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Hyster F006 (H135-155XL) Service Manual – PDF DOWNLOAD
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Description
Hyster F006 (H135-155XL) Service Manual – PDF DOWNLOAD
DESCRIPTION:
Hyster F006 (H135-155XL) Service Manual – PDF DOWNLOAD
SAFETY PRECAUTIONS MAINTENANCE AND REPAIR :
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly
fastened, and that the load being lifted is balanced. Make sure the crane, cables, and
chains have the capacity to support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair
on electric lift trucks. Disconnect the battery ground cable on internal combustion lift
trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT
THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance
section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts
must meet or exceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before
using force to remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit whenmaking repairs,
or if the unit needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel
are flammable. Be sure to follow the necessary safety precautions when handling these
fuels and when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks
away from the area. Make sure the area is well ventilated.
TABLE OF CONTENTS:
Hyster F006 (H135-155XL) Service Manual – PDF DOWNLOAD
897104-0100SRM0322-(02-2007)-US-EN.................................................. 1 toc............................................................................. 1 Frame....................................................................... 1 Safety Precautions Maintenance and Repair................................... 2 General..................................................................... 5 Description................................................................. 5 Counterweight Repair........................................................ 6 Remove.................................................................. 6 Install................................................................. 6 Hood Repair................................................................. 7 Remove.................................................................. 7 Install................................................................. 7 Overhead Guard Repair....................................................... 7 Remove.................................................................. 7 Install................................................................. 7 Operator Restraint System Repair............................................ 8 Automatic Locking Retractor (ALR)....................................... 8 Emergency Locking Retractor (ELR)....................................... 8 Hydraulic Tank Repair....................................................... 10 Remove.................................................................. 10 Inspect................................................................. 10 Small Leaks Repair...................................................... 10 Large Leaks Repair...................................................... 10 Clean................................................................... 10 Steam Method........................................................ 11 Chemical Solution Method............................................ 11 Other Methods of Preparation for Repair................................. 11 Install................................................................. 11 Fuel Tank Repair............................................................ 12 Remove.................................................................. 12 Repair.................................................................. 12 Install................................................................. 12 Radiator Repair............................................................. 12 Remove.................................................................. 12 Install................................................................. 12 Engine Repair............................................................... 13 Remove.................................................................. 13 Install................................................................. 13 Throttle Pedal Adjustment................................................... 15 Perkins 1104C-44(RE) Diesel Engine...................................... 15 Safety Labels............................................................... 16 Cab Repair.................................................................. 18 Cab, Replace............................................................ 18 Window, Replace......................................................... 18 Windshield Wipers and Heater............................................ 18 tables.......................................................................... 1 Table 1. Material Specifications for Cab Windows............................ 20 897106-1300SRM0324-(10-2003)-US-EN.................................................. 23 toc............................................................................. 23 Two-Speed Powershift Transmission........................................... 23 Safety Precautions Maintenance and Repair................................... 24 General..................................................................... 27 Mechanical Description...................................................... 27 Torque Converter........................................................ 27 Transmission Pump....................................................... 28 Shaft Assemblies........................................................ 28 Input Shaft............................................................. 29 Forward Clutch Shaft.................................................... 29 Clutch Assemblies....................................................... 29 Countershaft............................................................ 36 Output Shaft............................................................ 36 Hydraulic Operation......................................................... 37 Torque Converter........................................................ 37 Seal Rings.............................................................. 38 Control Valve............................................................... 38 System Pressure Regulator............................................... 41 Clutch Pressure Regulator............................................... 41 Torque Converter Regulator.............................................. 42 Inching Spool........................................................... 42 Direction Spool, Direction Control Lever................................ 42 Direction Spool, MONOTROL Pedal......................................... 43 Range Spool............................................................. 43 Drain Spool............................................................. 44 Accumulator............................................................. 44 Modulator Spool......................................................... 44 Operation............................................................... 44 Lubrication Circuit......................................................... 45 MONOTROL Pedal.............................................................. 45 Oil Flow Diagrams........................................................... 47 Neutral................................................................. 47 Forward-Low............................................................. 48 Forward-Low-Inching..................................................... 49 Reverse-Low............................................................. 50 897107-1300SRM0325-(10-2003)-US-EN.................................................. 53 toc............................................................................. 53 Two-Speed Powershift Transmission........................................... 53 Safety Precautions Maintenance and Repair................................... 54 General..................................................................... 57 Transmission Repair......................................................... 57 Transmission and Torque Converter, Remove............................... 57 Transmission, Disassemble............................................... 59 Reverse-Low Clutch, Disassemble......................................... 62 Reverse-High Clutch, Disassemble........................................ 65 Forward-Low Clutch, Disassemble......................................... 68 Forward-High Clutch, Disassemble........................................ 71 Clean and Inspect....................................................... 73 Forward Low and High Clutches Assembly...................................... 74 Forward Clutches, Assemble.............................................. 76 Reverse-Low Clutch, Assemble............................................ 82 Reverse Clutches, Assemble.............................................. 84 Transmission, Assemble.................................................. 91 Torque Converter, Install............................................... 98 Control Valve Repair........................................................ 99 Remove.................................................................. 99 Disassemble............................................................. 100 Assemble................................................................ 101 Install................................................................. 103 MONOTROL Pedal.............................................................. 103 Remove and Disassemble.................................................. 103 Assemble and Install.................................................... 103 Stall Test.................................................................. 106 Linkage Adjustments......................................................... 107 Linkage for Inching Pedal H6.00-7.00XL (H135-155XL, H135-155XL 2........ 107 Linkage for Inching Pedal S6.00-7.00XL (S135-155XL, S135-155XL 2........ 110 Linkage for Range Lever - Early Model H6.00-7.00XL (H135-155XL) ........ 113 Linkage for Direction Control Lever - Early Model H6.00-7.00XL (........ 113 Linkage for Range Lever - Later Model H6.00-7.00XL (H135-155XL, ........ 115 Linkage for Direction Control Lever - Later Model H6.00-7.00XL (........ 117 Linkage for Range Lever S6.00-7.00XL (S135-155XL, S135-155XL 2 )........ 119 Linkage for Direction Control Lever S6.00-7.00XL (S135-155XL, S1........ 119 Oil Pressure Check.......................................................... 121 System Pressure Check Port.............................................. 121 Torque Converter Check Port............................................. 121 Clutch Pressure Check Port.............................................. 121 Inching Pressure........................................................ 122 Solenoid Check Ports (MONOTROL Control Only)............................ 122 Lubrication Pressure Check Ports........................................ 122 Specifications.............................................................. 123 Troubleshooting............................................................. 123 Correct System Pressure: 1300 ±124 kPa ( 189 ±18 psi)................... 126 Correct Clutch Pressure: 924 ±69 kPa ( 134 ±10 psi)..................... 127 Correct Solenoid Pressure (MONOTROL Only): 965 ±138 kPa ( 140 ±2........ 128 Torque Converter Pressure: 834 ±69 kPa ( 121 ±10 psi)................... 128 Lubrication Pressure: 83 ±21 kPa ( 12 ±3 psi)........................... 128 tables.......................................................................... 53 Table 1. Stall Speed Specifications......................................... 106 897108-1600SRM0326-(03-2007)-US-EN.................................................. 131 toc............................................................................. 131 Steering Axle............................................................... 131 Safety Precautions Maintenance and Repair................................... 132 General..................................................................... 135 Description................................................................. 135 Steering Axle Assembly Repair............................................... 140 Steering Axle H3.50-5.00XL (H70-110XL) (G005), S3.50-5.50XL (S70........ 140 Remove.............................................................. 140 Install............................................................. 140 Steering Axle H6.00-7.00XL (H135-155XL, H135-155XL 2 ) (F006, G0........ 141 Remove.............................................................. 141 Install............................................................. 141 Wheels and Hubs Repair (All Units).......................................... 142 Remove and Disassemble.................................................. 142 Clean................................................................... 142 Inspect................................................................. 142 Assemble and Install.................................................... 142 Spindles and Bearings Repair (All Units).................................... 144 Remove.................................................................. 144 Clean................................................................... 144 Assemble and Install.................................................... 145 Tie Rods Repair (All Units)................................................. 