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Hyster F005 (H70XL-H110XL) Service Manual – PDF DOWNLOAD
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Description
Hyster F005 (H70XL-H110XL) Service Manual – PDF DOWNLOAD
FILE DETAILS:
Hyster F005 (H70XL-H110XL) Service Manual – PDF DOWNLOAD
Language : English
Pages : 725
Downloadable : Yes
File Type : PDF
Size: 25.3 MB
TABLE OF CONTENTS:
Hyster F005 (H70XL-H110XL) Service Manual – PDF DOWNLOAD
alternator...................................................................................................................... 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 CAPACITIES AND SPECIFICATIONS................................................................................................... 16 cooling system.................................................................................................................. 24 COOLING SYSTEM.............................................................................................................. 24 INTRODUCTION............................................................................................................ 24 DESCRIPTION............................................................................................................. 24 RADIATOR................................................................................................................ 24 RADIATOR CAP............................................................................................................ 24 THERMOSTAT.............................................................................................................. 24 WATER PUMP.............................................................................................................. 25 FAN AND FAN SHROUD ..................................................................................................... 25 REPAIRS..................................................................................................................... 25 COOLING SYSTEM CHECKS................................................................................................... 25 Exhaust Leaks....................................................................................................... 25 RADIATOR................................................................................................................ 25 Checks.............................................................................................................. 25 Cleaning The Radiator............................................................................................... 25 Drain The Cooling System............................................................................................ 27 Fill The Cooling System............................................................................................. 27 WATER PUMP.............................................................................................................. 27 Checks.............................................................................................................. 27 THERMOSTAT.............................................................................................................. 28 Checks.............................................................................................................. 28 FAN AND FAN SHROUD ..................................................................................................... 28 TROUBLESHOOTING............................................................................................................. 29 drive axle assembly............................................................................................................. 30 INTRODUCTION................................................................................................................ 30 GENERAL................................................................................................................. 30 DESCRIPTION............................................................................................................. 30 REPAIRS..................................................................................................................... 31 REMOVAL................................................................................................................. 31 Lift Trucks With A Manual Transmission.............................................................................. 31 Lift Trucks With A Powershift Transmission.......................................................................... 32 DISASSEMBLY............................................................................................................. 33 CLEANING................................................................................................................ 33 INSPECTION.............................................................................................................. 33 ASSEMBLY................................................................................................................ 33 INSTALLATION............................................................................................................ 34 Lift Trucks With A Manual Transmission.............................................................................. 34 Lift Trucks With A Powershift Transmission.......................................................................... 35 TROUBLESHOOTING............................................................................................................. 36 SPECIFICATIONS.............................................................................................................. 36 Electrical Schematic............................................................................................................ 37 FIGURE 1. ELECTRICAL SCHEMATIC (GASOLINE/LPG, EARLY PRODUCTION)............................................................. 37 FIGURE 2. ELECTRICAL SCHEMATIC (GASOLINE/LPG, LATER PRODUCTION)............................................................. 39 FIGURE 3. ELECTRICAL SCHEMATIC (DIESEL, PERKINS 4.2482)..................................................................... 41 FIGURE 4. ELECTRICAL SCHEMATIC (DIESEL, PERKINS 1004-4, EARLY PRODUCTION)................................................... 43 FIGURE 5. ELECTRICAL SCHEMATIC (DIESEL, PERKINS 1004-4, LATER PRODUCTION)................................................... 45 FIGURE 6. HYDRAULIC SCHEMATIC............................................................................................... 47 FIGURE 7. HYDRAULIC SCHEMATIC, POWERSHIFT TRANSMISSION WITH MANUAL CONTROL.................................................. 48 FIGURE 8. HYDRAULIC SCHEMATIC, POWERSHIFT TRANSMISSION WITH MONTROL PEDAL................................................... 49 FIGURE 9. WIRING DIAGRAM, BACK-UP ALARM..................................................................................... 50 electronic engine control system................................................................................................ 51 INTRODUCTION................................................................................................................ 51 GENERAL................................................................................................................. 51 DESCRIPTION AND OPERATION................................................................................................... 51 GENERAL................................................................................................................. 51 ECM (ELECTRONIC CONTROL MODULE)......................................................................................... 51 ALDL Connector...................................................................................................... 53 How The ECM Begins Operation........................................................................................ 53 ELECTRONIC ENGINE CONTROL............................................................................................... 54 What The ECM Does................................................................................................... 54 Pulse Generator, EST Distributor.................................................................................... 55 EST Module(See FIGURE 9.)........................................................................................... 56 When the Engine Is Being Started.................................................................................... 56 When the Engine Is Running.......................................................................................... 58 Electronic Control Module (ECM) With EST Distrubutor, Corrrections.................................................. 58 What The ECM Does................................................................................................... 58 FUEL CONTROL............................................................................................................ 59 Throttle Body Injection............................................................................................. 59 Fuel Injectors...................................................................................................... 60 Fuel Pressure Regulator............................................................................................. 60 Throttle Position Sensor............................................................................................ 60 Idle Air Control.................................................................................................... 60 Governor Motor And Throttle Drive Assembly.......................................................................... 61 Vacuum Ports........................................................................................................ 63 Fuel Pump........................................................................................................... 63 ECM SENSORS AND CONTROLLERS............................................................................................. 65 Manifold Absolute Pressure (MAP).................................................................................... 65 Coolant Temperature Sensor (CTS).................................................................................... 65 Initial Timing Connector (EST Distributor).......................................................................... 65 ELECTRONIC ENGINE CONTROL,TROUBLESHOOTING AND REPAIR............................................................................ 67 ELECTRONIC ENGINE CONTROL, TROUBLESHOOTING AND REPAIR....................................................................... 67 GENERAL................................................................................................................. 67 Engine Data......................................................................................................... 67 LIGHT BULB CHECK........................................................................................................ 67 SYSTEM CHECK............................................................................................................ 69 TROUBLESHOOTING WITH THE FAULT MONITOR SYSTEM IN THE ECM................................................................ 69 How To Clear A Code................................................................................................. 70 Fault In The ECM.................................................................................................... 70 Fault In The PROM................................................................................................... 71 CalPak Not Installed................................................................................................ 71 Fuel Control........................................................................................................ 71 Idle Air Control (IAC).............................................................................................. 71 Fuel Pump Circuit................................................................................................... 71 Coolant Temperature Sensor (CTS).................................................................................... 72 Manifold Absolute Pressuer Sensor (MAP)............................................................................. 72 Throttle Position Sensodr (TPS)..................................................................................... 72 Output Check, Throttle Position Sensor.............................................................................. 72 Electronic Spark Timing............................................................................................. 72 Engine Crank Signal................................................................................................. 73 Distributor Reference Signal........................................................................................ 73 TROUBLESHOOTING CHARTS...................................................................................................... 74 CHART A-1-No "Check Engine" Light....................................................................................... 74 Circuit Description, "Check Engine" Light........................................................................... 74 CHART A-1-No "Check Engine" Light....................................................................................... 75 CHART A-2-No ALDL Data Or No Code 12 From "Check Engine" Light. The "Check Engine" Light Is Continuosly Illuminated..... 76 Circuit Description, "Check Engine" Light........................................................................... 76 CHART A-2-No ALDL Data Or No Code 12 From "Check Engine" Light. The "Check Engine" Light Is Continuously Illuminated.... 77 CHART A-3-Starter Cranks The Engine, But Will Not Run................................................................... 78 Circuit Description................................................................................................. 79 CHART A-4-Fuel Injector Circuit......................................................................................... 80 Circuit Description................................................................................................. 80 CHART A-5-Fuel Pump Relay Circuit....................................................................................... 82 Circuit Description................................................................................................. 82 CHART A-6-Fuel System Pressure Test..................................................................................... 84 Circuit Description................................................................................................. 84 CHART A-7-MAP Output Check.............................................................................................. 86 Circuit Description................................................................................................. 86 CHART A-8-Engine Crank Signal Check..................................................................................... 88 Circuit Description................................................................................................. 88 CHART A-9-Ignition System Troubleshooting............................................................................... 89 CHART A-9 Ignition System Troubleshooting Chart......................................................................... 90 CHART A-10-Idle Air Control (IAC) System................................................................................ 92 Circuit Description................................................................................................. 92 FAULT CODES................................................................................................................. 94 CODE 14-Coolant Temperature Sensor Circuit (Indicates High Temperature)................................................. 94 Circuit Description................................................................................................. 94 CODE 15-Coolant Temperature Sensor Circuit (Indicates Low Temperature................................................... 96 Circuit Description................................................................................................. 96 CODE 21-Throttle Position Sensor Circuit (Signal Voltage High) ......................................................... 98 Circuit Description................................................................................................. 98 CODE 22-Throttle Position Sensor Circuit (Signal Voltage Low) ..........................................................100 Circuit Description.................................................................................................100 CODE 31-Engine Governor Circuit.........................................................................................102 Circuit Description.................................................................................................102 CODE 33-MAP Sensor Circuit, Signal Voltage High (Low Vacuum.............................................................104 Circuit Description.................................................................................................104 CODE 34-MAP Sensor Circuit, Signal Voltage Low (High Vacuum)............................................................106 Circuit Description.................................................................................................106 CODE 42-Electronic Spark Timing (EST)...................................................................................108 Circuit Description.................................................................................................108 CODE 54-Fuel Pump Circuit (Low Voltage).................................................................................110 Circuit Description.................................................................................................110 CODE 51-PROM In The ECM Has A Fault ....................................................................................112 CODE 52-Fuel CalPak Is Missing..........................................................................................112 CODE 55-ECM Has A Fault.................................................................................................112 TROUBLESHOOTING, POOR OPERATION.........................................................................................112 General.............................................................................................................112 Make A Careful Visual Check.........................................................................................112 FAULT: Fuel Usage Too High..........................................................................................112 FAULT: Codes Or Performance That Is Not Regular.....................................................................113 FAULT: "Dieseling"..................................................................................................113 FAULT: "Backfire"...................................................................................................113 FAULT: Rough Idle or Engine Stalls During Idle......................................................................113 FAULT: Smoke In The Exhaust Gases...................................................................................114 FAULT: Engine is Difficult To Start.................................................................................114 FAULT: Variation In Engine Power When The Throttle Is Held Steady...................................................115 FAULT: Decreased Engine Power.......................................................................................115 FAULT: "Detontion"..................................................................................................115 FAULT: Engine Momentarily Does Not Increase Power When Throttle Changes.............................................116 FAULT: One Cylinder In The Engine Does Not Operate Correctly. The Engine Does Not Idle Correctly....................116 REPAIRS, FUEL SYSTEM COMPONENTS ........................................................................................118 General.............................................................................................................118 Vacuum Ports........................................................................................................118 Throttle Body Injection (TBI) Unit..................................................................................118 TBI Unit, Removal...................................................................................................118 TBI Unit, Cleaning and Inspection...................................................................................119 TBI Unit, Installation..............................................................................................119 Cover For Fuel Meter Body, Replacement..............................................................................119 Fuel