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Hyster E004 (S70XM-120XM) Service Manual – PDF DOWNLOAD
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Description
Hyster E004 (S70XM-120XM) Service Manual – PDF DOWNLOAD
FILE DETAILS:
Hyster E004 (S70XM-120XM) Service Manual – PDF DOWNLOAD
Language : English
Pages : 990
Downloadable : Yes
File Type : PDF
Size: 31.5 MB
TABLE OF CONTENTS:
Hyster E004 (S70XM-120XM) Service Manual – PDF DOWNLOAD
Alternator with Regulator............................................................... 1 toc................................................................................. 1 Alternator with Regulator....................................................... 1 General......................................................................... 3 Description..................................................................... 3 Alternator Repair............................................................... 5 Alternator Type A........................................................... 5 Remove and Disassemble.................................................. 5 Clean................................................................... 6 Assemble................................................................ 7 Install................................................................. 7 Alternator Type B........................................................... 10 Remove and Disassemble.................................................. 10 Clean................................................................... 10 Assemble................................................................ 11 Install................................................................. 12 General Check and Adjustment.................................................... 13 Low Output Check (Type A or Type B)............................................. 13 High Output Check (Type A or Type B)............................................ 15 Brushes Circuit Check........................................................... 16 Delco Alternators........................................................... 16 Motorola Alternators........................................................ 17 Diodes Check.................................................................... 18 Diode Bridge Check.............................................................. 18 Delco and Leece-Neville Alternators......................................... 18 Motorola Alternators........................................................ 18 Rotor Field Winding Check....................................................... 19 Stator Windings Check........................................................... 20 Voltage Regulator Check......................................................... 20 Troubleshooting................................................................. 20 Brake System............................................................................ 24 toc................................................................................. 24 Brake System.................................................................... 24 General......................................................................... 26 Description and Operation....................................................... 26 Brake Booster and Master Cylinder........................................... 26 Service Brake Assembly...................................................... 26 Parking Brake............................................................... 26 Brake Shoe Assemblies Repair.................................................... 27 Remove and Disassemble...................................................... 27 Clean....................................................................... 27 Inspect..................................................................... 30 Assemble and Install........................................................ 30 Brake Booster and Master Cylinder............................................... 33 Remove...................................................................... 33 Disassemble................................................................. 33 Clean and Inspect........................................................... 33 Assemble.................................................................... 33 Install..................................................................... 33 Brake Booster Filter, Replace............................................... 33 Parking Brake Repair............................................................ 35 Remove and Disassemble...................................................... 35 Assemble and Install........................................................ 35 Brake System Air Removal........................................................ 37 Brake Pedal Adjustment.......................................................... 37 Parking Brake Adjustment........................................................ 37 Parking Brake Not Applied Switch Test........................................... 38 Parking Brake Switch Test ( MONOTROL® Pedal Only)............................... 38 Brake Shoes Adjustment.......................................................... 39 Troubleshooting................................................................. 39 Capacities and Specifications........................................................... 43 toc................................................................................. 43 Capacities and Specifications................................................... 43 Tire Sizes...................................................................... 45 Hydraulic System................................................................ 45 Electrical System............................................................... 45 Engine Specifications........................................................... 46 Capacities...................................................................... 46 Lift Truck Weights.............................................................. 47 Transmission Pressures (Single-Speed Powershift)................................ 48 Mast Speeds..................................................................... 49 Torque Specifications........................................................... 50 Frame....................................................................... 50 Engine - GM V-6............................................................. 50 Engine - Perkins............................................................ 50 Transmission................................................................ 50 Drive Axle.................................................................. 50 Steering System............................................................. 50 Brake System................................................................ 51 Hydraulic System............................................................ 51 Main Control Valve.......................................................... 51 Tilt Cylinders.............................................................. 51 Lift Cylinders.............................................................. 51 Mast........................................................................ 51 Cooling System.......................................................................... 54 toc................................................................................. 54 Cooling System.................................................................. 54 General......................................................................... 56 Description..................................................................... 57 Radiator.................................................................... 57 Radiator Cap................................................................ 57 Thermostat.................................................................. 57 Water Pump.................................................................. 58 Fan and Fan Shroud.......................................................... 58 Cooling System Checks........................................................... 58 Radiator.................................................................... 58 Thermostat.................................................................. 58 Water Pump.................................................................. 59 Exhaust Leaks............................................................... 59 Fan and Fan Shroud.......................................................... 59 Radiator Cleaning............................................................... 59 Drain....................................................................... 59 Clean....................................................................... 59 Fill........................................................................ 60 Troubleshooting................................................................. 61 Diagrams................................................................................ 63 toc................................................................................. 63 Diagrams........................................................................ 63 General......................................................................... 65 Drive Axle..............................................................................134 toc.................................................................................134 Drive Axle......................................................................134 General.........................................................................136 Description.....................................................................136 Drive Axle Repairs..............................................................136 Remove and Disassemble......................................................136 Clean and Inspect...........................................................138 Brakes..................................................................138 Drive Axle..............................................................139 Assembly and Installation...................................................139 Torque Specifications...........................................................141 Troubleshooting.................................................................142 Electronic Engine Control...............................................................145 toc.................................................................................145 Electronic Engine Control.......................................................145 General.........................................................................147 Description and Operation.......................................................147 General.....................................................................147 Electronic Control Module (ECM).............................................147 Diagnostic Connector....................................................147 How ECM Begins Operation................................................149 Electronic Engine Control...................................................152 What ECM Does...........................................................152 Distributor.............................................................153 Ignition Module.........................................................154 When Engine Is Being Started............................................155 When Engine Is Running..................................................156 Electronic Control Module (ECM) with Ignition Module Distributor........156 Fuel Control................................................................157 Throttle Body Injection (TBI)...........................................158 Fuel Injectors..........................................................159 Fuel Pressure Regulator.................................................159 Throttle Position Sensor (TPS)..........................................159 Idle Air Control (IAC)..................................................160 GM 4.3L Engine Governor System..........................................160 GM 3.0L Engine Governor System..........................................161 Vacuum Ports............................................................162 Fuel Pump...............................................................162 ECM Sensors and Controllers.................................................165 Manifold Absolute Pressure (MAP)........................................165 Engine Coolant Temperature (ECT) Sensor.................................165 Electronic Engine Control-2.............................................................168 toc.................................................................................168 Electronic Engine Control.......................................................168 General.........................................................................174 Troubleshooting Procedure...................................................174 How This Section Is Arranged................................................174 Where Do I Start?...........................................................174 Visual/Physical Inspection..................................................174 Knowledge/Tools Required....................................................174 Damage From Static Discharge (Static Electricity)...........................174 Troubleshooting Information.................................................175 Malfunction Indicator Lamp (MIL)........................................175 Reading Diagnostic Trouble Codes (DTC)..................................175 Clearing Diagnostic Trouble Codes (DTCs)................................179 ECM Diagnostic Codes Available..............................................180 Diagnostic Mode.........................................................180 Field Service Mode......................................................180 ECM Learning Ability....................................................181 SCAN Tool Information.......................................................181 On-Board Diagnostic (OBD) System Check......................................183 Test Description........................................................184 Troubleshooting Charts..........................................................185 General.....................................................................185 Tools and Test Equipment................................................185 Presssure Conversion Chart..............................................186 Troubleshooting Chart Description Summary...................................187 A-1 No Malfunction Indicator Lamp...............................................188 Circuit Description.........................................................188 Diagnostic Aids.............................................................188 Test Description............................................................188 A-2 No Scan Data, No DTC-12, Malfunction Indicator Lamp ON......................190 Circuit Description.........................................................190 Diagnostic Aids.............................................................190 Test Description............................................................190 A-3 Engine Cranks but Does Not Run..............................................192 Circuit Description.........................................................192 Diagnostic Aids.............................................................192 