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Hyster F005 (H3.50-5.00XL Europe) Service Manual – PDF DOWNLOAD
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Description
Hyster F005 (H3.50-5.00XL Europe) Service Manual – PDF DOWNLOAD
FILE DETAILS:
Hyster F005 (H3.50-5.00XL Europe) Service Manual – PDF DOWNLOAD
Language : English
Pages : 740
Downloadable : Yes
File Type : PDF
Size: 25.5 MB
TABLE OF CONTENTS:
Hyster F005 (H3.50-5.00XL Europe) Service Manual – PDF DOWNLOAD
22002........................................................................................................................... 1 INTRODUCTION................................................................................................................ 1 GENERAL................................................................................................................. 1 DESCRIPTION............................................................................................................. 1 REPAIRS..................................................................................................................... 3 GENERAL................................................................................................................. 3 REMOVAL AND DISASSEMBLY (Type A)........................................................................................ 3 CLEANING................................................................................................................ 3 ASSEMBLY (Type A)....................................................................................................... 4 REMOVAL AND DISAASSEMBLY (Type B)....................................................................................... 6 CLEANING................................................................................................................ 8 ASSEMBLY (Type B)....................................................................................................... 8 INSTALLATION (Type A and Type B)........................................................................................ 9 CHECKS AND ADJUSTMENTS...................................................................................................... 9 GENERAL................................................................................................................. 9 CHECK THE ALTERNATOR FOR LOW OUTPUT (Type A or Type B).................................................................. 10 CHECK THE ALTERNATOR FOR HIGH OUTPUT (Type A or Type B)................................................................. 11 CHECK THE CIRCUIT FOR THE BRUSHES....................................................................................... 13 Delco Alternators................................................................................................... 13 Motorola Alternators................................................................................................ 13 CHECK THE DIODES........................................................................................................ 13 CHECK THE DIODE BRIDGE.................................................................................................. 13 Delco and Leece–Neville Alternators................................................................................. 13 Motorola Alternators................................................................................................ 13 CHECK THE FIELD WINDING FOR THE ROTOR................................................................................... 14 CHECK THE WINDINGS IN THE STATOR........................................................................................ 14 CHECK THE VOLTAGE REGULATOR............................................................................................. 15 TROUBLESHOOTING............................................................................................................. 15 100345.......................................................................................................................... 16 THE FRAME................................................................................................................... 16 GENERAL................................................................................................................. 16 DESCRIPTION............................................................................................................. 16 REPAIRS................................................................................................................. 16 COUNTERWEIGHT........................................................................................................... 16 Removal............................................................................................................. 16 COUNTERWEIGHT........................................................................................................... 17 Installation........................................................................................................ 17 HOOD.................................................................................................................... 17 Removal............................................................................................................. 17 HOOD.................................................................................................................... 17 Installation........................................................................................................ 17 OVERHEAD GUARD.......................................................................................................... 18 Removal............................................................................................................. 18 Installation........................................................................................................ 18 OPERATOR RESTRAINT SYSTEM............................................................................................... 18 RADIATOR................................................................................................................ 18 Removal............................................................................................................. 18 Installation........................................................................................................ 19 EXHAUST SYSTEM.......................................................................................................... 19 Muffler Replacement................................................................................................. 19 ENGINE.................................................................................................................. 19 Removal............................................................................................................. 19 Installation........................................................................................................ 22 FUEL AND HYDRAULIC TANKS................................................................................................ 23 Inspection.......................................................................................................... 23 Repairs, Small Leaks................................................................................................ 23 Repairs, Large Leaks................................................................................................ 23 Cleaning............................................................................................................ 23 Other Methods Of Preparation For Repair............................................................................. 24 SAFETY LABELS........................................................................................................... 25 CAB................................................................................................................. 25 Cab Repalacement.................................................................................................... 25 Window Repalcement...................................................................................................... 25 Windshield Wipers, Heater and Fan................................................................................... 28 Material Specifications For Cab Windows............................................................................. 28 Cab Heater Hoses.................................................................................................... 28 160054.......................................................................................................................... 29 INTRODUCTION................................................................................................................ 29 GENERAL................................................................................................................. 29 DESCRIPTION............................................................................................................. 29 OPERATION............................................................................................................... 29 REPAIRS..................................................................................................................... 29 STEERING WHEEL AND COLUMN ASSEMBLY...................................................................................... 29 TYPE "A" STEERING COLUMN ASSEMBLY....................................................................................... 31 Removal And Disassembly............................................................................................. 31 Assembly And Installation........................................................................................... 31 TYPE "A" STEERING COLUMN................................................................................................ 32 TYPE "A" STEERING COLUMN................................................................................................ 33 TYPE "B" STEERING COLUMN................................................................................................ 34 Removal And Disassembly............................................................................................. 34 Assembly And Installation........................................................................................... 34 TYPE "B" STEERING COLUMN................................................................................................ 35 Disassembly of Steering Control Unit................................................................................ 36 Cleaning of Steering Control Unit................................................................................... 36 Assembly of Steering Control Unit................................................................................... 38 CHECKS AND ADJUSTMENTS...................................................................................................... 41 REMOVE AIR FROM THE SYSTEM.............................................................................................. 41 TROUBLESHOOTING............................................................................................................. 42 190097.......................................................................................................................... 43 INTRODUCTION................................................................................................................ 43 DESCRIPTION............................................................................................................. 43 OPERATION............................................................................................................... 43 Flow Control Valve.................................................................................................. 45 Relief Valve........................................................................................................ 45 REPAIRS..................................................................................................................... 46 REMOVAL................................................................................................................. 46 DISASSEMBLY............................................................................................................. 46 CLEANING................................................................................................................ 48 INSPECTION.............................................................................................................. 48 ASSEMBLY................................................................................................................ 49 INSTALLATION............................................................................................................ 50 CHECKS AND ADUSTMENTS....................................................................................................... 51 CHECK THE OUTPUT OF THE PUMP............................................................................................ 51 CHECK FOR AIR IN THE HYDRAULIC SYSTEM................................................................................... 51 TROUBLESHOOTING............................................................................................................. 53 200077.......................................................................................................................... 56 INTRODUCTION................................................................................................................ 56 GENERAL................................................................................................................. 56 DESCRIPTION............................................................................................................. 56 OPERATION............................................................................................................... 57 Lift Section........................................................................................................ 58 Tilt Section........................................................................................................ 58 Relief Valve........................................................................................................ 60 SOLENOID VALVE FOR AUXILIARY FUNCTION................................................................................... 61 Operation........................................................................................................... 61 REPAIRS..................................................................................................................... 61 MAIN CONTROL VALVE...................................................................................................... 61 Removal and Disassembly............................................................................................. 61 Cleaning and Inspection............................................................................................. 62 Assembly............................................................................................................ 62 Installation........................................................................................................ 62 SOLENOID VALVE FOR AUXILIARY FUNCTION................................................................................... 62 Removal and Disassembly............................................................................................. 62 Assembly and Installation........................................................................................... 64 CHECKS AND ADJUSTMENTS...................................................................................................... 64 PRESSURE RELIEF VALVES.................................................................................................. 64 Primary Relief Valve................................................................................................ 64 Seconday Relief Valve............................................................................................... 65 CONTROL LEVER ARRANGEMENT............................................................................................... 65 TROUBLESHOOTING............................................................................................................. 68 SPECIFICATIONS.............................................................................................................. 70 600105.......................................................................................................................... 71 INTRODUCTION................................................................................................................ 71 GENERAL................................................................................................................. 71 DESCRIPTION............................................................................................................. 71 ENGINE SERIAL NUMBER CODES.............................................................................................. 72 REMOVAL AND INSTALLATION................................................................................................ 72 ENGINE...................................................................................................................... 72 CYLINDER HEAD........................................................................................................... 72 Removal............................................................................................................. 72 Installation........................................................................................................ 73 Cylinder Head Repairs............................................................................................... 74 OIL PUMP................................................................................................................ 76 Removal............................................................................................................. 76 Disassembly......................................................................................................... 76 Inspection.......................................................................................................... 76 Assembly............................................................................................................ 77 Installation........................................................................................................ 77 RELIEF VALVE............................................................................................................ 78 TIMING GEAR CASE AND TIMING GEARS....................................................................................... 78 Removal............................................................................................................. 78 Installation........................................................................................................ 79 PISTONS AND CONNECTING RODS............................................................................................. 80 Removal............................................................................................................. 80 Disassembly......................................................................................................... 80 Inspection.......................................................................................................... 81 Assembly............................................................................................................ 82 Installation........................................................................................................ 82 CRANKSHAFT AND MAIN BEARINGS............................................................................................ 83 Removal............................................................................................................. 83 Inspection.......................................................................................................... 83 Assembly............................................................................................................ 84 CAMSHAFT AND CAM FOLLOWERS.............................................................................................. 85 Removal............................................................................................................. 85 Inspection.......................................................................................................... 86 Assembly............................................................................................................ 86 FLYWHEEL AND FLYWHEEL HOUSING........................................................................................... 87 Removal............................................................................................................. 87 Repairs............................................................................................................. 87 Installation........................................................................................................ 87 STEERING PUMP DRIVE..................................................................................................... 87 Removal............................................................................................................. 87 Installation........................................................................................................ 88 PCV VALVE............................................................................................................... 88 FUEL SYSTEM................................................................................................................. 88 FUEL PUMP............................................................................................................... 88 Removal............................................................................................................. 