Injectors......................................................................................................120 Fuel Injectors, Removal.............................................................................................120 Fuel Injectors, Installation........................................................................................121 Pressure Regulator, Removal.........................................................................................121 Pressure Regulator, Inspection......................................................................................121 Pressure Regulator, Installation ...................................................................................121 Fuel Meter Body, Removal............................................................................................122 Fuel Meter Body, Installation.......................................................................................122 Throttle Position Sensor (TPS), Removal.............................................................................122 Throttle Position Sensor (TPS), Installation........................................................................122 Idle Air Control (IAC) Valve, Removal...............................................................................123 Cleaning and Inspection.............................................................................................123 Idle Air Control (IAC) Valve, Installation..........................................................................123 Governor Throttle Drive Assembly, Removal...........................................................................123 Governor Throttle Drive Assembly, Inspection........................................................................123 Cleaning and Lubrication............................................................................................124 Governor Throttle Drive Assembly, Installation......................................................................124 Governor Drive Motor, Removal.......................................................................................125 Governor Drive Motor, Cleaning and Lubrication......................................................................125 Governor Drive Motor, Installation..................................................................................126 Governor Drive Motor, Inspection....................................................................................126 Throttle Body, Removal and Disassembly..............................................................................126 Throttle Body, Inspection...........................................................................................126 Throttle Body, Assembly and Installation............................................................................126 Fuel Pump, Removal and Disassembly..................................................................................127 Fuel Pump, Inspection...............................................................................................127 REPAIRS, ELECTRICAL COMPONENTS..........................................................................................127 General.............................................................................................................127 Ignition Coil Test..................................................................................................127 Ignition Module Test................................................................................................128 Distributor, Removal................................................................................................128 Distributor, Disassembly............................................................................................129 Distributor, Assembly...............................................................................................129 Distributor, Installation...........................................................................................130 Firing Order........................................................................................................131 Ignition Timing.....................................................................................................131 Ignition Coil, Removal..............................................................................................132 Ignition Coil, Installation.........................................................................................132 Procedures For Spark Plugs, Spark Plug Wires And Boots .............................................................132 Troubleshooting of Spark Plugs......................................................................................133 Coolant Temperature Sensor (CTS), Replacement ......................................................................134 Manifold Absolute Pressure (MAP) Sensor, Replacement................................................................134 Oil Pressure Switch, Replacement....................................................................................135 Coolant Temperature Sender, Replacement.............................................................................135 Wire Harness........................................................................................................135 Connectors And Terminals............................................................................................135 Electronic Control Module (ECM).....................................................................................139 ECM CONNECTOR A-B IDENTIFICATION........................................................................................143 ECM CONNECTOR C-D IDENTIFICATION........................................................................................144 SPECIAL TOOLS...............................................................................................................145 fasteners.......................................................................................................................148 INTRODUCTION................................................................................................................148 NOMENCLATURE, THREADS...................................................................................................148 STRENGTH IDENTIFICATION.................................................................................................149 TABLE 1. BOLTS AND SCREWS...................................................................................................149 TABLE 2. STUDS AND NUTS.....................................................................................................150 TABLE 3. TORQUE NUTS........................................................................................................151 TABLE 4. TORQUE NUTS WITH NYLON INSERT......................................................................................152 TABLE 5. TORQUE VALUES FOR INCH FASTENERS...................................................................................153 TABLE 6. TORQUE VALUES FOR METRIC FASTENERS.................................................................................154 frame...........................................................................................................................157 THE FRAME...................................................................................................................157 GENERAL.................................................................................................................157 DESCRIPTION.............................................................................................................157 REPAIRS.................................................................................................................157 COUNTERWEIGHT...........................................................................................................157 Removal.............................................................................................................157 COUNTERWEIGHT...........................................................................................................158 Installation........................................................................................................158 HOOD....................................................................................................................158 Removal.............................................................................................................158 HOOD....................................................................................................................158 Installation........................................................................................................158 OVERHEAD GUARD..........................................................................................................159 Removal.............................................................................................................159 Installation........................................................................................................159 OPERATOR RESTRAINT SYSTEM...............................................................................................159 RADIATOR................................................................................................................159 Removal.............................................................................................................159 Installation........................................................................................................160 EXHAUST SYSTEM..........................................................................................................160 Muffler Replacement.................................................................................................160 ENGINE..................................................................................................................160 Removal.............................................................................................................160 Installation........................................................................................................163 FUEL AND HYDRAULIC TANKS................................................................................................164 Inspection..........................................................................................................164 Repairs, Small Leaks................................................................................................164 Repairs, Large Leaks................................................................................................164 Cleaning............................................................................................................164 Other Methods Of Preparation For Repair.............................................................................165 SAFETY LABELS...........................................................................................................166 CAB.................................................................................................................166 Cab Repalacement....................................................................................................166 Window Repalcement......................................................................................................166 Windshield Wipers, Heater and Fan...................................................................................169 Material Specifications For Cab Windows.............................................................................169 Cab Heater Hoses....................................................................................................169 Gear pumps......................................................................................................................170 INTRODUCTION................................................................................................................170 DESCRIPTION.............................................................................................................170 OPERATION...............................................................................................................170 Flow Control Valve..................................................................................................172 Relief Valve........................................................................................................172 REPAIRS.....................................................................................................................173 REMOVAL.................................................................................................................173 DISASSEMBLY.............................................................................................................173 CLEANING................................................................................................................175 INSPECTION..............................................................................................................175 ASSEMBLY................................................................................................................176 INSTALLATION............................................................................................................177 CHECKS AND ADUSTMENTS.......................................................................................................178 CHECK THE OUTPUT OF THE PUMP............................................................................................178 CHECK FOR AIR IN THE HYDRAULIC SYSTEM...................................................................................178 TROUBLESHOOTING.............................................................................................................180 GM 4.3 litre V-6 and 5.7 litre V-8 engines......................................................................................182 WEBER CARBURETOR WITH GOVERNOR..............................................................................................182 GENERAL.................................................................................................................182 DESCRIPTION.............................................................................................................182 Carburetor..........................................................................................................182 Governor............................................................................................................182 OPERATION...............................................................................................................183 Carburetor, Float System............................................................................................183 Carburetor, Idle System.............................................................................................183 Carburetor, Main Metering System....................................................................................183 Carburetor, Power System............................................................................................184 Carburetor, Accelerator Pump System.................................................................................184 Carburetor, Choke System............................................................................................185 GOVERNOR................................................................................................................186 REPAIRS.....................................................................................................................187 CARBURETOR..............................................................................................................187 Removal.............................................................................................................187 Disassembly.........................................................................................................187 Cleaning............................................................................................................187 Assembly............................................................................................................187 Installation........................................................................................................188 GOVERNOR................................................................................................................188 CHECKS AND ADJUSTMENTS......................................................................................................189 GENERAL.................................................................................................................189 CHOKE SYSTEM............................................................................................................189 ELECTRIC CHOKE..........................................................................................................189 IDLE MIXTURE ADJUSTMENT.................................................................................................190 IDLE SPEED ADJUSTMENT...................................................................................................190 THROTTLE LINKAGE ADJUSTMENT.............................................................................................191 TROUBLESHOOTING.........................................................................................................192 GM 4.3 Litre V-6................................................................................................................193 GM 4.3 LITRE V-6............................................................................................................193 INTRODUCTION............................................................................................................193 DESCRIPTION.............................................................................................................193 ENGINE, REMOVAL AND INSTALLATION........................................................................................194 CYLINDER HEAD...........................................................................................................194 Removal And Disassembly.............................................................................................194 Cleaning And Inspection.............................................................................................194 Repairs, Valve Guides and Seats.....................................................................................194 Repairs, Valves.....................................................................................................195 Repairs, Valve Seats................................................................................................195 Valve Springs.......................................................................................................196 Studs For The Rocker Arms (Early Models)............................................................................197 Studs For The Rocker Arms (Late Models).............................................................................198 Assembly And Installation...........................................................................................198 CYLINDER BLOCK, CLEANING AND INSPECTION.................................................................................200 PISTON BORE PREPARATION.................................................................................................200 ENGINE MOUNTS...........................................................................................................200 LUBRICATION SYSTEM......................................................................................................200 Oil Pump, Removal and Disassembly...................................................................................200 Cleaning and Inspection.............................................................................................201 Oil Pump, Assembly and Installation.................................................................................201 Oil Sump, Installation..............................................................................................201 TIMING COVER, TIMING SPROCKETS, CAMSHAFT AND VALVE LIFTERS..............................................................202 Timing Cover, Removal...............................................................................................202 Installation........................................................................................................203 Timing Sprockets, Removal...........................................................................................204 Timing Sprockets, Installation......................................................................................204 Camshaft, Removal...................................................................................................204 Camshaft, Inspection................................................................................................204 