146 Remove.................................................................. 146 Clean................................................................... 146 Install................................................................. 146 Steering Cylinder Repair.................................................... 149 Remove and Disassemble.................................................. 149 Clean and Inspect....................................................... 149 Assemble and Install.................................................... 149 Troubleshooting............................................................. 150 897109-1800SRM0327-(09-2003)-US-EN.................................................. 155 toc............................................................................. 155 Brake System................................................................ 155 Safety Precautions Maintenance and Repair................................... 156 General..................................................................... 159 Description................................................................. 159 Operation................................................................... 160 Brake Booster and Master Cylinder....................................... 160 Brake Booster....................................................... 160 Master Cylinder..................................................... 161 Service Brake Assembly.................................................. 162 Parking Brake........................................................... 163 Brake Shoe Assemblies Repair................................................ 164 Remove and Disassemble.................................................. 164 Clean and Inspect....................................................... 165 Cleaning Procedures................................................. 165 Inspect............................................................. 165 Assemble and Install.................................................... 166 Master Cylinder Repair...................................................... 167 Remove.................................................................. 167 Disassemble............................................................. 167 Assemble................................................................ 169 Install................................................................. 169 Brake Booster Repair........................................................ 169 Remove.................................................................. 169 Disassemble............................................................. 169 Clean and Inspect....................................................... 171 Assemble................................................................ 171 Install................................................................. 171 Brake System Air Removal.................................................... 171 Brake Pedal Adjustment...................................................... 172 Brake Shoes Adjustment...................................................... 173 Parking Brake Adjustment.................................................... 173 Parking Brake Switch Adjustment............................................. 173 Brake Booster Relief Valve Check............................................ 173 Troubleshooting............................................................. 174 897110-1900SRM0328-(09-2003)-US-EN.................................................. 179 toc............................................................................. 179 Hydraulic System............................................................ 179 Safety Precautions Maintenance and Repair................................... 180 General..................................................................... 183 Description and Operation................................................... 183 Hydraulic Pumps......................................................... 185 Main Control Valve...................................................... 185 Control Valve Lever..................................................... 186 Steering Control Unit................................................... 186 Brake Valve............................................................. 186 Oil Clutch, H6.00-7.00XL (H135-155XL) (F006)............................ 187 Troubleshooting............................................................. 187 Lift, Lower, and Tilt Circuit........................................... 188 Steering, Brake, and Oil Clutch System.................................. 189 897111-4000SRM0329-(10-2003)-US-EN.................................................. 193 toc............................................................................. 193 Masts....................................................................... 193 Safety Precautions Maintenance and Repair................................... 194 General..................................................................... 197 Description and Operation................................................... 197 General................................................................. 197 Safety Procedures When Working Near Mast................................ 198 Two-Stage Mast.......................................................... 198 Three-Stage Mast........................................................ 200 Carriage Repair............................................................. 202 Remove.................................................................. 202 Sideshift Carriage, Disassemble......................................... 202 Sideshift Carriage, Assemble............................................ 203 Install................................................................. 203 Two-Stage Mast Repair....................................................... 205 Remove.................................................................. 205 Disassemble............................................................. 206 Clean and Inspect....................................................... 207 Assemble................................................................ 208 Install................................................................. 208 Three-Stage Mast Repair..................................................... 210 Remove.................................................................. 210 Disassemble............................................................. 210 Clean and Inspect....................................................... 210 Assemble................................................................ 210 Install................................................................. 212 Mast Operation Check........................................................ 212 Lift and Tilt System Leaks Check............................................ 213 Lift System............................................................. 213 Tilt System............................................................. 213 Tilt Cylinder Stroke and Backward Tilt Angle Adjustment..................... 214 Lift Chain Adjustments...................................................... 214 Mast Adjustments............................................................ 217 Carriage Adjustment......................................................... 217 Troubleshooting............................................................. 219 tables.......................................................................... 193 Table 1. Mast Parts Weight.................................................. 206 Table 2. Hook-Type Carriage Chain Adjustment................................ 215 Table 3. Pin-Type Carriage Chain Adjustment................................. 215 897113-8000SRM0331-(09-2003)-US-EN.................................................. 223 toc............................................................................. 223 Capacities and Specifications............................................... 223 Safety Precautions Maintenance and Repair................................... 224 Lift Truck Weights.......................................................... 227 Capacities.................................................................. 227 Tire Sizes.................................................................. 228 Tire Pressure............................................................... 228 Electrical System........................................................... 228 Wheel Nut Torque............................................................ 228 Engine Specifications....................................................... 229 Hydraulic System............................................................ 229 Mast Speeds................................................................. 230 Transmission Oil Pressures.................................................. 230 Torque Specifications....................................................... 231 Engine - GM 4.3L V-6.................................................... 231 Engine - Perkins 4.2482................................................. 231 Engine - Perkins 1004.4................................................. 231 Clutch.................................................................. 231 Manual Transmission..................................................... 232 Powershift Transmission................................................. 232 Speed Reducer........................................................... 232 Drive Axle.............................................................. 232 Steering System......................................................... 232 Brake System............................................................ 232 Hydraulic System........................................................ 233 Tilt Cylinder........................................................... 233 Mast.................................................................... 233 897114-8000SRM0332-(03-2003)-US-EN.................................................. 237 toc............................................................................. 237 Diagrams.................................................................... 237 Safety Precautions Maintenance and Repair................................... 238 897123-8000SRM0341-(06-2007)-US-EN.................................................. 261 toc............................................................................. 261 Periodic Maintenance........................................................ 261 Safety Precautions Maintenance and Repair................................... 262 General..................................................................... 267 Serial Number Data...................................................... 267 How to Move Disabled Truck.............................................. 267 How to Tow Lift Truck............................................... 267 How to Put Lift Truck on Blocks......................................... 268 How to Raise Drive Tires............................................ 268 How to Raise Steering Tires......................................... 268 Maintenance Schedule........................................................ 269 Maintenance Procedures Every 8 Hours or Daily............................... 282 How to Make Checks With Engine Stopped.................................. 282 Hydraulic System Oil................................................ 282 Engine Oil.......................................................... 284 Drive Belts......................................................... 284 Intake Manifold Rubber Cap.......................................... 285 Cooling System...................................................... 285 Air Filter.......................................................... 285 Fuel System......................................................... 286 Primary Fuel Filter, Diesel Engine.................................. 286 Battery............................................................. 286 Tires and Wheels.................................................... 286 Forks............................................................... 287 Adjust.......................................................... 287 Remove and Install.............................................. 289 Forks, Mast, and Lift Chains, Inspect............................... 290 Operator Restraint System........................................... 291 Automatic Locking Retractor (ALR)............................... 291 Emergency Locking Retractor (ELR)............................... 291 Safety Labels....................................................... 292 How to Make Checks With Engine Running.................................. 293 Gauges, Lights, Horn, and Fuses..................................... 293 Oil Level, Powershift Transmission.................................. 294 Oil Level, Oil Clutch System, H3.50-5.00XL (H70-110XL).............. 295 Control Levers and Pedals........................................... 295 Lift System Operation............................................... 295 Inching/Brake Pedal................................................. 295 Service Brakes...................................................... 295 Parking Brake....................................................... 296 Steering System..................................................... 296 Maintenance Procedures Every 250 Hours or 6 Weeks........................... 296 Engine Oil and Filter, GM V-6 Engine.................................... 