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Hyster F006 (H6.00-7.00XL Europe) Service Manual – PDF DOWNLOAD
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Hyster F006 (H6.00-7.00XL Europe) Service Manual – PDF DOWNLOAD
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Description
Hyster F006 (H6.00-7.00XL Europe) Service Manual – PDF DOWNLOAD
DESCRIPTION:
Hyster F006 (H6.00-7.00XL Europe) 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 (H6.00-7.00XL Europe) Service Manual – PDF DOWNLOAD
897104-0100SRM0322-(02-2007)-UK-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)-UK-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)-UK-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)-UK-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)-UK-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)-UK-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)-UK-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)-UK-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-(09-1997)-UK-EN.............................................................................................. 237 ELECTRICAL SCHEMATIC (GASOLINE & LPG)....................................................................................... 237 ELECTRICAL SCHEMATIC (DIESEL, PERKINS 4.2482)............................................................................... 239 ELECTRICAL SCHEMATIC (DIESEL, PERKINS 1004.4)............................................................................... 241 HYDRAULIC SCHEMATIC......................................................................................................... 243 HYDRAULIC SCHEMATIC, POWERSHIFT TRANSMISSION WITH MANUAL CONTROL............................................................ 244 HYDRAULIC SCHEMATIC, POWERSHIFT TRANSMISSION WITH MONOTROL PEDAL............................................................ 245 897123-8000SRM0341-(06-2007)-UK-EN.............................................................................................. 246 toc......................................................................................................................... 246 Periodic Maintenance.................................................................................................... 246 Safety Precautions Maintenance and Repair............................................................................... 247 General................................................................................................................. 252 Serial Number Data.................................................................................................. 252 How to Move Disabled Truck.......................................................................................... 252 How to Tow Lift Truck........................................................................................... 252 How to Put Lift Truck on Blocks..................................................................................... 253 How to Raise Drive Tires........................................................................................ 253 How to Raise Steering Tires..................................................................................... 253 Maintenance Schedule.................................................................................................... 254 Maintenance Procedures Every 8 Hours or Daily........................................................................... 267 How to Make Checks With Engine Stopped.............................................................................. 267 Hydraulic System Oil............................................................................................ 267 Engine Oil...................................................................................................... 269 Drive Belts..................................................................................................... 269 Intake Manifold Rubber Cap...................................................................................... 270 Cooling System.................................................................................................. 270 Air Filter...................................................................................................... 270 Fuel System..................................................................................................... 271 Primary Fuel Filter, Diesel Engine.............................................................................. 271 Battery......................................................................................................... 271 Tires and Wheels................................................................................................ 271 Forks........................................................................................................... 272 Adjust...................................................................................................... 272 Remove and Install.......................................................................................... 274 Forks, Mast, and Lift Chains, Inspect........................................................................... 275 Operator Restraint System....................................................................................... 276 Automatic Locking Retractor (ALR)........................................................................... 276 Emergency Locking Retractor (ELR)........................................................................... 276 Safety Labels................................................................................................... 277 How to Make Checks With Engine Running.............................................................................. 278 Gauges, Lights, Horn, and Fuses................................................................................. 278 Oil Level, Powershift Transmission.............................................................................. 279 Oil Level, Oil Clutch System, H3.50-5.00XL (H70-110XL).......................................................... 280 Control Levers and Pedals....................................................................................... 280 Lift System Operation........................................................................................... 280 Inching/Brake Pedal............................................................................................. 280 Service Brakes.................................................................................................. 280 Parking Brake................................................................................................... 281 Steering System................................................................................................. 281 Maintenance Procedures Every 250 Hours or 6 Weeks....................................................................... 281 Engine Oil and Filter, GM V-6 Engine................................................................................ 281 Lift Chains, Lubrication............................................................................................ 281 Drive Shafts........................................................................................................ 281 Mast Lubrication.................................................................................................... 282 Crankcase Breather, GM V-6.......................................................................................... 283 Air Filter, GM V-6 EPA Compliant Engine ............................................................................ 283 Maintenance Procedures Every 350 Hours or 2 Months...................................................................... 284 Engine Oil and Filter, Perkins 4.2482 Diesel Engine................................................................. 284 Drive Belts......................................................................................................... 284 Perkins Diesel Engine........................................................................................... 284 GM V-6 Engine (Early Models).................................................................................... 284 GM V-6 Engine (Late Models)..................................................................................... 285 Brake Fluid......................................................................................................... 287 Lift Chains Wear Check.............................................................................................. 287 Forks Wear and Damage Check......................................................................................... 287 Steering Axle Lubrication........................................................................................... 287 Fuel System, Checks and Adjustments................................................................................. 288 Diesel Fuel System.............................................................................................. 288 LPG Carburetor (Early Models)................................................................................... 288 Gasoline Carburetor (Early Models).............................................................................. 289 Fuel Injection (Late Models).................................................................................... 289 Crankcase Breather, Perkins 4.2482 Diesel Engine.................................................................... 289 Hydraulic Tank Breather............................................................................................. 289 Cooling System, Clean Debris from Radiator Core..................................................................... 289 Maintenance Procedures Every 500 Hours or 3 Months...................................................................... 290 Engine Oil and Filter, Perkins Diesel Engine........................................................................ 290 Crankcase Breather, Perkins Diesel Engine........................................................................... 290 PCV Valve, GM V-6................................................................................................... 290 Maintenance Procedures Every 1000 Hours or 6 Months..................................................................... 290 Manifold Heat Valve, GM V-6 (Early Models).......................................................................... 290 Ignition System, GM V-6............................................................................................. 290 Valve Clearance Adjustment.......................................................................................... 290 Fuel Filter, Replace (Diesel Engine)................................................................................ 291 Fuel System Air Removal (Perkins 1004-4 Diesel Engine).............................................................. 291 Fuel Injection Pump With Vent Tube.............................................................................. 291 Fuel Injection Pump With Vent Screw............................................................................. 292 Fuel System Air Removal (Perkins 4.2482 Diesel Engine).............................................................. 294 Oil Level Check in Transmission..................................................................................... 294 Manual Transmission, H3.50-5.00XL (H70-110XL)................................................................... 294 Speed Reducer for Powershift Transmission, H3.50-5.00XL (H70-110................................................ 294 Manual Transmission, H6.00-7.00XL (H135-155XL).................................................................. 294 Differential and Drive Axle for Powershift Transmission, H6.00-7................................................ 294 Differential, Speed Reducer, and Drive Axle for Manual Transmiss................................................ 295 Control Levers and Pedals, Lubricate................................................................................ 295 Crankcase Breather, Replace......................................................................................... 295 Cooling System, GM V-6 EPA Compliant Engine......................................................................... 295 Spark Plug Replacement.............................................................................................. 295 Remove.......................................................................................................... 295 Install......................................................................................................... 296 LPG Fuel Filter GM V-6 EPA Compliant Engine, Replace................................................................ 296 Inspect Engine Electrical System, Connectors, and FCVS Connectio.................................................... 297 Maintenance Procedures Every 2000 Hours or Yearly....................................................................... 297 Hydraulic System.................................................................................................... 297 Hydraulic Oil and Filter, H3.50-5.00XL (H70-110XL), Replace..................................................... 297 Hydraulic Oil and Filter, H6.00-7.00XL (H135-155XL, H135-155XL 2................................................ 298 Oil Change and Oil Filter Replacement, Powershift Transmission, .................................................... 298 Oil Change, Manual Transmission, H3.50-5.00XL (H70-110XL)........................................................... 298 Oil Change, Manual Transmission, H6.00-7.00XL (H135-155XL).......................................................... 298 Oil Change, Speed Reducer, Powershift Transmission, H3.50-5.00XL.................................................... 298 Oil and Filter Change, Oil Clutch System, H3.50-5.00XL (H70-110X.................................................... 299 Oil Change, Differential and Drive Axle, Powershift Transmission.................................................... 299 Oil Change, Differential, Speed Reducer, and Drive Axle, Manual .................................................... 299 Cooling System...................................................................................................... 299 PCV Valve, GM V-6................................................................................................... 299 Service Brakes...................................................................................................... 300 LPG Filter, Replace................................................................................................. 300 Gasoline Fuel Filter, Replace....................................................................................... 301 Hood Latch Check, H3.50-5.00XL (H70-110XL).......................................................................... 301 Air Filter Element, GM V-6 EPA Compliant Engine..................................................................... 301 Oxygen Sensor GM V-6 EPA Compliant Engine........................................................................... 301 Inspect Low Pressure Regulator (LPR) for Oil Buildup and Leaks...................................................... 302 Check Throttle Shaft for Sticking................................................................................... 303 Inspect Exhaust Manifold and Piping for Leaks....................................................................... 303 Test LPG/GAS Regulator Pressure..................................................................................... 303 Safety Procedures When Working Near Mast................................................................................ 303 Lift Chain Adjustments.................................................................................................. 305 Fuel Injectors Repair................................................................................................... 307 Lift and Tilt System Leak Check......................................................................................... 308 Lift Cylinders, Leak Check.......................................................................................... 308 Tilt Cylinders, Leak Check.......................................................................................... 308 Welding Repairs......................................................................................................... 309 Overhead Guard Changes.................................................................................................. 309 Wheel and Tire Replacement.............................................................................................. 310 Remove Wheels From Lift Truck....................................................................................... 310 Remove Wheels From Tire............................................................................................. 310 Remove Tire From Two-Piece Wheel................................................................................ 312 Remove Tire From Three- and Four-Piece Wheels................................................................... 314 Install Wheel in Tire............................................................................................... 315 Install Three- or Four-Piece Wheel in Tire...................................................................... 316 Install Two-Piece Wheel in Tire................................................................................. 317 Add Air to Pneumatic Tires.......................................................................................... 318 Wheels, Install..................................................................................................... 318 Solid Rubber Tires Repair............................................................................................... 319 Wheel, Tire Remove.................................................................................................. 319 Wheel, Tire Install................................................................................................. 321 SIT Tire, Change for H3.50-5.00XL (G005), and H6.00-7.00XL (F006.................................................... 323 Remove SIT Solid Tire From Wheel................................................................................ 323 Install SIT Solid Tire on Wheel................................................................................. 324 Adhesives and Sealants.................................................................................................. 325 Hydraulic Oil, Lubricant, and Coolant Specifications.................................................................... 326 tables...................................................................................................................... 246 Table 1. Maintenance Schedule........................................................................................... 256 Table 2. Hook-Type Carriage Chain Adjustment............................................................................ 306 Table 3. Pin-Type Carriage Chain Adjustment............................................................................. 306 897125-1300SRM0344-(07-1993)-UK-EN.............................................................................................. 330 INTRODUCTION................................................................................................................ 