Camshaft, Installation..............................................................................................204 Balance Shaft, Removal..............................................................................................205 Balance Shaft, Installation.........................................................................................206 Hydraulic Valve Lifters, Removal....................................................................................207 Hydraulic Valve Lifters, Disassembly................................................................................207 Hydraulic Valve Lifters, Cleaning And Inspection....................................................................207 Hydraulic Valve Lifters, Assembly...................................................................................208 Hydraulic Valve Lifters, Installation...............................................................................208 CRANKSHAFT..............................................................................................................209 Removal.............................................................................................................209 Inspection and Repair...............................................................................................209 How To Check The Clearance Between The Main Bearings And Their Journals.............................................210 Installation........................................................................................................211 PISTON AND CONNECTING ROD ASSEMBLIES....................................................................................212 Connecting Rod Bearings, Replacement................................................................................212 Piston And Connecting Rod Assemblies, Removal.......................................................................213 Disassembly.........................................................................................................213 Piston, Cleaning And Inspection.....................................................................................213 Cylinder Bores, Inspection And Repair...............................................................................214 Piston Rings........................................................................................................215 Assembly............................................................................................................215 Piston And Connecting Rod Assemblies, Installation..................................................................216 FLYWHEEL AND FLYWHEEL HOUSING...........................................................................................216 Flywheel Repairs....................................................................................................216 Flywheel, Installation..............................................................................................216 Flywheel Housing....................................................................................................217 Engine Adapter......................................................................................................217 COOLANT PUMP............................................................................................................217 THERMOSTAT..............................................................................................................217 FAN MOUNT, EARLY MODELS.................................................................................................217 FAN MOUNT ASSEMBLY, LATE MODELS.........................................................................................218 DRIVE BELT, INSTALLATION................................................................................................219 CHECKS AND ADJUSTMENTS......................................................................................................221 VALVE CLEARANCE ADJUSTMENT, EARLY MODELS................................................................................221 VALVE CLEARANCE ADJUSTMENT, NEW MODELS..................................................................................221 CHECK THE COMPRESSION...................................................................................................221 ENGINE SPECIFICATIONS.......................................................................................................222 Engine Data.............................................................................................................222 Cylinder head...........................................................................................................222 Hydraulic Valve Lifter..................................................................................................222 Camshaft................................................................................................................222 Pistons.................................................................................................................222 Crankshaft..............................................................................................................223 Connecting Rods.........................................................................................................223 Connecting Rods.........................................................................................................223 Balance Shaft...........................................................................................................223 Cooling System..........................................................................................................223 Lubrication System......................................................................................................223 TORQUE SPECIFICATIONS.......................................................................................................224 TROUBLESHOOTING.............................................................................................................225 High Energy Ignition (HEI)......................................................................................................228 HIGH ENERGY IGNITION (HEI)..................................................................................................228 DESCRIPTION.............................................................................................................228 REPAIRS.....................................................................................................................230 DISTRIBUTOR.............................................................................................................230 Removal.............................................................................................................230 Disassembly.........................................................................................................230 Assembly............................................................................................................235 INSTALLATION, IF THE CRANKSHAFT WAS NOT ROTATED WHEN DISTRIBUTOR WAS REMOVED............................................236 INSTALLATION, IF THE CRANKSHAFT WAS ROTATED WHEN THE DISTRIBUTOR WAS REMOVED............................................237 IGNITION COIL...........................................................................................................237 Removal, Some 4 and 6 Cylinder Models...............................................................................237 Installation, Some 4 and 6 Cylinder Models..........................................................................238 Removal, V8, Some 4 and 6 Cylinder Models...........................................................................238 Installation, V8, Some 4 and 6 Cylinder Models......................................................................239 ELECTRONIC MODULE.......................................................................................................240 Removal.............................................................................................................240 Installation........................................................................................................240 SENSING COIL............................................................................................................241 Removal.............................................................................................................241 Installation........................................................................................................241 SPARK PLUGS.............................................................................................................241 Removal.............................................................................................................241 Installation........................................................................................................242 CHECKS AND ADJUSTMENTS..................................................................................................242 Visual Checks.......................................................................................................242 Check The High Voltage Wires........................................................................................242 Checking The Ignition Coil..........................................................................................242 Coil In Distributor Cap Design......................................................................................242 Separate Coil Design................................................................................................243 Checking The Sensing Coil...........................................................................................243 Check The Electronic Module.........................................................................................244 Ignition Timing Adjustment..........................................................................................244 Ignition System, GM V8-366 (6-litre)................................................................................245 Ignition Timing and Idle Speed Adjustment, GM V6-LPG (4.3-litre)....................................................245 SPECIFICATIONS..............................................................................................................245 TROUBLESHOOTING.............................................................................................................246 hydraulic brake system..........................................................................................................247 INTRODUCTION................................................................................................................247 GENERAL.................................................................................................................247 DESCRIPTION AND OPERATION...............................................................................................247 BRAKE BOOSTER AND MASTER CYLINDER.......................................................................................247 MASTER CYLINDER.........................................................................................................247 SERVICE BRAKE ASSEMBLY..................................................................................................249 PARKING BRAKE...........................................................................................................250 REPAIRS.....................................................................................................................250 BRAKE SHOE ASSEMBLIES...................................................................................................250 Removal and Disassembly.............................................................................................250 Cleaning and Inspection.............................................................................................251 Assembly and Installation...........................................................................................253 MASTER CYLINDER.........................................................................................................256 S3.50-5.50XL (S70-120XL) and H3.50-5.00XL (H70-110XL....................................................................256 Removal ............................................................................................................256 Disassembly.........................................................................................................256 Assembly............................................................................................................257 Installation........................................................................................................257 MASTER CYLINDER, E3.50-5.50XL (E70-120XL)...............................................................................257 Removal and Disassebly..............................................................................................257 Cleaning and Inspection.............................................................................................258 Assembly and Installation...........................................................................................258 BRAKE BOOSTER...........................................................................................................258 Removal.............................................................................................................258 Disassembly.........................................................................................................258 Cleaning and Inspection.............................................................................................259 Assembly............................................................................................................259 Installation........................................................................................................260 CHECKS AND ADJUSTMENTS......................................................................................................260 REMOVE THE AIR FROM THE BRAKE SYSTEM....................................................................................260 ADJUST THE BRAKE PEDAL..................................................................................................260 ADJUST THE BRAKE SHOES..................................................................................................261 ADJUST THE PARKING BRAKE................................................................................................262 CHECK THE RELIEF VALVE ON THE PARKING BOOSTER...........................................................................262 TROUBLESHOOTING.............................................................................................................262 hydraulic pump..................................................................................................................264 INTRODUCTION................................................................................................................264 GENERAL.................................................................................................................264 DESCRIPTION.............................................................................................................264 REPAIRS.....................................................................................................................266 REMOVAL AND DISASSEMBLY.................................................................................................266 CLEANING................................................................................................................266 INSPECTION..............................................................................................................266 ASSEMBLY AND INSTALLATION...............................................................................................267 TROUBLESHOOTING.............................................................................................................268 GENERAL.................................................................................................................268 hydraulic system................................................................................................................269 INTRODUCTION................................................................................................................269 GENERAL.................................................................................................................269 DESCRIPTION AND OPERATION...............................................................................................269 Hydraulic Pump......................................................................................................269 Main Control Valve..................................................................................................270 Steering Control Unit...............................................................................................272 Brake Booster.......................................................................................................272 REPAIRS.....................................................................................................................272 HYDRAULIC PUMP..........................................................................................................272 Removal.............................................................................................................272 Disassembly.........................................................................................................273 Cleaning and Inspection.............................................................................................273 Assembly............................................................................................................273 Installation........................................................................................................274 Adjust the Flow Divider.............................................................................................274 SPECIFICATIONS..............................................................................................................274 TROUBLESHOOTING.............................................................................................................275 LPG fuel system.................................................................................................................277 INTRODUCTION................................................................................................................277 GENERAL.................................................................................................................277 DESCRIPTION AND OPERATION...............................................................................................277 Fuel Tank...........................................................................................................278 Fuel Filter and Fuel Valve Unit.....................................................................................278 Vaporizer...........................................................................................................279 Carburetor..........................................................................................................280 Governor............................................................................................................281 REPAIRS.....................................................................................................................283 LPG TANK................................................................................................................283 Removal.............................................................................................................283 Installation........................................................................................................283 HYDROSTATIC RELIEF VALVE................................................................................................283 Removal and Installation............................................................................................283 FILTER UNIT.............................................................................................................285 Replacement Of The Fuel Filter Element..............................................................................285 Replacement of the Diaphragm and Fuel Valve ........................................................................285 REPLACEMENT OF THE HOSES................................................................................................285 VAPORIZER...............................................................................................................285 Removal.............................................................................................................285 Vaporizer Disassembly...............................................................................................287 Cleaning............................................................................................................287 