERTER................................................................................1180 DIFFERENTIAL AND HYPOID ASSEMBLY................................................................1182 DIFFERENTIAL AND HYPOID ASSEMBLY................................................................1184 DRIVE AXLE......................................................................................1186 DRIVE TIRES AND WHEELS..........................................................................1189 STEERING SYSTEM.....................................................................................1191 STEER COLUMN....................................................................................1194 SHIFT LEVERS....................................................................................1196 STEER AXLE......................................................................................1198 STEER CYLINDER..................................................................................1202 STEERING CYLINDER...............................................................................1204 STEER TIRES AND WHEELS..........................................................................1206 BRAKE SYSTEM........................................................................................1207 BRAKE LINKAGE SINGLE PEDAL......................................................................1210 BRAKE LINKAGE DUAL PEDALS.......................................................................1212 BRAKE LINES.....................................................................................1214 MASTER CYLINDER AND BRAKE BOOSTER...............................................................1216 PARK BRAKE LEVER................................................................................1218 BRAKE ASSEMBLY SHORT WHEEL BASE.................................................................1220 BRAKE ASSEMBLY LONG WHEEL BASE..................................................................1222 BRAKE ASSEMBLY OPTIONAL 4 INCH (100 MM) WIDE....................................................1224 HYDRAULIC SYSTEM....................................................................................1227 HYDRAULIC HOSES AND FITTINGS SUPPLY AND RETURN..................................................1230 HYDRAULIC HOSES AND FITTINGS TILT...............................................................1232 HYDRAULIC HOSES AND FITTINGS AUXILIARY - 3, 4 AND 5 FUNCTION ...................................1234 HYDRAULIC HOSE AND FITTINGS STEERING AND HOIST..................................................1236 CONTROL VALVE AND ATTACHING PARTS THREE FUNCTION (→ S/N F004V02247B) ..........................1238 CONTROL VALVE AND ATTACHING PARTS FOUR FUNCTION (→ S/N F004V02247B) ...........................1242 CONTROL VALVE AND ATTACHING PARTS FIVE FUNCTION (→ S/N F004V02247B) ...........................1246 HYDRAULIC CONTROL VALVE.........................................................................1250 CONTROL VALVE AND ATTACHING PARTS THREE FUNCTION (S/N F004V02148B →) ..........................1254 CONTROL VALVE AND ATTACHING PARTS FOUR FUNCTION (S/N F004V02248B →) ...........................1258 CONTROL VALVE AND ATTACHING PARTS FIVE FUNCTION (S/N F004V02248B →) ...........................1262 HYDRAULIC CONTROL VALVE THREE, FOUR, AND FIVE FUNCTION (S/N F004V02161B →) ....................1266 TRANSMISSION COOLING AND STEERING LINES.........................................................1270 HYDRAULIC FILTER HOUSING........................................................................1272 HYDRAULIC PUMP..................................................................................1274 TILT CYLINDER...................................................................................1275 MAST INSTALLATION...............................................................................1278 PRESSURE REGULATOR USED WITH PAPER ROLL.........................................................1280 Mast-Two Stage Limited Free-Lift....................................................................1283 OUTER MAST TWO STAGE FULL FREE-LIFT.............................................................1286 INNER MAST TWO STAGE LIMITED FREE-LIFT..........................................................1288 MAIN LIFT TWO STAGE LIMITED FREE-LIFT...........................................................1290 MAIN CYLINDER TWO STAGE LIMITED FREE-LIFT - S70-80XM ...........................................1294 MAIN CYLINDER TWO STAGE LIMITED FREE-LIFT - S100-120XM .........................................1296 HEADER HOSE TWO STAGE LIMITED FREE-LIFT.........................................................1298 CARRIAGE TWO STAGE LIMITED FREE-LIFT............................................................1302 Mast-Two Stage Full Free-Lift.......................................................................1305 OUTER MAST AND MAIN LIFT TWO STAGE FULL FREE-LIFT...............................................1308 INNER MAST AND FREE-LIFT TWO STAGE FULL FREE-LIFT...............................................1312 MAIN CYLINDER TWO STAGE FULL FREE-LIFT - S70-80XM ..............................................1316 MAIN CYLINDER TWO STAGE FULL FREE-LIFT - S100-120XM ............................................1320 FREE-LIFT CYLINDER TWO STAGE FULL FREE-LIFT.....................................................1324 HEADER HOSE TWO STAGE FULL FREE-LIFT............................................................1328 CARRIAGE TWO STAGE FULL FREE-LIFT...............................................................1334 Mast-Three Stage Full Free-Lift.....................................................................1337 OUTER MAST THREE STAGE FULL FREE-LIFT...........................................................1340 INTERMEDIATE MAST THREE STAGE FULL FREE-LIFT....................................................1344 INNER MAST THREE STAGE FULL FREE-LIFT...........................................................1348 MAIN LIFT THREE STAGE FULL FREE-LIFT............................................................1350 FREE-LIFT THREE STAGE FULL FREE-LIFT............................................................1354 MAIN CYLINDER THREE STAGE FULL FREE-LIFT........................................................1358 FREE-LIFT CYLINDER THREE STAGE FULL FREE-LIFT...................................................1362 HEADER HOSE THREE STAGE FULL FREE-LIFT..........................................................1366 CARRIAGE THREE STAGE FULL FREE-LIFT.............................................................1370 OPTIONS.............................................................................................1373 INTEGRAL SIDE-SHIFT TWO STAGE LIMITED FREE-LIFT - S70-80XM .....................................1376 INTEGRAL SIDE-SHIFT TWO STAGE LIMITED FREE-LIFT - S100-120XM ...................................1378 INTEGRAL SIDE-SHIFT CARRIAGE 1067 MM (42 IN.) CLASS III - TWO STAGE LIMITED FREE-LIFT ..........1380 INTEGRAL SIDE-SHIFT CARRIAGE 1219 MM (48 IN.) CLASS III - TWO STAGE LIMITED FREE-LIFT ..........1382 INTEGRAL SIDE-SHIFT CARRIAGE 1219 MM (48 IN.) CLASS IV - TWO STAGE LIMITED FREE-LIFT ...........1384 INTEGRAL SIDE-SHIFT TWO STAGE FULL FREE-LIFT - S70-80XM ........................................1386 INTEGRAL SIDE-SHIFT TWO STAGE FULL FREE-LIFT - S100-120XM ......................................1388 INTEGRAL SIDE-SHIFT CARRIAGE 1067 MM (42 IN.) CLASS III - TWO STAGE FULL FREE-LIFT .............1390 INTEGRAL SIDE-SHIFT CARRIAGE 1219 MM (48 IN.) CLASS III - TWO STAGE FULL FREE-LIFT .............1392 INTEGRAL SIDE-SHIFT CARRIAGE 1219 MM (48 IN.) CLASS IV - TWO STAGE FULL FREE-LIFT ..............1394 INTEGRAL SIDE-SHIFT THREE STAGE FULL FREE-LIFT - S70-80XM ......................................1396 INTEGRAL SIDE-SHIFT THREE STAGE FULL FREE-LIFT - S100-120XM ....................................1398 INTEGRAL SIDE-SHIFT CARRIAGE 1067 MM (42 IN.) CLASS III - THREE STAGE FULL FREE-LIFT ...........1400 INTEGRAL SIDE-SHIFT CARRIAGE 1219 MM (48 IN.) CLASS III - THREE STAGE FULL FREE-LIFT ...........1402 INTEGRAL SIDE-SHIFT CARRIAGE 1219 MM (48 IN.) CLASS IV - THREE STAGE FULL FREE-LIFT ............1404 AUXILIARY TUBE EXTENSION KIT TWO STAGE LIMITED FREE-LIFT........................................1406 TUBE EXTENSION KITS TWO AND THREE STAGE FULL FREE-LIFT..........................................1408 QUICK DISCONNECT................................................................................1410 FRONT HEADLIGHTS................................................................................1412 REAR DRIVE LIGHT................................................................................1414 PLUGS WITHOUT BACK-UP AND BRAKE LIGHTS..........................................................1416 LIGHTS, LED BACK-UP AND BRAKE...................................................................1418 WIRE HARNESS PRESSURE SWITCH - LED BRAKE LIGHTS ................................................1420 LIGHTS BACK-UP AND BRAKE WITHOUT HEAVY DUTY AIR INTAKE OR OVERHEAD EXHAUST......................1422 LIGHTS REAR DRIVE, BACK-UP AND BRAKE WITH HEAVY DUTY AIR INTAKE - OR OVERHEAD EXHAUST ..........1424 LED LIGHTS, BACK-UP AND BRAKE WITH HEAVY DUTY AIR INTAKE AND OVERHEAD EXHAUST...................1426 STROBE LIGHT HIGH MOUNT.........................................................................1428 STROBE LIGHT LOW MOUNT..........................................................................1430 