330 GENERAL................................................................................................................. 330 DESCRIPTION............................................................................................................. 330 OPERATION............................................................................................................... 331 REPAIRS..................................................................................................................... 331 REMOVAL................................................................................................................. 331 DISASSEMBLY............................................................................................................. 331 CLEANING AND INSPECTION................................................................................................. 332 ASSEMBLY................................................................................................................ 332 INSTALLATION............................................................................................................ 334 CHECKS AND ADJUSTMENTS...................................................................................................... 334 ADJUST THE DIRECTION CONTROL LINKAGE.................................................................................... 334 897129-0900SRM0348-(09-2001)-UK-EN.............................................................................................. 335 toc......................................................................................................................... 335 LPG Fuel System......................................................................................................... 335 Safety Precautions Maintenance and Repair............................................................................... 336 General................................................................................................................. 339 Description and Operation............................................................................................... 341 Fuel Tank........................................................................................................... 341 Fuel Filter and Fuel Valve Unit..................................................................................... 342 Vaporizer........................................................................................................... 343 Carburetor.......................................................................................................... 344 Governor............................................................................................................ 346 LPG Tank Repair......................................................................................................... 347 Remove.............................................................................................................. 347 LPG Tanks with Fixed Mounting Bracket........................................................................... 347 LPG Tanks with EZ Lift Mounting Bracket......................................................................... 347 Install............................................................................................................. 348 LPG Tanks with Fixed Mounting Bracket........................................................................... 348 LPG Tanks with EZ Lift Mounting Bracket......................................................................... 349 Hydrostatic Relief Valve Repair......................................................................................... 350 Remove and Install.................................................................................................. 350 Filter Unit Repair...................................................................................................... 350 Fuel Filter Element, Replace........................................................................................ 350 Diaphragm and Fuel Valve, Replace................................................................................... 350 Hoses Replacement....................................................................................................... 352 Vaporizer Repair........................................................................................................ 352 Remove.............................................................................................................. 352 Disassemble......................................................................................................... 352 Clean............................................................................................................... 352 Inspect............................................................................................................. 352 Assemble............................................................................................................ 354 Install............................................................................................................. 357 Carburetor Repair....................................................................................................... 358 Remove.............................................................................................................. 358 Disassemble......................................................................................................... 358 Clean............................................................................................................... 358 Assemble............................................................................................................ 358 Install............................................................................................................. 358 Governor Repair......................................................................................................... 359 Filter Unit Check....................................................................................................... 361 Vaporizer Check......................................................................................................... 361 Pressure Reducer Valve.............................................................................................. 361 Vapor Valve......................................................................................................... 361 Carburetor Adjustment................................................................................................... 361 Idle Mixture........................................................................................................ 361 Idle Speed.......................................................................................................... 361 Power Mixture....................................................................................................... 362 Throttle Linkage Adjustment............................................................................................. 362 Troubleshooting......................................................................................................... 364 897341-0600SRM0412-(08-1997)-UK-EN.............................................................................................. 371 PERKINS DIESEL ENGINES, SERIES 1000......................................................................................... 371 1.1 GENERAL............................................................................................................. 371 GENERAL SAFETY RULES.................................................................................................... 371 Viton Seals......................................................................................................... 371 1.2 DESCRIPTION......................................................................................................... 374 1.3 Engine Serial Number Codes...................................................................................... 374 1.4 Engine Data..................................................................................................... 374 1.5 1004–4 ENGINE................................................................................................... 375 1.6 1004–4T ENGINE.................................................................................................. 375 1.7 1006–6 ENGINE................................................................................................... 375 1.8 1006–6T ENGINE.................................................................................................. 375 1.9 REMOVAL AND INSTALLATION............................................................................................ 375 CYLINDER HEAD ASSEMBLY...................................................................................................... 376 1.10 VALVE COVER........................................................................................................ 376 1.11 Removal........................................................................................................ 376 1.12 Installation................................................................................................... 376 1.13 ROCKER ARM ASSEMBLY................................................................................................ 376 1.14 Removal........................................................................................................ 376 1.15 Installation................................................................................................... 376 1.16 Disassembly.................................................................................................... 377 1.17 Inspection..................................................................................................... 377 1.18 Assembly....................................................................................................... 377 1.19 VALVE CLEARANCE ADJUSTMENTS........................................................................................ 377 1.20 Four Cylinder Engines.......................................................................................... 378 1.21 Six Cylinder Engines........................................................................................... 378 1.22 VALVE SPRINGS...................................................................................................... 378 1.23 CYLINDER HEAD ASSEMBLY............................................................................................. 380 1.24 Removal........................................................................................................ 380 1.25 Installation................................................................................................... 381 1.26 VALVES AND VALVE SPRINGS........................................................................................... 384 1.27 Removal........................................................................................................ 384 1.28 Inspection..................................................................................................... 385 1.29 Installation................................................................................................... 385 1.30 VALVE GUIDES....................................................................................................... 385 1.31 Inspection..................................................................................................... 385 1.32 Removal........................................................................................................ 386 1.33 Installation................................................................................................... 386 1.34 CYLINDER HEAD AND VALVE SEATS...................................................................................... 386 1.35 Inspection..................................................................................................... 386 1.36 Repair......................................................................................................... 387 1.37 Installation Of New Valve Seats................................................................................ 387 PISTON AND CONNECTING ROD ASSEMBLIES........................................................................................ 388 1.38 ROD BEARINGS....................................................................................................... 388 1.39 Removal........................................................................................................ 388 1.40 Installation................................................................................................... 389 1.41 PISTON AND CONNECTING ROD ASSEMBLY................................................................................. 389 1.42 Service Note................................................................................................... 389 1.43 Removal........................................................................................................ 389 1.44 Installation................................................................................................... 390 1.45 PISTON RINGS....................................................................................................... 391 1.46 Removal........................................................................................................ 391 1.47 Inspection..................................................................................................... 391 1.48 Installation................................................................................................... 392 1.49 PISTON AND CONNECTING ROD.......................................................................................... 393 1.50 Disassembly.................................................................................................... 393 1.51 Inspection..................................................................................................... 393 1.52 Installation................................................................................................... 393 1.53 PISTON COOLING JETS................................................................................................ 394 1.54 Removal........................................................................................................ 394 1.55 Installation................................................................................................... 394 CRANKSHAFT ASSEMBLY......................................................................................................... 395 1.56 GENERAL............................................................................................................ 395 1.57 CRANKSHAFT PULLEY.................................................................................................. 395 1.58 Removal, Engines AA and AB..................................................................................... 395 1.59 Installation, Engines AA and AB................................................................................ 395 1.60 Removal, Engines YA and YB..................................................................................... 395 1.61 Installation, Engines YA and YB................................................................................ 395 1.62 REAR OIL SEAL...................................................................................................... 396 1.63 Replacement.................................................................................................... 396 1.64 MAIN BEARINGS...................................................................................................... 397 1.65 Removal........................................................................................................ 397 1.66 Installation................................................................................................... 397 1.67 THRUST WASHERS..................................................................................................... 398 1.68 Check The Axial Movement Of The Crankshaft..................................................................... 398 1.69 Removal........................................................................................................ 399 1.70 Installation................................................................................................... 399 1.71 CRANKSHAFT......................................................................................................... 399 1.72 Removal........................................................................................................ 399 1.73 Inspection..................................................................................................... 400 1.74 Installation................................................................................................... 400 TIMING CASE AND TIMING GEARS................................................................................................ 402 1.75 GENERAL............................................................................................................ 402 1.76 TIMING CASE COVER.................................................................................................. 402 1.77 Removal........................................................................................................ 402 1.78 Installation................................................................................................... 402 1.79 FRONT OIL SEAL..................................................................................................... 403 1.80 Removal........................................................................................................ 403 1.81 Installation................................................................................................... 403 1.82 IDLER GEAR AND HUB................................................................................................. 403 1.83 Removal........................................................................................................ 403 1.84 Installation................................................................................................... 404 1.85 GEAR FOR THE FUEL INJECTION PUMP OR THE CAMSHAFT GEAR.............................................................. 405 1.86 Removal........................................................................................................ 405 1.87 Installation................................................................................................... 405 1.88 CRANKSHAFT GEAR.................................................................................................... 406 1.89 Removal........................................................................................................ 406 1.90 Installation................................................................................................... 406 1.91 TIMING CASE........................................................................................................ 406 1.92 Removal........................................................................................................ 406 1.93 Installation................................................................................................... 406 1.94 CAMSHAFT AND TAPPETS............................................................................................... 407 1.95 Removal........................................................................................................ 