Inspection..........................................................................................................287 Vaporizer Assembly..................................................................................................287 Installation........................................................................................................289 CARBURETOR..............................................................................................................289 Removal.............................................................................................................289 Disassembly.........................................................................................................289 Cleaning............................................................................................................290 Assembly............................................................................................................290 Installation........................................................................................................290 GOVERNOR................................................................................................................290 CHECKS AND ADJUSTMENTS......................................................................................................291 CHECK THE FILTER UNIT...................................................................................................291 CHECK THE VAPORIZER.....................................................................................................291 Pressure Reducer Valve..............................................................................................291 Vapor Valve.........................................................................................................291 ADJUST THE CARBURETOR...................................................................................................292 Idle Mixture........................................................................................................292 Idle Speed .........................................................................................................292 Power Mixture.......................................................................................................292 ADJUST THE THROTTLE LINKAGE.............................................................................................292 TROUBLESHOOTING.............................................................................................................293 main control valve..............................................................................................................296 INTRODUCTION................................................................................................................296 GENERAL.................................................................................................................296 DESCRIPTION.............................................................................................................296 OPERATION...............................................................................................................297 Lift Section........................................................................................................298 Tilt Section........................................................................................................298 Relief Valve........................................................................................................300 SOLENOID VALVE FOR AUXILIARY FUNCTION...................................................................................301 Operation...........................................................................................................301 REPAIRS.....................................................................................................................301 MAIN CONTROL VALVE......................................................................................................301 Removal and Disassembly.............................................................................................301 Cleaning and Inspection.............................................................................................302 Assembly............................................................................................................302 Installation........................................................................................................302 SOLENOID VALVE FOR AUXILIARY FUNCTION...................................................................................302 Removal and Disassembly.............................................................................................302 Assembly and Installation...........................................................................................304 CHECKS AND ADJUSTMENTS......................................................................................................304 PRESSURE RELIEF VALVES..................................................................................................304 Primary Relief Valve................................................................................................304 Seconday Relief Valve...............................................................................................305 CONTROL LEVER ARRANGEMENT...............................................................................................305 TROUBLESHOOTING.............................................................................................................308 SPECIFICATIONS..............................................................................................................310 Mast............................................................................................................................311 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST................................................................................311 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST............................................................................311 LIFT CYLINDERS..............................................................................................................314 GENERAL.................................................................................................................314 DESCRIPTION.............................................................................................................314 Lowering Control Valve..............................................................................................314 Cylinders (General).................................................................................................317 Cylinders (H520-620B,H700-800A).....................................................................................319 Cylinders (H360-460B)...............................................................................................320 Cylinders (Two-Speed)...............................................................................................320 REPAIRS.....................................................................................................................321 REMOVAL OF THE LIFT CYLINDER WITHOUT REMOVING THE MAST..................................................................321 Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast............................321 Standard and Full Free-Lift Masts with the Lift Cylinder to a Crosshead.............................................325 Masts that have Two Cylinders, A Main Lift Cylinder and a Free-Lift Cylinder.......................................323 DISASSEMBLY.............................................................................................................323 ASSEMBLY................................................................................................................325 INSTALLATION OF THE LIFT CYLINDER IN THE MAST...........................................................................325 Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast............................325 Standard and Full-Free-Lift Masts with the Lift Cylinder Fastened to a Crosshead....................................325 CHEVRON PACKING.........................................................................................................326 LIFT CYLINDERS FOR VISTA MASTS..............................................................................................329 DESCRIPTION.............................................................................................................329 Lowering Control Valve..............................................................................................331 REMOVAL.................................................................................................................332 DISASSEMBLY.............................................................................................................332 ASSEMBLY................................................................................................................332 INSTALLATION............................................................................................................333 Main Lift Cylinders.................................................................................................333 Free-Lift Cylinders.................................................................................................333 CHECKS AND ADJUSTMENTS......................................................................................................334 CHECK FOR LEAKS IN LIFT SYSTEM..........................................................................................334 TROUBLESHOOTING.............................................................................................................335 SPECIFICATIONS..............................................................................................................336 Mast-2..........................................................................................................................337 VISTA® MASTS................................................................................................................337 GENERAL.................................................................................................................337 DESCRIPTION AND OPERATION...............................................................................................337 CARRIAGES...............................................................................................................337 TWO-STAGE MAST WITH LIMITED FREE-LIFT...................................................................................337 TWO-STAGE MAST WITH FULL FREE-LIFT MAST.................................................................................338 THREE-STAGE MAST WITH FULL FREE-LIFT....................................................................................339 REPAIRS.....................................................................................................................341 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST (1 OF 2)...................................................................341 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST (2 OF 2)...................................................................342 FORKS...................................................................................................................342 Forks, Removal And Installation.....................................................................................342 CARRIAGE................................................................................................................344 Removal.............................................................................................................344 SIDE-SHIFT CARRIAGE (EARLIER DESIGNS)...................................................................................345 Disassembly, Side Shift Carriage....................................................................................345 Assembly, Side Shift Carriage.......................................................................................347 Installation........................................................................................................348 SIDE-SHIFT CARRIAGE (1993 AND LATER DESIGN).............................................................................348 Removal.............................................................................................................348 Repairs.............................................................................................................349 Installation........................................................................................................350 TABLE 1. WEIGHT OF MAST PARTS...........................................................................................350 TWO-STAGE MAST WITH LIMITED FREE-LIFT...................................................................................351 Removal.............................................................................................................351 Disassembly.........................................................................................................351 Cleaning and Inspection.............................................................................................353 Assembly............................................................................................................353 Installation........................................................................................................354 TWO-STAGE MAST WITH FULL FREE-LIFT......................................................................................354 Removal.............................................................................................................354 Disassembly.........................................................................................................354 Cleaning and Inspection.............................................................................................355 Assembly............................................................................................................355 Installation........................................................................................................355 THREE-STAGE MAST WITH FULL FREE LIFT....................................................................................356 Removal.............................................................................................................356 Disassembly.........................................................................................................356 Cleaning and Inspection.............................................................................................357 Assembly............................................................................................................357 Installation........................................................................................................359 CHECKS AND ADJUSTMENTS......................................................................................................361 CHECK THE OPERATION OF THE MAST.........................................................................................361 CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM.............................................................................361 Lift System.........................................................................................................361 Tilt System.........................................................................................................361 ADJUST THE TILT CYLINDER STROKE AND THE BACKWARD TILT ANGLE.............................................................362 LIFT CHAIN ADJUSTMENTS..................................................................................................362 MAST ADJUSTMENTS........................................................................................................363 CARRIAGE ADJUSTMENT.....................................................................................................364 TROUBLESHOOTING.............................................................................................................367 MICROPROCESSOR SPARK TIMING SYSTEM (MSTS).......................................................................................369 MICROPROCESSOR SPARK TIMING SYSTEM (MSTS)...................................................................................369 GENERAL.................................................................................................................369 DESCRIPTION.............................................................................................................369 What MSTS Does......................................................................................................371 How MSTS Begins Operation...........................................................................................371 OPERATION...............................................................................................................371 Pulse Generator.....................................................................................................371 HEI Module..........................................................................................................372 When the Engine Is Being Started....................................................................................372 When the Engine Is Running..........................................................................................374 Manifold Absolute Pressure (MAP)....................................................................................374 Coolant Temperature Sensor (CTS)....................................................................................374 Electronic Control Module (ECM), Corrections........................................................................375 The Initial Timing Connector........................................................................................375 Gasoline and LPG Conversions........................................................................................376 TROUBLESHOOTING.............................................................................................................378 GENERAL.................................................................................................................378 TOOLS AND TEST EQUIPMENT................................................................................................378 MSTS TROUBLESHOOTING....................................................................................................379 Test Description....................................................................................................379 IGNITION SYSTEM TROUBLESHOOTING.........................................................................................381 Test Description....................................................................................................381 ELECTRONIC SPARK TIMING (EST) TROUBLESHOOTING...........................................................................384 Circuit Description.................................................................................................384 Test Description....................................................................................................384 MANIFOLD ABSOLUTE PRESSURE (MAP) TROUBLESHOOTING........................................................................387 Circuit Description.................................................................................................387 Test Description....................................................................................................387 COOLANT TEMPERATURE SENSOR (CTS) TROUBLESHOOTING........................................................................390 Circuit Description.................................................................................................390 Test Description....................................................................................................390 REPAIRS.....................................................................................................................392 DISTRIBUTOR.............................................................................................................392 Removal.............................................................................................................392 Disassembly.........................................................................................................393 Inspection..........................................................................................................393 Assembly............................................................................................................394 Installation........................................................................................................394 Igntion Timing......................................................................................................394 HEI