ACCUMULATOR.....................................................................................1432 BACK-UP ALARM...................................................................................1433 FIELD CONVERSION KITS...............................................................................1435 MISCELLANEOUS KITS..............................................................................1438 HYDRAULIC CONTROL CONVERSIONS HUSCO VALVES ONLY.................................................1438 SWING OUT DROP DOWN LPG KITS....................................................................1438 OPERATOR PRESENCE SYSTEM KITS...................................................................1438 TUBE EXTENSION CONVERSION KITS TWO STAGE LIMITED FREE-LIFT......................................1438 TUBE EXTENSION CONVERSION KITS THREE STAGE FULL FREE-LIFT.......................................1439 TUBE EXTENSION CONVERSION KITS TWO STAGE FULL FREE-LIFT.........................................1439 NUMERICAL INDEX.....................................................................................1441 Perkins enine...........................................................................................1475 toc.................................................................................................1475 Perkins Diesel Engines..........................................................................1475 Safety Precautions Maintenance and Repair.......................................................1476 General.........................................................................................1483 General Safety Rules........................................................................1483 Description.....................................................................................1484 Engine Serial Number Codes..................................................................1487 Engine Data.................................................................................1487 Engine Removal and Installation.................................................................1489 Lift Engine.................................................................................1489 Cylinder Head Assembly Repair...................................................................1489 Valve Cover.................................................................................1489 Remove..................................................................................1489 Install.................................................................................1490 Rocker Arm Assembly.........................................................................1490 Remove..................................................................................1490 Install.................................................................................1490 Disassemble.............................................................................1490 Inspect.................................................................................1491 Assemble................................................................................1491 Valve Clearance Adjustments.................................................................1491 Four-Cylinder Engines...................................................................1492 Six-Cylinder Engines....................................................................1492 Valve Springs...............................................................................1492 Cylinder Head Assembly......................................................................1494 Remove..................................................................................1494 Install.................................................................................1496 Valves and Valve Springs....................................................................1500 Remove..................................................................................1500 Inspect.................................................................................1500 Install.................................................................................1501 Valve Guides................................................................................1501 Inspect.................................................................................1501 Remove..................................................................................1502 Install.................................................................................1502 Cylinder Head and Valve Seats...............................................................1502 Inspect.................................................................................1502 Repair..................................................................................1502 New Valve Seats, Install................................................................1502 Piston and Connecting Rod Assemblies Repair.....................................................1504 Rod Bearings................................................................................1504 Remove..................................................................................1505 Install.................................................................................1505 Piston and Connecting Rod Assembly..........................................................1506 Service Note............................................................................1506 Remove..................................................................................1506 Install.................................................................................1507 Piston Rings................................................................................1508 Remove..................................................................................1508 Inspect.................................................................................1508 Install.................................................................................1508 Piston and Connecting Rod...................................................................1509 Disassemble.............................................................................1509 Inspect.................................................................................1510 How to Select Correct Replacements......................................................1510 Install.................................................................................1511 Piston Cooling Jets.........................................................................1511 Remove..................................................................................1511 Install.................................................................................1512 Crankshaft Assembly Repair......................................................................1512 General.....................................................................................1512 Crankshaft Pulley...........................................................................1513 Engine AR, Remove.......................................................................1513 Engines YG and YH, Remove...............................................................1513 Inspect.................................................................................1514 Engine AR, Install......................................................................1514 Engines YG and YH, Install..............................................................1514 Rear Oil Seal...............................................................................1515 Replace.................................................................................1515 Main Bearings...............................................................................1516 Remove..................................................................................1516 Inspect.................................................................................1517 Install.................................................................................1517 Thrust Washers..............................................................................1517 Crankshaft Axial Movement, Check........................................................1517 Remove..................................................................................1518 Install.................................................................................1518 Crankshaft..................................................................................1519 Remove..................................................................................1519 Inspect.................................................................................1519 Install.................................................................................1519 Flywheel....................................................................................1521 Remove..................................................................................1521 Ring Gear, Replace......................................................................1521 Install.................................................................................1521 Flywheel Housing............................................................................1522 Remove..................................................................................1522 Install.................................................................................1522 Timing Case and Timing Gears