Test Description............................................................192 A-4 Fuel Injector Circuit.......................................................195 Circuit Description.........................................................195 Test Description............................................................195 A-5 Fuel Pump Relay Circuit.....................................................197 Circuit Description.........................................................197 Diagnostic Aids.............................................................198 Test Description............................................................198 A-6 Fuel System Troubleshooting.................................................200 Circuit Description.........................................................200 Diagnostic Aids.............................................................200 Test Description............................................................201 Test Description............................................................203 A-7 Ignition System Troubleshooting.............................................205 Circuit Description.........................................................205 Diagnostic Aids.............................................................206 Test Description............................................................206 DTC 14 ECT Sensor Circuit - Low Temp Indicated (Scan Diagnostics................209 Circuit Description.........................................................209 Diagnostic Aids.............................................................210 Test Description............................................................210 DTC 15 Engine Coolant Temperature (ECT) Sensor Circuit High Temp................211 Circuit Description.........................................................211 Diagnostic Aids.............................................................212 Test Description............................................................212 DTC 21 Throttle Position (TP) Sensor Circuit Signal Voltage High................213 Circuit Description.........................................................213 Diagnostic Aids.............................................................214 Test Description............................................................214 DTC 22 Throttle Position (TP) Sensor Circuit Signal Voltage Low.................215 Circuit Description.........................................................215 Diagnostic Aids.............................................................216 Test Description............................................................216 DTC 31 Engine Governor Circuit..................................................217 Circuit Description.........................................................217 Diagnostic Aids.............................................................218 Test Description............................................................218 DTC 33 Manifold Absolute Pressure (MAP) Sensor Circuit Signal Vo................220 Circuit Description.........................................................220 Diagnostic Aids.............................................................220 Test Description............................................................220 DTC 34 Manifold Absolute Pressure (MAP) Sensor Circuit Signal Vo................222 Circuit Description.........................................................222 Diagnostic Aids.............................................................223 Test Description............................................................223 DTC 41 Electronic Spark Timing (EST) - Open EST Circuit.........................225 Circuit Description.........................................................225 Diagnostic Aids.............................................................225 Test Description............................................................225 DTC 42 EST - Grounded EST Circuit, Open or Grounded Bypass Circu................227 Circuit Description.........................................................227 Diagnostic Aids.............................................................227 Test Description............................................................227 DTC 51 Calibration Checksum Failure.............................................229 Circuit Description.........................................................229 Diagnostic Aids.............................................................229 Test Description............................................................229 DTC 81 Fuel Pump Relay Driver Circuit High, Low, or Open........................230 Circuit Description.........................................................230 Diagnostic Aids.............................................................231 Test Description............................................................231 DTC 81 5-Volt Reference Circuit Out of Range....................................233 Circuit Description.........................................................233 Diagnostic Aids.............................................................234 Test Description............................................................234 DTC 81 FPRSENSE Circuit Fault...................................................235 Circuit Description.........................................................235 Diagnostic Aids.............................................................236 Test Description............................................................236 Troubleshooting, Poor Operation.................................................237 General.....................................................................237 Make a Careful Visual Check.................................................237 FAULT: Codes or Performance That Is Abnormal................................237 FAULT: Loss of Diagnostic Trouble Code (DTC) Memory.........................237 FAULT: Engine Quits While Driving...........................................237 Additional Checks.......................................................237 FAULT: Engine Is Difficult to Start.........................................237 FAULT: Variation in Engine Power When Throttle Is Held Steady...............238 FAULT: Decreased Engine Power...............................................238 FAULT: Detonation/Spark Knock...............................................239 FAULT: Engine Momentarily Does Not Increase Power When Throttle ............239 FAULT: One or More Cylinders Do Not Operate Correctly - Engine D............240 FAULT: Rough Idle or Engine Stalls During Idle..............................240 FAULT: Fuel Usage Too High..................................................240 FAULT: Dieseling............................................................241 FAULT: Backfire.............................................................241 System Test Charts..............................................................241 General.....................................................................241 Engine Coolant Temperature (ECT) Sensor Test................................241 Throttle Position (TP) Sensor Check.........................................242 Minimum Idle Speed..........................................................242 Adjustment..............................................................242 B-1 - Idle Air Control (IAC) System Check.......................................244 Circuit Description.........................................................244 Diagnostic Aids.............................................................244 B-2 - Manifold Absolute Pressure (MAP) Sensor Output Test.......................245 Circuit Description.........................................................245 Test Description............................................................246 B-3 - Check Governor System.....................................................248 Governor System Not Operating Correctly.....................................248 Check Function of Governor System...........................................248 Check PCV System............................................................248 Fuel System Components Repair...................................................249 General.....................................................................249 Fuel Pressure Relief Procedure..............................................249 Fuel Pump Replacement.......................................................249 Throttle Body Injection Unit (TBI)..........................................250 Remove..................................................................250 Clean and Inspect.......................................................250 Install.................................................................251 Fuel Meter Body.............................................................253 Remove..................................................................253 Install.................................................................253 Fuel Injector...............................................................254 Remove..................................................................254 Install.................................................................254 Pressure Regulator..........................................................255 Remove..................................................................255 Inspect.................................................................255 Install.................................................................255 Throttle Position Sensor (TPS)..............................................255 Remove..................................................................255 Install.................................................................256 Idle Air Control (IAC) Valve................................................256 Remove..................................................................256 Clean and Inspect.......................................................256 Install.................................................................256 Governor System 3.0L Engine Repair..............................................257 Governor Module, Replace....................................................257 Governor Motor, Replace.....................................................257 Throttle Cables, Install and Adjust.........................................257 MONOTROL® Pedal, Check......................................................258 Governor System 4.3L Engine Repair..............................................259 Governor Throttle Drive Assembly............................................259 Remove..................................................................259 Inspect.................................................................260 Install.................................................................260 Governor Drive Motor........................................................260 Remove..................................................................260 Clean and Lubricate.....................................................261 Install.................................................................261 Inspect.................................................................262 MONOTROL® Pedal, Check......................................................262 Ignition System Components Repair...............................................262 ECM Replacement.............................................................262 Function Check..............................................................263 Distributor.................................................................263 Remove..................................................................263 Disassemble.............................................................263 Inspect.................................................................264 Assemble................................................................264 Install.................................................................264 Firing Order............................................................264 Ignition Timing.........................................................265 Ignition Module Repair..........................................................265 Test For Fault..............................................................265 Replace.....................................................................266 Sensing Coil................................................................266 Test....................................................................266 Replace.................................................................266 Ignition Coil...............................................................266 Test....................................................................266 Remove..................................................................267 Install.................................................................267 Sensors Repair..................................................................267 Engine Coolant Temperature (ECT) Sensor, Replace............................267 MAP Sensor, Replace.........................................................268 PCV System Repair...............................................................268 Replace.....................................................................268 Wiring..........................................................................268 Connectors and Terminals....................................................269 Procedures for Spark Plugs, Spark Plug Wires, and Boots.....................272 Wiring Diagram..............................................................272 Spark Plugs Troubleshooting.....................................................276 Special Tools...................................................................277 tables..............................................................................168 Table 1. ECM Diagnostic Codes Available.........................................180 Table 2. Rinda SCAN Tool Information............................................181 Table 3. TECH 1 SCAN Tool Information...........................................182 Table 4. On-Board Diagnostic System Checks......................................184 Table 5. Voltage and Pressure Chart.............................................186 Table 6. Troubleshooting Chart Description Summary..............................187 Table 7. No Malfunction Indicator Lamp (GM 3.0L Engine Only)....................189 Table 8. No Scan Data, No DTC-12, Malfunction Indicator Lamp ON.................191 Table 9. Engine Cranks but Does Not Run.........................................193 Table 10. Fuel Injector Circuit.................................................195 Table 11. Fuel Pump Relay Circuit...............................................198 Table 12. A-6A Fuel System Troubleshooting......................................201 Table 13. A-6B Fuel system Troubleshooting......................................204 Table 14. Ignition System Troubleshooting.......................................206 Table 15. Engine Coolant Temperature Sensor.....................................210 Table 16. DTC 14 Engine Coolant Temperature (ECT) Sensor Circuit................211 Table 17. Engine Coolant Temperature Sensor Table...............................212 Table 18. DTC 15 Engine Coolant Temperature (ECT) Sensor Circuit................213 Table 19. DTC 21 Throttle Position (TP) Sensor Circuit Signal Vo................214 Table 20. DTC 22 Throttle Position (TP) Sensor Circuit Signal Vo................216 Table 21. DTC 31 Engine Governor Circuit........................................218 Table 22. DTC 33 Manifold Absolute Pressure (MAP) Sensor Circuit................221 Table 23. DTC 34 Manifold Absolute Pressure (MAP) Sensor Circuit................223 Table 24. DTC 41 Electronic Spark Timing (EST) - Open EST Circui................226 Table 25. DTC 42 Electronic Spark Timing (EST) - Grounded EST Ci................228 Table 26. DTC 51 Calibration Checksum Failure...................................230 Table 27. DTC 81 Fuel Pump Relay Driver Circuit High, Low, or Op................231 Table 28. DTC 81 5 Volt Reference Circuit Out of Range..........................234 Table 29. DTC 81 FPRSENSE Circuit Fault.........................................236 Table 30. ECT Sensor - Temperature vs. Resistance...............................242 Table 31. Idle Air Control (IAC) System Check...................................245 Table 32. Altitude Voltage Chart................................................246 Table 33. Manifold Absolute Pressure (MAP) Sensor Output Test...................247 Table 34. Weather-Pack Terminal Repair..........................................271 Table 35. ECM Connector J1 Identification.......................................273 Table 36. ECM Connector J2 Identification.......................................275 Frame...................................................................................281 toc.................................................................................281 Frame...........................................................................281 Description.....................................................................283 Counterweight Repair............................................................284 Remove......................................................................284 Install.....................................................................289 Exhaust System Repair...........................................................291 Muffler.....................................................................291 Remove..................................................................291 Install.................................................................291 Exhaust Pipe - LPG/Gas Engine...............................................292 Remove..................................................................292 Install.................................................................295 Exhaust Pipe - Diesel Engine................................................295 Remove..................................................................295 Install.................................................................296 Hood Repair.....................................................................296 Remove......................................................................296 Install.....................................................................296 Overhead Guard Repair...........................................................297 Remove......................................................................297 Install.....................................................................297 LED Backup and Brake Lights, Replace........................................298 Remove..................................................................298 Install.................................................................298 Operator Restraint System Repair................................................298 Automatic Locking Retractor (ALR)...........................................299 Emergency Locking Retractor (ELR)...........................................299 Radiator and Coolant System.....................................................300 Remove......................................................................300 Install.....................................................................300 Alternator Replacement..........................................................302 Remove......................................................................302 Install.....................................................................302 Engine Removal and Installation.................................................302 Remove......................................................................302 Install.....................................................................306 Fuel and Hydraulic Tanks Repair.................................................308 Inspect.....................................................................308 Repairs, Small Leaks........................................................308 Repairs, Large Leaks........................................................308 Clean.......................................................................308 Steam Method of Cleaning................................................308 Chemical Solution Method of Cleaning....................................309 Other Methods of Preparation for Repair.................................309 Safety Labels...................................................................311 tables..............................................................................281 Table 1. Weight of Counterweights...............................................289 GM Engines..............................................................................314 toc.................................................................................314 GM Engines......................................................................314 General.........................................................................317 Description.....................................................................317 Engine Removal and Installation.................................................318 Cylinder Head Repair............................................................318 Remove and Disassemble......................................................318 Clean and Inspect...........................................................318 Valve Guides and Seats, Repairs.............................................319 Valves, Repair..............................................................319 Valve Seats, Repair.........................................................320 Valve Springs...............................................................320 Rocker Arm Studs (Early Models).............................................322 Rocker Arm Studs (Late Models)..............................................322 Assemble and Install........................................................323 Cylinder Block Cleaning and Inspection..........................................326 Piston Bore Preparation.........................................................326 Engine Mounts Installation......................................................327 Lubrication System Repair.......................................................327 Oil Pump, Remove and Disassemble............................................327 Clean and Inspect...........................................................327 Oil Pump, Assemble and Install..............................................328 Oil Sump, Install...........................................................328 Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters.....................329 Timing Cover................................................................329 Remove..................................................................329 Install.................................................................331 Timing Sprockets............................................................331 Remove..................................................................331 Install.................................................................331 Camshaft....................................................................332 Remove..................................................................332 Inspect.................................................................332 Install.................................................................332 Balance Shaft...............................................................333 Remove..................................................................333 Install.................................................................334 Hydraulic Valve Lifters.....................................................334 Remove..................................................................334 Disassemble.............................................................335 Clean and Inspect.......................................................335 Assemble................................................................335 Install.................................................................336 Crankshaft Repair...............................................................337 Remove......................................................................337 Inspect and Repair..........................................................337 How to Check Clearance Between Main Bearings and Their Journals.............338 Install.....................................................................339 Piston and Connecting Rod Assemblies Repair.....................................340 Connecting Rod Bearings, Replace............................................340 Piston and Connecting Rod Assemblies, Remove................................341 Disassemble.................................................................341 Piston, Clean and Inspect...................................................342 Cylinder Bores, Inspect and Repair..........................................342 Piston Rings................................................................343 Assemble....................................................................344 Piston and Connecting Rod Assemblies, Install...............................344 Flywheel and Flywheel Housing Repair............................................345 Flywheel, Repair............................................................345 Flywheel, Install...........................................................345 H3.50-5.00XL (H70-110XL), S3.50-5.50XL (S70-120XL), S6.00-7.00XL........345 H6.00-7.00XL (H135-155XL)...............................................345 Flywheel Housing H3.50-5.00XL (H70-110XL), H3.50-5.50XM (H70-120............345 Engine Adapter H6.00-7.00XL (H135-155XL)....................................345 Coolant Pump Repair.............................................................346 Thermostat Replacement..........................................................346 Fan Mount Repair (Early Models).................................................346 Fan Mount Assembly Repair (Late Models).........................................346 Drive Belt Installation.........................................................348 Valve Clearance Adjustment (Early Models).......................................349 Valve Clearance Adjustment (New Models).........................................350 Compression Check...............................................................350 Engine Specifications...........................................................351 Engine Data.................................................................351 Cylinder Head...............................................................351 Hydraulic Valve Lifter......................................................352 Camshaft....................................................................352 Pistons.....................................................................352 Crankshaft..................................................................353 Connecting Rods.............................................................353 Balance Shaft...............................................................354 Cooling System..............................................................354 Lubrication System..........................................................354 Torque Specifications...........................................................354 Troubleshooting.................................................................355 tables..............................................................................314 Table 1. Piston Rings Arrangement on Piston.....................................344 High Energy Ignition (HEI) System.......................................................360 toc.................................................................................360 High Energy Ignition (HEI) System...............................................360 Description.....................................................................362 Distributor Repair..............................................................364 Remove......................................................................364 Disassemble.................................................................364 Assemble....................................................................369 Install, If Crankshaft WAS NOT Rotated when Distributor was Remo............370 Install, If Crankshaft WAS Rotated when Distributor was Removed.............370 Ignition Coil Replacement.......................................................371 Some Four- and Six-Cylinder Models..........................................371 Remove..................................................................371 Install.................................................................372 V8, Some Four- and Six-Cylinder Models......................................372 Remove..................................................................372 Install.................................................................373 Electronic Module Replacement...................................................374 Remove......................................................................374 Install.....................................................................374 Sensing Coil Replacement........................................................375 Remove......................................................................375 Install.....................................................................375 Spark Plugs Replacement.........................................................375 Remove......................................................................375 Install.....................................................................376 Visual Check....................................................................376 High Voltage Wires Check........................................................376 Ignition Coil Check.............................................................377 Coil in Distributor Cap Design..............................................377 Separate Coil Design........................................................377 Sensing Coil, Check.........................................................378 Electronic Module Check.........................................................378 Ignition Timing Adjustment......................................................378 GM V8-366 (6-liter) Ignition System Check.......................................380 GM V6-LPG (4.3 liter) GM V6-LPG (4.3 liter) Ignition Timing and ................380 Specifications..................................................................380 Troubleshooting.................................................................381 Hydraulic Gear Pumps....................................................................385 toc.................................................................................385 