296 Lift Chains, Lubrication................................................ 296 Drive Shafts............................................................ 296 Mast Lubrication........................................................ 297 Crankcase Breather, GM V-6.............................................. 298 Air Filter, GM V-6 EPA Compliant Engine ................................ 298 Maintenance Procedures Every 350 Hours or 2 Months.......................... 299 Engine Oil and Filter, Perkins 4.2482 Diesel Engine..................... 299 Drive Belts............................................................. 299 Perkins Diesel Engine............................................... 299 GM V-6 Engine (Early Models)........................................ 299 GM V-6 Engine (Late Models)......................................... 300 Brake Fluid............................................................. 302 Lift Chains Wear Check.................................................. 302 Forks Wear and Damage Check............................................. 302 Steering Axle Lubrication............................................... 302 Fuel System, Checks and Adjustments..................................... 303 Diesel Fuel System.................................................. 303 LPG Carburetor (Early Models)....................................... 303 Gasoline Carburetor (Early Models).................................. 304 Fuel Injection (Late Models)........................................ 304 Crankcase Breather, Perkins 4.2482 Diesel Engine........................ 304 Hydraulic Tank Breather................................................. 304 Cooling System, Clean Debris from Radiator Core......................... 304 Maintenance Procedures Every 500 Hours or 3 Months.......................... 305 Engine Oil and Filter, Perkins Diesel Engine............................ 305 Crankcase Breather, Perkins Diesel Engine............................... 305 PCV Valve, GM V-6....................................................... 305 Maintenance Procedures Every 1000 Hours or 6 Months......................... 305 Manifold Heat Valve, GM V-6 (Early Models).............................. 305 Ignition System, GM V-6................................................. 305 Valve Clearance Adjustment.............................................. 305 Fuel Filter, Replace (Diesel Engine).................................... 306 Fuel System Air Removal (Perkins 1004-4 Diesel Engine).................. 306 Fuel Injection Pump With Vent Tube.................................. 306 Fuel Injection Pump With Vent Screw................................. 307 Fuel System Air Removal (Perkins 4.2482 Diesel Engine).................. 309 Oil Level Check in Transmission......................................... 309 Manual Transmission, H3.50-5.00XL (H70-110XL)....................... 309 Speed Reducer for Powershift Transmission, H3.50-5.00XL (H70-110.... 309 Manual Transmission, H6.00-7.00XL (H135-155XL)...................... 309 Differential and Drive Axle for Powershift Transmission, H6.00-7.... 309 Differential, Speed Reducer, and Drive Axle for Manual Transmiss.... 310 Control Levers and Pedals, Lubricate.................................... 310 Crankcase Breather, Replace............................................. 310 Cooling System, GM V-6 EPA Compliant Engine............................. 310 Spark Plug Replacement.................................................. 310 Remove.............................................................. 310 Install............................................................. 311 LPG Fuel Filter GM V-6 EPA Compliant Engine, Replace.................... 311 Inspect Engine Electrical System, Connectors, and FCVS Connectio........ 312 Maintenance Procedures Every 2000 Hours or Yearly........................... 312 Hydraulic System........................................................ 312 Hydraulic Oil and Filter, H3.50-5.00XL (H70-110XL), Replace......... 312 Hydraulic Oil and Filter, H6.00-7.00XL (H135-155XL, H135-155XL 2.... 313 Oil Change and Oil Filter Replacement, Powershift Transmission, ........ 313 Oil Change, Manual Transmission, H3.50-5.00XL (H70-110XL)............... 313 Oil Change, Manual Transmission, H6.00-7.00XL (H135-155XL).............. 313 Oil Change, Speed Reducer, Powershift Transmission, H3.50-5.00XL........ 313 Oil and Filter Change, Oil Clutch System, H3.50-5.00XL (H70-110X........ 314 Oil Change, Differential and Drive Axle, Powershift Transmission........ 314 Oil Change, Differential, Speed Reducer, and Drive Axle, Manual ........ 314 Cooling System.......................................................... 314 PCV Valve, GM V-6....................................................... 314 Service Brakes.......................................................... 315 LPG Filter, Replace..................................................... 315 Gasoline Fuel Filter, Replace........................................... 316 Hood Latch Check, H3.50-5.00XL (H70-110XL).............................. 316 Air Filter Element, GM V-6 EPA Compliant Engine......................... 316 Oxygen Sensor GM V-6 EPA Compliant Engine............................... 316 Inspect Low Pressure Regulator (LPR) for Oil Buildup and Leaks.......... 317 Check Throttle Shaft for Sticking....................................... 318 Inspect Exhaust Manifold and Piping for Leaks........................... 318 Test LPG/GAS Regulator Pressure......................................... 318 Safety Procedures When Working Near Mast.................................... 318 Lift Chain Adjustments...................................................... 320 Fuel Injectors Repair....................................................... 322 Lift and Tilt System Leak Check............................................. 323 Lift Cylinders, Leak Check.............................................. 323 Tilt Cylinders, Leak Check.............................................. 323 Welding Repairs............................................................. 324 Overhead Guard Changes...................................................... 324 Wheel and Tire Replacement.................................................. 325 Remove Wheels From Lift Truck........................................... 325 Remove Wheels From Tire................................................. 325 Remove Tire From Two-Piece Wheel.................................... 327 Remove Tire From Three- and Four-Piece Wheels....................... 329 Install Wheel in Tire................................................... 330 Install Three- or Four-Piece Wheel in Tire.......................... 331 Install Two-Piece Wheel in Tire..................................... 332 Add Air to Pneumatic Tires.............................................. 333 Wheels, Install......................................................... 333 Solid Rubber Tires Repair................................................... 334 Wheel, Tire Remove...................................................... 334 Wheel, Tire Install..................................................... 336 SIT Tire, Change for H3.50-5.00XL (G005), and H6.00-7.00XL (F006........ 338 Remove SIT Solid Tire From Wheel.................................... 338 Install SIT Solid Tire on Wheel..................................... 339 Adhesives and Sealants...................................................... 340 Hydraulic Oil, Lubricant, and Coolant Specifications........................ 341 tables.......................................................................... 261 Table 1. Maintenance Schedule............................................... 271 Table 2. Hook-Type Carriage Chain Adjustment................................ 321 Table 3. Pin-Type Carriage Chain Adjustment................................. 321 897129-0900SRM0348-(09-2001)-US-EN.................................................. 345 toc............................................................................. 345 LPG Fuel System............................................................. 345 Safety Precautions Maintenance and Repair................................... 346 General..................................................................... 349 Description and Operation................................................... 351 Fuel Tank............................................................... 351 Fuel Filter and Fuel Valve Unit......................................... 352 Vaporizer............................................................... 353 Carburetor.............................................................. 354 Governor................................................................ 356 LPG Tank Repair............................................................. 357 Remove.................................................................. 357 LPG Tanks with Fixed Mounting Bracket............................... 357 LPG Tanks with EZ Lift Mounting Bracket............................. 357 Install................................................................. 358 LPG Tanks with Fixed Mounting Bracket............................... 358 LPG Tanks with EZ Lift Mounting Bracket............................. 359 Hydrostatic Relief Valve Repair............................................. 360 Remove and Install...................................................... 360 Filter Unit Repair.......................................................... 360 Fuel Filter Element, Replace............................................ 360 Diaphragm and Fuel Valve, Replace....................................... 360 Hoses Replacement........................................................... 362 Vaporizer Repair............................................................ 362 Remove.................................................................. 362 Disassemble............................................................. 362 Clean................................................................... 362 Inspect................................................................. 362 Assemble................................................................ 364 Install................................................................. 368 Carburetor Repair........................................................... 368 Remove.................................................................. 368 Disassemble............................................................. 368 Clean................................................................... 368 Assemble................................................................ 368 Install................................................................. 368 Governor Repair............................................................. 370 Filter Unit Check........................................................... 372 Vaporizer Check............................................................. 372 Pressure Reducer Valve.................................................. 372 Vapor Valve............................................................. 372 Carburetor Adjustment....................................................... 372 Idle Mixture............................................................ 372 Idle Speed.............................................................. 372 Power Mixture........................................................... 373 Throttle Linkage Adjustment................................................. 373 Troubleshooting............................................................. 375 897412-2200SRM0463-(04-1993)-US-EN.................................................. 381 ................................................................................ 381 ................................................................................ 382 ................................................................................ 383 ................................................................................ 384 ................................................................................ 385 ................................................................................ 386 ................................................................................ 387 ................................................................................ 388 ................................................................................ 389 ................................................................................ 390 ................................................................................ 391 ................................................................................ 392 ................................................................................ 393 ................................................................................ 394 ................................................................................ 395 ................................................................................ 396 ................................................................................ 397 ................................................................................ 398 ................................................................................ 399 ................................................................................ 400 ................................................................................ 401 ................................................................................ 402 ................................................................................ 