Repair.............................................................1523 General.....................................................................................1523 Timing Case Cover...........................................................................1523 Remove..................................................................................1523 Install.................................................................................1524 Front Oil Seal..............................................................................1524 Remove..................................................................................1524 Install.................................................................................1524 Crankshaft Pulley Wear Sleeve...............................................................1525 Install.................................................................................1525 Idler Gear and Hub..........................................................................1525 Remove..................................................................................1525 Install.................................................................................1526 Air Compressor Drive, Bendix................................................................1527 Disassemble.............................................................................1527 Assemble................................................................................1528 Fuel Injection Pump Gear....................................................................1528 Remove..................................................................................1529 Install.................................................................................1529 Camshaft Gear...............................................................................1530 Remove..................................................................................1530 Install.................................................................................1530 Crankshaft Gear.............................................................................1531 Remove..................................................................................1531 Install.................................................................................1531 Timing Case.................................................................................1531 Remove..................................................................................1531 Install.................................................................................1532 Camshaft and Tappets........................................................................1533 Remove..................................................................................1533 Install.................................................................................1533 Cylinder Block Assembly Repair..................................................................1534 Description.................................................................................1534 Cylinder Block..............................................................................1534 Disassemble.............................................................................1534 Inspect.................................................................................1535 Assemble................................................................................1535 Cylinder Bore (Four-Cylinder Engines).......................................................1536 Cylinder Liner (Six-Cylinder Engines).......................................................1536 Inspect.................................................................................1536 Cylinder Liner Condition, Check.........................................................1536 Remove..................................................................................1537 Service Liner, Install..................................................................1538 Partially Finished Liner, Install.......................................................1539 Engine Timing...................................................................................1540 Description.................................................................................1540 How to Set Number One Piston to TDC on Compression Stroke...............................1541 How to Set Number One Piston to TDC on Compression Stroke (Alter........................1542 Valve Timing, Check.....................................................................1542 Fuel Injection Pump Timing, Check.......................................................1543 Turbocharger - Engine YH Repair.................................................................1544 General.....................................................................................1544 Remove..................................................................................1544 Install.................................................................................1544 Impeller and Compressor Housing, Clean..................................................1545 Lubrication System Repair.......................................................................1546 General.....................................................................................1546 Oil Filter, Replace.........................................................................1546 Filter Head.................................................................................1547 Remove and Install......................................................................1547 Oil Sump....................................................................................1547 Remove..................................................................................1547 Install.................................................................................1548 Oil Pump....................................................................................1548 Remove..................................................................................1548 Inspect.................................................................................1548 Install.................................................................................1549 Relief Valve................................................................................1549 Remove..................................................................................1549 Disassemble.............................................................................1550 Inspect.................................................................................1550 Assemble................................................................................1550 Install.................................................................................1551 Idler Gear Shaft, Replace...................................................................1551 Remove..................................................................................1551 Remove (Alternative)....................................................................1551 Install.................................................................................1552 Install (Alternative)...................................................................1552 Install (Alternative for Four-Cylinder Engines Only)....................................1553 Fuel System Repair..............................................................................1553 Description.................................................................................1553 Fuel Injection Pump.........................................................................1554 Remove..................................................................................1554 Install.................................................................................1555 Check and Adjust........................................................................1556 Fuel System Air Removal.....................................................................1556 Fuel Filter, Replace........................................................................1557 Canister Type...........................................................................1558 Quick Release Canister Type.............................................................1558 Fuel Injectors..............................................................................1559 Remove..................................................................................1559 Inspect.................................................................................1560 Install.................................................................................1560 Fuel Pump...................................................................................1561 Remove..................................................................................1561 Disassemble.............................................................................1561 Assemble................................................................................1561 Install.................................................................................1562 Test....................................................................................1562 Cooling System Repair...........................................................................1563 General.....................................................................................1563 Thermostat..................................................................................1563 