Hydraulic Gear Pumps............................................................385 Description.....................................................................387 Operation.......................................................................388 Flow Control Valve..........................................................388 Relief Valve................................................................389 Hydraulic Gear Pump Repair......................................................389 Remove......................................................................389 Disassemble.................................................................390 Clean.......................................................................390 Inspect.....................................................................391 Assemble....................................................................394 Install.....................................................................396 Pump Output Check...............................................................396 Method No. 1................................................................396 Method No. 2................................................................397 Hydraulic System Air Check......................................................398 Troubleshooting.................................................................399 Hydraulic Pump Drive Assembly...........................................................404 toc.................................................................................404 Hydraulic Pump Drive Assembly...................................................404 General.........................................................................406 Description.....................................................................406 Hydraulic Pump Drive Assembly Repair............................................408 Remove and Disassemble......................................................408 Clean.......................................................................409 Inspect.....................................................................409 Assemble and Install........................................................409 Troubleshooting.................................................................410 Hydraulic System........................................................................413 toc.................................................................................413 Hydraulic System................................................................413 General.........................................................................415 Description.....................................................................415 Operation.......................................................................417 Hydraulic Pump H3.50-5.50XM (H70-120XM).....................................417 Hydraulic Pump S3.50-5.50XM (S70-120XM).....................................417 Main Control Valve..........................................................417 Steering Control Unit.......................................................418 Specifications..................................................................418 Hydraulic System Capacity (Powershift)......................................418 Hydraulic System Capacity (Hydrostatic).....................................418 Hydraulic Tank Capacity (Powershift and Hydrostatic)........................419 Hydraulic Tank Capacity.....................................................419 Relief Pressures @ 2200 RPM, 50 to 80 C ( 120 to 180 F).....................419 Hydraulic Pump Flow to Valve................................................419 Steering Priority Flow......................................................419 Troubleshooting.................................................................419 Lift, Lower and Tilt Circuit................................................420 Steering Circuit............................................................421 Instrument Panel Indicators and Senders.................................................424 toc.................................................................................424 Instrument Panel Indicators and Senders.........................................424 General.........................................................................426 Description.....................................................................426 Instruments and Senders.....................................................426 Password Function...........................................................433 Supervisor Password Function............................................433 Entering Operator Passwords.........................................433 Deleting Operator Passwords.........................................434 Retrieve the Most Recent Operator Password Used to Enable the Tr....434 Display All Operator Passwords Programmed Into the System...........434 Enable and Disable Operator Passwords Function......................434 Allow Supervisor Password to Enable the Truck to Start..............434 Operator Passwords Function.............................................434 Component Replacement - General Information.....................................435 Sender Replacement..............................................................435 Fuel Level Sender...........................................................435 Pressure and Temperature Sender.............................................436 Seat Sensor, Operator Presence System (OPS).................................437 Remove..................................................................437 Install.................................................................437 Operator Presence System Module Replacement.................................438 Remove..................................................................438 Install.................................................................439 Display Panel Replacement.......................................................440 Specifications..................................................................441 Troubleshooting.................................................................443 Troubleshooting For Operator Presence System H3.50-5.50XM (H70-1................444 Troubleshooting For Operator Presence System S70-120XM (E004, F0................446 tables..............................................................................424 Table 1. Instrument Panel Description...........................................427 Table 2. Sender Description.....................................................432 Table 3. Meter and Sender Specifications........................................441 Table 4. Troubleshooting Procedure for the Operator Presence Mod................444 Table 5. Troubleshooting Procedure for the Operator Presence Mod................446 Lift Cylinders..........................................................................451 toc.................................................................................451 Lift Cylinders..................................................................451 Safety Procedures When Working Near Mast........................................453 General.........................................................................455 Description.....................................................................455 Lowering Control Valve (Velocity Fuse)......................................455 Lift Cylinder Repair............................................................458 Remove......................................................................458 Disassemble.................................................................459 Assemble....................................................................459 Install.....................................................................460 Lift System Leak Check..........................................................460 Troubleshooting.................................................................461 LPG Fuel System.........................................................................463 toc.................................................................................463 LPG Fuel System.................................................................463 General.........................................................................466 Description and Operation.......................................................468 Fuel Tank...................................................................468 Fuel Filter and Fuel Valve Unit.............................................469 Vaporizer...................................................................470 Carburetor..................................................................471 Governor....................................................................473 LPG Tank Repair.................................................................474 Remove......................................................................474 LPG Tanks with Fixed Mounting Bracket...................................474 LPG Tanks with EZ Lift Mounting Bracket.................................474 Install.....................................................................475 LPG Tanks with Fixed Mounting Bracket...................................475 LPG Tanks with EZ Lift Mounting Bracket.................................476 Hydrostatic Relief Valve Repair.................................................477 Remove and Install..........................................................477 Filter Unit Repair..............................................................477 Fuel Filter Element, Replace................................................477 Diaphragm and Fuel Valve, Replace...........................................477 Hoses Replacement...............................................................479 Vaporizer Repair................................................................479 Remove......................................................................479 Disassemble.................................................................479 Clean.......................................................................479 Inspect.....................................................................479 Assemble....................................................................481 Install.....................................................................484 Carburetor Repair...............................................................485 Remove......................................................................485 Disassemble.................................................................485 Clean.......................................................................485 Assemble....................................................................485 Install.....................................................................485 Governor Repair.................................................................486 Filter Unit Check...............................................................488 Vaporizer Check.................................................................488 Pressure Reducer Valve......................................................488 Vapor Valve.................................................................488 Carburetor Adjustment...........................................................488 Idle Mixture................................................................488 Idle Speed..................................................................488 Power Mixture...............................................................489 Throttle Linkage Adjustment.....................................................489 Troubleshooting.................................................................491 Main Control Valve......................................................................497 toc.................................................................................497 Main Control Valve..............................................................497 General.........................................................................499 Description.....................................................................499 Operation.......................................................................499 Lift Section................................................................499 Tilt and Auxiliary Sections.................................................503 Reattaching the Clevis End of the Tilt Spool............................504 Relief Valve................................................................504 Main Control Valve Repair.......................................................504 Remove and Disassemble......................................................504 Clean and Inspect...........................................................506 Assemble....................................................................508 Install.....................................................................508 Pressure Relief Valve Check and Adjustment......................................509 Main Relief Valve (Lift)....................................................509 Steering Relief Valve.......................................................509 Secondary Relief Valve (Tilt and Auxiliary).................................512 Specifications..................................................................513 Troubleshooting.................................................................513 Masts...................................................................................518 toc.................................................................................518 Masts...........................................................................518 General.........................................................................521 Description and Operation.......................................................521 Carriages...................................................................521 Two-Stage Mast With Limited Free-Lift.......................................521 Two-Stage Mast With Full Free-Lift..........................................522 Three-Stage Mast With Full Free-Lift........................................523 Safety Procedures When Working Near Mast........................................525 Fork Replacement................................................................527 Remove......................................................................528 Install.....................................................................528 Carriage Repair.................................................................529 Remove......................................................................529 Sideshift Carriage Repair.......................................................530 Remove......................................................................530 Disassemble.................................................................531 Assemble....................................................................531 Install.....................................................................531 Two-Stage Mast With Limited Free-Lift Repair....................................532 Remove, H3.50-5.50XM (H70-120XM) Model Lift Trucks..........................532 Remove, S3.50-5.50XM (S70-120XM), E3.50-5.50XL 3 (E70-120XL 3 ) ............532 Disassemble.................................................................536 Clean and Inspect...........................................................536 