403 ................................................................................ 404 ................................................................................ 405 ................................................................................ 406 ................................................................................ 407 ................................................................................ 408 ................................................................................ 409 ................................................................................ 410 ................................................................................ 411 ................................................................................ 412 ................................................................................ 413 ................................................................................ 414 ................................................................................ 415 ................................................................................ 416 897435-2200SRM0473-(03-1994)-US-EN.................................................. 417 ................................................................................ 417 ................................................................................ 418 ................................................................................ 419 ................................................................................ 420 ................................................................................ 421 ................................................................................ 422 ................................................................................ 423 ................................................................................ 424 ................................................................................ 425 ................................................................................ 426 ................................................................................ 427 ................................................................................ 428 ................................................................................ 429 ................................................................................ 430 ................................................................................ 431 ................................................................................ 432 ................................................................................ 433 ................................................................................ 434 ................................................................................ 435 ................................................................................ 436 ................................................................................ 437 ................................................................................ 438 897501-8000SRM0519-(06-2007)-US-EN.................................................. 439 toc............................................................................. 439 Diagrams.................................................................... 439 Safety Precautions Maintenance and Repair................................... 440 897800-0600SRM0590-(08-2005)-US-EN.................................................. 527 toc............................................................................. 527 GM Engines.................................................................. 527 Safety Precautions Maintenance and Repair................................... 528 General..................................................................... 531 Description................................................................. 531 Engine Removal and Installation............................................. 532 Cylinder Head Repair........................................................ 532 Remove and Disassemble.................................................. 532 Clean and Inspect....................................................... 532 Valve Guides and Seats, Repairs......................................... 533 Valves, Repair.......................................................... 533 Valve Seats, Repair..................................................... 534 Valve Springs........................................................... 534 Rocker Arm Studs (Early Models)......................................... 536 Rocker Arm Studs (Late Models).......................................... 536 Assemble and Install.................................................... 537 Cylinder Block Cleaning and Inspection...................................... 540 Piston Bore Preparation..................................................... 540 Engine Mounts Installation.................................................. 541 Lubrication System Repair................................................... 541 Oil Pump, Remove and Disassemble........................................ 541 Clean and Inspect....................................................... 541 Oil Pump, Assemble and Install.......................................... 542 Oil Sump, Install....................................................... 542 Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters................. 543 Timing Cover............................................................ 543 Remove.............................................................. 543 Install............................................................. 545 Timing Sprockets........................................................ 545 Remove.............................................................. 545 Install............................................................. 545 Camshaft................................................................ 546 Remove.............................................................. 546 Inspect............................................................. 546 Install............................................................. 546 Balance Shaft........................................................... 547 Remove.............................................................. 547 Install............................................................. 548 Hydraulic Valve Lifters................................................. 548 Remove.............................................................. 548 Disassemble......................................................... 549 Clean and Inspect................................................... 549 Assemble............................................................ 549 Install............................................................. 550 Crankshaft Repair........................................................... 551 Remove.................................................................. 551 Inspect and Repair...................................................... 551 How to Check Clearance Between Main Bearings and Their Journals......... 552 Install................................................................. 553 Piston and Connecting Rod Assemblies Repair................................. 554 Connecting Rod Bearings, Replace........................................ 554 Piston and Connecting Rod Assemblies, Remove............................ 555 Disassemble............................................................. 555 Piston, Clean and Inspect............................................... 556 Cylinder Bores, Inspect and Repair...................................... 556 Piston Rings............................................................ 557 Assemble................................................................ 558 Piston and Connecting Rod Assemblies, Install........................... 558 Flywheel and Flywheel Housing Repair........................................ 559 Flywheel, Repair........................................................ 559 Flywheel, Install....................................................... 559 H3.50-5.00XL (H70-110XL), S3.50-5.50XL (S70-120XL), S6.00-7.00XL.... 559 H6.00-7.00XL (H135-155XL)........................................... 559 Flywheel Housing H3.50-5.00XL (H70-110XL), H3.50-5.50XM (H70-120........ 559 Engine Adapter H6.00-7.00XL (H135-155XL)................................ 559 Coolant Pump Repair......................................................... 560 Thermostat Replacement...................................................... 560 Fan Mount Repair (Early Models)............................................. 560 Fan Mount Assembly Repair (Late Models)..................................... 560 Drive Belt Installation..................................................... 562 Valve Clearance Adjustment (Early Models)................................... 563 Valve Clearance Adjustment (New Models)..................................... 564 Compression Check........................................................... 564 Engine Specifications....................................................... 565 Engine Data............................................................. 565 Cylinder Head........................................................... 565 Hydraulic Valve Lifter.................................................. 566 Camshaft................................................................ 566 Pistons................................................................. 566 Crankshaft.............................................................. 567 Connecting Rods......................................................... 567 Balance Shaft........................................................... 568 Cooling System.......................................................... 568 Lubrication System...................................................... 568 Torque Specifications....................................................... 568 Troubleshooting............................................................. 569 tables.......................................................................... 527 Table 1. Piston Rings Arrangement on Piston................................. 558 897934-0700SRM0626-(11-2001)-US-EN.................................................. 575 toc............................................................................. 575 Cooling System.............................................................. 575 Safety Precautions Maintenance and Repair................................... 576 General..................................................................... 579 Description................................................................. 580 Radiator................................................................ 580 Radiator Cap............................................................ 580 Thermostat.............................................................. 580 Water Pump.............................................................. 581 Fan and Fan Shroud...................................................... 581 Cooling System Checks....................................................... 581 Radiator................................................................ 581 Thermostat.............................................................. 581 Water Pump.............................................................. 582 Exhaust Leaks........................................................... 582 Fan and Fan Shroud...................................................... 582 Radiator Cleaning........................................................... 582 Drain................................................................... 582 Clean................................................................... 582 Fill.................................................................... 583 Troubleshooting............................................................. 584 899783-2000SRM0090-(10-2003)-US-EN.................................................. 587 toc............................................................................. 587 Main Control Valve.......................................................... 587 Safety Precautions Maintenance and Repair................................... 588 General..................................................................... 591 Description................................................................. 591 Operation................................................................... 594 Lift Spool.............................................................. 594 Tilt Spool.............................................................. 595 Tilt Backward....................................................... 595 Tilt Forward........................................................ 596 Single-Stage Relief Valve............................................... 598 Two-Stage Relief Valve.................................................. 599 Main Control Valve Repair................................................... 600 Remove and Disassemble.................................................. 600 Clean and Inspect....................................................... 600 Assemble................................................................ 600 Install................................................................. 601 Single-Stage Relief Valve Adjustment........................................ 601 Two-Stage Relief Valve...................................................... 602 Auxiliary Control Valve Relief Valve Adjustment (H60-110E Only)............. 