88 Disassembly......................................................................................................... 88 Assembly............................................................................................................ 88 Installation........................................................................................................ 89 FUEL INJECTION PUMP..................................................................................................... 89 Removal............................................................................................................. 89 Repairs............................................................................................................. 89 Installation........................................................................................................ 89 FUEL INJECTORS.......................................................................................................... 89 Removal............................................................................................................. 89 Repairs............................................................................................................. 90 Installation........................................................................................................ 90 COLD START AID.......................................................................................................... 90 Description......................................................................................................... 90 Removal............................................................................................................. 90 Installation........................................................................................................ 90 COOLING SYSTEM.............................................................................................................. 91 THERMOSTAT.............................................................................................................. 91 Removal............................................................................................................. 91 Inspection.......................................................................................................... 91 Installation........................................................................................................ 91 WATER PUMP.............................................................................................................. 91 Removal............................................................................................................. 91 Disassembly......................................................................................................... 91 Assembly............................................................................................................ 91 Installation........................................................................................................ 91 CHECKS AND ADJUSTMENTS...................................................................................................... 91 CHECKING THE INJECTORS.................................................................................................. 91 Repairs............................................................................................................. 92 Installation........................................................................................................ 92 REMOVING AIR FROM THE FUEL SYSTEM....................................................................................... 92 CHECKING THE TIMING MARKS............................................................................................... 93 Method A............................................................................................................ 93 Method B............................................................................................................ 94 CHECKING THE TIMING ANGLE OF THE FUEL INJECTION PUMP WITH THE SPECIAL TOOL.............................................. 95 VALVE CLEARANCE ADJUSTMENT.............................................................................................. 96 ADJUSTING THE THROTTLE LINKAGE.......................................................................................... 96 TROUBLESHOOTING............................................................................................................. 98 SPECIFICATIONS.............................................................................................................. 99 TORQUE SPECIFICATIONS.......................................................................................................102 600412..........................................................................................................................103 PERKINS DIESEL ENGINES, SERIES 1000.........................................................................................103 1.1 GENERAL.............................................................................................................103 GENERAL SAFETY RULES....................................................................................................103 Viton Seals.........................................................................................................103 1.2 DESCRIPTION.........................................................................................................106 1.3 Engine Serial Number Codes......................................................................................106 1.4 Engine Data.....................................................................................................106 1.5 1004–4 ENGINE...................................................................................................107 1.6 1004–4T ENGINE..................................................................................................107 1.7 1006–6 ENGINE...................................................................................................107 1.8 1006–6T ENGINE..................................................................................................107 1.9 REMOVAL AND INSTALLATION............................................................................................107 CYLINDER HEAD ASSEMBLY......................................................................................................108 1.10 VALVE COVER........................................................................................................108 1.11 Removal........................................................................................................108 1.12 Installation...................................................................................................108 1.13 ROCKER ARM ASSEMBLY................................................................................................108 1.14 Removal........................................................................................................108 1.15 Installation...................................................................................................108 1.16 Disassembly....................................................................................................109 1.17 Inspection.....................................................................................................109 1.18 Assembly.......................................................................................................109 1.19 VALVE CLEARANCE ADJUSTMENTS........................................................................................109 1.20 Four Cylinder Engines..........................................................................................110 1.21 Six Cylinder Engines...........................................................................................110 1.22 VALVE SPRINGS......................................................................................................110 1.23 CYLINDER HEAD ASSEMBLY.............................................................................................112 1.24 Removal........................................................................................................112 1.25 Installation...................................................................................................113 1.26 VALVES AND VALVE SPRINGS...........................................................................................116 1.27 Removal........................................................................................................116 1.28 Inspection.....................................................................................................117 1.29 Installation...................................................................................................117 1.30 VALVE GUIDES.......................................................................................................117 1.31 Inspection.....................................................................................................117 1.32 Removal........................................................................................................118 1.33 Installation...................................................................................................118 1.34 CYLINDER HEAD AND VALVE SEATS......................................................................................118 1.35 Inspection.....................................................................................................118 1.36 Repair.........................................................................................................119 1.37 Installation Of New Valve Seats................................................................................119 PISTON AND CONNECTING ROD ASSEMBLIES........................................................................................120 1.38 ROD BEARINGS.......................................................................................................120 1.39 Removal........................................................................................................120 1.40 Installation...................................................................................................121 1.41 PISTON AND CONNECTING ROD ASSEMBLY.................................................................................121 1.42 Service Note...................................................................................................121 1.43 Removal........................................................................................................121 1.44 Installation...................................................................................................122 1.45 PISTON RINGS.......................................................................................................123 1.46 Removal........................................................................................................123 1.47 Inspection.....................................................................................................123 1.48 Installation...................................................................................................124 1.49 PISTON AND CONNECTING ROD..........................................................................................125 1.50 Disassembly....................................................................................................125 1.51 Inspection.....................................................................................................125 1.52 Installation...................................................................................................125 1.53 PISTON COOLING JETS................................................................................................126 1.54 Removal........................................................................................................126 1.55 Installation...................................................................................................126 CRANKSHAFT ASSEMBLY.........................................................................................................127 1.56 GENERAL............................................................................................................127 1.57 CRANKSHAFT PULLEY..................................................................................................127 1.58 Removal, Engines AA and AB.....................................................................................127 1.59 Installation, Engines AA and AB................................................................................127 1.60 Removal, Engines YA and YB.....................................................................................127 1.61 Installation, Engines YA and YB................................................................................127 1.62 REAR OIL SEAL......................................................................................................128 1.63 Replacement....................................................................................................128 1.64 MAIN BEARINGS......................................................................................................129 1.65 Removal........................................................................................................129 1.66 Installation...................................................................................................129 1.67 THRUST WASHERS.....................................................................................................130 1.68 Check The Axial Movement Of The Crankshaft.....................................................................130 1.69 Removal........................................................................................................131 1.70 Installation...................................................................................................131 1.71 CRANKSHAFT.........................................................................................................131 1.72 Removal........................................................................................................131 1.73 Inspection.....................................................................................................132 1.74 Installation...................................................................................................132 TIMING CASE AND TIMING GEARS................................................................................................134 1.75 GENERAL............................................................................................................134 1.76 TIMING CASE COVER..................................................................................................134 1.77 Removal........................................................................................................134 1.78 Installation...................................................................................................134 1.79 FRONT OIL SEAL.....................................................................................................135 1.80 Removal........................................................................................................135 1.81 Installation...................................................................................................135 1.82 IDLER GEAR AND HUB.................................................................................................135 1.83 Removal........................................................................................................135 1.84 Installation...................................................................................................136 1.85 GEAR FOR THE FUEL INJECTION PUMP OR THE CAMSHAFT GEAR..............................................................137 1.86 Removal........................................................................................................137 1.87 Installation...................................................................................................137 1.88 CRANKSHAFT GEAR....................................................................................................138 1.89 Removal........................................................................................................138 1.90 Installation...................................................................................................138 1.91 TIMING CASE........................................................................................................138 1.92 Removal........................................................................................................138 1.93 Installation...................................................................................................138 1.94 CAMSHAFT AND TAPPETS...............................................................................................139 1.95 Removal........................................................................................................140 1.96 Installation...................................................................................................140 ENGINE BLOCK ASSEMBLY.......................................................................................................141 1.97 DESCRIPTION........................................................................................................141 1.98 ENGINE BLOCK.......................................................................................................141 1.99 Disassembly....................................................................................................141 1.100 Inspection....................................................................................................142 1.101 Assembly......................................................................................................142 1.102 CYLINDER LINER....................................................................................................142 1.103 Inspection....................................................................................................142 1.104 Hone..........................................................................................................143 1.105 Removal.......................................................................................................143 1.106 Installation..................................................................................................144 TURBOCHARGER, ENGINES AB AND YB.............................................................................................145 1.107 GENERAL...........................................................................................................145 1.108 Removal.......................................................................................................145 1.109 Installation..................................................................................................146 1.110 Clean The Impeller And Compressor Housing.....................................................................146 LUBRICATION SYSTEM..........................................................................................................147 1.111 GENERAL...........................................................................................................147 1.112 OIL FILTER, REPLACEMENT...........................................................................................147 1.113 OIL SUMP..........................................................................................................148 1.114 Removal.......................................................................................................148 1.115 Installation..................................................................................................148 1.116 OIL PUMP..........................................................................................................148 1.117 Removal.......................................................................................................148 1.118 Inspection....................................................................................................149 1.119 Installation..................................................................................................149 1.120 RELIEF VALVE......................................................................................................150 1.121 Removal.......................................................................................................150 1.122 Disassembly...................................................................................................150 1.123 Inspection....................................................................................................151 1.124 Installation..................................................................................................151 FUEL SYSTEM.................................................................................................................151 1.125 DESCRIPTION.......................................................................................................151 1.126 CAV FUEL INJECTION PUMP...........................................................................................152 1.127 Removal.......................................................................................................152 1.128 Installation..................................................................................................152 1.129 CAV FUEL INJECTION PUMP, CHECKS AND ADJUSTMENTS...................................................................153 1.130 Timing Gear Marks.............................................................................................153 1.131 How To Set Number 1 Piston To TDC On The Compression Stroke...................................................154 1.132 Check The Valve Timing........................................................................................154 1.133 Check The Timing Of The Fuel Injection