Assemble....................................................................537 Install, H3.50-5.50XM (H70-120XM) Lift Truck Models.........................538 Install, S3.50-5.50XM (S70-120XM), E3.50-5.50XL 3 (E70-120XL 3 )............540 Two-Stage Mast With Full Free-Lift Repair.......................................542 Remove......................................................................542 Disassemble.................................................................542 Clean and Inspect...........................................................542 Assemble....................................................................544 Install.....................................................................544 Three-Stage Mast With Full Free-Lift Repair.....................................546 Remove......................................................................546 Disassemble.................................................................546 Clean and Inspect...........................................................550 Assemble....................................................................550 Install.....................................................................550 Mast Operation Check............................................................555 Lift and Tilt System Leak Check.................................................555 Lift System.................................................................555 Tilt System.................................................................556 Tilt Cylinder Stroke and Backward Tilt Angle Adjustment.........................557 Lift Chain Adjustments..........................................................559 Mast Adjustments................................................................561 Carriage Adjustment.............................................................563 Troubleshooting.................................................................563 tables..............................................................................518 Table 1. Tilt Cylinder Leak Check Specifications, S3.50-5.50XM (................557 Table 2. Hook type Carriage Chain Adjustment....................................559 Table 3. Pin-Type Carriage Chain Adjustment.....................................560 Metric and Inch (SAE) Fasteners.........................................................568 toc.................................................................................568 Metric and Inch (SAE) Fasteners.................................................568 General.........................................................................570 Threaded Fasteners..........................................................570 Nomenclature, Threads.......................................................570 Strength Identification.....................................................571 Cotter (Split) Pins.........................................................571 Fastener Torque Tables......................................................576 Conversion Table............................................................578 tables..............................................................................568 Table 1. Bolts and Screws.......................................................572 Table 2. Studs and Nuts.........................................................573 Table 3. Torque Nuts............................................................574 Table 4. Torque Nuts With Nylon Insert..........................................575 Table 5. Torque Values for Metric Fasteners*....................................576 Table 6. Torque Values for Inch Fasteners*......................................577 Table 7. Conversion Table for Metric and English Units..........................578 Table 8. Cotter Pin Dimensional Data............................................579 Table 9. Cotter Pin Dimensional Data............................................580 Table 10. Cotter Pin Dimensional Data...........................................581 Table 11. Cotter Pin Dimensional Data...........................................583 Microprocessor Spark Timing System (MSTS)...............................................587 toc.................................................................................587 Microprocessor Spark Timing System (MSTS).......................................587 General.........................................................................590 Description.....................................................................591 What MSTS Does..............................................................591 How MSTS Begins Operation...................................................591 Operation.......................................................................592 Distributor.................................................................592 Ignition Coil...............................................................592 Ignition Module.............................................................592 When Engine Is Being Started................................................593 When Engine Is Running......................................................594 Manifold Absolute Pressure (MAP) Sensor.....................................595 Engine Coolant Temperature (ECT) Sensor.....................................595 MSTS Module Corrections.....................................................596 Troubleshooting.................................................................597 General.....................................................................597 Tools and Test Equipment....................................................599 MSTS........................................................................600 Troubleshooting Procedure...................................................600 Where to Start..........................................................600 Visual/Physical Inspection..............................................600 Knowledge/Tools Required................................................600 Damage from Static Discharge (Static Electricity).......................600 Troubleshooting Information.................................................601 Malfunction Indicator Lamp (MIL)........................................601 Connecting CodeMate Tester..............................................601 Reading Diagnostic Trouble Codes (DTC)..................................602 Clearing Diagnostic Trouble Codes (DTC's)...............................603 On-Board Diagnostic (OBD) System Check......................................603 Test Description........................................................603 No Malfunction Indicator Lamp...................................................605 Circuit Description.........................................................605 Test Description............................................................605 No DTC-12, Malfunction Indicator Lamp ON........................................607 Circuit Description.........................................................607 Test Description............................................................607 Starter Rotates Engine, Engine Does Not Run.....................................608 Test Description............................................................608 DTC-14 Engine Coolant Temperature (ECT) (Low Temperature Indicat................612 Circuit Description.........................................................612 Test Description............................................................612 DTC-15 Engine Coolant Temperature Sensor (ECT) (High Temperature................614 Circuit Description.........................................................614 Test Description............................................................614 DTC-34 Manifold Absolute Pressure (MAP) Sensor..................................616 Circuit Description.........................................................616 Test Description............................................................616 DTC-41 Electronic Spark Timing (EST) Open Circuit...............................619 Circuit Description.........................................................619 Test Description............................................................619 DTC-42 Electronic Spark Timing (EST) Grounded Circuit...........................621 Circuit Description.........................................................621 Test Description............................................................621 DTC-51 MSTS Failure.............................................................623 Circuit Description.........................................................623 Distributor Repair..............................................................623 Remove......................................................................623 Disassemble.................................................................624 Inspect.....................................................................624 Assemble....................................................................624 Install.....................................................................625 Ignition Timing.............................................................625 Ignition Module Repair..........................................................626 Test For Fault..............................................................626 Replace.....................................................................627 Sensing Coil Repair.............................................................627 Test For Fault..............................................................627 Replace.....................................................................627 Ignition Coil Repair............................................................628 Test For Fault..............................................................628 Remove......................................................................628 Install.....................................................................628 MSTS Module Repair..............................................................629 Remove......................................................................629 Install.....................................................................629 ECT Sensor Replacement..........................................................629 MAP Sensor Replacement..........................................................630 tables..............................................................................587 Table 1. MSTS Module Connections................................................598 Table 2. Pressure Conversion Chart..............................................599 Table 3. MSTS Diagnostic Codes..................................................601 Periodic Maintenance....................................................................633 toc.................................................................................633 Periodic Maintenance............................................................633 General.........................................................................637 Serial Number Data..........................................................637 How to Move Disabled Lift Truck.............................................637 How to Tow Lift Truck...................................................637 How to Put Lift Truck on Blocks.............................................638 How to Raise Drive Tires................................................638 How to Raise Steering Tires.............................................638 Maintenance Schedule............................................................639 Maintenance Procedures Every 8 Hours or Daily...................................645 How to Make Checks With Engine Stopped......................................645 Engine Oil..............................................................646 Hydraulic System Oil....................................................646 Cooling System Reservoir Level..........................................647 Fuel System.............................................................647 Battery.................................................................648 Tires and Wheels........................................................648 Forks...................................................................648 Adjust..............................................................648 Hook Fork, Remove...................................................650 Hook Fork, Install..................................................650 Forks, Mast, and Lift Chains, Inspect...................................650 Operator Restraint System...............................................651 Automatic Locking Retractor (ALR)...................................651 Emergency Locking Retractor (ELR)...................................651 Safety Labels...........................................................652 Cooling System, Clean Debris from Radiator Core.............................652 How to Make Checks With Engine Running......................................653 Gauges, Lights, Horn, and Fuses.........................................653 Engine Oil Pressure.....................................................654 Cooling System Temperature..............................................654 Powershift Transmission Oil level Check.................................654 Control Levers and Pedals...............................................655 Lift System Operation...................................................655 Service Brakes..........................................................655 Parking Brakes..........................................................655 Steering System.........................................................656 Maintenance Procedures Every 500 Hours or 3 Months..............................657 Engine Oil and Filter, GM V-6 Engines.......................................657 Sideshift Carriage Lubrication..............................................657 Tilt Cylinder Lubrication...................................................658 Lift Chain Lubrication......................................................659 Engine Oil and Filter, Perkins Diesel Engine................................659 Drive Belts.................................................................659 Fan Drive Belts.........................................................659 Perkins Diesel Engine.......................................................659 Alternator Drive Belt...................................................659 GM 4.3L Engine..............................................................660 Serpentine Drive Belt...................................................660 Tension Screw Adjustment............................................660 Hydraulic Tank Breather, Clean and Check....................................661 Brake Fluid.................................................................662 Lift Chains Wear Check......................................................662 Forks, Wear and Damage Check................................................662 Mast Lubrication............................................................662 Control Levers and Pedals Lubrication.......................................663 Steering Axle Lubrication...................................................663 Fuel System, Checks and Adjustments.........................................663 LPG Carburetor..........................................................663 Fuel Injection (Perkins Engine).........................................663 GM V-6 