602 Troubleshooting............................................................. 603 tables.......................................................................... 587 Table 1. Relief Pressures (Oil temperature at 55 to 66 C ( 131 t............ 601 899784-2200SRM0002-(12-2004)-US-EN.................................................. 607 toc............................................................................. 607 Alternator with Regulator................................................... 607 Safety Precautions Maintenance and Repair................................... 608 General..................................................................... 611 Description................................................................. 611 Alternator Repair........................................................... 613 Alternator Type A....................................................... 613 Remove and Disassemble.............................................. 613 Clean............................................................... 614 Assemble............................................................ 615 Install............................................................. 615 Alternator Type B....................................................... 618 Remove and Disassemble.............................................. 618 Clean............................................................... 618 Assemble............................................................ 619 Install............................................................. 620 General Check and Adjustment................................................ 621 Low Output Check (Type A or Type B)......................................... 621 High Output Check (Type A or Type B)........................................ 623 Brushes Circuit Check....................................................... 624 Delco Alternators....................................................... 624 Motorola Alternators.................................................... 625 Diodes Check................................................................ 626 Diode Bridge Check.......................................................... 626 Delco and Leece-Neville Alternators..................................... 626 Motorola Alternators.................................................... 626 Rotor Field Winding Check................................................... 627 Stator Windings Check....................................................... 628 Voltage Regulator Check..................................................... 628 Troubleshooting............................................................. 628 910072-1400SRM0046-(07-2007)-US-EN.................................................. 633 toc............................................................................. 633 Differential................................................................ 633 Safety Precautions Maintenance and Repair................................... 634 General..................................................................... 637 Description................................................................. 637 Differential Repair......................................................... 638 Remove.................................................................. 638 Differential Carrier From Axle Housing, Remove...................... 638 Differential and Ring Gear From Differential Carrier, Remove........ 640 Drive Pinion and Pinion Carrier From Differential Carrier, Remov.... 642 Disassemble............................................................. 643 Differential and Ring Gear Assembly, Disassemble.................... 643 Drive Pinion and Pinion Carrier, Disassemble........................ 645 Clean and Inspect....................................................... 648 Assemble................................................................ 649 Pinion, Bearings, and Pinion Carrier, Assemble...................... 649 Pinion Bearings, Adjust Preload..................................... 649 Press Method.................................................... 649 Yoke or Flange Method........................................... 650 Triple-Lip Seal, Install............................................ 651 Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion)......... 652 Differential and Ring Gear, Assemble................................ 654 Differential Gears Rotating Torque, Check........................... 656 Differential and Ring Gear Assembly, Install........................ 657 Differential Bearings, Preload Adjust............................... 659 Ring Gear, Runout Check............................................. 660 Ring Gear Backlash, Adjust.......................................... 660 Gear Set, Tooth Contact Pattern Check............................... 662 Thrust Screw, Install and Adjust.................................... 665 Install................................................................. 665 Differential Assembly Into Axle Housing, Install.................... 665 Specifications.............................................................. 667 Troubleshooting............................................................. 672 tables.......................................................................... 633 Table 1. Ring Gear Backlash Adjustment Specifications....................... 662 Table 2. Ring and Pinion Tooth Contact Adjustment........................... 663 Table 3. General Specifications............................................. 667 Table 4. Rivet Installation Pressure........................................ 667 Table 5. Pinion Adjustment.................................................. 668 Table 6. Pinion Preload Pressure............................................ 668 Table 7. Torque Specifications.............................................. 669 Table 8. Torque Specifications for Metric Hardware.......................... 670 Table 9. Torque Specifications for Metric (Fine) Hardware................... 671 910073-1400SRM0049-(09-2003)-US-EN.................................................. 675 toc............................................................................. 675 Drive Axle.................................................................. 675 Safety Precautions Maintenance and Repair................................... 676 General..................................................................... 679 Description................................................................. 679 Drive Axle Repair........................................................... 680 Disassemble (Type 1 Shown).............................................. 680 Clean................................................................... 683 Inspect................................................................. 683 Assemble (Type 1 Shown)................................................. 684 Torque Specifications....................................................... 687 Troubleshooting............................................................. 688 910076-1600SRM0054-(10-2003)-US-EN.................................................. 691 toc............................................................................. 691 Steering Control Unit....................................................... 691 Safety Precautions Maintenance and Repair................................... 692 General..................................................................... 695 Description................................................................. 695 Operation................................................................... 695 Steering Wheel and Column Assembly Repair................................... 697 Steering Column Assembly Repair............................................. 697 Type A Steering Column Assembly......................................... 697 Remove and Disassemble.............................................. 697 Assemble and Install................................................ 699 Type B Steering Column Assembly......................................... 701 Remove and Disassemble.............................................. 701 Assemble and Install................................................ 701 Steering Control Unit............................................... 704 Disassemble..................................................... 704 Clean........................................................... 707 Assemble........................................................ 708 System Air Removal.......................................................... 713 Troubleshooting............................................................. 713 910091-1900SRM0097-(07-2006)-US-EN.................................................. 717 toc............................................................................. 717 Hydraulic Gear Pumps........................................................ 717 Safety Precautions Maintenance and Repair................................... 718 Description................................................................. 721 Operation................................................................... 722 Flow Control Valve...................................................... 722 Relief Valve............................................................ 723 Hydraulic Gear Pump Repair.................................................. 723 Remove.................................................................. 723 Disassemble............................................................. 724 Clean................................................................... 724 Inspect................................................................. 725 Assemble................................................................ 728 Install................................................................. 730 Pump Output Check........................................................... 730 Method No. 1............................................................ 730 Method No. 2............................................................ 731 Hydraulic System Air Check.................................................. 732 Troubleshooting............................................................. 733 910092-1900SRM0098-(07-2003)-US-EN.................................................. 739 toc............................................................................. 739 Hydraulic Vane Pumps........................................................ 739 Safety Precautions Maintenance and Repair................................... 740 General..................................................................... 743 Description................................................................. 743 Operation................................................................... 744 Pump.................................................................... 744 Relief Valve............................................................ 744 Hydraulic Vane Pumps Repair................................................. 745 Remove.................................................................. 745 Disassemble............................................................. 745 Assemble................................................................ 746 Install................................................................. 749 Relief Valve Relief Pressure Check.......................................... 749 Lift Trucks With Internal Combustion Engines............................ 749 Electric Lift Trucks.................................................... 749 Electric Lift Trucks With Adjustable Relief Valve....................... 750 Specifications.............................................................. 751 Pressure Relief Valve................................................... 751 Troubleshooting............................................................. 751 910102-2100SRM0103-(03-2007)-US-EN.................................................. 755 toc............................................................................. 755 Tilt Cylinders.............................................................. 755 Safety Precautions Maintenance and Repair................................... 756 General..................................................................... 759 Description................................................................. 759 Tilt Cylinder Repair........................................................ 759 Remove.................................................................. 759 Disassemble............................................................. 759 Clean................................................................... 759 Assemble................................................................ 759 Tilt Cylinders With O-Ring or Single-Lip Seals...................... 759 Tilt Cylinders for XM and XMS Models................................ 761 Tilt Cylinders for XL, XLS, and XL 3 Models......................... 762 Tilt Cylinders for H700-800A and Early Model H700-920B.............. 764 Install................................................................. 765 Tilt Cylinders Using Chevron Packing................................ 765 Install......................................................... 766 Tilt Cylinder Leak Check.................................................... 768 Tilt Cylinder Stroke and Mast Tilt Angle Adjustment......................... 770 Torque Specifications....................................................... 