Pump...................................................................155 1.134 Check The Timing Mark Of The Fuel Injection Pump..............................................................155 1.135 Check The Engine Timing Mark..................................................................................156 1.136 REMOVE AIR FROM THE FUEL SYSTEM...................................................................................157 1.137 Fuel Injection Pump With Vent Tube............................................................................157 1.138 Fuel Injection Pump With Vent Screw...........................................................................158 1.139 FUEL FILTER (REPLACEMENT).........................................................................................159 1.140 FUEL INJECTORS....................................................................................................159 1.141 Removal.......................................................................................................159 1.142 Inspection....................................................................................................160 1.143 Installation..................................................................................................161 1.144 FUEL PUMP.........................................................................................................161 1.145 Removal.......................................................................................................161 1.146 Disassembly...................................................................................................161 1.147 Assembly......................................................................................................162 1.148 Installation..................................................................................................162 1.149 Test..........................................................................................................163 COOLING SYSTEM..............................................................................................................163 1.150 GENERAL...........................................................................................................163 1.151 THERMOSTAT........................................................................................................163 1.152 Replacement...................................................................................................163 1.153 COOLANT PUMP......................................................................................................164 1.154 Removal.......................................................................................................164 1.155 Disassembly...................................................................................................164 1.156 Assembly......................................................................................................165 1.157 Installation..................................................................................................165 1.158 FAN AND FAN DRIVE.................................................................................................165 1.159 Removal.......................................................................................................165 1.160 Disassembly...................................................................................................165 1.161 Assembly......................................................................................................166 1.162 Installation..................................................................................................166 1.163 OIL COOLER........................................................................................................166 1.164 Removal, Engine AB............................................................................................166 1.165 Removal, Engines YA and YB....................................................................................166 1.166 Disassembly And Assembly......................................................................................167 1.167 Installation, Engine AB.......................................................................................167 1.168 Installation, Engines YA and YB...............................................................................168 1.169 By–Pass Valve, Oil Cooler.....................................................................................168 FLYWHEEL AND FLYWHEEL HOUSING...............................................................................................168 1.170 GENERAL...........................................................................................................168 1.171 FLYWHEEL..........................................................................................................168 1.172 Removal.......................................................................................................168 1.173 Ring Gear (Replacement).......................................................................................168 1.174 Installation..................................................................................................168 1.175 FLYWHEEL HOUSING..................................................................................................169 1.176 Removal.......................................................................................................169 1.177 Installation..................................................................................................169 ELECTRICAL EQUIPMENT........................................................................................................170 1.178 DRIVE BELTS.......................................................................................................170 1.179 ALTERNATOR........................................................................................................171 1.180 STARTER MOTOR.....................................................................................................171 1.181 Removal.......................................................................................................171 1.182 Installation..................................................................................................171 1.183 COLD START AID....................................................................................................171 AIR COMPRESSOR, ENGINES YA AND YB...........................................................................................171 1.184 GENERAL...........................................................................................................171 1.185 Air Compressor, Removal, WABCO................................................................................171 1.186 Compressor Drive, Inspection..................................................................................172 1.187 Air Compressor, Installation, WABCO...........................................................................172 1.188 Compressor Drive, Disassembly, WABCO..........................................................................172 1.189 Compressor Drive, Assembly, WABCO.............................................................................173 1.190 Air Compressor, Removal, BENDIX...............................................................................173 1.191 Air Compressor, Installation, BENDIX..........................................................................174 1.192 Compressor Drive, Disassembly, BENDIX.........................................................................175 1.193 Compressor Drive, Assembly, BENDIX............................................................................175 ENGINE SPECIFICATIONS.......................................................................................................177 1.194 CYLINDER HEAD ASSEMBLY............................................................................................177 1.195 Cylinder Head.................................................................................................177 1.196 Valve Guides..................................................................................................177 1.197 Inlet Valves..................................................................................................178 1.198 Exhaust Valves................................................................................................178 1.199 Double Valve Springs To Outer.................................................................................178 1.200 Double Valve Springs To Inner.................................................................................178 1.201 Single Valve Springs..........................................................................................178 1.202 Tappets.......................................................................................................178 1.203 Rocker Arm Shaft..............................................................................................178 1.204 Rocker Arms And Bushings......................................................................................179 1.205 PISTON AND CONNECTING RODS........................................................................................179 1.206 Pistons, Engines AA And YA....................................................................................179 1.207 Pistons, Engines AB And YB....................................................................................179 1.208 Piston Rings, Engines AA And YA...............................................................................179 1.209 Piston Rings, Engines AB And YB...............................................................................179 1.210 Connecting Rods, Engines AB And YB............................................................................180 1.211 Connecting Rods, Engines AB And YB............................................................................180 1.212 Piston Pins, Engines AA And YA................................................................................180 1.213 Piston Pins, Engines AB and YB................................................................................180 1.214 Small End Bushings, Engines AA And YA.........................................................................180 1.215 Small End Bushings, Engines AB And YB.........................................................................180 1.216 Connecting Rod Bearings, Engines AA And YA....................................................................181 1.217 Connecting Rod Bearings, Engines AB And YB....................................................................181 1.218 Piston Cooling Jets, Engines AB And YB........................................................................181 1.219 CRANKSHAFT ASSEMBLY...............................................................................................181 1.220 Crankshaft....................................................................................................181 1.221 Crankshaft Heat Treatment.....................................................................................181 1.222 Crankshaft Overhaul...........................................................................................181 1.223 Main Bearings.................................................................................................183 1.224 Crankshaft Thrust Washers.....................................................................................183 1.225 TIMING CASE AND DRIVE ASSEMBLY....................................................................................183 1.226 Camshaft......................................................................................................183 1.227 Camshaft Thrust Washer........................................................................................183 1.228 Camshaft Gear.................................................................................................184 1.229 Gear For Fuel Injection Pump..................................................................................184 1.230 Crankshaft Gear...............................................................................................184 1.231 Idler Gear And Hub............................................................................................184 1.232 ENGINE BLOCK ASSEMBLY.............................................................................................184 1.233 Engine Block..................................................................................................184 1.234 Cylinder Liners...............................................................................................184 1.235 TURBOCHARGER......................................................................................................185 1.236 LUBRICATION SYSTEM................................................................................................185 1.237 Oil Pump, Engines AA And AB...................................................................................185 1.238 Oil Pump, Engines YA And YB...................................................................................185 1.239 Relief Valve..................................................................................................185 1.240 Oil Filter....................................................................................................185 1.241 FUEL SYSTEM.......................................................................................................185 1.242 Cav Fuel Injection Pump.......................................................................................185 1.243 FUEL INJECTORS................................................................................................186 1.244 Fuel Pump, Engines AA And AB..................................................................................187 1.245 Fuel Pump, Engines YA And YB..................................................................................187 1.246 Fuel Filter...................................................................................................187 1.247 COOLING SYSTEM....................................................................................................187 1.248 Coolant Pump..................................................................................................187 1.249 Thermostat....................................................................................................188 1.250 Fan Drive Housing.............................................................................................188 1.251 FLYWHEEL AND HOUSING..............................................................................................188 1.252 Limits for flywheel ''run out'' and alignment (total indicator reading).......................................188 1.253 ELECTRICAL EQUIPMENT..............................................................................................188 1.254 Alternator....................................................................................................188 1.255 Starter Motor.................................................................................................188 1.256 Cold Start Aid................................................................................................188 TORQUE SPECIFICATIONS.......................................................................................................189 SPECIAL TOOLS...............................................................................................................190 600590..........................................................................................................................194 GM 4.3 LITRE V-6............................................................................................................194 INTRODUCTION............................................................................................................194 DESCRIPTION.............................................................................................................194 ENGINE, REMOVAL AND INSTALLATION........................................................................................195 CYLINDER HEAD...........................................................................................................195 Removal And Disassembly.............................................................................................195 Cleaning And Inspection.............................................................................................195 Repairs, Valve Guides and Seats.....................................................................................195 Repairs, Valves.....................................................................................................196 Repairs, Valve Seats................................................................................................196 Valve Springs.......................................................................................................197 Studs For The Rocker Arms (Early Models)............................................................................198 Studs For The Rocker Arms (Late Models).............................................................................199 Assembly And Installation...........................................................................................199 CYLINDER BLOCK, CLEANING AND INSPECTION.................................................................................201 PISTON BORE PREPARATION.................................................................................................201 ENGINE MOUNTS...........................................................................................................201 LUBRICATION SYSTEM......................................................................................................201 Oil Pump, Removal and Disassembly...................................................................................201 Cleaning and Inspection.............................................................................................202 Oil Pump, Assembly and Installation.................................................................................202 Oil Sump, Installation..............................................................................................202 TIMING COVER, TIMING SPROCKETS, CAMSHAFT AND VALVE LIFTERS..............................................................203 Timing Cover, Removal...............................................................................................203 Installation........................................................................................................204 Timing Sprockets, Removal...........................................................................................205 Timing Sprockets, Installation......................................................................................205 Camshaft, Removal...................................................................................................205 Camshaft, Inspection................................................................................................205 Camshaft, Installation..............................................................................................205 Balance Shaft, Removal..............................................................................................206 Balance Shaft, Installation.........................................................................................207 Hydraulic Valve Lifters, Removal....................................................................................208 Hydraulic Valve Lifters, Disassembly................................................................................208 Hydraulic Valve Lifters, Cleaning And Inspection....................................................................208 Hydraulic Valve Lifters, Assembly...................................................................................209 Hydraulic Valve Lifters, Installation...............................................................................209 CRANKSHAFT..............................................................................................................210 Removal.............................................................................................................210 Inspection and Repair...............................................................................................210 How To Check The Clearance Between The Main Bearings And Their Journals.............................................211 Installation........................................................................................................212 PISTON AND CONNECTING ROD ASSEMBLIES....................................................................................213 Connecting Rod Bearings, Replacement................................................................................213 Piston And Connecting Rod Assemblies, Removal.......................................................................214 Disassembly.........................................................................................................214 Piston, Cleaning And Inspection.....................................................................................214 Cylinder Bores, Inspection And Repair...............................................................................215 Piston Rings........................................................................................................216 Assembly............................................................................................................216 Piston And Connecting Rod Assemblies, Installation..................................................................217 FLYWHEEL AND FLYWHEEL HOUSING...........................................................................................217 Flywheel