408 1.96 Installation................................................................................................... 408 ENGINE BLOCK ASSEMBLY....................................................................................................... 409 1.97 DESCRIPTION........................................................................................................ 409 1.98 ENGINE BLOCK....................................................................................................... 409 1.99 Disassembly.................................................................................................... 409 1.100 Inspection.................................................................................................... 410 1.101 Assembly...................................................................................................... 410 1.102 CYLINDER LINER.................................................................................................... 410 1.103 Inspection.................................................................................................... 410 1.104 Hone.......................................................................................................... 411 1.105 Removal....................................................................................................... 411 1.106 Installation.................................................................................................. 412 TURBOCHARGER, ENGINES AB AND YB............................................................................................. 413 1.107 GENERAL........................................................................................................... 413 1.108 Removal....................................................................................................... 413 1.109 Installation.................................................................................................. 414 1.110 Clean The Impeller And Compressor Housing..................................................................... 414 LUBRICATION SYSTEM.......................................................................................................... 415 1.111 GENERAL........................................................................................................... 415 1.112 OIL FILTER, REPLACEMENT........................................................................................... 415 1.113 OIL SUMP.......................................................................................................... 416 1.114 Removal....................................................................................................... 416 1.115 Installation.................................................................................................. 416 1.116 OIL PUMP.......................................................................................................... 416 1.117 Removal....................................................................................................... 416 1.118 Inspection.................................................................................................... 417 1.119 Installation.................................................................................................. 417 1.120 RELIEF VALVE...................................................................................................... 418 1.121 Removal....................................................................................................... 418 1.122 Disassembly................................................................................................... 418 1.123 Inspection.................................................................................................... 419 1.124 Installation.................................................................................................. 419 FUEL SYSTEM................................................................................................................. 419 1.125 DESCRIPTION....................................................................................................... 419 1.126 CAV FUEL INJECTION PUMP........................................................................................... 420 1.127 Removal....................................................................................................... 420 1.128 Installation.................................................................................................. 420 1.129 CAV FUEL INJECTION PUMP, CHECKS AND ADJUSTMENTS................................................................... 421 1.130 Timing Gear Marks............................................................................................. 421 1.131 How To Set Number 1 Piston To TDC On The Compression Stroke................................................... 422 1.132 Check The Valve Timing........................................................................................ 422 1.133 Check The Timing Of The Fuel Injection Pump................................................................... 423 1.134 Check The Timing Mark Of The Fuel Injection Pump.............................................................. 423 1.135 Check The Engine Timing Mark.................................................................................. 424 1.136 REMOVE AIR FROM THE FUEL SYSTEM................................................................................... 425 1.137 Fuel Injection Pump With Vent Tube............................................................................ 425 1.138 Fuel Injection Pump With Vent Screw........................................................................... 426 1.139 FUEL FILTER (REPLACEMENT)......................................................................................... 427 1.140 FUEL INJECTORS.................................................................................................... 427 1.141 Removal....................................................................................................... 427 1.142 Inspection.................................................................................................... 428 1.143 Installation.................................................................................................. 429 1.144 FUEL PUMP......................................................................................................... 429 1.145 Removal....................................................................................................... 429 1.146 Disassembly................................................................................................... 429 1.147 Assembly...................................................................................................... 430 1.148 Installation.................................................................................................. 430 1.149 Test.......................................................................................................... 431 COOLING SYSTEM.............................................................................................................. 431 1.150 GENERAL........................................................................................................... 431 1.151 THERMOSTAT........................................................................................................ 431 1.152 Replacement................................................................................................... 431 1.153 COOLANT PUMP...................................................................................................... 432 1.154 Removal....................................................................................................... 432 1.155 Disassembly................................................................................................... 432 1.156 Assembly...................................................................................................... 433 1.157 Installation.................................................................................................. 433 1.158 FAN AND FAN DRIVE................................................................................................. 433 1.159 Removal....................................................................................................... 433 1.160 Disassembly................................................................................................... 433 1.161 Assembly...................................................................................................... 434 1.162 Installation.................................................................................................. 434 1.163 OIL COOLER........................................................................................................ 434 1.164 Removal, Engine AB............................................................................................ 434 1.165 Removal, Engines YA and YB.................................................................................... 434 1.166 Disassembly And Assembly...................................................................................... 435 1.167 Installation, Engine AB....................................................................................... 435 1.168 Installation, Engines YA and YB............................................................................... 436 1.169 By–Pass Valve, Oil Cooler..................................................................................... 436 FLYWHEEL AND FLYWHEEL HOUSING............................................................................................... 436 1.170 GENERAL........................................................................................................... 436 1.171 FLYWHEEL.......................................................................................................... 436 1.172 Removal....................................................................................................... 436 1.173 Ring Gear (Replacement)....................................................................................... 436 1.174 Installation.................................................................................................. 436 1.175 FLYWHEEL HOUSING.................................................................................................. 437 1.176 Removal....................................................................................................... 437 1.177 Installation.................................................................................................. 437 ELECTRICAL EQUIPMENT........................................................................................................ 438 1.178 DRIVE BELTS....................................................................................................... 438 1.179 ALTERNATOR........................................................................................................ 439 1.180 STARTER MOTOR..................................................................................................... 439 1.181 Removal....................................................................................................... 439 1.182 Installation.................................................................................................. 439 1.183 COLD START AID.................................................................................................... 439 AIR COMPRESSOR, ENGINES YA AND YB........................................................................................... 439 1.184 GENERAL........................................................................................................... 439 1.185 Air Compressor, Removal, WABCO................................................................................ 439 1.186 Compressor Drive, Inspection.................................................................................. 440 1.187 Air Compressor, Installation, WABCO........................................................................... 440 1.188 Compressor Drive, Disassembly, WABCO.......................................................................... 440 1.189 Compressor Drive, Assembly, WABCO............................................................................. 441 1.190 Air Compressor, Removal, BENDIX............................................................................... 441 1.191 Air Compressor, Installation, BENDIX.......................................................................... 442 1.192 Compressor Drive, Disassembly, BENDIX......................................................................... 443 1.193 Compressor Drive, Assembly, BENDIX............................................................................ 443 ENGINE SPECIFICATIONS....................................................................................................... 445 1.194 CYLINDER HEAD ASSEMBLY............................................................................................ 445 1.195 Cylinder Head................................................................................................. 445 1.196 Valve Guides.................................................................................................. 445 1.197 Inlet Valves.................................................................................................. 446 1.198 Exhaust Valves................................................................................................ 446 1.199 Double Valve Springs To Outer................................................................................. 446 1.200 Double Valve Springs To Inner................................................................................. 446 1.201 Single Valve Springs.......................................................................................... 446 1.202 Tappets....................................................................................................... 446 1.203 Rocker Arm Shaft.............................................................................................. 446 1.204 Rocker Arms And Bushings...................................................................................... 447 1.205 PISTON AND CONNECTING RODS........................................................................................ 447 1.206 Pistons, Engines AA And YA.................................................................................... 447 1.207 Pistons, Engines AB And YB.................................................................................... 447 1.208 Piston Rings, Engines AA And YA............................................................................... 447 1.209 Piston Rings, Engines AB And YB............................................................................... 447 1.210 Connecting Rods, Engines AB And YB............................................................................ 448 1.211 Connecting Rods, Engines AB And YB............................................................................ 448 1.212 Piston Pins, Engines AA And YA................................................................................ 448 1.213 Piston Pins, Engines AB and YB................................................................................ 448 1.214 Small End Bushings, Engines AA And YA......................................................................... 448 1.215 Small End Bushings, Engines AB And YB......................................................................... 448 1.216 Connecting Rod Bearings, Engines AA And YA.................................................................... 449 1.217 Connecting Rod Bearings, Engines AB And YB.................................................................... 449 1.218 Piston Cooling Jets, Engines AB And YB........................................................................ 449 1.219 CRANKSHAFT ASSEMBLY............................................................................................... 449 1.220 Crankshaft.................................................................................................... 449 1.221 Crankshaft Heat Treatment..................................................................................... 449 1.222 Crankshaft Overhaul........................................................................................... 449 1.223 Main Bearings................................................................................................. 451 1.224 Crankshaft Thrust Washers..................................................................................... 451 1.225 TIMING CASE AND DRIVE ASSEMBLY.................................................................................... 451 1.226 Camshaft...................................................................................................... 451 1.227 Camshaft Thrust Washer........................................................................................ 451 1.228 Camshaft Gear................................................................................................. 452 1.229 Gear For Fuel Injection Pump.................................................................................. 452 1.230 Crankshaft Gear............................................................................................... 452 1.231 Idler Gear And Hub............................................................................................ 452 1.232 ENGINE BLOCK ASSEMBLY............................................................................................. 452 1.233 Engine Block.................................................................................................. 452 1.234 Cylinder Liners............................................................................................... 452 1.235 TURBOCHARGER...................................................................................................... 453 1.236 LUBRICATION SYSTEM................................................................................................ 453 1.237 Oil Pump, Engines AA And AB................................................................................... 453 1.238 Oil Pump, Engines YA And YB................................................................................... 453 1.239 Relief Valve.................................................................................................. 453 1.240 Oil Filter.................................................................................................... 453 1.241 FUEL SYSTEM....................................................................................................... 453 1.242 Cav Fuel Injection Pump....................................................................................... 453 1.243 FUEL INJECTORS................................................................................................ 454 1.244 Fuel Pump, Engines AA And AB.................................................................................. 455 1.245 Fuel Pump, Engines YA And YB.................................................................................. 455 1.246 Fuel Filter................................................................................................... 455 1.247 COOLING SYSTEM.................................................................................................... 