MODULE..............................................................................................................395 Test For A Fault....................................................................................................395 HEI Module Replacement..............................................................................................395 SENSING COIL............................................................................................................396 Test For A Fault....................................................................................................396 Sensing Coil Replacement............................................................................................396 IGNITION COIL...........................................................................................................396 Test For A Fault....................................................................................................396 ELECTRONIC CONTROL MODULE (ECM).........................................................................................397 Removal.............................................................................................................397 Installation........................................................................................................397 COOLANT TEMPERATURE SENSOR (CTS)........................................................................................397 Removal.............................................................................................................397 Installation........................................................................................................398 MANIFOLD ABSOLUTE PRESSURE (MAP)........................................................................................398 Removal.............................................................................................................398 Installation........................................................................................................398 PRESSURE CONVERSION CHART...........................................................................................399 oil clutch system...............................................................................................................400 INTRODUCTION................................................................................................................400 General.................................................................................................................400 Description.............................................................................................................400 REPAIRS.....................................................................................................................402 Removal and Disassembly.................................................................................................402 Cleaning and Inspection.................................................................................................403 Assembly and Installation...............................................................................................404 CHECKS AND ADJUSTMENTS......................................................................................................406 Adjusting the Clutch Pedal and Linkage..................................................................................406 Adjusting the By-pass Valve for Cold Oil................................................................................406 TROUBLESHOOTING.............................................................................................................407 PERIODIC MAINTENANCE............................................................................................................409 PERIODIC MAINTENANCE........................................................................................................409 GENERAL.................................................................................................................409 SERIAL NUMBER DATA......................................................................................................409 HOW TO MOVE A DISABLED LIFT TRUCK.......................................................................................409 How To Tow the Lift Truck...........................................................................................409 HOW TO PUT A LIFT TRUCK ON BLOCKS.......................................................................................410 How To Raise the Drive Tires........................................................................................410 How To Raise the Steering Tires.....................................................................................410 MAINTENANCE SCHEDULE........................................................................................................412 MAINTENANCE PROCEDURES......................................................................................................415 EVERY 8 HOURS OR DAILY......................................................................................................415 HOW TO MAKE THE CHECKS WITH THE ENGINE STOPPED..........................................................................415 Hydraulic System Oil................................................................................................415 Engine Oil..........................................................................................................417 Drive Belts.........................................................................................................417 Cooling System......................................................................................................417 Air Filter..........................................................................................................417 Fuel System.........................................................................................................418 Primary Fuel Filter, Diesel Engine..................................................................................418 Battery.............................................................................................................418 Tires and Wheels....................................................................................................418 Forks...............................................................................................................419 Forks, Adjustment...................................................................................................419 Forks, Removal And Installation.....................................................................................419 Inspection of Forks, Mast, And Lift Chains..........................................................................420 Operator Restraint System...........................................................................................422 Safety Labels.......................................................................................................423 HOW TO MAKE THE CHECKS WITH THE ENGINE RUNNING..........................................................................423 Gauges, Lights, Horn, and Fuses.....................................................................................423 Oil Level, Powershift Transmission..................................................................................423 Oil Level, Oil Clutch System, H3.50-5.00XL (H70-110XL)..............................................................424 Control Levers and Pedals...........................................................................................424 Lift System Operation...............................................................................................424 Inching/Brake Pedal.................................................................................................425 Service Brakes......................................................................................................425 Parking Brake.......................................................................................................425 Steering System.....................................................................................................425 EVRY 150 HOURS OR MONTHLY...................................................................................................425 THRUST SCREW FOR THE DIFFERENTIAL, H6.00-7.00XL (H135-155XL)............................................................425 LIFT CHAINS, LUBRICATION................................................................................................425 DRIVE SHAFTS............................................................................................................426 EVERY 350 HOURS OR TWO MONTHS...............................................................................................426 ENGINE OIL AND FILTER...................................................................................................426 DRIVE BELTS.............................................................................................................427 Perkins Diesel Engine...............................................................................................427 GM V-6 Engine (Early Models)........................................................................................427 GM V-6 Engine (Later Models)........................................................................................428 HYDRAULIC TANK BREATHER, CLEAN AND CHECK................................................................................429 BRAKE FLUID.............................................................................................................429 LIFT CHAINS, CHECK FOR WEAR.............................................................................................429 FORKS, CHECK FOR WEAR AND DAMAGE........................................................................................430 MAST, LUBRICATION.......................................................................................................430 CONTROL LEVERS AND PEDALS, LUBRICATION..................................................................................430 STEERING AXLE, LUBRICATION..............................................................................................431 FUEL SYSTEM, CHECKS AND ADJUSTMENTS.....................................................................................431 Diesel Fuel System..................................................................................................431 LPG Carburetor (Early Models).......................................................................................431 Gasoline Carburetor (Early Models)..................................................................................432 Fuel Injection (Late Models)........................................................................................432 EVERY 1000 HOURS OR SIX MONTHS..............................................................................................432 PCV VALVE, GM V-6.......................................................................................................432 MANIFOLD HEAT VALVE, GM V-6 (EARLY MODELS)..............................................................................432 CRANKCASE BREATHER, GM-V6...............................................................................................432 IGNITION SYSTEM (GM V-6)................................................................................................432 VALVE CLEARANCE ADJUSTMENT..............................................................................................433 FUEL FILTER (REPLACEMENT), DIESEL ENGINE................................................................................433 REMOVE AIR FROM THE FUEL SYSTEM: PERKINS 1004-4 DIESEL ENGINE...........................................................433 Fuel Injection Pump With A Vent Tube................................................................................433 Fuel Injection Pump With A Vent Screw...............................................................................434 REMOVE AIR FROM THE FUEL SYSTEM: PERKINS 4.2482 DIESEL ENGINE...........................................................435 CHECK THE OIL LEVEL IN THE TRANSMISSION.................................................................................435 Manual Transmission, H3.50-5.00XL (H70-110XL).......................................................................435 Speed Reducer For The Powershift Transmission, H3.50-5.00XL (H70-110XL).............................................436 Manual Transmission, H6.00-7.00XL (H135-155XL)......................................................................436 Differential And Drive Axle For The Powershift Transmission, H6.00-7.00XL (H135-155XL...............................436 Differential, Speed Reducer, And Drive Axle For The Manual Transmission, H6.00-7.00XL (H135-155XL)..................436 EVERY 2000 HOURS OR YEARLY..................................................................................................436 HYDRAULIC SYSTEM........................................................................................................436 Replace the Hydraulic Oil and Filter, H3.50-5.00XL (H70-110XL)......................................................436 Replace the Hydraulic Oil and Filter, H6.00-7.00XL (H135-155XL).....................................................437 CHANGE THE OIL AND REPLACE THE OIL FILTER, POWERSHIFT TRANSMISSION, ALL UNITS...........................................437 CHANGE THE OIL, MANUAL TRANSMISSION, H3.50-5.00XL (H70-110XL)...........................................................437 CHANGE THE OIL, MANUAL TRANSMISSION, H6.00-7.00XL (H135-155XL)..........................................................437 CHANGE THE OIL, SPEED REDUCER, POWERSHIFT TRANSMISSION, H3.50-5.00XL (H70-110XL)........................................438 CHANGE THE OIL AND FILTER, OIL CLUTCH SYSTEM, H3.50-5.00XL (H70-110XL)..................................................438 CHANGE THE OIL, DIFFERENTIAL AND DRIVE AXLE FOR THE POWERSHIFT TRANSMISSION, H6.00-7.00XL (H135-155XL)..................438 CHANGE THE OIL, DIFFERENTIAL, SPEED REDUCER, AND DRIVE AXLE FOR MANUAL TRANSMISSION, H6.00-7.00XL (H135-155XL)..........438 COOLING SYSTEM..........................................................................................................439 WHEEL BEARINGS..........................................................................................................439 Steering Wheels, lubrication........................................................................................439 Drive Wheels, Lubrication...........................................................................................439 PCV VALVE, GM V-6.......................................................................................................439 SERVICE BRAKES..........................................................................................................439 LPG FILTER, REPLACEMENT.................................................................................................440 GASOLINE FUEL FILTER, REPLACEMENT.......................................................................................440 CHECK THE HOOD LATCH, H3.50-5.00XL (H70-110XL)..........................................................................440 GENERAL PROCEDURES..........................................................................................................441 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST............................................................................441 LIFT CHAIN ADJUSTMENTS..................................................................................................443 FUEL INJECTORS..........................................................................................................443 CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM.............................................................................444 Check the Lift Cylinder for Leaks...................................................................................444 Check the Tilt Cylinder for Leaks...................................................................................444 WELDING REPAIRS.........................................................................................................444 CHANGES TO THE OVERHEAD GUARD...........................................................................................445 WHEELS AND TIRES........................................................................................................446 Remove The Wheels From The Lift Truck...............................................................................446 Remove The Wheel From The Tire......................................................................................446 Install The Wheel In The Tire.......................................................................................448 Pneumatic Tires, Add Air To The Tires...............................................................................449 Install the Wheels..................................................................................................449 SOLID RUBBER TIRES......................................................................................................450 Remove The Tire From The Wheel......................................................................................450 Install The Tire On The Wheel.......................................................................................451 REFERENCE TABLE.............................................................................................................452 Perkins 4.236 and the Perkins 4.2482 diesel engines.............................................................................453 INTRODUCTION................................................................................................................453 GENERAL.................................................................................................................453 DESCRIPTION.............................................................................................................453 ENGINE SERIAL NUMBER CODES..............................................................................................454 REMOVAL AND INSTALLATION................................................................................................454 ENGINE......................................................................................................................454 CYLINDER HEAD...........................................................................................................454 Removal.............................................................................................................454 Installation........................................................................................................455 Cylinder Head Repairs...............................................................................................456 OIL PUMP................................................................................................................458 Removal.............................................................................................................458 Disassembly.........................................................................................................458 Inspection..........................................................................................................458 Assembly............................................................................................................459 Installation........................................................................................................459 RELIEF VALVE............................................................................................................460 TIMING GEAR CASE AND TIMING GEARS.......................................................................................460 Removal.............................................................................................................460 Installation........................................................................................................461 PISTONS AND CONNECTING RODS.............................................................................................462 Removal.............................................................................................................462 Disassembly.........................................................................................................462 Inspection..........................................................................................................463 Assembly............................................................................................................464 Installation........................................................................................................464 CRANKSHAFT AND MAIN BEARINGS............................................................................................465 Removal.............................................................................................................465 