770 Piston Rod Nut.......................................................... 770 Retainer................................................................ 771 Troubleshooting............................................................. 773 tables.......................................................................... 755 Table 1. Movement Rates (Maximum) for Tilt Cylinders........................ 769 910107-2200SRM0106-(12-2004)-US-EN.................................................. 777 toc............................................................................. 777 Starter..................................................................... 777 Safety Precautions Maintenance and Repair................................... 778 General..................................................................... 781 Description and Operation................................................... 781 Starter Repair.............................................................. 783 Remove.................................................................. 783 Disassemble............................................................. 783 Clean................................................................... 784 Assemble................................................................ 784 Install................................................................. 785 General Checks and Adjustments.............................................. 785 Troubleshooting............................................................. 788 910110-2200SRM0143-(02-2007)-US-EN.................................................. 793 toc............................................................................. 793 Instrument Panel Indicators and Senders..................................... 793 Safety Precautions Maintenance and Repair................................... 794 General..................................................................... 797 Description................................................................. 798 Steering Column Gauges, Meters, and Indicators.......................... 798 LED Display Panel....................................................... 798 Battery Discharge Indicators........................................ 798 Brush Wear Indicators............................................... 804 Motor Temperature Indicators........................................ 804 LX Series Display Panel................................................. 806 Hourmeter Functions................................................. 807 Battery Indicator Function.......................................... 807 Status Code Function................................................ 807 ZX Series Display Panels................................................ 809 Display Panel....................................................... 809 Basic Display Panels................................................ 809 Performance Display................................................. 811 Brush Wear Indicators............................................... 815 Adjustments - General....................................................... 815 Replacement - General Information........................................... 815 Meter Replacement........................................................... 816 Sender Replacement.......................................................... 817 Fuel Level Sender....................................................... 817 Pressure and Temperature Sender......................................... 817 Seat Sensor, Operator Presence System (OPS)............................. 818 Remove.............................................................. 818 Install............................................................. 818 Operator Presence System Module Replacement............................. 818 Remove.............................................................. 819 Install............................................................. 820 ITW Display Panel Replacement............................................... 821 Remove.................................................................. 821 Column Mount Display Panel (EV-100/200ZX Motor Controllers) Repl............ 821 Remove.................................................................. 821 Display Panel Assembly, Replace......................................... 821 Indicator LEDs.......................................................... 822 Battery Indicators...................................................... 822 Digital Display (Performance Display Panel Only)........................ 822 Status Code or Performance Level Switches and Indicator LEDs (Pe........ 823 Basic Display Panel, Replace Parts...................................... 823 Performance Display Panel, Replace Parts................................ 825 Dash Mount Display Panel (EV100/200ZX Motor Controllers) Replace............ 825 Remove and Replace...................................................... 825 Specifications.............................................................. 826 Meter Specifications.................................................... 826 Sender Specifications................................................... 826 Troubleshooting............................................................. 827 Meter................................................................... 827 Troubleshooting for Operator Presence System................................ 828 tables.......................................................................... 793 Table 1. Troubleshooting Procedure for Operator Presence Module............. 828 910119-4000SRM0135-(10-2003)-US-EN.................................................. 833 toc............................................................................. 833 Lift Cylinders.............................................................. 833 Safety Precautions Maintenance and Repair................................... 834 Safety Procedures When Working Near Mast.................................... 837 General..................................................................... 841 Description................................................................. 841 Lowering Control Valve.................................................. 841 Cylinders (General)..................................................... 844 Cylinders (H520-620B, H700-800A)........................................ 844 Retainer, Install................................................... 844 Cylinders (H360-460B)................................................... 846 Cylinders (Two-Speed)................................................... 848 Lift Cylinder Repair........................................................ 850 Lift Cylinder Removal Without Removing Mast............................. 850 Standard Masts With Main Lift Cylinder Fastened to Crossmember o.... 850 Standard and Full Free-Lift Masts With Lift Cylinder Fastened to.... 850 Masts That Have Two Cylinders, Main Lift Cylinder and Free-Lift .... 850 Disassemble............................................................. 852 Assemble................................................................ 852 Lift Cylinder Installation in Mast...................................... 854 Standard Masts With Main Lift Cylinder Fastened to Crossmember o.... 854 Standard and Full Free-Lift Masts With Lift Cylinder Fastened to.... 854 Chevron-Style Packing................................................... 854 Chevron-Style Packing Installation on Piston........................ 855 Chevron-Style Packing Installation in Packing Gland................. 857 Lift Cylinders for VISTA® Masts............................................. 858 Description............................................................. 858 Lowering Control Valve.............................................. 858 Remove.................................................................. 860 Disassemble............................................................. 861 Assemble................................................................ 862 Install................................................................. 863 Main Lift Cylinders................................................. 863 Free-Lift Cylinder.................................................. 863 Lift System Leak Check...................................................... 864 Specifications.............................................................. 865 Troubleshooting............................................................. 866 tables.......................................................................... 833 Table 1. Lift Trucks with Two-Speed Lift Cylinders.......................... 849 Table 2. Cylinder Retainer Torque Specifications and Weight Guid............ 865 910442-8000SRM0231-(12-2004)-US-EN.................................................. 869 toc............................................................................. 869 Metric and Inch (SAE) Fasteners............................................. 869 Safety Precautions Maintenance and Repair................................... 870 General..................................................................... 873 Threaded Fasteners...................................................... 873 Nomenclature, Threads................................................... 873 Strength Identification................................................. 874 Cotter (Split) Pins..................................................... 874 Fastener Torque Tables.................................................. 879 Conversion Table........................................................ 881 tables.......................................................................... 869 Table 1. Bolts and Screws................................................... 875 Table 2. Studs and Nuts..................................................... 876 Table 3. Torque Nuts........................................................ 877 Table 4. Torque Nuts With Nylon Insert...................................... 878 Table 5. Torque Values for Metric Fasteners*................................ 879 Table 6. Torque Values for Inch Fasteners*.................................. 880 Table 7. Conversion Table for Metric and English Units...................... 881 Table 8. Cotter Pin Dimensional Data........................................ 882 Table 9. Cotter Pin Dimensional Data........................................ 883 Table 10. Cotter Pin Dimensional Data....................................... 884 Table 11. Cotter Pin Dimensional Data....................................... 886 1455747-0600SRM0705-(03-2006)-US-EN................................................. 891 toc............................................................................. 891 Perkins Diesel Engines...................................................... 891 Safety Precautions Maintenance and Repair................................... 892 General..................................................................... 899 General Safety Rules.................................................... 899 Description................................................................. 900 Engine Serial Number Codes.............................................. 903 Engine Data............................................................. 903 Engine Removal and Installation............................................. 905 Lift Engine............................................................. 905 Cylinder Head Assembly Repair............................................... 905 Valve Cover............................................................. 905 Remove.............................................................. 905 Install............................................................. 906 Rocker Arm Assembly..................................................... 906 Remove.............................................................. 906 Install............................................................. 906 Disassemble......................................................... 906 Inspect............................................................. 907 Assemble............................................................ 907 Valve Clearance Adjustments............................................. 907 Four-Cylinder Engines............................................... 908 Six-Cylinder Engines................................................ 908 Valve Springs........................................................... 908 Cylinder Head Assembly.................................................. 910 Remove.............................................................. 910 Install............................................................. 912 Valves and Valve Springs................................................ 916 Remove.............................................................. 916 Inspect............................................................. 916 Install............................................................. 917 Valve Guides............................................................ 917 Inspect............................................................. 917 Remove.............................................................. 918 Install............................................................. 918 Cylinder Head and Valve Seats........................................... 918 Inspect............................................................. 918 Repair.............................................................. 918 New Valve Seats, Install............................................ 