455 1.248 Coolant Pump.................................................................................................. 455 1.249 Thermostat.................................................................................................... 456 1.250 Fan Drive Housing............................................................................................. 456 1.251 FLYWHEEL AND HOUSING.............................................................................................. 456 1.252 Limits for flywheel ''run out'' and alignment (total indicator reading)....................................... 456 1.253 ELECTRICAL EQUIPMENT.............................................................................................. 456 1.254 Alternator.................................................................................................... 456 1.255 Starter Motor................................................................................................. 456 1.256 Cold Start Aid................................................................................................ 456 TORQUE SPECIFICATIONS....................................................................................................... 457 SPECIAL TOOLS............................................................................................................... 458 897412-2200SRM0463-(04-1993)-UK-EN.............................................................................................. 462 MICROPROCESSOR SPARK TIMING SYSTEM (MSTS)................................................................................... 462 GENERAL................................................................................................................. 462 DESCRIPTION............................................................................................................. 462 What MSTS Does...................................................................................................... 464 How MSTS Begins Operation........................................................................................... 464 OPERATION............................................................................................................... 464 Pulse Generator..................................................................................................... 464 HEI Module.......................................................................................................... 465 When the Engine Is Being Started.................................................................................... 465 When the Engine Is Running.......................................................................................... 467 Manifold Absolute Pressure (MAP).................................................................................... 467 Coolant Temperature Sensor (CTS).................................................................................... 467 Electronic Control Module (ECM), Corrections........................................................................ 468 The Initial Timing Connector........................................................................................ 468 Gasoline and LPG Conversions........................................................................................ 469 TROUBLESHOOTING............................................................................................................. 471 GENERAL................................................................................................................. 471 TOOLS AND TEST EQUIPMENT................................................................................................ 471 MSTS TROUBLESHOOTING.................................................................................................... 472 Test Description.................................................................................................... 472 IGNITION SYSTEM TROUBLESHOOTING......................................................................................... 474 Test Description.................................................................................................... 474 ELECTRONIC SPARK TIMING (EST) TROUBLESHOOTING........................................................................... 477 Circuit Description................................................................................................. 477 Test Description.................................................................................................... 477 MANIFOLD ABSOLUTE PRESSURE (MAP) TROUBLESHOOTING........................................................................ 480 Circuit Description................................................................................................. 480 Test Description.................................................................................................... 480 COOLANT TEMPERATURE SENSOR (CTS) TROUBLESHOOTING........................................................................ 483 Circuit Description................................................................................................. 483 Test Description.................................................................................................... 483 REPAIRS..................................................................................................................... 485 DISTRIBUTOR............................................................................................................. 485 Removal............................................................................................................. 485 Disassembly......................................................................................................... 486 Inspection.......................................................................................................... 486 Assembly............................................................................................................ 487 Installation........................................................................................................ 487 Igntion Timing...................................................................................................... 487 HEI MODULE.............................................................................................................. 488 Test For A Fault.................................................................................................... 488 HEI Module Replacement.............................................................................................. 488 SENSING COIL............................................................................................................ 489 Test For A Fault.................................................................................................... 489 Sensing Coil Replacement............................................................................................ 489 IGNITION COIL........................................................................................................... 489 Test For A Fault.................................................................................................... 489 ELECTRONIC CONTROL MODULE (ECM)......................................................................................... 490 Removal............................................................................................................. 490 Installation........................................................................................................ 490 COOLANT TEMPERATURE SENSOR (CTS)........................................................................................ 490 Removal............................................................................................................. 490 Installation........................................................................................................ 491 MANIFOLD ABSOLUTE PRESSURE (MAP)........................................................................................ 491 Removal............................................................................................................. 491 Installation........................................................................................................ 491 PRESSURE CONVERSION CHART........................................................................................... 492 897420-2200SRM0468-(05-1996)-UK-EN.............................................................................................. 493 ELECTRONIC ENGINE CONTROL, TROUBLESHOOTING AND REPAIR....................................................................... 493 GENERAL................................................................................................................. 493 Engine Data......................................................................................................... 493 LIGHT BULB CHECK........................................................................................................ 493 SYSTEM CHECK............................................................................................................ 495 TROUBLESHOOTING WITH THE FAULT MONITOR SYSTEM IN THE ECM................................................................ 495 How To Clear A Code................................................................................................. 496 Fault In The ECM.................................................................................................... 496 Fault In The PROM................................................................................................... 497 CalPak Not Installed................................................................................................ 497 Fuel Control........................................................................................................ 497 Idle Air Control (IAC).............................................................................................. 497 Fuel Pump Circuit................................................................................................... 497 Coolant Temperature Sensor (CTS).................................................................................... 498 Manifold Absolute Pressuer Sensor (MAP)............................................................................. 498 Throttle Position Sensodr (TPS)..................................................................................... 498 Output Check, Throttle Position Sensor.............................................................................. 498 Electronic Spark Timing............................................................................................. 498 Engine Crank Signal................................................................................................. 499 Distributor Reference Signal........................................................................................ 499 TROUBLESHOOTING CHARTS...................................................................................................... 500 CHART A-1-No "Check Engine" Light....................................................................................... 500 Circuit Description, "Check Engine" Light........................................................................... 500 CHART A-1-No "Check Engine" Light....................................................................................... 501 CHART A-2-No ALDL Data Or No Code 12 From "Check Engine" Light. The "Check Engine" Light Is Continuosly Illuminated..... 502 Circuit Description, "Check Engine" Light........................................................................... 502 CHART A-2-No ALDL Data Or No Code 12 From "Check Engine" Light. The "Check Engine" Light Is Continuously Illuminated.... 503 CHART A-3-Starter Cranks The Engine, But Will Not Run................................................................... 504 Circuit Description................................................................................................. 505 CHART A-4-Fuel Injector Circuit......................................................................................... 506 Circuit Description................................................................................................. 506 CHART A-5-Fuel Pump Relay Circuit....................................................................................... 508 Circuit Description................................................................................................. 508 CHART A-6-Fuel System Pressure Test..................................................................................... 510 Circuit Description................................................................................................. 510 CHART A-7-MAP Output Check.............................................................................................. 512 Circuit Description................................................................................................. 512 CHART A-8-Engine Crank Signal Check..................................................................................... 514 Circuit Description................................................................................................. 514 CHART A-9-Ignition System Troubleshooting............................................................................... 515 CHART A-9 Ignition System Troubleshooting Chart......................................................................... 516 CHART A-10-Idle Air Control (IAC) System................................................................................ 518 Circuit Description................................................................................................. 518 FAULT CODES................................................................................................................. 520 CODE 14-Coolant Temperature Sensor Circuit (Indicates High Temperature)................................................. 520 Circuit Description................................................................................................. 520 CODE 15-Coolant Temperature Sensor Circuit (Indicates Low Temperature................................................... 522 Circuit Description................................................................................................. 522 CODE 21-Throttle Position Sensor Circuit (Signal Voltage High) ......................................................... 524 Circuit Description................................................................................................. 524 CODE 22-Throttle Position Sensor Circuit (Signal Voltage Low) .......................................................... 526 Circuit Description................................................................................................. 526 CODE 31-Engine Governor Circuit......................................................................................... 528 Circuit Description................................................................................................. 528 CODE 33-MAP Sensor Circuit, Signal Voltage High (Low Vacuum............................................................. 530 Circuit Description................................................................................................. 530 CODE 34-MAP Sensor Circuit, Signal Voltage Low (High Vacuum)............................................................ 532 Circuit Description................................................................................................. 532 CODE 42-Electronic Spark Timing (EST)................................................................................... 534 Circuit Description................................................................................................. 534 CODE 54-Fuel Pump Circuit (Low Voltage)................................................................................. 536 Circuit Description................................................................................................. 536 CODE 51-PROM In The ECM Has A Fault .................................................................................... 538 CODE 52-Fuel CalPak Is Missing.......................................................................................... 538 CODE 55-ECM Has A Fault................................................................................................. 538 TROUBLESHOOTING, POOR OPERATION......................................................................................... 538 General............................................................................................................. 538 Make A Careful Visual Check......................................................................................... 538 FAULT: Fuel Usage Too High.......................................................................................... 538 FAULT: Codes Or Performance That Is Not Regular..................................................................... 539 FAULT: "Dieseling".................................................................................................. 539 FAULT: "Backfire"................................................................................................... 539 FAULT: Rough Idle or Engine Stalls During Idle...................................................................... 539 FAULT: Smoke In The Exhaust Gases................................................................................... 540 FAULT: Engine is Difficult To Start................................................................................. 540 FAULT: Variation In Engine Power When The Throttle Is Held Steady................................................... 541 FAULT: Decreased Engine Power....................................................................................... 541 FAULT: "Detontion".................................................................................................. 541 FAULT: Engine Momentarily Does Not Increase Power When Throttle Changes............................................. 542 FAULT: One Cylinder In The Engine Does Not Operate Correctly. The Engine Does Not Idle Correctly.................... 542 REPAIRS, FUEL SYSTEM COMPONENTS ........................................................................................ 544 General............................................................................................................. 544 Vacuum Ports........................................................................................................ 544 Throttle Body Injection (TBI) Unit.................................................................................. 544 TBI Unit, Removal................................................................................................... 544 TBI Unit, Cleaning and Inspection................................................................................... 545 TBI Unit, Installation.............................................................................................. 545 Cover For Fuel Meter Body, Replacement.............................................................................. 545 Fuel Injectors...................................................................................................... 546 Fuel Injectors, Removal............................................................................................. 546 Fuel Injectors, Installation........................................................................................ 547 Pressure Regulator, Removal......................................................................................... 