Repairs....................................................................................................217 Flywheel, Installation..............................................................................................217 Flywheel Housing....................................................................................................218 Engine Adapter......................................................................................................218 COOLANT PUMP............................................................................................................218 THERMOSTAT..............................................................................................................218 FAN MOUNT, EARLY MODELS.................................................................................................218 FAN MOUNT ASSEMBLY, LATE MODELS.........................................................................................219 DRIVE BELT, INSTALLATION................................................................................................220 CHECKS AND ADJUSTMENTS......................................................................................................222 VALVE CLEARANCE ADJUSTMENT, EARLY MODELS................................................................................222 VALVE CLEARANCE ADJUSTMENT, NEW MODELS..................................................................................222 CHECK THE COMPRESSION...................................................................................................222 ENGINE SPECIFICATIONS.......................................................................................................223 Engine Data.............................................................................................................223 Cylinder head...........................................................................................................223 Hydraulic Valve Lifter..................................................................................................223 Camshaft................................................................................................................223 Pistons.................................................................................................................223 Crankshaft..............................................................................................................224 Connecting Rods.........................................................................................................224 Connecting Rods.........................................................................................................224 Balance Shaft...........................................................................................................224 Cooling System..........................................................................................................224 Lubrication System......................................................................................................224 TORQUE SPECIFICATIONS.......................................................................................................225 TROUBLESHOOTING.............................................................................................................226 700626..........................................................................................................................229 COOLING SYSTEM..............................................................................................................229 INTRODUCTION............................................................................................................229 DESCRIPTION.............................................................................................................229 RADIATOR................................................................................................................229 RADIATOR CAP............................................................................................................229 THERMOSTAT..............................................................................................................229 WATER PUMP..............................................................................................................230 FAN AND FAN SHROUD .....................................................................................................230 REPAIRS.....................................................................................................................230 COOLING SYSTEM CHECKS...................................................................................................230 Exhaust Leaks.......................................................................................................230 RADIATOR................................................................................................................230 Checks..............................................................................................................230 Cleaning The Radiator...............................................................................................230 Drain The Cooling System............................................................................................232 Fill The Cooling System.............................................................................................232 WATER PUMP..............................................................................................................232 Checks..............................................................................................................232 THERMOSTAT..............................................................................................................233 Checks..............................................................................................................233 FAN AND FAN SHROUD .....................................................................................................233 TROUBLESHOOTING.............................................................................................................234 900347..........................................................................................................................235 WEBER CARBURETOR WITH GOVERNOR..............................................................................................235 GENERAL.................................................................................................................235 DESCRIPTION.............................................................................................................235 Carburetor..........................................................................................................235 Governor............................................................................................................235 OPERATION...............................................................................................................236 Carburetor, Float System............................................................................................236 Carburetor, Idle System.............................................................................................236 Carburetor, Main Metering System....................................................................................236 Carburetor, Power System............................................................................................237 Carburetor, Accelerator Pump System.................................................................................237 Carburetor, Choke System............................................................................................238 GOVERNOR................................................................................................................239 REPAIRS.....................................................................................................................240 CARBURETOR..............................................................................................................240 Removal.............................................................................................................240 Disassembly.........................................................................................................240 Cleaning............................................................................................................240 Assembly............................................................................................................240 Installation........................................................................................................241 GOVERNOR................................................................................................................241 CHECKS AND ADJUSTMENTS......................................................................................................242 GENERAL.................................................................................................................242 CHOKE SYSTEM............................................................................................................242 ELECTRIC CHOKE..........................................................................................................242 IDLE MIXTURE ADJUSTMENT.................................................................................................243 IDLE SPEED ADJUSTMENT...................................................................................................243 THROTTLE LINKAGE ADJUSTMENT.............................................................................................244 TROUBLESHOOTING.........................................................................................................245 900348..........................................................................................................................246 INTRODUCTION................................................................................................................246 GENERAL.................................................................................................................246 DESCRIPTION AND OPERATION...............................................................................................246 Fuel Tank...........................................................................................................247 Fuel Filter and Fuel Valve Unit.....................................................................................247 Vaporizer...........................................................................................................248 Carburetor..........................................................................................................249 Governor............................................................................................................250 REPAIRS.....................................................................................................................252 LPG TANK................................................................................................................252 Removal.............................................................................................................252 Installation........................................................................................................252 HYDROSTATIC RELIEF VALVE................................................................................................252 Removal and Installation............................................................................................252 FILTER UNIT.............................................................................................................254 Replacement Of The Fuel Filter Element..............................................................................254 Replacement of the Diaphragm and Fuel Valve ........................................................................254 REPLACEMENT OF THE HOSES................................................................................................254 VAPORIZER...............................................................................................................254 Removal.............................................................................................................254 Vaporizer Disassembly...............................................................................................256 Cleaning............................................................................................................256 Inspection..........................................................................................................256 Vaporizer Assembly..................................................................................................256 Installation........................................................................................................258 CARBURETOR..............................................................................................................258 Removal.............................................................................................................258 Disassembly.........................................................................................................258 Cleaning............................................................................................................259 Assembly............................................................................................................259 Installation........................................................................................................259 GOVERNOR................................................................................................................259 CHECKS AND ADJUSTMENTS......................................................................................................260 CHECK THE FILTER UNIT...................................................................................................260 CHECK THE VAPORIZER.....................................................................................................260 Pressure Reducer Valve..............................................................................................260 Vapor Valve.........................................................................................................260 ADJUST THE CARBURETOR...................................................................................................261 Idle Mixture........................................................................................................261 Idle Speed .........................................................................................................261 Power Mixture.......................................................................................................261 ADJUST THE THROTTLE LINKAGE.............................................................................................261 TROUBLESHOOTING.............................................................................................................262 1200334.........................................................................................................................265 INTRODUCTION................................................................................................................265 General.................................................................................................................265 Description.............................................................................................................265 REPAIRS.....................................................................................................................267 Removal and Disassembly.................................................................................................267 Cleaning and Inspection.................................................................................................268 Assembly and Installation...............................................................................................269 CHECKS AND ADJUSTMENTS......................................................................................................271 Adjusting the Clutch Pedal and Linkage..................................................................................271 Adjusting the By-pass Valve for Cold Oil................................................................................271 TROUBLESHOOTING.............................................................................................................272 1300335.........................................................................................................................274 INTRODUCTION................................................................................................................274 General.................................................................................................................274 Description.............................................................................................................274 Operation...............................................................................................................274 REPAIRS.....................................................................................................................276 Removal.................................................................................................................276 Disassembly.............................................................................................................277 Cleaning................................................................................................................279 Inspection..............................................................................................................280 Assembly................................................................................................................280 Installation............................................................................................................291 CHECKS AND ADJUSTMENTS......................................................................................................292 Adjusting The Shift Linkage H3.50-5.00XL (H70-110XL)....................................................................292 Adjusting The Shift Linkage S6.00-7.00XL (S135-155XL)...................................................................294 Adjusting The Clutch Pedal And Linkage..................................................................................294 TROUBLESHOOTING.............................................................................................................296 SPECIFICATIONS..............................................................................................................298 1300336.........................................................................................................................299 DESCRIPTION.................................................................................................................299 GENERAL.................................................................................................................299 MECHANICAL DESCRIPTION......................................................................................................299 TORQUE CONVERTER........................................................................................................299 OIL LAMP................................................................................................................300 SHAFT AND CLUTCH ASSEMBLIES.............................................................................................300 Input Shaft.........................................................................................................301 Forward Clutch Shaft................................................................................................301 Clutch Assemblies...................................................................................................301 Output Gear.........................................................................................................302 HYDRAULIC OPERATION.........................................................................................................302 TORQUE CONVERTER........................................................................................................302 SHAFT ASSEMBLIES........................................................................................................303 CONTROL VALVE...........................................................................................................305 General.............................................................................................................305 System Regulator....................................................................................................305 Clutch Pressure Regulator...........................................................................................305 Torque Converter Regulator..........................................................................................306 Inching Spool.......................................................................................................306 Direction Spool, Manual Control.....................................................................................306 Drain Spool.........................................................................................................307 Accumulator.........................................................................................................307 Modulation Spool....................................................................................................308 LUBRICATION CIRCUIT.....................................................................................................309 MONOTROL PEDAL..........................................................................................................309 OIL FLOW DIAGRAMS.......................................................................................................309 