Engine...........................................................663 Inching/Brake Pedal.........................................................663 Steering Tie Rods...........................................................664 Fork Pins and Guides........................................................664 Wheel Nuts..................................................................664 Air Filter..................................................................664 Battery.....................................................................664 Maintenance Procedures Every 1000 Hours or 6 Months.............................665 Fuel Filter, Replace (Diesel Engine)........................................665 Fuel System, Remove Air (Perkins 1004.42 Diesel Engine).....................665 Water Separator, Diesel Engine..............................................667 PCV Valve, GM V-6...........................................................667 Crankcase Breather, GM V-6..................................................667 Valve Clearance, Check and Adjust...........................................667 Differential and Drive Axle Oil.............................................667 Spark Plugs, GM V-6.........................................................667 Ignition Timing.............................................................667 Cooling System, GM V-6 EPA Compliant Engine.................................668 LPG Fuel Filter GM V-6 EPA Compliant Engine, Replace........................668 Inspect Engine Electrical System, Connectors, and FCVS Connectio............669 Maintenance Procedures Every 2000 Hours or Annually.............................669 Differential Thrust Screw...................................................669 Hydraulic System............................................................670 Hydraulic Oil and Filter, Replace.......................................670 Powershift Transmission Oil and Filter, Replace.............................670 Spark Plugs, GM V-6.........................................................671 Cooling System..............................................................671 Wheel Bearings..............................................................671 Steering Wheels, Lubrication............................................671 Drive Wheels, Lubrication...............................................671 PCV Valve, GM V-6...........................................................671 LPG Filter, Replace.........................................................671 Gasoline Fuel Filter, Replace...............................................672 Brake Booster Filter, Replace...............................................672 Differential Oil for Powershift Transmission, Replace.......................672 Air Filter Element, GM V-6 EPA Compliant Engine.............................672 Oxygen Sensor GM V-6 EPA Compliant Engine...................................672 Test LPG Regulator Pressure.................................................673 Inspect Low Pressure Regulator (LPR) for Oil Buildup and Leaks..............673 Check Throttle Shaft for Sticking...........................................674 Inspect Exhaust Manifold and Piping for Leaks...............................674 Safety Procedures When Working Near Mast........................................674 Lift Chain Adjustments..........................................................676 Fuel Injectors Repair...........................................................678 Lift and Tilt System Leak Check.................................................679 Lift Cylinders, Leak Check..................................................679 Tilt System.................................................................679 Welding Repairs.................................................................680 Overhead Guard Changes..........................................................681 Wheel and Tire Replacement......................................................682 Solid Rubber Tire, Change...................................................682 Wheels, Install.........................................................682 Adhesives and Sealants..........................................................683 Hydraulic Oil, Lubricant, and Coolant Specifications............................683 tables..............................................................................633 Table 1. Maintenance Schedule...................................................640 Table 2. Hook-Type Carriage Chain Adjustment....................................677 Table 3. Pin-Type Carriage Chain Adjustment.....................................677 Table 4. Tilt Cylinder Leak Check Specifications................................680 Perkins Diesel Engines..................................................................686 toc.................................................................................686 Perkins Diesel Engines..........................................................686 General.........................................................................693 General Safety Rules........................................................693 Description.....................................................................694 Engine Serial Number Codes..................................................697 Engine Data.................................................................697 Engine Removal and Installation.................................................699 Lift Engine.................................................................699 Cylinder Head Assembly Repair...................................................699 Valve Cover.................................................................699 Remove..................................................................699 Install.................................................................700 Rocker Arm Assembly.........................................................700 Remove..................................................................700 Install.................................................................700 Disassemble.............................................................700 Inspect.................................................................701 Assemble................................................................701 Valve Clearance Adjustments.................................................701 Four-Cylinder Engines...................................................702 Six-Cylinder Engines....................................................702 Valve Springs...............................................................702 Cylinder Head Assembly......................................................704 Remove..................................................................704 Install.................................................................706 Valves and Valve Springs....................................................710 Remove..................................................................710 Inspect.................................................................710 Install.................................................................711 Valve Guides................................................................711 Inspect.................................................................711 Remove..................................................................712 Install.................................................................712 Cylinder Head and Valve Seats...............................................712 Inspect.................................................................712 Repair..................................................................712 New Valve Seats, Install................................................712 Piston and Connecting Rod Assemblies Repair.....................................714 Rod Bearings................................................................714 Remove..................................................................715 Install.................................................................715 Piston and Connecting Rod Assembly..........................................716 Service Note............................................................716 Remove..................................................................716 Install.................................................................717 Piston Rings................................................................718 Remove..................................................................718 Inspect.................................................................718 Install.................................................................718 Piston and Connecting Rod...................................................719 Disassemble.............................................................719 Inspect.................................................................720 How to Select Correct Replacements......................................720 Install.................................................................721 Piston Cooling Jets.........................................................721 Remove..................................................................721 Install.................................................................722 Crankshaft Assembly Repair......................................................722 General.....................................................................722 Crankshaft Pulley...........................................................723 Engine AR, Remove.......................................................723 Engines YG and YH, Remove...............................................723 Inspect.................................................................724 Engine AR, Install......................................................724 Engines YG and YH, Install..............................................724 Rear Oil Seal...............................................................725 Replace.................................................................725 Main Bearings...............................................................726 Remove..................................................................726 Inspect.................................................................727 Install.................................................................727 Thrust Washers..............................................................727 Crankshaft Axial Movement, Check........................................727 Remove..................................................................728 Install.................................................................728 Crankshaft..................................................................729 Remove..................................................................729 Inspect.................................................................729 Install.................................................................729 Flywheel....................................................................731 Remove..................................................................731 Ring Gear, Replace......................................................731 Install.................................................................731 Flywheel Housing............................................................732 Remove..................................................................732 Install.................................................................732 Timing Case and Timing Gears Repair.............................................733 General.....................................................................733 Timing Case Cover...........................................................733 Remove..................................................................733 Install.................................................................734 Front Oil Seal..............................................................734 Remove..................................................................734 Install.................................................................734 Crankshaft Pulley Wear Sleeve...............................................735 Install.................................................................735 Idler Gear and Hub..........................................................735 Remove..................................................................735 Install.................................................................736 Air Compressor Drive, Bendix................................................737 Disassemble.............................................................737 Assemble................................................................738 Fuel Injection Pump Gear....................................................738 Remove..................................................................739 Install.................................................................739 Camshaft Gear...............................................................740 Remove..................................................................740 Install.................................................................740 Crankshaft Gear.............................................................741 Remove..................................................................741 Install.................................................................741 Timing Case.................................................................741 Remove..................................................................741 Install.................................................................742 Camshaft and Tappets........................................................743 Remove..................................................................743 Install.................................................................743 Cylinder Block Assembly Repair..................................................744 Description.................................................................744 Cylinder Block..............................................................744 Disassemble.............................................................744 Inspect.................................................................745 Assemble................................................................745 Cylinder Bore (Four-Cylinder Engines).......................................746 Cylinder Liner (Six-Cylinder Engines).......................................746 Inspect.................................................................746 Cylinder Liner Condition, Check.........................................746 Remove..................................................................747 Service Liner, Install..................................................748 Partially Finished Liner, Install.......................................749 Engine Timing...................................................................750 Description.................................................................750 How to Set Number One Piston to TDC on Compression Stroke...............751 How to Set Number One Piston to TDC on Compression Stroke (Alter........752 Valve Timing, Check.....................................................752 Fuel Injection Pump Timing, Check.......................................753 Turbocharger - Engine YH Repair.................................................754 General.....................................................................754 Remove..................................................................754 