547 Pressure Regulator, Inspection...................................................................................... 547 Pressure Regulator, Installation ................................................................................... 547 Fuel Meter Body, Removal............................................................................................ 548 Fuel Meter Body, Installation....................................................................................... 548 Throttle Position Sensor (TPS), Removal............................................................................. 548 Throttle Position Sensor (TPS), Installation........................................................................ 548 Idle Air Control (IAC) Valve, Removal............................................................................... 549 Cleaning and Inspection............................................................................................. 549 Idle Air Control (IAC) Valve, Installation.......................................................................... 549 Governor Throttle Drive Assembly, Removal........................................................................... 549 Governor Throttle Drive Assembly, Inspection........................................................................ 549 Cleaning and Lubrication............................................................................................ 550 Governor Throttle Drive Assembly, Installation...................................................................... 550 Governor Drive Motor, Removal....................................................................................... 551 Governor Drive Motor, Cleaning and Lubrication...................................................................... 551 Governor Drive Motor, Installation.................................................................................. 552 Governor Drive Motor, Inspection.................................................................................... 552 Throttle Body, Removal and Disassembly.............................................................................. 552 Throttle Body, Inspection........................................................................................... 552 Throttle Body, Assembly and Installation............................................................................ 552 Fuel Pump, Removal and Disassembly.................................................................................. 553 Fuel Pump, Inspection............................................................................................... 553 REPAIRS, ELECTRICAL COMPONENTS.......................................................................................... 553 General............................................................................................................. 553 Ignition Coil Test.................................................................................................. 553 Ignition Module Test................................................................................................ 554 Distributor, Removal................................................................................................ 554 Distributor, Disassembly............................................................................................ 555 Distributor, Assembly............................................................................................... 555 Distributor, Installation........................................................................................... 556 Firing Order........................................................................................................ 557 Ignition Timing..................................................................................................... 557 Ignition Coil, Removal.............................................................................................. 558 Ignition Coil, Installation......................................................................................... 558 Procedures For Spark Plugs, Spark Plug Wires And Boots ............................................................. 558 Troubleshooting of Spark Plugs...................................................................................... 559 Coolant Temperature Sensor (CTS), Replacement ...................................................................... 560 Manifold Absolute Pressure (MAP) Sensor, Replacement................................................................ 560 Oil Pressure Switch, Replacement.................................................................................... 561 Coolant Temperature Sender, Replacement............................................................................. 561 Wire Harness........................................................................................................ 561 Connectors And Terminals............................................................................................ 561 Electronic Control Module (ECM)..................................................................................... 565 ECM CONNECTOR A-B IDENTIFICATION........................................................................................ 569 ECM CONNECTOR C-D IDENTIFICATION........................................................................................ 570 SPECIAL TOOLS............................................................................................................... 571 897435-2200SRM0473-(03-1994)-UK-EN.............................................................................................. 574 INTRODUCTION................................................................................................................ 574 GENERAL................................................................................................................. 574 DESCRIPTION AND OPERATION................................................................................................... 574 GENERAL................................................................................................................. 574 ECM (ELECTRONIC CONTROL MODULE)......................................................................................... 574 ALDL Connector...................................................................................................... 576 How The ECM Begins Operation........................................................................................ 576 ELECTRONIC ENGINE CONTROL............................................................................................... 577 What The ECM Does................................................................................................... 577 Pulse Generator, EST Distributor.................................................................................... 578 EST Module(See FIGURE 9.)........................................................................................... 579 When the Engine Is Being Started.................................................................................... 579 When the Engine Is Running.......................................................................................... 581 Electronic Control Module (ECM) With EST Distrubutor, Corrrections.................................................. 581 What The ECM Does................................................................................................... 581 FUEL CONTROL............................................................................................................ 582 Throttle Body Injection............................................................................................. 582 Fuel Injectors...................................................................................................... 583 Fuel Pressure Regulator............................................................................................. 583 Throttle Position Sensor............................................................................................ 583 Idle Air Control.................................................................................................... 583 Governor Motor And Throttle Drive Assembly.......................................................................... 584 Vacuum Ports........................................................................................................ 586 Fuel Pump........................................................................................................... 586 ECM SENSORS AND CONTROLLERS............................................................................................. 588 Manifold Absolute Pressure (MAP).................................................................................... 588 Coolant Temperature Sensor (CTS).................................................................................... 588 Initial Timing Connector (EST Distributor).......................................................................... 588 897501-8000SRM0519-(06-2007)-UK-EN.............................................................................................. 590 toc......................................................................................................................... 590 Diagrams................................................................................................................ 590 Safety Precautions Maintenance and Repair............................................................................... 591 897800-0600SRM0590-(08-2005)-UK-EN.............................................................................................. 678 toc......................................................................................................................... 678 GM Engines.............................................................................................................. 678 Safety Precautions Maintenance and Repair............................................................................... 679 General................................................................................................................. 682 Description............................................................................................................. 682 Engine Removal and Installation......................................................................................... 683 Cylinder Head Repair.................................................................................................... 683 Remove and Disassemble.............................................................................................. 683 Clean and Inspect................................................................................................... 683 Valve Guides and Seats, Repairs..................................................................................... 684 Valves, Repair...................................................................................................... 684 Valve Seats, Repair................................................................................................. 685 Valve Springs....................................................................................................... 685 Rocker Arm Studs (Early Models)..................................................................................... 687 Rocker Arm Studs (Late Models)...................................................................................... 687 Assemble and Install................................................................................................ 688 Cylinder Block Cleaning and Inspection.................................................................................. 691 Piston Bore Preparation................................................................................................. 691 Engine Mounts Installation.............................................................................................. 692 Lubrication System Repair............................................................................................... 692 Oil Pump, Remove and Disassemble.................................................................................... 692 Clean and Inspect................................................................................................... 692 Oil Pump, Assemble and Install...................................................................................... 693 Oil Sump, Install................................................................................................... 693 Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters............................................................. 694 Timing Cover........................................................................................................ 694 Remove.......................................................................................................... 694 Install......................................................................................................... 696 Timing Sprockets.................................................................................................... 696 Remove.......................................................................................................... 696 Install......................................................................................................... 696 Camshaft............................................................................................................ 697 Remove.......................................................................................................... 697 Inspect......................................................................................................... 697 Install......................................................................................................... 697 Balance Shaft....................................................................................................... 698 Remove.......................................................................................................... 698 Install......................................................................................................... 699 Hydraulic Valve Lifters............................................................................................. 699 Remove.......................................................................................................... 699 Disassemble..................................................................................................... 700 Clean and Inspect............................................................................................... 700 Assemble........................................................................................................ 700 Install......................................................................................................... 701 Crankshaft Repair....................................................................................................... 702 Remove.............................................................................................................. 702 Inspect and Repair.................................................................................................. 702 How to Check Clearance Between Main Bearings and Their Journals..................................................... 703 Install............................................................................................................. 704 Piston and Connecting Rod Assemblies Repair............................................................................. 705 Connecting Rod Bearings, Replace.................................................................................... 705 Piston and Connecting Rod Assemblies, Remove........................................................................ 706 Disassemble......................................................................................................... 706 Piston, Clean and Inspect........................................................................................... 707 Cylinder Bores, Inspect and Repair.................................................................................. 707 Piston Rings........................................................................................................ 708 Assemble............................................................................................................ 709 Piston and Connecting Rod Assemblies, Install....................................................................... 709 Flywheel and Flywheel Housing Repair.................................................................................... 710 Flywheel, Repair.................................................................................................... 710 Flywheel, Install................................................................................................... 710 H3.50-5.00XL (H70-110XL), S3.50-5.50XL (S70-120XL), S6.00-7.00XL................................................ 710 H6.00-7.00XL (H135-155XL)....................................................................................... 710 Flywheel Housing H3.50-5.00XL (H70-110XL), H3.50-5.50XM (H70-120.................................................... 710 Engine Adapter H6.00-7.00XL (H135-155XL)............................................................................ 710 Coolant Pump Repair..................................................................................................... 711 Thermostat Replacement.................................................................................................. 711 Fan Mount Repair (Early Models)......................................................................................... 711 Fan Mount Assembly Repair (Late Models)................................................................................. 711 Drive Belt Installation................................................................................................. 713 Valve Clearance Adjustment (Early Models)............................................................................... 714 Valve Clearance Adjustment (New Models)................................................................................. 715 Compression Check....................................................................................................... 715 Engine Specifications................................................................................................... 716 Engine Data......................................................................................................... 716 Cylinder Head....................................................................................................... 716 Hydraulic Valve Lifter.............................................................................................. 717 Camshaft............................................................................................................ 717 Pistons............................................................................................................. 717 Crankshaft.......................................................................................................... 718 Connecting Rods..................................................................................................... 718 Balance Shaft....................................................................................................... 719 Cooling System...................................................................................................... 