Remove..................................................................................1563 Install.................................................................................1563 Test....................................................................................1564 Coolant Pump................................................................................1564 Remove..................................................................................1564 Disassemble.............................................................................1564 Assemble................................................................................1566 Install.................................................................................1568 Fan and Fan Drive...........................................................................1569 Remove..................................................................................1569 Install.................................................................................1569 Oil Cooler (Six-Cylinder Engines)...........................................................1570 Remove..................................................................................1570 Disassemble and Assemble................................................................1570 Install.................................................................................1570 Oil Cooler Bypass Valve.................................................................1570 Electrical Equipment Repair.....................................................................1571 Drive Belts.................................................................................1571 Adjustment..............................................................................1571 Remove..................................................................................1572 Install.................................................................................1572 Alternator..................................................................................1572 Remove..................................................................................1572 Install.................................................................................1572 Starter Motor...............................................................................1572 Remove..................................................................................1572 Install.................................................................................1572 Cold Start Aid..............................................................................1572 Air Compressor - Engines YG and YH..............................................................1573 General.....................................................................................1573 Repair......................................................................................1573 Remove..................................................................................1573 Install.................................................................................1573 Rotary Exhauster Replacement....................................................................1575 Remove......................................................................................1575 Clean.......................................................................................1575 Install.....................................................................................1575 Engine Specifications...........................................................................1576 Cylinder Head Assembly......................................................................1576 Piston and Connecting Rods..................................................................1579 Crankshaft Assembly.........................................................................1582 Crankshaft Overhaul.....................................................................1584 Timing Case and Drive Assembly..............................................................1586 Engine Block Assembly.......................................................................1587 Turbocharger................................................................................1590 Lubrication System..........................................................................1590 Fuel System.................................................................................1591 Cooling System..............................................................................1593 Flywheel and Housing........................................................................1593 Electrical Equipment........................................................................1594 Torque Specifications...........................................................................1594 Cylinder Head Assembly......................................................................1594 Piston and Connecting Rod Assemblies........................................................1594 Crankshaft Assembly.........................................................................1594 Timing Case and Drive Assembly..............................................................1595 Turbocharger................................................................................1595 Lubrication System..........................................................................1595 Fuel System.................................................................................1595 Cooling System..............................................................................1595 Flywheel....................................................................................1595 Auxiliary Equipment.........................................................................1595 Special Torque Specifications...................................................................1596 Flywheel and Housing........................................................................1596 Turbocharger................................................................................1596 Electrical Equipment........................................................................1596 Auxiliary Equipment.........................................................................1596 Special Tools*..................................................................................1597 Troubleshooting.................................................................................1602 tables..............................................................................................1475 Table 1. Cylinder Head..........................................................................1576 Table 2. Valve Guides...........................................................................1576 Table 3. Inlet Valves...........................................................................1576 Table 4. Exhaust Valves.........................................................................1577 Table 5. Valve Springs..........................................................................1579 Table 6. Tappets................................................................................1579 Table 7. Rocker Arm Shaft.......................................................................1579 Table 8. Rocker Arms and Bushings...............................................................1579 Table 9. Pistons (Engine AR)....................................................................1579 Table 10. Pistons (Engines YG and YH)...........................................................1579 Table 11. Piston Rings (Engine AR)..............................................................1580 Table 12. Piston Rings (Engines YG and YH)......................................................1580 Table 13. Piston Pins...........................................................................1581 Table 14. Connecting Rods.......................................................................1581 Table 15. Small End Bushings....................................................................1581 Table 16. Connecting Rod Bearings (Engines AR and YG)...........................................1581 Table 17. Connecting Rod Bearings (Engine YH)...................................................1581 Table 18. Piston Cooling Jets...................................................................1582 Table 19. Crankshaft............................................................................1582 Table 20. Main Bearings.........................................................................1583 Table 21. Crankshaft Thrust Washers.............................................................1583 Table 22. Crankshaft Heat Treatment.............................................................1583 Table 23. Crankshaft Overhaul Specifications....................................................1584 Table 24. Maximum Variation (Run-out)...........................................................1586 Table 25. Camshaft..............................................................................1586 Table 26. Camshaft Thrust Washer................................................................1586 Table 27. Camshaft Gear.........................................................................1586 Table 28. Gear for Fuel Injection Pump..........................................................1587 Table 29. Crankshaft Gear.......................................................................1587 Table 30. Idler