918 Piston and Connecting Rod Assemblies Repair................................. 920 Rod Bearings............................................................ 920 Remove.............................................................. 921 Install............................................................. 921 Piston and Connecting Rod Assembly...................................... 922 Service Note........................................................ 922 Remove.............................................................. 922 Install............................................................. 923 Piston Rings............................................................ 924 Remove.............................................................. 924 Inspect............................................................. 924 Install............................................................. 924 Piston and Connecting Rod............................................... 925 Disassemble......................................................... 925 Inspect............................................................. 926 How to Select Correct Replacements.................................. 926 Install............................................................. 927 Piston Cooling Jets..................................................... 927 Remove.............................................................. 927 Install............................................................. 928 Crankshaft Assembly Repair.................................................. 928 General................................................................. 928 Crankshaft Pulley....................................................... 929 Engine AR, Remove................................................... 929 Engines YG and YH, Remove........................................... 929 Inspect............................................................. 930 Engine AR, Install.................................................. 930 Engines YG and YH, Install.......................................... 930 Rear Oil Seal........................................................... 931 Replace............................................................. 931 Main Bearings........................................................... 932 Remove.............................................................. 932 Inspect............................................................. 933 Install............................................................. 933 Thrust Washers.......................................................... 933 Crankshaft Axial Movement, Check.................................... 933 Remove.............................................................. 934 Install............................................................. 934 Crankshaft.............................................................. 935 Remove.............................................................. 935 Inspect............................................................. 935 Install............................................................. 935 Flywheel................................................................ 937 Remove.............................................................. 937 Ring Gear, Replace.................................................. 937 Install............................................................. 937 Flywheel Housing........................................................ 938 Remove.............................................................. 938 Install............................................................. 938 Timing Case and Timing Gears Repair......................................... 939 General................................................................. 939 Timing Case Cover....................................................... 939 Remove.............................................................. 939 Install............................................................. 940 Front Oil Seal.......................................................... 940 Remove.............................................................. 940 Install............................................................. 940 Crankshaft Pulley Wear Sleeve........................................... 941 Install............................................................. 941 Idler Gear and Hub...................................................... 941 Remove.............................................................. 941 Install............................................................. 942 Air Compressor Drive, Bendix............................................ 943 Disassemble......................................................... 943 Assemble............................................................ 944 Fuel Injection Pump Gear................................................ 944 Remove.............................................................. 945 Install............................................................. 945 Camshaft Gear........................................................... 946 Remove.............................................................. 946 Install............................................................. 946 Crankshaft Gear......................................................... 947 Remove.............................................................. 947 Install............................................................. 947 Timing Case............................................................. 947 Remove.............................................................. 947 Install............................................................. 948 Camshaft and Tappets.................................................... 949 Remove.............................................................. 949 Install............................................................. 949 Cylinder Block Assembly Repair.............................................. 950 Description............................................................. 950 Cylinder Block.......................................................... 950 Disassemble......................................................... 950 Inspect............................................................. 951 Assemble............................................................ 951 Cylinder Bore (Four-Cylinder Engines)................................... 952 Cylinder Liner (Six-Cylinder Engines)................................... 952 Inspect............................................................. 952 Cylinder Liner Condition, Check..................................... 952 Remove.............................................................. 953 Service Liner, Install.............................................. 954 Partially Finished Liner, Install................................... 955 Engine Timing............................................................... 956 Description............................................................. 956 How to Set Number One Piston to TDC on Compression Stroke........... 957 How to Set Number One Piston to TDC on Compression Stroke (Alter.... 958 Valve Timing, Check................................................. 958 Fuel Injection Pump Timing, Check................................... 959 Turbocharger - Engine YH Repair............................................. 960 General................................................................. 960 Remove.............................................................. 960 Install............................................................. 960 Impeller and Compressor Housing, Clean.............................. 961 Lubrication System Repair................................................... 962 General................................................................. 962 Oil Filter, Replace..................................................... 962 Filter Head............................................................. 963 Remove and Install.................................................. 963 Oil Sump................................................................ 963 Remove.............................................................. 963 Install............................................................. 964 Oil Pump................................................................ 964 Remove.............................................................. 964 Inspect............................................................. 964 Install............................................................. 965 Relief Valve............................................................ 965 Remove.............................................................. 965 Disassemble......................................................... 966 Inspect............................................................. 966 Assemble............................................................ 966 Install............................................................. 967 Idler Gear Shaft, Replace............................................... 967 Remove.............................................................. 967 Remove (Alternative)................................................ 967 Install............................................................. 968 Install (Alternative)............................................... 968 Install (Alternative for Four-Cylinder Engines Only)................ 969 Fuel System Repair.......................................................... 969 Description............................................................. 969 Fuel Injection Pump..................................................... 970 Remove.............................................................. 970 Install............................................................. 971 Check and Adjust.................................................... 972 Fuel System Air Removal................................................. 972 Fuel Filter, Replace.................................................... 973 Canister Type....................................................... 974 Quick Release Canister Type......................................... 974 Fuel Injectors.......................................................... 975 Remove.............................................................. 975 Inspect............................................................. 976 Install............................................................. 976 Fuel Pump............................................................... 977 Remove.............................................................. 977 Disassemble......................................................... 977 Assemble............................................................ 977 Install............................................................. 978 Test................................................................ 978 Cooling System Repair....................................................... 979 General................................................................. 979 Thermostat.............................................................. 979 Remove.............................................................. 979 Install............................................................. 979 Test................................................................ 980 Coolant Pump............................................................ 980 Remove.............................................................. 980 Disassemble......................................................... 980 Assemble............................................................ 982 Install............................................................. 984 Fan and Fan Drive....................................................... 985 Remove.............................................................. 985 Install............................................................. 985 Oil Cooler (Six-Cylinder Engines)....................................... 986 Remove.............................................................. 986 Disassemble and Assemble............................................ 986 Install............................................................. 986 Oil Cooler Bypass Valve............................................. 986 Electrical Equipment Repair................................................. 987 Drive Belts............................................................. 987 Adjustment.......................................................... 987 Remove.............................................................. 988 Install............................................................. 988 Alternator.............................................................. 988 Remove.............................................................. 988 Install............................................................. 988 Starter Motor........................................................... 988 Remove.............................................................. 988 Install............................................................. 988 Cold Start Aid.......................................................... 988 Air Compressor - Engines YG and YH.......................................... 989 General................................................................. 989 Repair.................................................................. 989 Remove.............................................................. 989 Install............................................................. 