Inspection..........................................................................................................465 Assembly............................................................................................................466 CAMSHAFT AND CAM FOLLOWERS..............................................................................................467 Removal.............................................................................................................467 Inspection..........................................................................................................468 Assembly............................................................................................................468 FLYWHEEL AND FLYWHEEL HOUSING...........................................................................................469 Removal.............................................................................................................469 Repairs.............................................................................................................469 Installation........................................................................................................469 STEERING PUMP DRIVE.....................................................................................................469 Removal.............................................................................................................469 Installation........................................................................................................470 PCV VALVE...............................................................................................................470 FUEL SYSTEM.................................................................................................................470 FUEL PUMP...............................................................................................................470 Removal.............................................................................................................470 Disassembly.........................................................................................................470 Assembly............................................................................................................470 Installation........................................................................................................471 FUEL INJECTION PUMP.....................................................................................................471 Removal.............................................................................................................471 Repairs.............................................................................................................471 Installation........................................................................................................471 FUEL INJECTORS..........................................................................................................471 Removal.............................................................................................................471 Repairs.............................................................................................................472 Installation........................................................................................................472 COLD START AID..........................................................................................................472 Description.........................................................................................................472 Removal.............................................................................................................472 Installation........................................................................................................472 COOLING SYSTEM..............................................................................................................473 THERMOSTAT..............................................................................................................473 Removal.............................................................................................................473 Inspection..........................................................................................................473 Installation........................................................................................................473 WATER PUMP..............................................................................................................473 Removal.............................................................................................................473 Disassembly.........................................................................................................473 Assembly............................................................................................................473 Installation........................................................................................................473 CHECKS AND ADJUSTMENTS......................................................................................................473 CHECKING THE INJECTORS..................................................................................................473 Repairs.............................................................................................................474 Installation........................................................................................................474 REMOVING AIR FROM THE FUEL SYSTEM.......................................................................................474 CHECKING THE TIMING MARKS...............................................................................................475 Method A............................................................................................................475 Method B............................................................................................................476 CHECKING THE TIMING ANGLE OF THE FUEL INJECTION PUMP WITH THE SPECIAL TOOL..............................................477 VALVE CLEARANCE ADJUSTMENT..............................................................................................478 ADJUSTING THE THROTTLE LINKAGE..........................................................................................478 TROUBLESHOOTING.............................................................................................................480 SPECIFICATIONS..............................................................................................................481 TORQUE SPECIFICATIONS.......................................................................................................484 PERKINS DIESEL ENGINES, SERIES 1000.............................................................................................485 PERKINS DIESEL ENGINES, SERIES 1000.........................................................................................485 1.1 GENERAL.............................................................................................................485 GENERAL SAFETY RULES....................................................................................................485 Viton Seals.........................................................................................................485 1.2 DESCRIPTION.........................................................................................................488 1.3 Engine Serial Number Codes......................................................................................488 1.4 Engine Data.....................................................................................................488 1.5 1004–4 ENGINE...................................................................................................489 1.6 1004–4T ENGINE..................................................................................................489 1.7 1006–6 ENGINE...................................................................................................489 1.8 1006–6T ENGINE..................................................................................................489 1.9 REMOVAL AND INSTALLATION............................................................................................489 CYLINDER HEAD ASSEMBLY......................................................................................................490 1.10 VALVE COVER........................................................................................................490 1.11 Removal........................................................................................................490 1.12 Installation...................................................................................................490 1.13 ROCKER ARM ASSEMBLY................................................................................................490 1.14 Removal........................................................................................................490 1.15 Installation...................................................................................................490 1.16 Disassembly....................................................................................................491 1.17 Inspection.....................................................................................................491 1.18 Assembly.......................................................................................................491 1.19 VALVE CLEARANCE ADJUSTMENTS........................................................................................491 1.20 Four Cylinder Engines..........................................................................................492 1.21 Six Cylinder Engines...........................................................................................492 1.22 VALVE SPRINGS......................................................................................................492 1.23 CYLINDER HEAD ASSEMBLY.............................................................................................494 1.24 Removal........................................................................................................494 1.25 Installation...................................................................................................495 1.26 VALVES AND VALVE SPRINGS...........................................................................................498 1.27 Removal........................................................................................................498 1.28 Inspection.....................................................................................................499 1.29 Installation...................................................................................................499 1.30 VALVE GUIDES.......................................................................................................499 1.31 Inspection.....................................................................................................499 1.32 Removal........................................................................................................500 1.33 Installation...................................................................................................500 1.34 CYLINDER HEAD AND VALVE SEATS......................................................................................500 1.35 Inspection.....................................................................................................500 1.36 Repair.........................................................................................................501 1.37 Installation Of New Valve Seats................................................................................501 PISTON AND CONNECTING ROD ASSEMBLIES........................................................................................502 1.38 ROD BEARINGS.......................................................................................................502 1.39 Removal........................................................................................................502 1.40 Installation...................................................................................................503 1.41 PISTON AND CONNECTING ROD ASSEMBLY.................................................................................503 1.42 Service Note...................................................................................................503 1.43 Removal........................................................................................................503 1.44 Installation...................................................................................................504 1.45 PISTON RINGS.......................................................................................................505 1.46 Removal........................................................................................................505 1.47 Inspection.....................................................................................................505 1.48 Installation...................................................................................................506 1.49 PISTON AND CONNECTING ROD..........................................................................................507 1.50 Disassembly....................................................................................................507 1.51 Inspection.....................................................................................................507 1.52 Installation...................................................................................................507 1.53 PISTON COOLING JETS................................................................................................508 1.54 Removal........................................................................................................508 1.55 Installation...................................................................................................508 CRANKSHAFT ASSEMBLY.........................................................................................................509 1.56 GENERAL............................................................................................................509 1.57 CRANKSHAFT PULLEY..................................................................................................509 1.58 Removal, Engines AA and AB.....................................................................................509 1.59 Installation, Engines AA and AB................................................................................509 1.60 Removal, Engines YA and YB.....................................................................................509 1.61 Installation, Engines YA and YB................................................................................509 1.62 REAR OIL SEAL......................................................................................................510 1.63 Replacement....................................................................................................510 1.64 MAIN BEARINGS......................................................................................................511 1.65 Removal........................................................................................................511 1.66 Installation...................................................................................................511 1.67 THRUST WASHERS.....................................................................................................512 1.68 Check The Axial Movement Of The Crankshaft.....................................................................512 1.69 Removal........................................................................................................513 1.70 Installation...................................................................................................513 1.71 CRANKSHAFT.........................................................................................................513 1.72 Removal........................................................................................................513 1.73 Inspection.....................................................................................................514 1.74 Installation...................................................................................................514 TIMING CASE AND TIMING GEARS................................................................................................516 1.75 GENERAL............................................................................................................516 1.76 TIMING CASE COVER..................................................................................................516 1.77 Removal........................................................................................................516 1.78 Installation...................................................................................................516 1.79 FRONT OIL SEAL.....................................................................................................517 1.80 Removal........................................................................................................517 1.81 Installation...................................................................................................517 1.82 IDLER GEAR AND HUB.................................................................................................517 1.83 Removal........................................................................................................517 1.84 Installation...................................................................................................518 1.85 GEAR FOR THE FUEL INJECTION PUMP OR THE CAMSHAFT GEAR..............................................................519 1.86 Removal........................................................................................................519 1.87 Installation...................................................................................................519 1.88 CRANKSHAFT GEAR....................................................................................................520 1.89 Removal........................................................................................................520 1.90 Installation...................................................................................................520 1.91 TIMING CASE........................................................................................................520 1.92 Removal........................................................................................................520 1.93 Installation...................................................................................................520 1.94 CAMSHAFT AND TAPPETS...............................................................................................521 1.95 Removal........................................................................................................522 1.96 Installation...................................................................................................522 ENGINE BLOCK ASSEMBLY.......................................................................................................523 1.97 DESCRIPTION........................................................................................................523 1.98 ENGINE BLOCK.......................................................................................................523 1.99 Disassembly....................................................................................................523 1.100 Inspection....................................................................................................524 1.101 Assembly......................................................................................................524 1.102 CYLINDER LINER....................................................................................................524 1.103 Inspection....................................................................................................524 1.104 Hone..........................................................................................................525 1.105 Removal.......................................................................................................525 1.106 Installation..................................................................................................526 TURBOCHARGER, ENGINES AB AND YB.............................................................................................527 1.107 GENERAL...........................................................................................................527 1.108 Removal.......................................................................................................527 1.109 Installation..................................................................................................528 1.110 Clean The Impeller And Compressor