Neutral.............................................................................................................309 Forward.............................................................................................................309 Forward-Inching.....................................................................................................309 Reverse.............................................................................................................310 1300337.........................................................................................................................315 REPAIRS ....................................................................................................................315 GENERAL.................................................................................................................315 REMOVAL.................................................................................................................315 TRANSMISSION, DISASSEMBLY...............................................................................................317 Input Shaft, Disassembly............................................................................................318 Forward Shaft, Disassembly..........................................................................................320 Cleaning and Inspection.............................................................................................321 TRANSMISSION, ASSEMBLY..................................................................................................322 Forward Shaft, Assembly.............................................................................................322 Input Shaft, Assembly...............................................................................................324 Assembly............................................................................................................326 Installation........................................................................................................329 CONTROL VALVE...........................................................................................................330 Removal.............................................................................................................330 Disassembly.........................................................................................................331 Assembly............................................................................................................331 Installation........................................................................................................333 THROTTLE PEDAL..........................................................................................................333 MONOTROL PEDAL..........................................................................................................333 Removal and Disassembly.............................................................................................333 Assembly and Installation...........................................................................................333 CHECKS AND ADJUSTMENTS......................................................................................................336 STALL TEST..............................................................................................................336 ADJUST THE LINKAGE FOR THE INCHING PEDAL................................................................................337 Linkage For Models With An Inching Pedal And A Brake Pedal..........................................................337 Linkage For ModelsWith One Inching/Brake Pedal......................................................................339 ADJUST THE LINKAGE FOR THE DIRECTION CONTROL LEVER......................................................................340 Earlier Production..................................................................................................340 Later Production....................................................................................................341 CHECK THE OIL PRESSURE FOR THE TRANSMISSION.............................................................................342 System Pressure Check Port..........................................................................................343 Torque Converter Check Port.........................................................................................343 Clutch Pressure Check Port..........................................................................................344 Inching Pressure....................................................................................................344 Solenoid Check Ports (Monotrol Control Only)........................................................................344 Lubrication Pressure Check Ports....................................................................................344 TROUBLESHOOTING.............................................................................................................345 1300346.........................................................................................................................348 INTRODUCTION................................................................................................................348 GENERAL.................................................................................................................348 DESCRIPTION.............................................................................................................348 REPAIRS.....................................................................................................................348 REMOVAL.................................................................................................................348 DISASSEMBLY.............................................................................................................348 CLEANING................................................................................................................351 INSPECTION..............................................................................................................351 ASSEMBLY................................................................................................................351 Pinion Assembly.....................................................................................................351 Differential........................................................................................................352 INSTALLATION............................................................................................................358 TROUBLESHOOTING.............................................................................................................359 SPECIFICATIONS..............................................................................................................360 1400361.........................................................................................................................361 INTRODUCTION................................................................................................................361 GENERAL.................................................................................................................361 DESCRIPTION.............................................................................................................361 REPAIRS.....................................................................................................................362 REMOVAL.................................................................................................................362 Lift Trucks With A Manual Transmission..............................................................................362 Lift Trucks With A Powershift Transmission..........................................................................363 DISASSEMBLY.............................................................................................................364 CLEANING................................................................................................................364 INSPECTION..............................................................................................................364 ASSEMBLY................................................................................................................364 INSTALLATION............................................................................................................365 Lift Trucks With A Manual Transmission..............................................................................365 Lift Trucks With A Powershift Transmission..........................................................................366 TROUBLESHOOTING.............................................................................................................367 SPECIFICATIONS..............................................................................................................367 1600326.........................................................................................................................368 INTRODUCTION................................................................................................................368 GENERAL.................................................................................................................368 DESCRIPTION.............................................................................................................368 REPAIRS.....................................................................................................................369 STEERING AXLE, H3.50-5.00XL (H70-110XL) and S/E 3.50-5.50XL (S/E 70-120XL)..............................................369 Removal.............................................................................................................369 Installation........................................................................................................369 STEERING AXLE, H6.00-7.00XL (H135-155XL) H8.00-16.00XL (H165-360XL).....................................................370 Removal.............................................................................................................370 Installation........................................................................................................371 WHEELS AND HUBS, ALL UNITS..............................................................................................371 Removal and Disassembly.............................................................................................371 Cleaning............................................................................................................371 Assembly and Installation...........................................................................................371 SPINDLES AND BEARINGS, ALL UNITS........................................................................................372 Removal.............................................................................................................372 Cleaning............................................................................................................373 Assembly and Installation...........................................................................................373 TIE RODS, ALL UNITS.....................................................................................................373 Removal.............................................................................................................373 Cleaning............................................................................................................373 Installation........................................................................................................374 STEERING CYLINDER.......................................................................................................375 Removal and Disassembly.............................................................................................375 Cleaning and Inspection.............................................................................................375 Assembly and Installation...........................................................................................375 TROUBLESHOOTING.............................................................................................................376 1800338.........................................................................................................................377 INTRODUCTION................................................................................................................377 GENERAL.................................................................................................................377 DESCRIPTION AND OPERATION...............................................................................................377 BRAKE BOOSTER AND MASTER CYLINDER.......................................................................................377 MASTER CYLINDER.........................................................................................................377 SERVICE BRAKE ASSEMBLY..................................................................................................379 PARKING BRAKE...........................................................................................................380 REPAIRS.....................................................................................................................380 BRAKE SHOE ASSEMBLIES...................................................................................................380 Removal and Disassembly.............................................................................................380 Cleaning and Inspection.............................................................................................381 Assembly and Installation...........................................................................................383 MASTER CYLINDER.........................................................................................................386 S3.50-5.50XL (S70-120XL) and H3.50-5.00XL (H70-110XL....................................................................386 Removal ............................................................................................................386 Disassembly.........................................................................................................386 Assembly............................................................................................................387 Installation........................................................................................................387 MASTER CYLINDER, E3.50-5.50XL (E70-120XL)...............................................................................387 Removal and Disassebly..............................................................................................387 Cleaning and Inspection.............................................................................................388 Assembly and Installation...........................................................................................388 BRAKE BOOSTER...........................................................................................................388 Removal.............................................................................................................388 Disassembly.........................................................................................................388 Cleaning and Inspection.............................................................................................389 Assembly............................................................................................................389 Installation........................................................................................................390 CHECKS AND ADJUSTMENTS......................................................................................................390 REMOVE THE AIR FROM THE BRAKE SYSTEM....................................................................................390 ADJUST THE BRAKE PEDAL..................................................................................................390 ADJUST THE BRAKE SHOES..................................................................................................391 ADJUST THE PARKING BRAKE................................................................................................392 CHECK THE RELIEF VALVE ON THE PARKING BOOSTER...........................................................................392 TROUBLESHOOTING.............................................................................................................392 1900333.........................................................................................................................394 INTRODUCTION................................................................................................................394 GENERAL.................................................................................................................394 DESCRIPTION AND OPERATION...............................................................................................394 Hydraulic Pump......................................................................................................394 Main Control Valve..................................................................................................395 Steering Control Unit...............................................................................................397 Brake Booster.......................................................................................................397 REPAIRS.....................................................................................................................397 HYDRAULIC PUMP..........................................................................................................397 Removal.............................................................................................................397 Disassembly.........................................................................................................398 Cleaning and Inspection.............................................................................................398 Assembly............................................................................................................398 Installation........................................................................................................399 Adjust the Flow Divider.............................................................................................399 SPECIFICATIONS..............................................................................................................399 TROUBLESHOOTING.............................................................................................................400 1900339.........................................................................................................................402 INTRODUCTION................................................................................................................402 GENERAL.................................................................................................................402 DESCRIPTION.............................................................................................................402 REPAIRS.....................................................................................................................404 REMOVAL AND DISASSEMBLY.................................................................................................404 CLEANING................................................................................................................404 INSPECTION..............................................................................................................404 ASSEMBLY AND INSTALLATION...............................................................................................405 TROUBLESHOOTING.............................................................................................................406 GENERAL.................................................................................................................406 2100103.........................................................................................................................407 INTRODUCTION................................................................................................................410 GENERAL.................................................................................................................410 DESCRIPTION.............................................................................................................410 REPAIRS.....................................................................................................................410 REMOVAL.................................................................................................................410 DISASSEMBLY.............................................................................................................410 CLEANING................................................................................................................410 ASSEMBLY................................................................................................................410 Tilt Cylinders for the XM and XMS Models............................................................................410 Tilt Cylinders with O-Ring or Single Lip Seals......................................................................412 Tilt Cylinders for H700-800A and Early Model H700-920B..............................................................412 INSTALLATION............................................................................................................412 Tilt Cylinders with Chevron Packing.................................................................................412 CHECKS AND