Gear and Hub....................................................................1587 Table 31. Cylinder Block (Engine AR)............................................................1587 Table 32. Cylinder Bore Specifications..........................................................1588 Table 33. Cylinder Block (Engines YG and YH)....................................................1589 Table 34. Cylinder Liners (Engines YG and YH)...................................................1589 Table 35. Cylinder Liner Specifications (Partially Finished)....................................1589 Table 36. Oil Pump (Engine AR)..................................................................1590 Table 37. Oil Pump (Engines YG and YH)..........................................................1590 Table 38. Idler Gear for Oil Pump...............................................................1591 Table 39. Relief Valve..........................................................................1591 Table 40. Oil Filter............................................................................1591 Table 41. Lucas Fuel Injection Pump.............................................................1591 Table 42. Fuel Injector Codes...................................................................1592 Table 43. Fuel Pump (Engine AR).................................................................1593 Table 44. Fuel Pump (Engines YG and YH).........................................................1593 Table 45. Fuel Filter...........................................................................1593 Table 46. Coolant Pump..........................................................................1593 Table 47. Thermostat............................................................................1593 Table 48. Fan Drive Housing.....................................................................1593 Table 49. Limits for Flywheel Run Out and Alignment (Total Indic................................1594 Table 50. Alternator............................................................................1594 Table 51. Starter Motor.........................................................................1594 Table 52. Cold Start Aid........................................................................1594 Table 53. List of Possible Causes...............................................................1602 PM......................................................................................................1607 toc.................................................................................................1607 Periodic Maintenance............................................................................1607 Safety Precautions Maintenance and Repair.......................................................1608 General.........................................................................................1613 Serial Number Data..........................................................................1613 How to Move Disabled Lift Truck.............................................................1613 How to Tow Lift Truck...................................................................1613 How to Put Lift Truck on Blocks.............................................................1614 How to Raise Drive Tires................................................................1614 How to Raise Steering Tires.............................................................1614 Maintenance Schedule............................................................................1615 Maintenance Procedures Every 8 Hours or Daily...................................................1622 How to Make Checks With Engine Stopped......................................................1622 Engine Oil..............................................................................1622 Hydraulic System Oil....................................................................1623 Cooling System Reservoir Level..........................................................1624 Fuel System.............................................................................1624 Battery.................................................................................1624 Tires and Wheels........................................................................1625 Forks...................................................................................1625 Adjust..............................................................................1625 Hook Fork, Remove...................................................................1626 Hook Fork, Install..................................................................1627 Forks, Mast, and Lift Chains, Inspect...................................................1627 Operator Restraint System...............................................................1628 Automatic Locking Retractor (ALR)...................................................1628 Emergency Locking Retractor (ELR)...................................................1628 Safety Labels...........................................................................1629 Cooling System, Clean Debris from Radiator Core.............................................1629 How to Make Checks With Engine Running......................................................1630 Gauges, Lights, Horn, and Fuses.........................................................1630 Engine Oil Pressure.....................................................................1631 Cooling System Temperature..............................................................1631 Powershift Transmission Oil level Check.................................................1631 Control Levers and Pedals...............................................................1632 Lift System Operation...................................................................1632 Service Brakes..........................................................................1632 Parking Brakes..........................................................................1633 Steering System.........................................................................1633 Maintenance Procedures Every 500 Hours or 3 Months..............................................1634 Lift Chain Lubrication......................................................................1634 Engine Oil and Filter, Perkins Diesel Engine................................................1634 Drive Belts.................................................................................1634 Fan Drive Belts.........................................................................1634 Perkins Diesel Engine.......................................................................1634 Alternator Drive Belt...................................................................1634 GM 4.3L Engine..............................................................................1635 Serpentine Drive Belt...................................................................1635 Tension Screw Adjustment............................................................1635 Hydraulic Tank Breather, Clean and Check....................................................1636 Brake Fluid.................................................................................1637 Lift Chains Wear Check......................................................................1637 Forks, Wear and Damage Check................................................................1637 Mast Lubrication............................................................................1638 Control Levers and Pedals Lubrication.......................................................1638 Steering Axle Lubrication...................................................................1638 Fuel System, Checks and Adjustments.........................................................1638 LPG Carburetor..........................................................................1638 Fuel Injection (Perkins Engine).........................................................1638 GM V-6 Engine...........................................................................1638 Inching/Brake Pedal.........................................................................1639 Steering Tie Rods...........................................................................1639 Fork Pins and Guides........................................................................1639 Wheel Nuts..................................................................................1639 Air Filter..................................................................................1639 Battery.....................................................................................1639 Maintenance Procedures Every 1000 Hours or 6 Months.............................................1640 Fuel Filter, Replace (Diesel Engine)........................................................1640 Fuel System, Remove Air (Perkins 1004.42 Diesel Engine).....................................1640 Water Separator, Diesel Engine..............................................................1642 PCV Valve, GM V-6...........................................................................1642 Crankcase Breather, GM V-6..................................................................1642 Valve Clearance, Check and Adjust...........................................................1642 Differential and Drive Axle Oil.............................................................1642 Spark Plugs, GM