Housing.....................................................................528 LUBRICATION SYSTEM..........................................................................................................529 1.111 GENERAL...........................................................................................................529 1.112 OIL FILTER, REPLACEMENT...........................................................................................529 1.113 OIL SUMP..........................................................................................................530 1.114 Removal.......................................................................................................530 1.115 Installation..................................................................................................530 1.116 OIL PUMP..........................................................................................................530 1.117 Removal.......................................................................................................530 1.118 Inspection....................................................................................................531 1.119 Installation..................................................................................................531 1.120 RELIEF VALVE......................................................................................................532 1.121 Removal.......................................................................................................532 1.122 Disassembly...................................................................................................532 1.123 Inspection....................................................................................................533 1.124 Installation..................................................................................................533 FUEL SYSTEM.................................................................................................................533 1.125 DESCRIPTION.......................................................................................................533 1.126 CAV FUEL INJECTION PUMP...........................................................................................534 1.127 Removal.......................................................................................................534 1.128 Installation..................................................................................................534 1.129 CAV FUEL INJECTION PUMP, CHECKS AND ADJUSTMENTS...................................................................535 1.130 Timing Gear Marks.............................................................................................535 1.131 How To Set Number 1 Piston To TDC On The Compression Stroke...................................................536 1.132 Check The Valve Timing........................................................................................536 1.133 Check The Timing Of The Fuel Injection Pump...................................................................537 1.134 Check The Timing Mark Of The Fuel Injection Pump..............................................................537 1.135 Check The Engine Timing Mark..................................................................................538 1.136 REMOVE AIR FROM THE FUEL SYSTEM...................................................................................539 1.137 Fuel Injection Pump With Vent Tube............................................................................539 1.138 Fuel Injection Pump With Vent Screw...........................................................................540 1.139 FUEL FILTER (REPLACEMENT).........................................................................................541 1.140 FUEL INJECTORS....................................................................................................541 1.141 Removal.......................................................................................................541 1.142 Inspection....................................................................................................542 1.143 Installation..................................................................................................543 1.144 FUEL PUMP.........................................................................................................543 1.145 Removal.......................................................................................................543 1.146 Disassembly...................................................................................................543 1.147 Assembly......................................................................................................544 1.148 Installation..................................................................................................544 1.149 Test..........................................................................................................545 COOLING SYSTEM..............................................................................................................545 1.150 GENERAL...........................................................................................................545 1.151 THERMOSTAT........................................................................................................545 1.152 Replacement...................................................................................................545 1.153 COOLANT PUMP......................................................................................................546 1.154 Removal.......................................................................................................546 1.155 Disassembly...................................................................................................546 1.156 Assembly......................................................................................................547 1.157 Installation..................................................................................................547 1.158 FAN AND FAN DRIVE.................................................................................................547 1.159 Removal.......................................................................................................547 1.160 Disassembly...................................................................................................547 1.161 Assembly......................................................................................................548 1.162 Installation..................................................................................................548 1.163 OIL COOLER........................................................................................................548 1.164 Removal, Engine AB............................................................................................548 1.165 Removal, Engines YA and YB....................................................................................548 1.166 Disassembly And Assembly......................................................................................549 1.167 Installation, Engine AB.......................................................................................549 1.168 Installation, Engines YA and YB...............................................................................550 1.169 By–Pass Valve, Oil Cooler.....................................................................................550 FLYWHEEL AND FLYWHEEL HOUSING...............................................................................................550 1.170 GENERAL...........................................................................................................550 1.171 FLYWHEEL..........................................................................................................550 1.172 Removal.......................................................................................................550 1.173 Ring Gear (Replacement).......................................................................................550 1.174 Installation..................................................................................................550 1.175 FLYWHEEL HOUSING..................................................................................................551 1.176 Removal.......................................................................................................551 1.177 Installation..................................................................................................551 ELECTRICAL EQUIPMENT........................................................................................................552 1.178 DRIVE BELTS.......................................................................................................552 1.179 ALTERNATOR........................................................................................................553 1.180 STARTER MOTOR.....................................................................................................553 1.181 Removal.......................................................................................................553 1.182 Installation..................................................................................................553 1.183 COLD START AID....................................................................................................553 AIR COMPRESSOR, ENGINES YA AND YB...........................................................................................553 1.184 GENERAL...........................................................................................................553 1.185 Air Compressor, Removal, WABCO................................................................................553 1.186 Compressor Drive, Inspection..................................................................................554 1.187 Air Compressor, Installation, WABCO...........................................................................554 1.188 Compressor Drive, Disassembly, WABCO..........................................................................554 1.189 Compressor Drive, Assembly, WABCO.............................................................................555 1.190 Air Compressor, Removal, BENDIX...............................................................................555 1.191 Air Compressor, Installation, BENDIX..........................................................................556 1.192 Compressor Drive, Disassembly, BENDIX.........................................................................557 1.193 Compressor Drive, Assembly, BENDIX............................................................................557 ENGINE SPECIFICATIONS.......................................................................................................559 1.194 CYLINDER HEAD ASSEMBLY............................................................................................559 1.195 Cylinder Head.................................................................................................559 1.196 Valve Guides..................................................................................................559 1.197 Inlet Valves..................................................................................................560 1.198 Exhaust Valves................................................................................................560 1.199 Double Valve Springs To Outer.................................................................................560 1.200 Double Valve Springs To Inner.................................................................................560 1.201 Single Valve Springs..........................................................................................560 1.202 Tappets.......................................................................................................560 1.203 Rocker Arm Shaft..............................................................................................560 1.204 Rocker Arms And Bushings......................................................................................561 1.205 PISTON AND CONNECTING RODS........................................................................................561 1.206 Pistons, Engines AA And YA....................................................................................561 1.207 Pistons, Engines AB And YB....................................................................................561 1.208 Piston Rings, Engines AA And YA...............................................................................561 1.209 Piston Rings, Engines AB And YB...............................................................................561 1.210 Connecting Rods, Engines AB And YB............................................................................562 1.211 Connecting Rods, Engines AB And YB............................................................................562 1.212 Piston Pins, Engines AA And YA................................................................................562 1.213 Piston Pins, Engines AB and YB................................................................................562 1.214 Small End Bushings, Engines AA And YA.........................................................................562 1.215 Small End Bushings, Engines AB And YB.........................................................................562 1.216 Connecting Rod Bearings, Engines AA And YA....................................................................563 1.217 Connecting Rod Bearings, Engines AB And YB....................................................................563 1.218 Piston Cooling Jets, Engines AB And YB........................................................................563 1.219 CRANKSHAFT ASSEMBLY...............................................................................................563 1.220 Crankshaft....................................................................................................563 1.221 Crankshaft Heat Treatment.....................................................................................563 1.222 Crankshaft Overhaul...........................................................................................563 1.223 Main Bearings.................................................................................................565 1.224 Crankshaft Thrust Washers.....................................................................................565 1.225 TIMING CASE AND DRIVE ASSEMBLY....................................................................................565 1.226 Camshaft......................................................................................................565 1.227 Camshaft Thrust Washer........................................................................................565 1.228 Camshaft Gear.................................................................................................566 1.229 Gear For Fuel Injection Pump..................................................................................566 1.230 Crankshaft Gear...............................................................................................566 1.231 Idler Gear And Hub............................................................................................566 1.232 ENGINE BLOCK ASSEMBLY.............................................................................................566 1.233 Engine Block..................................................................................................566 1.234 Cylinder Liners...............................................................................................566 1.235 TURBOCHARGER......................................................................................................567 1.236 LUBRICATION SYSTEM................................................................................................567 1.237 Oil Pump, Engines AA And AB...................................................................................567 1.238 Oil Pump, Engines YA And YB...................................................................................567 1.239 Relief Valve..................................................................................................567 1.240 Oil Filter....................................................................................................567 1.241 FUEL SYSTEM.......................................................................................................567 1.242 Cav Fuel Injection Pump.......................................................................................567 1.243 FUEL INJECTORS................................................................................................568 1.244 Fuel Pump, Engines AA And AB..................................................................................569 1.245 Fuel Pump, Engines YA And YB..................................................................................569 1.246 Fuel Filter...................................................................................................569 1.247 COOLING SYSTEM....................................................................................................569 1.248 Coolant Pump..................................................................................................569 1.249 Thermostat....................................................................................................570 1.250 Fan Drive Housing.............................................................................................570 1.251 FLYWHEEL AND HOUSING..............................................................................................570 1.252 Limits for flywheel ''run out'' and alignment (total indicator reading).......................................570 1.253 ELECTRICAL EQUIPMENT..............................................................................................570 1.254 Alternator....................................................................................................570 1.255 Starter Motor.................................................................................................570 1.256 Cold Start Aid................................................................................................570 TORQUE SPECIFICATIONS.......................................................................................................571 SPECIAL TOOLS...............................................................................................................572 single speed powershift transmission............................................................................................576 DESCRIPTION.................................................................................................................576 GENERAL.................................................................................................................576 MECHANICAL DESCRIPTION......................................................................................................576 TORQUE CONVERTER........................................................................................................576 OIL LAMP................................................................................................................577 SHAFT AND CLUTCH ASSEMBLIES.............................................................................................577 Input Shaft.........................................................................................................578 Forward Clutch Shaft................................................................................................578 Clutch Assemblies...................................................................................................578 Output Gear.........................................................................................................579 HYDRAULIC OPERATION.........................................................................................................579 TORQUE CONVERTER........................................................................................................579 SHAFT ASSEMBLIES........................................................................................................580 CONTROL VALVE...........................................................................................................582 General.............................................................................................................582 System Regulator....................................................................................................582 Clutch Pressure Regulator...........................................................................................582 Torque Converter Regulator..........................................................................................583 Inching Spool.......................................................................................................583 Direction Spool, Manual Control.....................................................................................583 