ADJUSTMENTS......................................................................................................416 CHECK THE TILT CYLINDERS FOR LEAKS......................................................................................416 ADJUST THE TILT CYLINDER STROKE AND THE MAST TILT ANGLE.................................................................416 TROUBLESHOOTING.............................................................................................................419 2200106.........................................................................................................................422 INTRODUCTION................................................................................................................422 GENERAL.................................................................................................................422 DESCRIPTION AND OPERATION...............................................................................................422 REPAIRS.....................................................................................................................424 REMOVAL.................................................................................................................424 DISSASEMBLY.............................................................................................................424 CLEANING................................................................................................................425 ASSEMBLY................................................................................................................425 INSTALLATION............................................................................................................425 CHECKS AND ADJUSTMENTS......................................................................................................426 GENERAL.................................................................................................................426 TROUBLESHOOTING.............................................................................................................428 2200107.........................................................................................................................430 HIGH ENERGY IGNITION (HEI)..................................................................................................430 DESCRIPTION.............................................................................................................430 REPAIRS.....................................................................................................................432 DISTRIBUTOR.............................................................................................................432 Removal.............................................................................................................432 Disassembly.........................................................................................................432 Assembly............................................................................................................437 INSTALLATION, IF THE CRANKSHAFT WAS NOT ROTATED WHEN DISTRIBUTOR WAS REMOVED............................................438 INSTALLATION, IF THE CRANKSHAFT WAS ROTATED WHEN THE DISTRIBUTOR WAS REMOVED............................................439 IGNITION COIL...........................................................................................................439 Removal, Some 4 and 6 Cylinder Models...............................................................................439 Installation, Some 4 and 6 Cylinder Models..........................................................................440 Removal, V8, Some 4 and 6 Cylinder Models...........................................................................440 Installation, V8, Some 4 and 6 Cylinder Models......................................................................441 ELECTRONIC MODULE.......................................................................................................442 Removal.............................................................................................................442 Installation........................................................................................................442 SENSING COIL............................................................................................................443 Removal.............................................................................................................443 Installation........................................................................................................443 SPARK PLUGS.............................................................................................................443 Removal.............................................................................................................443 Installation........................................................................................................444 CHECKS AND ADJUSTMENTS..................................................................................................444 Visual Checks.......................................................................................................444 Check The High Voltage Wires........................................................................................444 Checking The Ignition Coil..........................................................................................444 Coil In Distributor Cap Design......................................................................................444 Separate Coil Design................................................................................................445 Checking The Sensing Coil...........................................................................................445 Check The Electronic Module.........................................................................................446 Ignition Timing Adjustment..........................................................................................446 Ignition System, GM V8-366 (6-litre)................................................................................447 Ignition Timing and Idle Speed Adjustment, GM V6-LPG (4.3-litre)....................................................447 SPECIFICATIONS..............................................................................................................447 TROUBLESHOOTING.............................................................................................................448 2200143.........................................................................................................................449 INTRODUCTION................................................................................................................449 GENERAL.................................................................................................................449 DESCRIPTION.................................................................................................................449 GENERAL.................................................................................................................449 STEERING COLUMN GAUGES, METERS AND INDICATORS...........................................................................452 LED DISPLAY PANEL.......................................................................................................452 Battery Discharge Indicators .......................................................................................452 Brush Wear Indicators...............................................................................................453 Motor Temperature Indicators........................................................................................454 "LX" SERIES INSTRUMENT PANEL DISPLAY....................................................................................455 Hourmeter Functions.................................................................................................456 Battery Indicator Function..........................................................................................456 Status Code Function................................................................................................456 CHECKS AND ADJUSTMENTS......................................................................................................456 GENERAL.................................................................................................................456 REPLACEMENT.................................................................................................................457 GENERAL.................................................................................................................457 METER REPLACEMENT.......................................................................................................457 SENDER REPLACEMENT......................................................................................................458 Fuel Level Sender...................................................................................................458 Pressure And Temperature Sender.....................................................................................459 I.T.W. DISPLAY PANEL....................................................................................................459 Removal.............................................................................................................459 SPECIFICATIONS..............................................................................................................460 TROUBLESHOOTING.............................................................................................................461 2200144.........................................................................................................................462 ELECTRICAL WARNING DEVICES..................................................................................................462 GENERAL.................................................................................................................462 DESCRIPTION.............................................................................................................462 Operator Controlled Horns...........................................................................................462 System Warning Lights, Buzzers and Bells............................................................................462 Reverse Warning Horns...............................................................................................463 Warning Lights......................................................................................................463 REPLACEMENT.............................................................................................................464 General.............................................................................................................464 Replacing Horns or Bells............................................................................................464 Replacing Horn Relay or Buzzer......................................................................................464 Replacing Warning Lights............................................................................................464 Light Assemblies....................................................................................................465 Replacing Flashing Units............................................................................................465 2200463.........................................................................................................................466 MICROPROCESSOR SPARK TIMING SYSTEM (MSTS)...................................................................................466 GENERAL.................................................................................................................466 DESCRIPTION.............................................................................................................466 What MSTS Does......................................................................................................468 How MSTS Begins Operation...........................................................................................468 OPERATION...............................................................................................................468 Pulse Generator.....................................................................................................468 HEI Module..........................................................................................................469 When the Engine Is Being Started....................................................................................469 When the Engine Is Running..........................................................................................471 Manifold Absolute Pressure (MAP)....................................................................................471 Coolant Temperature Sensor (CTS)....................................................................................471 Electronic Control Module (ECM), Corrections........................................................................472 The Initial Timing Connector........................................................................................472 Gasoline and LPG Conversions........................................................................................473 TROUBLESHOOTING.............................................................................................................475 GENERAL.................................................................................................................475 TOOLS AND TEST EQUIPMENT................................................................................................475 MSTS TROUBLESHOOTING....................................................................................................476 Test Description....................................................................................................476 IGNITION SYSTEM TROUBLESHOOTING.........................................................................................478 Test Description....................................................................................................478 ELECTRONIC SPARK TIMING (EST) TROUBLESHOOTING...........................................................................481 Circuit Description.................................................................................................481 Test Description....................................................................................................481 MANIFOLD ABSOLUTE PRESSURE (MAP) TROUBLESHOOTING........................................................................484 Circuit Description.................................................................................................484 Test Description....................................................................................................484 COOLANT TEMPERATURE SENSOR (CTS) TROUBLESHOOTING........................................................................487 Circuit Description.................................................................................................487 Test Description....................................................................................................487 REPAIRS.....................................................................................................................489 DISTRIBUTOR.............................................................................................................489 Removal.............................................................................................................489 Disassembly.........................................................................................................490 Inspection..........................................................................................................490 Assembly............................................................................................................491 Installation........................................................................................................491 Igntion Timing......................................................................................................491 HEI MODULE..............................................................................................................492 Test For A Fault....................................................................................................492 HEI Module Replacement..............................................................................................492 SENSING COIL............................................................................................................493 Test For A Fault....................................................................................................493 Sensing Coil Replacement............................................................................................493 IGNITION COIL...........................................................................................................493 Test For A Fault....................................................................................................493 ELECTRONIC CONTROL MODULE (ECM).........................................................................................494 Removal.............................................................................................................494 Installation........................................................................................................494 COOLANT TEMPERATURE SENSOR (CTS)........................................................................................494 Removal.............................................................................................................494 Installation........................................................................................................495 MANIFOLD ABSOLUTE PRESSURE (MAP)........................................................................................495 Removal.............................................................................................................495 Installation........................................................................................................495 PRESSURE CONVERSION CHART...........................................................................................496 2200468.........................................................................................................................497 ELECTRONIC ENGINE CONTROL, TROUBLESHOOTING AND REPAIR.......................................................................497 GENERAL.................................................................................................................497 Engine Data.........................................................................................................497 LIGHT BULB CHECK........................................................................................................497 SYSTEM CHECK............................................................................................................499 TROUBLESHOOTING WITH THE FAULT MONITOR SYSTEM IN THE ECM................................................................499 How To Clear A Code.................................................................................................500 Fault In The ECM....................................................................................................500 Fault In The PROM...................................................................................................501 CalPak Not Installed................................................................................................501 Fuel Control........................................................................................................501 Idle Air Control (IAC)..............................................................................................501 Fuel Pump Circuit...................................................................................................501 Coolant Temperature Sensor (CTS)....................................................................................502 Manifold Absolute Pressuer Sensor (MAP).............................................................................502 Throttle Position Sensodr (TPS).....................................................................................502 Output Check, Throttle Position Sensor..............................................................................502 Electronic Spark Timing.............................................................................................502 Engine Crank Signal.................................................................................................503 Distributor Reference Signal........................................................................................503 TROUBLESHOOTING CHARTS......................................................................................................504 CHART A-1-No "Check Engine" Light.......................................................................................504 Circuit Description, "Check Engine" Light...........................................................................504 CHART A-1-No "Check Engine" Light.......................................................................................505 CHART A-2-No ALDL Data Or No Code 12 From "Check Engine" Light. The "Check Engine" Light Is Continuosly Illuminated.....506 Circuit Description, "Check Engine" Light...........................................................................506 CHART A-2-No ALDL Data Or No Code 12 From "Check Engine" Light. The "Check Engine" Light Is Continuously Illuminated....507 CHART A-3-Starter Cranks The Engine, But Will Not Run...................................................................508 Circuit