V-6.........................................................................1642 Ignition Timing.............................................................................1642 Cooling System, GM V-6 EPA Compliant Engine.................................................1643 LPG Fuel Filter GM V-6 EPA Compliant Engine, Replace........................................1643 Inspect Engine Electrical System, Connectors, and FCVS Connectio............................1644 Maintenance Procedures Every 2000 Hours or Annually.............................................1644 Differential Thrust Screw...................................................................1644 Hydraulic System............................................................................1645 Hydraulic Oil and Filter, Replace.......................................................1645 Powershift Transmission Oil and Filter, Replace.............................................1645 Spark Plugs, GM V-6.........................................................................1646 Cooling System..............................................................................1646 Wheel Bearings..............................................................................1646 Steering Wheels, Lubrication............................................................1646 Drive Wheels, Lubrication...............................................................1646 PCV Valve, GM V-6...........................................................................1646 LPG Filter, Replace.........................................................................1646 Gasoline Fuel Filter, Replace...............................................................1647 Brake Booster Filter, Replace...............................................................1647 Differential Oil for Powershift Transmission, Replace.......................................1647 Air Filter Element, GM V-6 EPA Compliant Engine.............................................1647 Oxygen Sensor GM V-6 EPA Compliant Engine...................................................1648 Test LPG /GAS Regulator Pressure............................................................1648 Inspect Low Pressure Regulator (LPR) for Oil Buildup and Leaks..............................1648 Check Throttle Shaft for Sticking...........................................................1649 Inspect Exhaust Manifold and Piping for Leaks...............................................1649 Safety Procedures When Working Near Mast........................................................1650 Lift Chain Adjustments..........................................................................1652 Fuel Injectors Repair...........................................................................1653 Lift and Tilt System Leak Check.................................................................1654 Lift Cylinders, Leak Check..................................................................1654 Tilt System.................................................................................1654 Welding Repairs.................................................................................1655 Overhead Guard Changes..........................................................................1656 Wheel and Tire Replacement......................................................................1657 Solid Rubber Tire, Change...................................................................1657 Wheels, Install.........................................................................1657 Adhesives and Sealants..........................................................................1658 Hydraulic Oil, Lubricant, and Coolant Specifications............................................1658 tables..............................................................................................1607 Table 1. Maintenance Schedule...................................................................1616 Table 2. Hook-Type Carriage Chain Adjustment....................................................1652 Table 3. Pin-Type Carriage Chain Adjustment.....................................................1653 Table 4. Tilt Cylinder Leak Check Specifications................................................1655 Pump drive..............................................................................................1661 toc.................................................................................................1661 Hydraulic Pump Drive Assembly...................................................................1661 Safety Precautions Maintenance and Repair.......................................................1662 General.........................................................................................1665 Description.....................................................................................1665 Hydraulic Pump Drive Assembly Repair............................................................1667 Remove and Disassemble......................................................................1667 Clean.......................................................................................1668 Inspect.....................................................................................1668 Assemble and Install........................................................................1668 Troubleshooting.................................................................................1669 Report-an-Error.........................................................................................1673 Single speed trans troubleshoot.........................................................................1674 toc.................................................................................................1674 Single-Speed Powershift Transmission............................................................1674 Safety Precautions Maintenance and Repair.......................................................1675 General.........................................................................................1678 Transmission Repair.............................................................................1678 Remove......................................................................................1678 Disassemble.................................................................................1679 Transmission, Disassemble...............................................................1679 Input Shaft, Disassemble................................................................1680 Reverse Clutch, Disassemble.............................................................1682 Output Shaft (Pinion) and Differential, Remove and Disassemble..........................1685 Clean and Inspect...........................................................................1687 Assemble....................................................................................1687 Input Shaft, Assemble...................................................................1688 Reverse Clutch, Assemble................................................................1696 Output Shaft (Pinion) and Differential, Assemble and Install............................1701 Transmission, Assemble..................................................................1708 Control Valve, Install..................................................................1711 Install.....................................................................................1711 Control Valve Repair............................................................................1712 Remove, Early Model S3.50-5.50XL (S70-120XL) Lift Trucks....................................1712 Disassemble, Early Model S3.50-5.50XL (S70-120XL) Lift Trucks...............................1712 Assemble, Early Model S3.50-5.50XL (S70-120XL) Lift Trucks..................................1713 Install, Early Model S3.50-5.50XL (S70-120XL) Lift Trucks...................................1713 Remove and Disassemble, Later Model S3.50-5.50XL (S70-120XL) Tru............................1713 Inspect, Later Model S3.50-5.50XL (S70-120XL) Trucks and S3.50-5............................1716 Assemble and Install, Later Model S3.50-5.50XL (S70-120XL) Truck............................1716 MONOTROL® Pedal Repair..........................................................................1718 Remove and Disassemble, S3.50-5.50XL (S70-120XL) Model Lift Truc............................1718 Assemble and Install, S3.50-5.50XL (S70-120XL) Model Lift Trucks............................1719 Remove and Disassemble, S3.50-5.50XM (S70-120XM) Model Lift Truc............................1721 Assemble and Install, S3.50-5.50XM (S70-120XM) Model Lift Trucks............................1721 Direction Control Lever Repair..................................................................1723 Remove and Disassemble......................................................................1723 Assemble and Install........................................................................1723 Stall Test......................................................................................1724 Linkages Adjustment.............................................................................1725 Linkage for Inching/Brake Pedal, S3.50-5.50XL (S70-120XL) (D004)............................1725 Linkage for Direction Control Lever.........................................................1727 Linkage for Inching/Brake Pedal, S3.50-5.50XM (S70-120XM) (E004,............................1727 Brake Shoe