719 Lubrication System.................................................................................................. 719 Torque Specifications................................................................................................... 719 Troubleshooting......................................................................................................... 720 tables...................................................................................................................... 678 Table 1. Piston Rings Arrangement on Piston............................................................................. 709 897934-0700SRM0626-(11-2001)-UK-EN.............................................................................................. 726 toc......................................................................................................................... 726 Cooling System.......................................................................................................... 726 Safety Precautions Maintenance and Repair............................................................................... 727 General................................................................................................................. 730 Description............................................................................................................. 731 Radiator............................................................................................................ 731 Radiator Cap........................................................................................................ 731 Thermostat.......................................................................................................... 731 Water Pump.......................................................................................................... 732 Fan and Fan Shroud.................................................................................................. 732 Cooling System Checks................................................................................................... 732 Radiator............................................................................................................ 732 Thermostat.......................................................................................................... 732 Water Pump.......................................................................................................... 733 Exhaust Leaks....................................................................................................... 733 Fan and Fan Shroud.................................................................................................. 733 Radiator Cleaning....................................................................................................... 733 Drain............................................................................................................... 733 Clean............................................................................................................... 733 Fill................................................................................................................ 734 Troubleshooting......................................................................................................... 735 899783-2000SRM0090-(10-2003)-UK-EN.............................................................................................. 738 toc......................................................................................................................... 738 Main Control Valve...................................................................................................... 738 Safety Precautions Maintenance and Repair............................................................................... 739 General................................................................................................................. 742 Description............................................................................................................. 742 Operation............................................................................................................... 745 Lift Spool.......................................................................................................... 745 Tilt Spool.......................................................................................................... 746 Tilt Backward................................................................................................... 746 Tilt Forward.................................................................................................... 747 Single-Stage Relief Valve........................................................................................... 749 Two-Stage Relief Valve.............................................................................................. 750 Main Control Valve Repair............................................................................................... 751 Remove and Disassemble.............................................................................................. 751 Clean and Inspect................................................................................................... 751 Assemble............................................................................................................ 751 Install............................................................................................................. 752 Single-Stage Relief Valve Adjustment.................................................................................... 752 Two-Stage Relief Valve.................................................................................................. 753 Auxiliary Control Valve Relief Valve Adjustment (H60-110E Only)......................................................... 753 Troubleshooting......................................................................................................... 754 tables...................................................................................................................... 738 Table 1. Relief Pressures (Oil temperature at 55 to 66 C ( 131 t........................................................ 752 899784-2200SRM0002-(10-2003)-UK-EN.............................................................................................. 758 toc......................................................................................................................... 758 Alternator with Regulator............................................................................................... 758 Safety Precautions Maintenance and Repair............................................................................... 759 General................................................................................................................. 762 Description............................................................................................................. 762 Alternator Repair....................................................................................................... 764 Alternator Type A................................................................................................... 764 Remove and Disassemble.......................................................................................... 764 Clean........................................................................................................... 765 Assemble........................................................................................................ 766 Install......................................................................................................... 766 Alternator Type B................................................................................................... 769 Remove and Disassemble.......................................................................................... 769 Clean........................................................................................................... 769 Assemble........................................................................................................ 770 Install......................................................................................................... 771 General Check and Adjustment............................................................................................ 772 Low Output Check (Type A or Type B)..................................................................................... 772 High Output Check (Type A or Type B).................................................................................... 774 Brushes Circuit Check................................................................................................... 775 Delco Alternators................................................................................................... 775 Motorola Alternators................................................................................................ 776 Diodes Check............................................................................................................ 777 Diode Bridge Check...................................................................................................... 777 Delco and Leece-Neville Alternators................................................................................. 777 Motorola Alternators................................................................................................ 777 Rotor Field Winding Check............................................................................................... 778 Stator Windings Check................................................................................................... 779 Voltage Regulator Check................................................................................................. 779 Troubleshooting......................................................................................................... 779 899788-2200SRM0107-(03-2002)-UK-EN.............................................................................................. 784 toc......................................................................................................................... 784 High Energy Ignition (HEI) System....................................................................................... 784 Safety Precautions Maintenance and Repair............................................................................... 785 Description............................................................................................................. 788 Distributor Repair...................................................................................................... 790 Remove.............................................................................................................. 790 Disassemble......................................................................................................... 790 Assemble............................................................................................................ 795 Install, If Crankshaft WAS NOT Rotated when Distributor was Remo.................................................... 796 Install, If Crankshaft WAS Rotated when Distributor was Removed..................................................... 796 Ignition Coil Replacement............................................................................................... 797 Some Four- and Six-Cylinder Models.................................................................................. 797 Remove.......................................................................................................... 797 Install......................................................................................................... 798 V8, Some Four- and Six-Cylinder Models.............................................................................. 798 Remove.......................................................................................................... 798 Install......................................................................................................... 799 Electronic Module Replacement........................................................................................... 800 Remove.............................................................................................................. 800 Install............................................................................................................. 800 Sensing Coil Replacement................................................................................................ 801 Remove.............................................................................................................. 801 Install............................................................................................................. 801 Spark Plugs Replacement................................................................................................. 801 Remove.............................................................................................................. 801 Install............................................................................................................. 802 Visual Check............................................................................................................ 802 High Voltage Wires Check................................................................................................ 802 Ignition Coil Check..................................................................................................... 803 Coil in Distributor Cap Design...................................................................................... 803 Separate Coil Design................................................................................................ 803 Sensing Coil, Check................................................................................................. 804 Electronic Module Check................................................................................................. 804 Ignition Timing Adjustment.............................................................................................. 804 GM V8-366 (6-liter) Ignition System Check............................................................................... 806 GM V6-LPG (4.3 liter) GM V6-LPG (4.3 liter) Ignition Timing and ........................................................ 806 Specifications.......................................................................................................... 806 Troubleshooting......................................................................................................... 807 910072-1400SRM0046-(07-2007)-UK-EN.............................................................................................. 812 toc......................................................................................................................... 812 Differential............................................................................................................ 812 Safety Precautions Maintenance and Repair............................................................................... 813 General................................................................................................................. 816 Description............................................................................................................. 816 Differential Repair..................................................................................................... 817 Remove.............................................................................................................. 817 Differential Carrier From Axle Housing, Remove.................................................................. 817 Differential and Ring Gear From Differential Carrier, Remove.................................................... 819 Drive Pinion and Pinion Carrier From Differential Carrier, Remov................................................ 821 Disassemble......................................................................................................... 822 Differential and Ring Gear Assembly, Disassemble................................................................ 822 Drive Pinion and Pinion Carrier, Disassemble.................................................................... 824 Clean and Inspect................................................................................................... 827 Assemble............................................................................................................ 828 Pinion, Bearings, and Pinion Carrier, Assemble.................................................................. 828 Pinion Bearings, Adjust Preload................................................................................. 828 Press Method................................................................................................ 828 Yoke or Flange Method....................................................................................... 829 Triple-Lip Seal, Install........................................................................................ 830 Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion)..................................................... 831 Differential and Ring Gear, Assemble............................................................................ 833 Differential Gears Rotating Torque, Check....................................................................... 835 Differential and Ring Gear Assembly, Install.................................................................... 836 Differential Bearings, Preload Adjust........................................................................... 838 Ring Gear, Runout Check......................................................................................... 839 Ring Gear Backlash, Adjust...................................................................................... 839 Gear Set, Tooth Contact Pattern Check........................................................................... 841 Thrust Screw, Install and Adjust................................................................................ 844 Install............................................................................................................. 844 Differential Assembly Into Axle Housing, Install................................................................ 844 Specifications.......................................................................................................... 846 Troubleshooting......................................................................................................... 851 tables...................................................................................................................... 812 Table 1. Ring Gear Backlash Adjustment Specifications................................................................... 841 Table 2. Ring and Pinion Tooth Contact Adjustment....................................................................... 842 Table 3. General Specifications......................................................................................... 846 Table 4. Rivet Installation Pressure.................................................................................... 846 Table 5. Pinion Adjustment.............................................................................................. 847 Table 6. Pinion Preload Pressure........................................................................................ 