Description.................................................................................................509 CHART A-4-Fuel Injector Circuit.........................................................................................510 Circuit Description.................................................................................................510 CHART A-5-Fuel Pump Relay Circuit.......................................................................................512 Circuit Description.................................................................................................512 CHART A-6-Fuel System Pressure Test.....................................................................................514 Circuit Description.................................................................................................514 CHART A-7-MAP Output Check..............................................................................................516 Circuit Description.................................................................................................516 CHART A-8-Engine Crank Signal Check.....................................................................................518 Circuit Description.................................................................................................518 CHART A-9-Ignition System Troubleshooting...............................................................................519 CHART A-9 Ignition System Troubleshooting Chart.........................................................................520 CHART A-10-Idle Air Control (IAC) System................................................................................522 Circuit Description.................................................................................................522 FAULT CODES.................................................................................................................524 CODE 14-Coolant Temperature Sensor Circuit (Indicates High Temperature).................................................524 Circuit Description.................................................................................................524 CODE 15-Coolant Temperature Sensor Circuit (Indicates Low Temperature...................................................526 Circuit Description.................................................................................................526 CODE 21-Throttle Position Sensor Circuit (Signal Voltage High) .........................................................528 Circuit Description.................................................................................................528 CODE 22-Throttle Position Sensor Circuit (Signal Voltage Low) ..........................................................530 Circuit Description.................................................................................................530 CODE 31-Engine Governor Circuit.........................................................................................532 Circuit Description.................................................................................................532 CODE 33-MAP Sensor Circuit, Signal Voltage High (Low Vacuum.............................................................534 Circuit Description.................................................................................................534 CODE 34-MAP Sensor Circuit, Signal Voltage Low (High Vacuum)............................................................536 Circuit Description.................................................................................................536 CODE 42-Electronic Spark Timing (EST)...................................................................................538 Circuit Description.................................................................................................538 CODE 54-Fuel Pump Circuit (Low Voltage).................................................................................540 Circuit Description.................................................................................................540 CODE 51-PROM In The ECM Has A Fault ....................................................................................542 CODE 52-Fuel CalPak Is Missing..........................................................................................542 CODE 55-ECM Has A Fault.................................................................................................542 TROUBLESHOOTING, POOR OPERATION.........................................................................................542 General.............................................................................................................542 Make A Careful Visual Check.........................................................................................542 FAULT: Fuel Usage Too High..........................................................................................542 FAULT: Codes Or Performance That Is Not Regular.....................................................................543 FAULT: "Dieseling"..................................................................................................543 FAULT: "Backfire"...................................................................................................543 FAULT: Rough Idle or Engine Stalls During Idle......................................................................543 FAULT: Smoke In The Exhaust Gases...................................................................................544 FAULT: Engine is Difficult To Start.................................................................................544 FAULT: Variation In Engine Power When The Throttle Is Held Steady...................................................545 FAULT: Decreased Engine Power.......................................................................................545 FAULT: "Detontion"..................................................................................................545 FAULT: Engine Momentarily Does Not Increase Power When Throttle Changes.............................................546 FAULT: One Cylinder In The Engine Does Not Operate Correctly. The Engine Does Not Idle Correctly....................546 REPAIRS, FUEL SYSTEM COMPONENTS ........................................................................................548 General.............................................................................................................548 Vacuum Ports........................................................................................................548 Throttle Body Injection (TBI) Unit..................................................................................548 TBI Unit, Removal...................................................................................................548 TBI Unit, Cleaning and Inspection...................................................................................549 TBI Unit, Installation..............................................................................................549 Cover For Fuel Meter Body, Replacement..............................................................................549 Fuel Injectors......................................................................................................550 Fuel Injectors, Removal.............................................................................................550 Fuel Injectors, Installation........................................................................................551 Pressure Regulator, Removal.........................................................................................551 Pressure Regulator, Inspection......................................................................................551 Pressure Regulator, Installation ...................................................................................551 Fuel Meter Body, Removal............................................................................................552 Fuel Meter Body, Installation.......................................................................................552 Throttle Position Sensor (TPS), Removal.............................................................................552 Throttle Position Sensor (TPS), Installation........................................................................552 Idle Air Control (IAC) Valve, Removal...............................................................................553 Cleaning and Inspection.............................................................................................553 Idle Air Control (IAC) Valve, Installation..........................................................................553 Governor Throttle Drive Assembly, Removal...........................................................................553 Governor Throttle Drive Assembly, Inspection........................................................................553 Cleaning and Lubrication............................................................................................554 Governor Throttle Drive Assembly, Installation......................................................................554 Governor Drive Motor, Removal.......................................................................................555 Governor Drive Motor, Cleaning and Lubrication......................................................................555 Governor Drive Motor, Installation..................................................................................556 Governor Drive Motor, Inspection....................................................................................556 Throttle Body, Removal and Disassembly..............................................................................556 Throttle Body, Inspection...........................................................................................556 Throttle Body, Assembly and Installation............................................................................556 Fuel Pump, Removal and Disassembly..................................................................................557 Fuel Pump, Inspection...............................................................................................557 REPAIRS, ELECTRICAL COMPONENTS..........................................................................................557 General.............................................................................................................557 Ignition Coil Test..................................................................................................557 Ignition Module Test................................................................................................558 Distributor, Removal................................................................................................558 Distributor, Disassembly............................................................................................559 Distributor, Assembly...............................................................................................559 Distributor, Installation...........................................................................................560 Firing Order........................................................................................................561 Ignition Timing.....................................................................................................561 Ignition Coil, Removal..............................................................................................562 Ignition Coil, Installation.........................................................................................562 Procedures For Spark Plugs, Spark Plug Wires And Boots .............................................................562 Troubleshooting of Spark Plugs......................................................................................563 Coolant Temperature Sensor (CTS), Replacement ......................................................................564 Manifold Absolute Pressure (MAP) Sensor, Replacement................................................................564 Oil Pressure Switch, Replacement....................................................................................565 Coolant Temperature Sender, Replacement.............................................................................565 Wire Harness........................................................................................................565 Connectors And Terminals............................................................................................565 Electronic Control Module (ECM).....................................................................................569 ECM CONNECTOR A-B IDENTIFICATION........................................................................................573 ECM CONNECTOR C-D IDENTIFICATION........................................................................................574 SPECIAL TOOLS...............................................................................................................575 2200473.........................................................................................................................578 INTRODUCTION................................................................................................................578 GENERAL.................................................................................................................578 DESCRIPTION AND OPERATION...................................................................................................578 GENERAL.................................................................................................................578 ECM (ELECTRONIC CONTROL MODULE).........................................................................................578 ALDL Connector......................................................................................................580 How The ECM Begins Operation........................................................................................580 ELECTRONIC ENGINE CONTROL...............................................................................................581 What The ECM Does...................................................................................................581 Pulse Generator, EST Distributor....................................................................................582 EST Module(See FIGURE 9.)...........................................................................................583 When the Engine Is Being Started....................................................................................583 When the Engine Is Running..........................................................................................585 Electronic Control Module (ECM) With EST Distrubutor, Corrrections..................................................585 What The ECM Does...................................................................................................585 FUEL CONTROL............................................................................................................586 Throttle Body Injection.............................................................................................586 Fuel Injectors......................................................................................................587 Fuel Pressure Regulator.............................................................................................587 Throttle Position Sensor............................................................................................587 Idle Air Control....................................................................................................587 Governor Motor And Throttle Drive Assembly..........................................................................588 Vacuum Ports........................................................................................................590 Fuel Pump...........................................................................................................590 ECM SENSORS AND CONTROLLERS.............................................................................................592 Manifold Absolute Pressure (MAP)....................................................................................592 Coolant Temperature Sensor (CTS)....................................................................................592 Initial Timing Connector (EST Distributor)..........................................................................592 4000135.........................................................................................................................594 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST................................................................................594 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST............................................................................594 LIFT CYLINDERS..............................................................................................................597 GENERAL.................................................................................................................597 DESCRIPTION.............................................................................................................597 Lowering Control Valve..............................................................................................597 Cylinders (General).................................................................................................600 Cylinders (H520-620B,H700-800A).....................................................................................602 Cylinders (H360-460B)...............................................................................................603 Cylinders (Two-Speed)...............................................................................................603 REPAIRS.....................................................................................................................604 REMOVAL OF THE LIFT CYLINDER WITHOUT REMOVING THE MAST..................................................................604 Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast............................604 Standard and Full Free-Lift Masts with the Lift Cylinder to a Crosshead.............................................608 Masts that have Two Cylinders, A Main Lift Cylinder and a Free-Lift Cylinder.......................................606 DISASSEMBLY.............................................................................................................606 ASSEMBLY................................................................................................................608 INSTALLATION OF THE LIFT CYLINDER IN THE MAST...........................................................................608 Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast............................608 Standard and Full-Free-Lift Masts with the Lift Cylinder Fastened to a Crosshead....................................608 CHEVRON PACKING.........................................................................................................609 LIFT CYLINDERS FOR VISTA MASTS..............................................................................................612 DESCRIPTION.............................................................................................................612 Lowering Control Valve..............................................................................................614 REMOVAL.................................................................................................................615 DISASSEMBLY.............................................................................................................615 ASSEMBLY................................................................................................................615 INSTALLATION............................................................................................................616 Main Lift Cylinders.................................................................................................616 Free-Lift Cylinders.................................................................................................616 CHECKS AND ADJUSTMENTS......................................................................................................617 CHECK FOR LEAKS IN LIFT SYSTEM..........................................................................................617 TROUBLESHOOTING.............................................................................................................618 SPECIFICATIONS..............................................................................................................619 4000340.........................................................................................................................620 VISTA® MASTS................................................................................................................620 GENERAL.................................................................................................................620 DESCRIPTION AND OPERATION...............................................................................................620 CARRIAGES...............................................................................................................620 TWO-STAGE MAST WITH LIMITED FREE-LIFT...................................................................................620 TWO-STAGE MAST WITH FULL FREE-LIFT MAST.................................................................................621 THREE-STAGE MAST WITH FULL FREE-LIFT....................................................................................622 REPAIRS.....................................................................................................................624 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST (1 OF 