Install.................................................................754 Impeller and Compressor Housing, Clean..................................755 Lubrication System Repair.......................................................756 General.....................................................................756 Oil Filter, Replace.........................................................756 Filter Head.................................................................757 Remove and Install......................................................757 Oil Sump....................................................................757 Remove..................................................................757 Install.................................................................758 Oil Pump....................................................................758 Remove..................................................................758 Inspect.................................................................758 Install.................................................................759 Relief Valve................................................................759 Remove..................................................................759 Disassemble.............................................................760 Inspect.................................................................760 Assemble................................................................760 Install.................................................................761 Idler Gear Shaft, Replace...................................................761 Remove..................................................................761 Remove (Alternative)....................................................761 Install.................................................................762 Install (Alternative)...................................................762 Install (Alternative for Four-Cylinder Engines Only)....................763 Fuel System Repair..............................................................763 Description.................................................................763 Fuel Injection Pump.........................................................764 Remove..................................................................764 Install.................................................................765 Check and Adjust........................................................766 Fuel System Air Removal.....................................................766 Fuel Filter, Replace........................................................767 Canister Type...........................................................768 Quick Release Canister Type.............................................768 Fuel Injectors..............................................................769 Remove..................................................................769 Inspect.................................................................770 Install.................................................................770 Fuel Pump...................................................................771 Remove..................................................................771 Disassemble.............................................................771 Assemble................................................................771 Install.................................................................772 Test....................................................................772 Cooling System Repair...........................................................773 General.....................................................................773 Thermostat..................................................................773 Remove..................................................................773 Install.................................................................773 Test....................................................................774 Coolant Pump................................................................774 Remove..................................................................774 Disassemble.............................................................774 Assemble................................................................776 Install.................................................................778 Fan and Fan Drive...........................................................779 Remove..................................................................779 Install.................................................................779 Oil Cooler (Six-Cylinder Engines)...........................................780 Remove..................................................................780 Disassemble and Assemble................................................780 Install.................................................................780 Oil Cooler Bypass Valve.................................................780 Electrical Equipment Repair.....................................................781 Drive Belts.................................................................781 Adjustment..............................................................781 Remove..................................................................782 Install.................................................................782 Alternator..................................................................782 Remove..................................................................782 Install.................................................................782 Starter Motor...............................................................782 Remove..................................................................782 Install.................................................................782 Cold Start Aid..............................................................782 Air Compressor - Engines YG and YH..............................................783 General.....................................................................783 Repair......................................................................783 Remove..................................................................783 Install.................................................................783 Rotary Exhauster Replacement....................................................785 Remove......................................................................785 Clean.......................................................................785 Install.....................................................................785 Engine Specifications...........................................................786 Cylinder Head Assembly......................................................786 Piston and Connecting Rods..................................................789 Crankshaft Assembly.........................................................792 Crankshaft Overhaul.....................................................794 Timing Case and Drive Assembly..............................................796 Engine Block Assembly.......................................................797 Turbocharger................................................................800 Lubrication System..........................................................800 Fuel System.................................................................801 Cooling System..............................................................803 Flywheel and Housing........................................................803 Electrical Equipment........................................................804 Torque Specifications...........................................................804 Cylinder Head Assembly......................................................804 Piston and Connecting Rod Assemblies........................................804 Crankshaft Assembly.........................................................804 Timing Case and Drive Assembly..............................................805 Turbocharger................................................................805 Lubrication System..........................................................805 Fuel System.................................................................805 Cooling System..............................................................805 Flywheel....................................................................805 Auxiliary Equipment.........................................................805 Special Torque Specifications...................................................806 Flywheel and Housing........................................................806 Turbocharger................................................................806 Electrical Equipment........................................................806 Auxiliary Equipment.........................................................806 Special Tools*..................................................................807 Troubleshooting.................................................................812 tables..............................................................................686 Table 1. Cylinder Head..........................................................786 Table 2. Valve Guides...........................................................786 Table 3. Inlet Valves...........................................................786 Table 4. Exhaust Valves.........................................................787 Table 5. Valve Springs..........................................................789 Table 6. Tappets................................................................789 Table 7. Rocker Arm Shaft.......................................................789 Table 8. Rocker Arms and Bushings...............................................789 Table 9. Pistons (Engine AR)....................................................789 Table 10. Pistons (Engines YG and YH)...........................................789 Table 11. Piston Rings (Engine AR)..............................................790 Table 12. Piston Rings (Engines YG and YH)......................................790 Table 13. Piston Pins...........................................................791 Table 14. Connecting Rods.......................................................791 Table 15. Small End Bushings....................................................791 Table 16. Connecting Rod Bearings (Engines AR and YG)...........................791 Table 17. Connecting Rod Bearings (Engine YH)...................................791 Table 18. Piston Cooling Jets...................................................792 Table 19. Crankshaft............................................................792 Table 20. Main Bearings.........................................................793 Table 21. Crankshaft Thrust Washers.............................................793 Table 22. Crankshaft Heat Treatment.............................................793 Table 23. Crankshaft Overhaul Specifications....................................794 Table 24. Maximum Variation (Run-out)...........................................796 Table 25. Camshaft..............................................................796 Table 26. Camshaft Thrust Washer................................................796 Table 27. Camshaft Gear.........................................................796 Table 28. Gear for Fuel Injection Pump..........................................797 Table 29. Crankshaft Gear.......................................................797 Table 30. Idler Gear and Hub....................................................797 Table 31. Cylinder Block (Engine AR)............................................797 Table 32. Cylinder Bore Specifications..........................................798 Table 33. Cylinder Block (Engines YG and YH)....................................799 Table 34. Cylinder Liners (Engines YG and YH)...................................799 Table 35. Cylinder Liner Specifications (Partially Finished)....................799 Table 36. Oil Pump (Engine AR)..................................................800 Table 37. Oil Pump (Engines YG and YH)..........................................800 Table 38. Idler Gear for Oil Pump...............................................801 Table 39. Relief Valve..........................................................801 Table 40. Oil Filter............................................................801 Table 41. Lucas Fuel Injection Pump.............................................801 Table 42. Fuel Injector Codes...................................................802 Table 43. Fuel Pump (Engine AR).................................................803 Table 44. Fuel Pump (Engines YG and YH).........................................803 Table 45. Fuel Filter...........................................................803 Table 46. Coolant Pump..........................................................803 Table 47. Thermostat............................................................803 Table 48. Fan Drive Housing.....................................................803 Table 49. Limits for Flywheel Run Out and Alignment (Total Indic................804 Table 50. Alternator............................................................804 Table 51. Starter Motor.........................................................804 Table 52. Cold Start Aid........................................................804 Table 53. List of Possible Causes...............................................812 Single-Speed Powershift Transmission....................................................816 toc.................................................................................816 Single-Speed Powershift Transmission............................................816 General.........................................................................819 Transmission Repair.............................................................819 Remove......................................................................819 Disassemble.................................................................820 Transmission, Disassemble...............................................820 Input Shaft, Disassemble................................................821 Reverse Clutch, Disassemble.............................................823 Output Shaft (Pinion) and Differential, Remove and Disassemble..........826 Clean and Inspect...........................................................828 Assemble....................................................................828 Input Shaft, Assemble...................................................829 Reverse Clutch, Assemble................................................837 Output Shaft (Pinion) and Differential, Assemble and Install............842 Transmission, Assemble..................................................849 Control Valve, Install..................................................852 Install.....................................................................852 Control Valve Repair............................................................853 Remove, Early Model S3.50-5.50XL (S70-120XL) Lift Trucks....................853 Disassemble, Early Model S3.50-5.50XL (S70-120XL) Lift Trucks...............853 Assemble, Early Model S3.50-5.50XL (S70-120XL) Lift Trucks..................854 Install, Early Model S3.50-5.50XL (S70-120XL) Lift Trucks...................854 Remove and Disassemble, Later Model S3.50-5.50XL (S70-120XL) Tru............854 Inspect, Later Model S3.50-5.50XL (S70-120XL) Trucks and S3.50-5............857 Assemble and Install, Later Model S3.50-5.50XL (S70-120XL) Truck............857 MONOTROL® Pedal Repair..........................................................859 Remove and Disassemble, S3.50-5.50XL (S70-120XL) Model Lift Truc............859 Assemble and Install, S3.50-5.50XL (S70-120XL) Model Lift Trucks............860 Remove and Disassemble, S3.50-5.50XM (S70-120XM) Model Lift Truc............862 Assemble and Install, S3.50-5.50XM (S70-120XM) Model Lift Trucks............862 Direction Control Lever Repair..................................................864 Remove and Disassemble......................................................864 Assemble and Install........................................................864 Stall Test......................................................................865 Linkages Adjustment.............................................................866 Linkage for Inching/Brake Pedal, S3.50-5.50XL (S70-120XL) (D004)............866 Linkage for Direction Control Lever.........................................868 Linkage for Inching/Brake Pedal, S3.50-5.50XM (S70-120XM) (E004,............868 Brake Shoe Adjustment...................................................868 Inching/Brake Pedal Height Adjustment...................................868 Single Pedal Height Adjustment......................................868 Two Pedal Height Adjustment.........................................868 Inching/Brake Linkage Adjustment........................................870 Oil Pressures Check.............................................................872 System Pressure Check Port..................................................872 Torque Converter Check Port.................................................872 Clutch Pressure Check Port..................................................873 Inching Pressure............................................................873 Solenoid Check Ports ( MONOTROL Control Only)...............................875 Lubrication Pressure Check Ports............................................875 System Pressure Check Port..................................................875 Torque Converter Check Port.................................................875 Reverse Clutch Pressure Check Port..........................................875 Forward Clutch Pressure Check Port..........................................875 Lubrication Pressure Check Port.............................................875 Modulator Pressure Check Port...............................................875 Troubleshooting.................................................................876 tables..............................................................................816 Table 1. Ring and Pinion Tooth Contact Adjustment...............................847 Table 2. Stall Speed Specifications.............................................865 Table 3. Transmission Oil Pressure Check, Early Model S3.50-5.50................873 Table 4. Transmission Oil Pressure Check, Later Model S3.50-5.50................874 Single-Speed Powershift Transmission-2..................................................882 toc.................................................................................882 Single-Speed Powershift Transmission............................................882 General.........................................................................884 Mechanical Description..........................................................884 General.....................................................................884 Torque Converter............................................................884 Oil Pump....................................................................884 Shaft Assemblies............................................................884 Input Shaft.............................................................884 Reverse Clutch Shaft....................................................884 Countershaft............................................................885 Ring Gear, Pinion, and Differential.....................................885 Clutch Assemblies.......................................................886 Hydraulic Operation.............................................................887 Torque Converter............................................................887 Shaft Assemblies............................................................888 Control Valve...............................................................888 General.................................................................888 System Regulator........................................................888 Clutch Pressure Regulator...............................................888 Torque Converter Regulator..............................................888 Inching Spool...........................................................888 Direction Spool, Manual Control.........................................890 Direction Spool, MONOTROL Pedal.........................................890 Modulation Spool........................................................890 Accumulator.............................................................890 Drain Spool.............................................................890 MONOTROL Pedal..............................................................890 Control Valve...............................................................892 General.................................................................892 Regulator for Clutch Pressure...........................................892 Inching Spool Assembly..................................................892 Direction Spool.........................................................895 Direction Spool, Manual Control.........................................896 Modulator Circuit.......................................................896 Regulator for Torque Convertor..........................................896 Lubrication Circuit.........................................................896 Direction Control Lever.....................................................896 MONOTROL Pedal..............................................................897 Start Circuit, MONOTROL Pedal...........................................897 Creep Speed Switch......................................................898 Oil Flow Diagrams...........................................................898 Neutral.................................................................898 Forward.................................................................898 Forward-Inching.........................................................898 Reverse.................................................................898 Starter.................................................................................913 toc.................................................................................913 Starter.........................................................................913 General.........................................................................915 Description and Operation.......................................................915 Starter Repair..................................................................917 Remove......................................................................917 Disassemble.................................................................917 Clean.......................................................................918 Assemble....................................................................918 Install.....................................................................919 General Checks and Adjustments..................................................919 Troubleshooting.................................................................922 Starter-2...............................................................................925 toc.................................................................................925 Starter.........................................................................925 General.........................................................................927 Description.....................................................................927 Yoke Assembly...............................................................928 Armature Assembly...........................................................928 Clutch Assembly.............................................................928 Magnetic Switch Assembly....................................................928 Operation.......................................................................928 Starter Repair..................................................................929 Remove......................................................................929 Disassemble.................................................................930 Clean.......................................................................933 Assemble....................................................................934 Install.....................................................................937 General Checks and Adjustments..................................................937 Armature Tests..................................................................938 Armature Short Circuit Test.................................................938 Armature Winding Ground Test................................................938 Commutator Run-Out Test.....................................................938 Yoke Test.......................................................................939 Brush and Brush Holder Check....................................................939 Brush Holder Insulation Test................................................939 Clutch Test.................................................................939 Magnetic Switch Test............................................................940 Pull-In Test................................................................940 Hold-In Test................................................................940 Return Test.................................................................940 Performance Tests...............................................................941 No-Load Test................................................................941 Troubleshooting.................................................................941 Steering Axle...........................................................................946 toc.................................................................................946 Steering Axle...................................................................946 General.........................................................................948 Description.....................................................................948 Steering Axle Assembly Repair...................................................953 Steering Axle H3.50-5.00XL (H70-110XL) (G005), S3.50-5.50XL (S70............953 Remove..................................................................953 Install.................................................................953 Steering Axle H6.00-7.00XL (H135-155XL, H135-155XL 2 ) (F006, G0............954 Remove..................................................................954 Install.................................................................954 Wheels and Hubs Repair (All Units)..............................................955 Remove and Disassemble......................................................955 Clean.......................................................................955 Inspect.....................................................................955 Assemble and Install........................................................955 Spindles and Bearings Repair (All Units)........................................957 Remove......................................................................957 Clean.......................................................................957 Assemble and Install........................................................958 Tie Rods Repair (All Units).....................................................959 Remove......................................................................959 Clean.......................................................................959 Install.....................................................................959 Steering Cylinder Repair........................................................962 Remove and Disassemble......................................................962 Clean and Inspect...........................................................962 Assemble and Install........................................................962 Troubleshooting.................................................................963 Steering Control Unit...................................................................967 toc.................................................................................967 Steering Control Unit...........................................................967 General.........................................................................969 Description.....................................................................969 Operation.......................................................................969 Steering Wheel and Column Assembly Repair.......................................971 Remove and Disassemble......................................................971 Assemble and Install........................................................971 Steering Control Unit.......................................................974 Disassemble.............................................................974 Clean...................................................................976 Assemble................................................................977 System Air Removal..............................................................980 Troubleshooting.................................................................980 Tilt Cylinders..........................................................................984 toc.................................................................................984 Tilt Cylinders..................................................................984 General.........................................................................986 Description.....................................................................986 Tilt Cylinder Repair............................................................986 Remove......................................................................986 Disassemble.................................................................986 Clean.......................................................................986 Inspect.....................................................................986 Assemble....................................................................987 Install.....................................................................988 Tilt Cylinder Leak Check........................................................989 Tilt Cylinder Stroke and Mast Tilt Angle Adjustment.............................989 Tilt Cylinder Specifications....................................................989 tables..............................................................................984 Table 1. Leak Check Specifications..............................................989
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