847 Table 7. Torque Specifications.......................................................................................... 848 Table 8. Torque Specifications for Metric Hardware...................................................................... 849 Table 9. Torque Specifications for Metric (Fine) Hardware............................................................... 850 910073-1400SRM0049-(09-2003)-UK-EN.............................................................................................. 854 toc......................................................................................................................... 854 Drive Axle.............................................................................................................. 854 Safety Precautions Maintenance and Repair............................................................................... 855 General................................................................................................................. 858 Description............................................................................................................. 858 Drive Axle Repair....................................................................................................... 859 Disassemble (Type 1 Shown).......................................................................................... 859 Clean............................................................................................................... 862 Inspect............................................................................................................. 862 Assemble (Type 1 Shown)............................................................................................. 863 Torque Specifications................................................................................................... 866 Troubleshooting......................................................................................................... 867 910076-1600SRM0054-(10-2003)-UK-EN.............................................................................................. 870 toc......................................................................................................................... 870 Steering Control Unit................................................................................................... 870 Safety Precautions Maintenance and Repair............................................................................... 871 General................................................................................................................. 874 Description............................................................................................................. 874 Operation............................................................................................................... 874 Steering Wheel and Column Assembly Repair............................................................................... 876 Steering Column Assembly Repair......................................................................................... 876 Type A Steering Column Assembly..................................................................................... 876 Remove and Disassemble.......................................................................................... 876 Assemble and Install............................................................................................ 878 Type B Steering Column Assembly..................................................................................... 880 Remove and Disassemble.......................................................................................... 880 Assemble and Install............................................................................................ 880 Steering Control Unit........................................................................................... 883 Disassemble................................................................................................. 883 Clean....................................................................................................... 886 Assemble.................................................................................................... 887 System Air Removal...................................................................................................... 892 Troubleshooting......................................................................................................... 892 910091-1900SRM0097-(07-2006)-UK-EN.............................................................................................. 896 toc......................................................................................................................... 896 Hydraulic Gear Pumps.................................................................................................... 896 Safety Precautions Maintenance and Repair............................................................................... 897 Description............................................................................................................. 900 Operation............................................................................................................... 901 Flow Control Valve.................................................................................................. 901 Relief Valve........................................................................................................ 902 Hydraulic Gear Pump Repair.............................................................................................. 902 Remove.............................................................................................................. 902 Disassemble......................................................................................................... 903 Clean............................................................................................................... 903 Inspect............................................................................................................. 904 Assemble............................................................................................................ 907 Install............................................................................................................. 909 Pump Output Check....................................................................................................... 909 Method No. 1........................................................................................................ 909 Method No. 2........................................................................................................ 910 Hydraulic System Air Check.............................................................................................. 911 Troubleshooting......................................................................................................... 912 910092-1900SRM0098-(07-2003)-UK-EN.............................................................................................. 918 toc......................................................................................................................... 918 Hydraulic Vane Pumps.................................................................................................... 918 Safety Precautions Maintenance and Repair............................................................................... 919 General................................................................................................................. 922 Description............................................................................................................. 922 Operation............................................................................................................... 923 Pump................................................................................................................ 923 Relief Valve........................................................................................................ 923 Hydraulic Vane Pumps Repair............................................................................................. 924 Remove.............................................................................................................. 924 Disassemble......................................................................................................... 924 Assemble............................................................................................................ 925 Install............................................................................................................. 928 Relief Valve Relief Pressure Check...................................................................................... 928 Lift Trucks With Internal Combustion Engines........................................................................ 928 Electric Lift Trucks................................................................................................ 928 Electric Lift Trucks With Adjustable Relief Valve................................................................... 929 Specifications.......................................................................................................... 930 Pressure Relief Valve............................................................................................... 930 Troubleshooting......................................................................................................... 930 910102-2100SRM0103-(03-2007)-UK-EN.............................................................................................. 934 toc......................................................................................................................... 934 Tilt Cylinders.......................................................................................................... 934 Safety Precautions Maintenance and Repair............................................................................... 935 General................................................................................................................. 938 Description............................................................................................................. 938 Tilt Cylinder Repair.................................................................................................... 938 Remove.............................................................................................................. 938 Disassemble......................................................................................................... 938 Clean............................................................................................................... 938 Assemble............................................................................................................ 938 Tilt Cylinders With O-Ring or Single-Lip Seals.................................................................. 938 Tilt Cylinders for XM and XMS Models............................................................................ 940 Tilt Cylinders for XL, XLS, and XL 3 Models..................................................................... 941 Tilt Cylinders for H700-800A and Early Model H700-920B.......................................................... 943 Install............................................................................................................. 944 Tilt Cylinders Using Chevron Packing............................................................................ 944 Install..................................................................................................... 945 Tilt Cylinder Leak Check................................................................................................ 947 Tilt Cylinder Stroke and Mast Tilt Angle Adjustment..................................................................... 949 Torque Specifications................................................................................................... 949 Piston Rod Nut...................................................................................................... 949 Retainer............................................................................................................ 950 Troubleshooting......................................................................................................... 952 tables...................................................................................................................... 934 Table 1. Movement Rates (Maximum) for Tilt Cylinders.................................................................... 948 910107-2200SRM0106-(02-2001)-UK-EN.............................................................................................. 956 toc......................................................................................................................... 956 Starter................................................................................................................. 956 Safety Precautions Maintenance and Repair............................................................................... 957 General................................................................................................................. 960 Description and Operation............................................................................................... 960 Starter Repair.......................................................................................................... 962 Remove.............................................................................................................. 962 Disassemble......................................................................................................... 962 Clean............................................................................................................... 963 Assemble............................................................................................................ 963 Install............................................................................................................. 964 General Checks and Adjustments.......................................................................................... 964 Troubleshooting......................................................................................................... 967 910110-2200SRM0143-(02-2007)-UK-EN.............................................................................................. 972 toc......................................................................................................................... 972 Instrument Panel Indicators and Senders................................................................................. 972 Safety Precautions Maintenance and Repair............................................................................... 973 General................................................................................................................. 976 Description............................................................................................................. 977 Steering Column Gauges, Meters, and Indicators...................................................................... 977 LED Display Panel................................................................................................... 977 Battery Discharge Indicators.................................................................................... 977 Brush Wear Indicators........................................................................................... 983 Motor Temperature Indicators.................................................................................... 983 LX Series Display Panel............................................................................................. 985 Hourmeter Functions............................................................................................. 986 Battery Indicator Function...................................................................................... 986 Status Code Function............................................................................................ 986 ZX Series Display Panels............................................................................................ 988 Display Panel................................................................................................... 988 Basic Display Panels............................................................................................ 988 Performance Display............................................................................................. 990 Brush Wear Indicators........................................................................................... 994 Adjustments - General................................................................................................... 994 Replacement - General Information....................................................................................... 994 Meter Replacement....................................................................................................... 995 Sender Replacement...................................................................................................... 996 Fuel Level Sender................................................................................................... 996 Pressure and Temperature Sender..................................................................................... 996 Seat Sensor, Operator Presence System (OPS)......................................................................... 997 Remove.......................................................................................................... 997 Install......................................................................................................... 997 Operator Presence System Module Replacement......................................................................... 997 Remove.......................................................................................................... 998 Install......................................................................................................... 999 ITW Display Panel Replacement...........................................................................................1000 Remove..............................................................................................................1000 Column Mount Display Panel (EV-100/200ZX Motor Controllers) Repl........................................................1000 Remove..............................................................................................................1000 Display Panel Assembly, Replace.....................................................................................1000 Indicator LEDs......................................................................................................1001 Battery Indicators..................................................................................................1001 Digital Display (Performance Display Panel Only)....................................................................1001 Status Code or Performance Level Switches and Indicator LEDs (Pe....................................................1002 Basic Display Panel, Replace Parts..................................................................................1002 Performance Display Panel, Replace Parts............................................................................1004 Dash Mount Display Panel (EV100/200ZX Motor Controllers) Replace........................................................1004 Remove and Replace..................................................................................................1004 Specifications..........................................................................................................1005 Meter Specifications................................................................................................1005 Sender Specifications...............................................................................................1005 Troubleshooting.........................................................................................................1006 Meter...............................................................................................................1006 Troubleshooting for Operator Presence System............................................................................1007 tables...................................................................................................................... 