2)...................................................................624 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST (2 OF 2)...................................................................625 FORKS...................................................................................................................625 Forks, Removal And Installation.....................................................................................625 CARRIAGE................................................................................................................627 Removal.............................................................................................................627 SIDE-SHIFT CARRIAGE (EARLIER DESIGNS)...................................................................................628 Disassembly, Side Shift Carriage....................................................................................628 Assembly, Side Shift Carriage.......................................................................................630 Installation........................................................................................................631 SIDE-SHIFT CARRIAGE (1993 AND LATER DESIGN).............................................................................631 Removal.............................................................................................................631 Repairs.............................................................................................................632 Installation........................................................................................................633 TABLE 1. WEIGHT OF MAST PARTS...........................................................................................633 TWO-STAGE MAST WITH LIMITED FREE-LIFT...................................................................................634 Removal.............................................................................................................634 Disassembly.........................................................................................................634 Cleaning and Inspection.............................................................................................636 Assembly............................................................................................................636 Installation........................................................................................................637 TWO-STAGE MAST WITH FULL FREE-LIFT......................................................................................637 Removal.............................................................................................................637 Disassembly.........................................................................................................637 Cleaning and Inspection.............................................................................................638 Assembly............................................................................................................638 Installation........................................................................................................638 THREE-STAGE MAST WITH FULL FREE LIFT....................................................................................639 Removal.............................................................................................................639 Disassembly.........................................................................................................639 Cleaning and Inspection.............................................................................................640 Assembly............................................................................................................640 Installation........................................................................................................642 CHECKS AND ADJUSTMENTS......................................................................................................644 CHECK THE OPERATION OF THE MAST.........................................................................................644 CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM.............................................................................644 Lift System.........................................................................................................644 Tilt System.........................................................................................................644 ADJUST THE TILT CYLINDER STROKE AND THE BACKWARD TILT ANGLE.............................................................645 LIFT CHAIN ADJUSTMENTS..................................................................................................645 MAST ADJUSTMENTS........................................................................................................646 CARRIAGE ADJUSTMENT.....................................................................................................647 TROUBLESHOOTING.............................................................................................................650 8000231.........................................................................................................................652 INTRODUCTION................................................................................................................652 NOMENCLATURE, THREADS...................................................................................................652 STRENGTH IDENTIFICATION.................................................................................................653 TABLE 1. BOLTS AND SCREWS...................................................................................................653 TABLE 2. STUDS AND NUTS.....................................................................................................654 TABLE 3. TORQUE NUTS........................................................................................................655 TABLE 4. TORQUE NUTS WITH NYLON INSERT......................................................................................656 TABLE 5. TORQUE VALUES FOR INCH FASTENERS...................................................................................657 TABLE 6. TORQUE VALUES FOR METRIC FASTENERS.................................................................................658 8000341.........................................................................................................................661 PERIODIC MAINTENANCE........................................................................................................661 GENERAL.................................................................................................................661 SERIAL NUMBER DATA......................................................................................................661 HOW TO MOVE A DISABLED LIFT TRUCK.......................................................................................661 How To Tow the Lift Truck...........................................................................................661 HOW TO PUT A LIFT TRUCK ON BLOCKS.......................................................................................662 How To Raise the Drive Tires........................................................................................662 How To Raise the Steering Tires.....................................................................................662 MAINTENANCE SCHEDULE........................................................................................................664 MAINTENANCE PROCEDURES......................................................................................................667 EVERY 8 HOURS OR DAILY......................................................................................................667 HOW TO MAKE THE CHECKS WITH THE ENGINE STOPPED..........................................................................667 Hydraulic System Oil................................................................................................667 Engine Oil..........................................................................................................669 Drive Belts.........................................................................................................669 Cooling System......................................................................................................669 Air Filter..........................................................................................................669 Fuel System.........................................................................................................670 Primary Fuel Filter, Diesel Engine..................................................................................670 Battery.............................................................................................................670 Tires and Wheels....................................................................................................670 Forks...............................................................................................................671 Forks, Adjustment...................................................................................................671 Forks, Removal And Installation.....................................................................................671 Inspection of Forks, Mast, And Lift Chains..........................................................................672 Operator Restraint System...........................................................................................674 Safety Labels.......................................................................................................675 HOW TO MAKE THE CHECKS WITH THE ENGINE RUNNING..........................................................................675 Gauges, Lights, Horn, and Fuses.....................................................................................675 Oil Level, Powershift Transmission..................................................................................675 Oil Level, Oil Clutch System, H3.50-5.00XL (H70-110XL)..............................................................676 Control Levers and Pedals...........................................................................................676 Lift System Operation...............................................................................................676 Inching/Brake Pedal.................................................................................................677 Service Brakes......................................................................................................677 Parking Brake.......................................................................................................677 Steering System.....................................................................................................677 EVRY 150 HOURS OR MONTHLY...................................................................................................677 THRUST SCREW FOR THE DIFFERENTIAL, H6.00-7.00XL (H135-155XL)............................................................677 LIFT CHAINS, LUBRICATION................................................................................................677 DRIVE SHAFTS............................................................................................................678 EVERY 350 HOURS OR TWO MONTHS...............................................................................................678 ENGINE OIL AND FILTER...................................................................................................678 DRIVE BELTS.............................................................................................................679 Perkins Diesel Engine...............................................................................................679 GM V-6 Engine (Early Models)........................................................................................679 GM V-6 Engine (Later Models)........................................................................................680 HYDRAULIC TANK BREATHER, CLEAN AND CHECK................................................................................681 BRAKE FLUID.............................................................................................................681 LIFT CHAINS, CHECK FOR WEAR.............................................................................................681 FORKS, CHECK FOR WEAR AND DAMAGE........................................................................................682 MAST, LUBRICATION.......................................................................................................682 CONTROL LEVERS AND PEDALS, LUBRICATION..................................................................................682 STEERING AXLE, LUBRICATION..............................................................................................683 FUEL SYSTEM, CHECKS AND ADJUSTMENTS.....................................................................................683 Diesel Fuel System..................................................................................................683 LPG Carburetor (Early Models).......................................................................................683 Gasoline Carburetor (Early Models)..................................................................................684 Fuel Injection (Late Models)........................................................................................684 EVERY 1000 HOURS OR SIX MONTHS..............................................................................................684 PCV VALVE, GM V-6.......................................................................................................684 MANIFOLD HEAT VALVE, GM V-6 (EARLY MODELS)..............................................................................684 CRANKCASE BREATHER, GM-V6...............................................................................................684 IGNITION SYSTEM (GM V-6)................................................................................................684 VALVE CLEARANCE ADJUSTMENT..............................................................................................685 FUEL FILTER (REPLACEMENT), DIESEL ENGINE................................................................................685 REMOVE AIR FROM THE FUEL SYSTEM: PERKINS 1004-4 DIESEL ENGINE...........................................................685 Fuel Injection Pump With A Vent Tube................................................................................685 Fuel Injection Pump With A Vent Screw...............................................................................686 REMOVE AIR FROM THE FUEL SYSTEM: PERKINS 4.2482 DIESEL ENGINE...........................................................687 CHECK THE OIL LEVEL IN THE TRANSMISSION.................................................................................687 Manual Transmission, H3.50-5.00XL (H70-110XL).......................................................................687 Speed Reducer For The Powershift Transmission, H3.50-5.00XL (H70-110XL).............................................688 Manual Transmission, H6.00-7.00XL (H135-155XL)......................................................................688 Differential And Drive Axle For The Powershift Transmission, H6.00-7.00XL (H135-155XL...............................688 Differential, Speed Reducer, And Drive Axle For The Manual Transmission, H6.00-7.00XL (H135-155XL)..................688 EVERY 2000 HOURS OR YEARLY..................................................................................................688 HYDRAULIC SYSTEM........................................................................................................688 Replace the Hydraulic Oil and Filter, H3.50-5.00XL (H70-110XL)......................................................688 Replace the Hydraulic Oil and Filter, H6.00-7.00XL (H135-155XL).....................................................689 CHANGE THE OIL AND REPLACE THE OIL FILTER, POWERSHIFT TRANSMISSION, ALL UNITS...........................................689 CHANGE THE OIL, MANUAL TRANSMISSION, H3.50-5.00XL (H70-110XL)...........................................................689 CHANGE THE OIL, MANUAL TRANSMISSION, H6.00-7.00XL (H135-155XL)..........................................................689 CHANGE THE OIL, SPEED REDUCER, POWERSHIFT TRANSMISSION, H3.50-5.00XL (H70-110XL)........................................690 CHANGE THE OIL AND FILTER, OIL CLUTCH SYSTEM, H3.50-5.00XL (H70-110XL)..................................................690 CHANGE THE OIL, DIFFERENTIAL AND DRIVE AXLE FOR THE POWERSHIFT TRANSMISSION, H6.00-7.00XL (H135-155XL)..................690 CHANGE THE OIL, DIFFERENTIAL, SPEED REDUCER, AND DRIVE AXLE FOR MANUAL TRANSMISSION, H6.00-7.00XL (H135-155XL)..........690 COOLING SYSTEM..........................................................................................................691 WHEEL BEARINGS..........................................................................................................691 Steering Wheels, lubrication........................................................................................691 Drive Wheels, Lubrication...........................................................................................691 PCV VALVE, GM V-6.......................................................................................................691 SERVICE BRAKES..........................................................................................................691 LPG FILTER, REPLACEMENT.................................................................................................692 GASOLINE FUEL FILTER, REPLACEMENT.......................................................................................692 CHECK THE HOOD LATCH, H3.50-5.00XL (H70-110XL)..........................................................................692 GENERAL PROCEDURES..........................................................................................................693 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST............................................................................693 LIFT CHAIN ADJUSTMENTS..................................................................................................695 FUEL INJECTORS..........................................................................................................695 CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM.............................................................................696 Check the Lift Cylinder for Leaks...................................................................................696 Check the Tilt Cylinder for Leaks...................................................................................696 WELDING REPAIRS.........................................................................................................696 CHANGES TO THE OVERHEAD GUARD...........................................................................................697 WHEELS AND TIRES........................................................................................................698 Remove The Wheels From The Lift Truck...............................................................................698 Remove The Wheel From The Tire......................................................................................698 Install The Wheel In The Tire.......................................................................................700 Pneumatic Tires, Add Air To The Tires...............................................................................701 Install the Wheels..................................................................................................701 SOLID RUBBER TIRES......................................................................................................702 Remove The Tire From The Wheel......................................................................................702 Install The Tire On The Wheel.......................................................................................703 REFERENCE TABLE.............................................................................................................704 8000342.........................................................................................................................705 8000343.........................................................................................................................713 FIGURE 1. ELECTRICAL SCHEMATIC (GASOLINE/LPG, EARLY PRODUCTION).............................................................713 FIGURE 2. ELECTRICAL SCHEMATIC (GASOLINE/LPG, LATER PRODUCTION).............................................................715 FIGURE 3. ELECTRICAL SCHEMATIC (DIESEL, PERKINS 4.2482).....................................................................717 FIGURE 4. ELECTRICAL SCHEMATIC (DIESEL, PERKINS 1004-4, EARLY PRODUCTION)...................................................719 FIGURE 5. ELECTRICAL SCHEMATIC (DIESEL, PERKINS 1004-4, LATER PRODUCTION)...................................................721 FIGURE 6. HYDRAULIC SCHEMATIC...............................................................................................723 FIGURE 7. HYDRAULIC SCHEMATIC, POWERSHIFT TRANSMISSION WITH MANUAL CONTROL..................................................724 FIGURE 8. HYDRAULIC SCHEMATIC, POWERSHIFT TRANSMISSION WITH MONTROL PEDAL...................................................725 FIGURE 9. WIRING DIAGRAM, BACK-UP ALARM.....................................................................................726 8000494.........................................................................................................................727
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