989 Rotary Exhauster Replacement................................................ 991 Remove.................................................................. 991 Clean................................................................... 991 Install................................................................. 991 Engine Specifications....................................................... 992 Cylinder Head Assembly.................................................. 992 Piston and Connecting Rods.............................................. 995 Crankshaft Assembly..................................................... 998 Crankshaft Overhaul.................................................1000 Timing Case and Drive Assembly..........................................1002 Engine Block Assembly...................................................1003 Turbocharger............................................................1006 Lubrication System......................................................1006 Fuel System.............................................................1007 Cooling System..........................................................1009 Flywheel and Housing....................................................1009 Electrical Equipment....................................................1010 Torque Specifications.......................................................1010 Cylinder Head Assembly..................................................1010 Piston and Connecting Rod Assemblies....................................1010 Crankshaft Assembly.....................................................1010 Timing Case and Drive Assembly..........................................1011 Turbocharger............................................................1011 Lubrication System......................................................1011 Fuel System.............................................................1011 Cooling System..........................................................1011 Flywheel................................................................1011 Auxiliary Equipment.....................................................1011 Special Torque Specifications...............................................1012 Flywheel and Housing....................................................1012 Turbocharger............................................................1012 Electrical Equipment....................................................1012 Auxiliary Equipment.....................................................1012 Special Tools*..............................................................1013 Troubleshooting.............................................................1018 tables.......................................................................... 891 Table 1. Cylinder Head...................................................... 992 Table 2. Valve Guides....................................................... 992 Table 3. Inlet Valves....................................................... 992 Table 4. Exhaust Valves..................................................... 993 Table 5. Valve Springs...................................................... 995 Table 6. Tappets............................................................ 995 Table 7. Rocker Arm Shaft................................................... 995 Table 8. Rocker Arms and Bushings........................................... 995 Table 9. Pistons (Engine AR)................................................ 995 Table 10. Pistons (Engines YG and YH)....................................... 995 Table 11. Piston Rings (Engine AR).......................................... 996 Table 12. Piston Rings (Engines YG and YH).................................. 996 Table 13. Piston Pins....................................................... 997 Table 14. Connecting Rods................................................... 997 Table 15. Small End Bushings................................................ 997 Table 16. Connecting Rod Bearings (Engines AR and YG)....................... 997 Table 17. Connecting Rod Bearings (Engine YH)............................... 997 Table 18. Piston Cooling Jets............................................... 998 Table 19. Crankshaft........................................................ 998 Table 20. Main Bearings..................................................... 999 Table 21. Crankshaft Thrust Washers......................................... 999 Table 22. Crankshaft Heat Treatment......................................... 999 Table 23. Crankshaft Overhaul Specifications................................1000 Table 24. Maximum Variation (Run-out).......................................1002 Table 25. Camshaft..........................................................1002 Table 26. Camshaft Thrust Washer............................................1002 Table 27. Camshaft Gear.....................................................1002 Table 28. Gear for Fuel Injection Pump......................................1003 Table 29. Crankshaft Gear...................................................1003 Table 30. Idler Gear and Hub................................................1003 Table 31. Cylinder Block (Engine AR)........................................1003 Table 32. Cylinder Bore Specifications......................................1004 Table 33. Cylinder Block (Engines YG and YH)................................1005 Table 34. Cylinder Liners (Engines YG and YH)...............................1005 Table 35. Cylinder Liner Specifications (Partially Finished)................1005 Table 36. Oil Pump (Engine AR)..............................................1006 Table 37. Oil Pump (Engines YG and YH)......................................1006 Table 38. Idler Gear for Oil Pump...........................................1007 Table 39. Relief Valve......................................................1007 Table 40. Oil Filter........................................................1007 Table 41. Lucas Fuel Injection Pump.........................................1007 Table 42. Fuel Injector Codes...............................................1008 Table 43. Fuel Pump (Engine AR).............................................1009 Table 44. Fuel Pump (Engines YG and YH).....................................1009 Table 45. Fuel Filter.......................................................1009 Table 46. Coolant Pump......................................................1009 Table 47. Thermostat........................................................1009 Table 48. Fan Drive Housing.................................................1009 Table 49. Limits for Flywheel Run Out and Alignment (Total Indic............1010 Table 50. Alternator........................................................1010 Table 51. Starter Motor.....................................................1010 Table 52. Cold Start Aid....................................................1010 Table 53. List of Possible Causes...........................................1018 1473385-2200SRM0765-(11-2001)-US-EN.................................................1023 toc.............................................................................1023 Microprocessor Spark Timing System (MSTS)...................................1023 Safety Precautions Maintenance and Repair...................................1024 General.....................................................................1027 Description.................................................................1028 What MSTS Does..........................................................1028 How MSTS Begins Operation...............................................1028 Operation...................................................................1029 Distributor.............................................................1029 Ignition Coil...........................................................1029 Ignition Module.........................................................1029 When Engine Is Being Started............................................1030 When Engine Is Running..................................................1031 Manifold Absolute Pressure (MAP) Sensor.................................1032 Engine Coolant Temperature (ECT) Sensor.................................1032 MSTS Module Corrections.................................................1033 Troubleshooting.............................................................1034 General.................................................................1034 Tools and Test Equipment................................................1036 MSTS....................................................................1037 Troubleshooting Procedure...............................................1037 Where to Start......................................................1037 Visual/Physical Inspection..........................................1037 Knowledge/Tools Required............................................1037 Damage from Static Discharge (Static Electricity)...................1037 Troubleshooting Information.............................................1038 Malfunction Indicator Lamp (MIL)....................................1038 Connecting CodeMate Tester..........................................1038 Reading Diagnostic Trouble Codes (DTC)..............................1039 Clearing Diagnostic Trouble Codes (DTC's)...........................1040 On-Board Diagnostic (OBD) System Check..................................1040 Test Description....................................................1040 No Malfunction Indicator Lamp...............................................1042 Circuit Description.....................................................1042 Test Description........................................................1042 No DTC-12, Malfunction Indicator Lamp ON....................................1044 Circuit Description.....................................................1044 Test Description........................................................1044 Starter Rotates Engine, Engine Does Not Run.................................1045 Test Description........................................................1045 DTC-14 Engine Coolant Temperature (ECT) (Low Temperature Indicat............1049 Circuit Description.....................................................1049 Test Description........................................................1049 DTC-15 Engine Coolant Temperature Sensor (ECT) (High Temperature............1051 Circuit Description.....................................................1051 Test Description........................................................1051 DTC-34 Manifold Absolute Pressure (MAP) Sensor..............................1053 Circuit Description.....................................................1053 Test Description........................................................1053 DTC-41 Electronic Spark Timing (EST) Open Circuit...........................1056 Circuit Description.....................................................1056 Test Description........................................................1056 DTC-42 Electronic Spark Timing (EST) Grounded Circuit.......................1058 Circuit Description.....................................................1058 Test Description........................................................1058 DTC-51 MSTS Failure.........................................................1060 Circuit Description.....................................................1060 Distributor Repair..........................................................1060 Remove..................................................................1060 Disassemble.............................................................1061 Inspect.................................................................1061 Assemble................................................................1061 Install.................................................................1062 Ignition Timing.........................................................1062 Ignition Module Repair......................................................1063 Test For Fault..........................................................1063 Replace.................................................................1064 Sensing Coil Repair.........................................................1064 Test For Fault..........................................................1064 Replace.................................................................1064 Ignition Coil Repair........................................................1065 Test For Fault..........................................................1065 Remove..................................................................1065 Install.................................................................1065 MSTS Module Repair..........................................................1066 Remove..................................................................1066 Install.................................................................1066 ECT Sensor Replacement......................................................1066 MAP Sensor Replacement......................................................1067 tables..........................................................................1023 Table 1. MSTS Module Connections............................................1035 Table 2. Pressure Conversion Chart..........................................1036 Table 3. MSTS Diagnostic Codes..............................................1038
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