Drain Spool.........................................................................................................584 Accumulator.........................................................................................................584 Modulation Spool....................................................................................................585 LUBRICATION CIRCUIT.....................................................................................................586 MONOTROL PEDAL..........................................................................................................586 OIL FLOW DIAGRAMS.......................................................................................................586 Neutral.............................................................................................................586 Forward.............................................................................................................586 Forward-Inching.....................................................................................................586 Reverse.............................................................................................................587 speed reducer and differential..................................................................................................592 INTRODUCTION................................................................................................................592 GENERAL.................................................................................................................592 DESCRIPTION.............................................................................................................592 REPAIRS.....................................................................................................................592 REMOVAL.................................................................................................................592 DISASSEMBLY.............................................................................................................592 CLEANING................................................................................................................595 INSPECTION..............................................................................................................595 ASSEMBLY................................................................................................................595 Pinion Assembly.....................................................................................................595 Differential........................................................................................................596 INSTALLATION............................................................................................................602 TROUBLESHOOTING.............................................................................................................603 SPECIFICATIONS..............................................................................................................604 starter,solenoid,solenoid switch................................................................................................605 INTRODUCTION................................................................................................................605 GENERAL.................................................................................................................605 DESCRIPTION AND OPERATION...............................................................................................605 REPAIRS.....................................................................................................................607 REMOVAL.................................................................................................................607 DISSASEMBLY.............................................................................................................607 CLEANING................................................................................................................608 ASSEMBLY................................................................................................................608 INSTALLATION............................................................................................................608 CHECKS AND ADJUSTMENTS......................................................................................................609 GENERAL.................................................................................................................609 TROUBLESHOOTING.............................................................................................................611 steering axle...................................................................................................................613 INTRODUCTION................................................................................................................613 GENERAL.................................................................................................................613 DESCRIPTION.............................................................................................................613 REPAIRS.....................................................................................................................614 STEERING AXLE, H3.50-5.00XL (H70-110XL) and S/E 3.50-5.50XL (S/E 70-120XL)..............................................614 Removal.............................................................................................................614 Installation........................................................................................................614 STEERING AXLE, H6.00-7.00XL (H135-155XL) H8.00-16.00XL (H165-360XL).....................................................615 Removal.............................................................................................................615 Installation........................................................................................................616 WHEELS AND HUBS, ALL UNITS..............................................................................................616 Removal and Disassembly.............................................................................................616 Cleaning............................................................................................................616 Assembly and Installation...........................................................................................616 SPINDLES AND BEARINGS, ALL UNITS........................................................................................617 Removal.............................................................................................................617 Cleaning............................................................................................................618 Assembly and Installation...........................................................................................618 TIE RODS, ALL UNITS.....................................................................................................618 Removal.............................................................................................................618 Cleaning............................................................................................................618 Installation........................................................................................................619 STEERING CYLINDER.......................................................................................................620 Removal and Disassembly.............................................................................................620 Cleaning and Inspection.............................................................................................620 Assembly and Installation...........................................................................................620 TROUBLESHOOTING.............................................................................................................621 steering housing and the steering control unit..................................................................................622 INTRODUCTION................................................................................................................622 GENERAL.................................................................................................................622 DESCRIPTION.............................................................................................................622 OPERATION...............................................................................................................622 REPAIRS.....................................................................................................................622 STEERING WHEEL AND COLUMN ASSEMBLY......................................................................................622 TYPE "A" STEERING COLUMN ASSEMBLY.......................................................................................624 Removal And Disassembly.............................................................................................624 Assembly And Installation...........................................................................................624 TYPE "A" STEERING COLUMN................................................................................................625 TYPE "A" STEERING COLUMN................................................................................................626 TYPE "B" STEERING COLUMN................................................................................................627 Removal And Disassembly.............................................................................................627 Assembly And Installation...........................................................................................627 TYPE "B" STEERING COLUMN................................................................................................628 Disassembly of Steering Control Unit................................................................................629 Cleaning of Steering Control Unit...................................................................................629 Assembly of Steering Control Unit...................................................................................631 CHECKS AND ADJUSTMENTS......................................................................................................634 REMOVE AIR FROM THE SYSTEM..............................................................................................634 TROUBLESHOOTING.............................................................................................................635 Tilt Cylinder...................................................................................................................636 transmission and differential...................................................................................................641 INTRODUCTION................................................................................................................641 General.................................................................................................................641 Description.............................................................................................................641 Operation...............................................................................................................641 REPAIRS.....................................................................................................................643 Removal.................................................................................................................643 Disassembly.............................................................................................................644 Cleaning................................................................................................................646 Inspection..............................................................................................................647 Assembly................................................................................................................647 Installation............................................................................................................658 CHECKS AND ADJUSTMENTS......................................................................................................659 Adjusting The Shift Linkage H3.50-5.00XL (H70-110XL)....................................................................659 Adjusting The Shift Linkage S6.00-7.00XL (S135-155XL)...................................................................661 Adjusting The Clutch Pedal And Linkage..................................................................................661 TROUBLESHOOTING.............................................................................................................663 SPECIFICATIONS..............................................................................................................665 transmission assembly...........................................................................................................666 REPAIRS ....................................................................................................................666 GENERAL.................................................................................................................666 REMOVAL.................................................................................................................666 TRANSMISSION, DISASSEMBLY...............................................................................................668 Input Shaft, Disassembly............................................................................................669 Forward Shaft, Disassembly..........................................................................................671 Cleaning and Inspection.............................................................................................672 TRANSMISSION, ASSEMBLY..................................................................................................673 Forward Shaft, Assembly.............................................................................................673 Input Shaft, Assembly...............................................................................................675 Assembly............................................................................................................677 Installation........................................................................................................680 CONTROL VALVE...........................................................................................................681 Removal.............................................................................................................681 Disassembly.........................................................................................................682 Assembly............................................................................................................682 Installation........................................................................................................684 THROTTLE PEDAL..........................................................................................................684 MONOTROL PEDAL..........................................................................................................684 Removal and Disassembly.............................................................................................684 Assembly and Installation...........................................................................................684 CHECKS AND ADJUSTMENTS......................................................................................................687 STALL TEST..............................................................................................................687 ADJUST THE LINKAGE FOR THE INCHING PEDAL................................................................................688 Linkage For Models With An Inching Pedal And A Brake Pedal..........................................................688 Linkage For ModelsWith One Inching/Brake Pedal......................................................................690 ADJUST THE LINKAGE FOR THE DIRECTION CONTROL LEVER......................................................................691 Earlier Production..................................................................................................691 Later Production....................................................................................................692 CHECK THE OIL PRESSURE FOR THE TRANSMISSION.............................................................................693 System Pressure Check Port..........................................................................................694 Torque Converter Check Port.........................................................................................694 Clutch Pressure Check Port..........................................................................................695 Inching Pressure....................................................................................................695 Solenoid Check Ports (Monotrol Control Only)........................................................................695 Lubrication Pressure Check Ports....................................................................................695 TROUBLESHOOTING.............................................................................................................696 various systems.................................................................................................................699 INTRODUCTION................................................................................................................699 GENERAL.................................................................................................................699 DESCRIPTION.................................................................................................................699 GENERAL.................................................................................................................699 STEERING COLUMN GAUGES, METERS AND INDICATORS...........................................................................702 LED DISPLAY PANEL.......................................................................................................702 Battery Discharge Indicators .......................................................................................702 Brush Wear Indicators...............................................................................................703 Motor Temperature Indicators........................................................................................704 "LX" SERIES INSTRUMENT PANEL DISPLAY....................................................................................705 Hourmeter Functions.................................................................................................706 Battery Indicator Function..........................................................................................706 Status Code Function................................................................................................706 CHECKS AND ADJUSTMENTS......................................................................................................706 GENERAL.................................................................................................................706 REPLACEMENT.................................................................................................................707 GENERAL.................................................................................................................707 METER REPLACEMENT.......................................................................................................707 SENDER REPLACEMENT......................................................................................................708 Fuel Level Sender...................................................................................................708 Pressure And Temperature Sender.....................................................................................709 I.T.W. DISPLAY PANEL....................................................................................................709 Removal.............................................................................................................709 SPECIFICATIONS..............................................................................................................710 TROUBLESHOOTING.............................................................................................................711 WIRE SCHEMATIC..................................................................................................................712
HYSTER F005 (H70XL-H110XL) SERVICE MANUAL – PDF DOWNLOAD:
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