Adjustment...................................................................1727 Inching/Brake Pedal Height Adjustment...................................................1727 Single Pedal Height Adjustment......................................................1727 Two Pedal Height Adjustment.........................................................1727 Inching/Brake Linkage Adjustment........................................................1729 Oil Pressures Check.............................................................................1731 System Pressure Check Port..................................................................1731 Torque Converter Check Port.................................................................1731 Clutch Pressure Check Port..................................................................1732 Inching Pressure............................................................................1732 Solenoid Check Ports ( MONOTROL Control Only)...............................................1734 Lubrication Pressure Check Ports............................................................1734 System Pressure Check Port..................................................................1734 Torque Converter Check Port.................................................................1734 Reverse Clutch Pressure Check Port..........................................................1734 Forward Clutch Pressure Check Port..........................................................1734 Lubrication Pressure Check Port.............................................................1734 Modulator Pressure Check Port...............................................................1734 Troubleshooting.................................................................................1735 tables..............................................................................................1674 Table 1. Ring and Pinion Tooth Contact Adjustment...............................................1706 Table 2. Stall Speed Specifications.............................................................1724 Table 3. Transmission Oil Pressure Check, Early Model S3.50-5.50................................1732 Table 4. Transmission Oil Pressure Check, Later Model S3.50-5.50................................1733 Single speed trans......................................................................................1742 toc.................................................................................................1742 Single-Speed Powershift Transmission............................................................1742 Safety Precautions Maintenance and Repair.......................................................1743 General.........................................................................................1746 Mechanical Description..........................................................................1746 General.....................................................................................1746 Torque Converter............................................................................1746 Oil Pump....................................................................................1746 Shaft Assemblies............................................................................1746 Input Shaft.............................................................................1746 Reverse Clutch Shaft....................................................................1746 Countershaft............................................................................1747 Ring Gear, Pinion, and Differential.....................................................1747 Clutch Assemblies.......................................................................1748 Hydraulic Operation.............................................................................1749 Torque Converter............................................................................1749 Shaft Assemblies............................................................................1750 Control Valve...............................................................................1750 General.................................................................................1750 System Regulator........................................................................1750 Clutch Pressure Regulator...............................................................1750 Torque Converter Regulator..............................................................1750 Inching Spool...........................................................................1750 Direction Spool, Manual Control.........................................................1752 Direction Spool, MONOTROL Pedal.........................................................1752 Modulation Spool........................................................................1752 Accumulator.............................................................................1752 Drain Spool.............................................................................1752 MONOTROL Pedal..............................................................................1752 Control Valve...............................................................................1754 General.................................................................................1754 Regulator for Clutch Pressure...........................................................1754 Inching Spool Assembly..................................................................1754 Direction Spool.........................................................................1757 Direction Spool, Manual Control.........................................................1758 Modulator Circuit.......................................................................1758 Regulator for Torque Convertor..........................................................1758 Lubrication Circuit.........................................................................1758 Direction Control Lever.....................................................................1758 MONOTROL Pedal..............................................................................1759 Start Circuit, MONOTROL Pedal...........................................................1759 Creep Speed Switch......................................................................1760 Oil Flow Diagrams...........................................................................1760 Neutral.................................................................................1760 Forward.................................................................................1760 Forward-Inching.........................................................................1760 Reverse.................................................................................1760 Specs...................................................................................................1776 toc.................................................................................................1776 Capacities and Specifications...................................................................1776 Safety Precautions Maintenance and Repair.......................................................1777 Tire Sizes......................................................................................1780 Hydraulic System................................................................................1780 Electrical System...............................................................................1780 Engine Specifications...........................................................................1781 Capacities......................................................................................1781 Lift Truck Weights..............................................................................1782 Transmission Pressures (Single-Speed Powershift)................................................1783 Mast Speeds.....................................................................................1784 Torque Specifications...........................................................................1785 Frame.......................................................................................1785 Engine - GM V-6.............................................................................1785 Engine - Perkins............................................................................1785 Transmission................................................................................1785 Drive Axle..................................................................................1785 Steering System.............................................................................1785 Brake System................................................................................1786 Hydraulic System............................................................................1786 Main Control Valve..........................................................................1786 Tilt Cylinders..............................................................................1786 Lift Cylinders..............................................................................1786 Mast........................................................................................1786 Starter.................................................................................................1790 toc.................................................................................................1790 Starter.........................................................................................1790 Safety Precautions Maintenance and Repair.......................................................1791 General.........................................................................................1794 Description.....................................................................................1794 Yoke Assembly...............................................................................1795 Armature Assembly...........................................................................1795 Clutch Assembly.............................................................................1795 Magnetic Switch Assembly....................................................................1795 Operation.......................................................................................1795 Starter Repair..................................................................................1796 Remove......................................................................................1796 Disassemble.................................................................................1797 Clean.......................................................................................1801 Assemble....................................................................................1801 Install.....................................................................................1804 General Checks and Adjustments..................................................................1805 Armature Tests..................................................................................1806 Armature Short Circuit Test.................................................................1806 Armature Winding Ground Test................................................................1806 Commutator Run-Out Test.....................................................................1806 Yoke Test.......................................................................................1807 Brush and Brush Holder Check....................................................................1807 Brush Holder Insulation Test................................................................1807 Clutch Test.................................................................................1807 Magnetic Switch Test............................................................................1808 Pull-In Test................................................................................1808 Hold-In Test................................................................................1808 Return Test.................................................................................1808 Performance Tests...............................................................................1809 No-Load Test................................................................................1809 Troubleshooting.................................................................................1809 Steer axle..............................................................................................1814 toc.................................................................................................1814 Steering Axle...................................................................................1814 Safety Precautions Maintenance and Repair.......................................................1815 General.........................................................................................1818 Description.....................................................................................1818 Steering Axle Assembly Repair...................................................................1823 Steering Axle H3.50-5.00XL (H70-110XL) (G005), S3.50-5.50XL (S70............................1823 Remove..................................................................................1823 Install.................................................................................1823 Steering Axle H6.00-7.00XL (H135-155XL, H135-155XL 2 ) (F006, G0............................1824 Remove..................................................................................1824 Install.................................................................................1824 Wheels and Hubs Repair (All Units)..............................................................1825 Remove and Disassemble......................................................................1825 Clean.......................................................................................1825 Inspect.....................................................................................1825 Assemble and Install........................................................................1825 Spindles and Bearings Repair (All Units)........................................................1827 Remove......................................................................................1827 Clean.......................................................................................1827 Assemble and Install........................................................................1828 Tie Rods Repair (All Units).....................................................................1829 Remove......................................................................................1829 Clean.......................................................................................1829 Install.....................................................................................1829 Steering Cylinder Repair........................................................................1832 Remove and Disassemble......................................................................1832 Clean and Inspect...........................................................................1832 Assemble and Install........................................................................1832 Troubleshooting.................................................................................1833 Steering control unit...................................................................................1838 toc.................................................................................................1838 Steering Control Unit...........................................................................1838 Safety Precautions Maintenance and Repair.......................................................1839 General.........................................................................................1842 Description.....................................................................................1842 Operation.......................................................................................1842 Steering Wheel and Column Assembly Repair.......................................................1844 Remove and Disassemble......................................................................1844 Assemble and Install........................................................................1844 Steering Control Unit.......................................................................1847 Disassemble.............................................................................1847 Clean...................................................................................1849 Assemble................................................................................1850 System Air Removal..............................................................................1853 Troubleshooting.................................................................................1853 Tilt cylinders..........................................................................................1858 toc.................................................................................................1858 Tilt Cylinders..................................................................................1858 Safety Precautions Maintenance and Repair.......................................................1859 General.........................................................................................1862 Description.....................................................................................1862 Tilt Cylinder Repair............................................................................1862 Remove......................................................................................1862 Disassemble.................................................................................1862 Clean.......................................................................................1862 Inspect.....................................................................................1862 Assemble....................................................................................1863 Install.....................................................................................1864 Tilt Cylinder Leak Check........................................................................1865 Tilt Cylinder Stroke and Mast Tilt Angle Adjustment.............................................1865 Tilt Cylinder Specifications....................................................................1865 tables..............................................................................................1858 Table 1. Leak Check Specifications..............................................................1865
HYSTER E004 (S3.50-5.0XM) SERVICE MANUAL – PDF DOWNLOAD:
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