972 Table 1. Troubleshooting Procedure for Operator Presence Module.........................................................1007 910111-2200SRM0144-(05-1997)-UK-EN..............................................................................................1012 ELECTRICAL WARNING DEVICES..................................................................................................1012 GENERAL.................................................................................................................1012 DESCRIPTION.............................................................................................................1012 Operator Controlled Horns...........................................................................................1012 System Warning Lights, Buzzers and Bells............................................................................1012 Reverse Warning Horns...............................................................................................1013 Warning Lights......................................................................................................1013 REPLACEMENT.............................................................................................................1014 General.............................................................................................................1014 Replacing Horns or Bells............................................................................................1014 Replacing Horn Relay or Buzzer......................................................................................1014 Replacing Warning Lights............................................................................................1014 Light Assemblies....................................................................................................1015 Replacing Flashing Units............................................................................................1015 910119-4000SRM0135-(10-2003)-UK-EN..............................................................................................1016 toc.........................................................................................................................1016 Lift Cylinders..........................................................................................................1016 Safety Precautions Maintenance and Repair...............................................................................1017 Safety Procedures When Working Near Mast................................................................................1020 General.................................................................................................................1024 Description.............................................................................................................1024 Lowering Control Valve..............................................................................................1024 Cylinders (General).................................................................................................1027 Cylinders (H520-620B, H700-800A)....................................................................................1027 Retainer, Install...............................................................................................1027 Cylinders (H360-460B)...............................................................................................1029 Cylinders (Two-Speed)...............................................................................................1031 Lift Cylinder Repair....................................................................................................1033 Lift Cylinder Removal Without Removing Mast.........................................................................1033 Standard Masts With Main Lift Cylinder Fastened to Crossmember o................................................1033 Standard and Full Free-Lift Masts With Lift Cylinder Fastened to................................................1033 Masts That Have Two Cylinders, Main Lift Cylinder and Free-Lift ................................................1033 Disassemble.........................................................................................................1035 Assemble............................................................................................................1035 Lift Cylinder Installation in Mast..................................................................................1037 Standard Masts With Main Lift Cylinder Fastened to Crossmember o................................................1037 Standard and Full Free-Lift Masts With Lift Cylinder Fastened to................................................1037 Chevron-Style Packing...............................................................................................1037 Chevron-Style Packing Installation on Piston....................................................................1038 Chevron-Style Packing Installation in Packing Gland.............................................................1040 Lift Cylinders for VISTA® Masts.........................................................................................1041 Description.........................................................................................................1041 Lowering Control Valve..........................................................................................1041 Remove..............................................................................................................1043 Disassemble.........................................................................................................1044 Assemble............................................................................................................1045 Install.............................................................................................................1046 Main Lift Cylinders.............................................................................................1046 Free-Lift Cylinder..............................................................................................1046 Lift System Leak Check..................................................................................................1047 Specifications..........................................................................................................1048 Troubleshooting.........................................................................................................1049 tables......................................................................................................................1016 Table 1. Lift Trucks with Two-Speed Lift Cylinders......................................................................1032 Table 2. Cylinder Retainer Torque Specifications and Weight Guid........................................................1048 910150-0600SRM0105-(06-1997)-UK-EN..............................................................................................1052 INTRODUCTION................................................................................................................1052 GENERAL.................................................................................................................1052 DESCRIPTION.............................................................................................................1052 ENGINE SERIAL NUMBER CODES..............................................................................................1053 REMOVAL AND INSTALLATION................................................................................................1053 ENGINE......................................................................................................................1053 CYLINDER HEAD...........................................................................................................1053 Removal.............................................................................................................1053 Installation........................................................................................................1054 Cylinder Head Repairs...............................................................................................1055 OIL PUMP................................................................................................................1057 Removal.............................................................................................................1057 Disassembly.........................................................................................................1057 Inspection..........................................................................................................1057 Assembly............................................................................................................1058 Installation........................................................................................................1058 RELIEF VALVE............................................................................................................1059 TIMING GEAR CASE AND TIMING GEARS.......................................................................................1059 Removal.............................................................................................................1059 Installation........................................................................................................1060 PISTONS AND CONNECTING RODS.............................................................................................1061 Removal.............................................................................................................1061 Disassembly.........................................................................................................1061 Inspection..........................................................................................................1062 Assembly............................................................................................................1063 Installation........................................................................................................1063 CRANKSHAFT AND MAIN BEARINGS............................................................................................1064 Removal.............................................................................................................1064 Inspection..........................................................................................................1064 Assembly............................................................................................................1065 CAMSHAFT AND CAM FOLLOWERS..............................................................................................1066 Removal.............................................................................................................1066 Inspection..........................................................................................................1067 Assembly............................................................................................................1067 FLYWHEEL AND FLYWHEEL HOUSING...........................................................................................1068 Removal.............................................................................................................1068 Repairs.............................................................................................................1068 Installation........................................................................................................1068 STEERING PUMP DRIVE.....................................................................................................1068 Removal.............................................................................................................1068 Installation........................................................................................................1069 PCV VALVE...............................................................................................................1069 FUEL SYSTEM.................................................................................................................1069 FUEL PUMP...............................................................................................................1069 Removal.............................................................................................................1069 Disassembly.........................................................................................................1069 Assembly............................................................................................................1069 Installation........................................................................................................1070 FUEL INJECTION PUMP.....................................................................................................1070 Removal.............................................................................................................1070 Repairs.............................................................................................................1070 Installation........................................................................................................1070 FUEL INJECTORS..........................................................................................................1070 Removal.............................................................................................................1070 Repairs.............................................................................................................1071 Installation........................................................................................................1071 COLD START AID..........................................................................................................1071 Description.........................................................................................................1071 Removal.............................................................................................................1071 Installation........................................................................................................1071 COOLING SYSTEM..............................................................................................................1072 THERMOSTAT..............................................................................................................1072 Removal.............................................................................................................1072 Inspection..........................................................................................................1072 Installation........................................................................................................1072 WATER PUMP..............................................................................................................1072 Removal.............................................................................................................1072 Disassembly.........................................................................................................1072 Assembly............................................................................................................1072 Installation........................................................................................................1072 CHECKS AND ADJUSTMENTS......................................................................................................1072 CHECKING THE INJECTORS..................................................................................................1072 Repairs.............................................................................................................1073 Installation........................................................................................................1073 REMOVING AIR FROM THE FUEL SYSTEM.......................................................................................1073 CHECKING THE TIMING MARKS...............................................................................................1074 Method A............................................................................................................1074 Method B............................................................................................................1075 CHECKING THE TIMING ANGLE OF THE FUEL INJECTION PUMP WITH THE SPECIAL TOOL..............................................1076 VALVE CLEARANCE ADJUSTMENT..............................................................................................1077 ADJUSTING THE THROTTLE LINKAGE..........................................................................................1077 TROUBLESHOOTING.............................................................................................................1079 SPECIFICATIONS..............................................................................................................1080 TORQUE SPECIFICATIONS.......................................................................................................1083 910233-1300SRM0061-(02-1997)-UK-EN..............................................................................................1084 INTRODUCTION................................................................................................................1084 GENERAL.................................................................................................................1084 DESCRIPTION.............................................................................................................1084 Oil Clutch Assembly, H6.00-7.00XL (H135-155XL)......................................................................1084 Manual Transmission.................................................................................................1086 REPAIRS.....................................................................................................................1086 OIL CLUTCH ASSEMBLY.....................................................................................................1086 Removal and Disassembly.............................................................................................1086 Cleaning............................................................................................................1086 Inspection..........................................................................................................1086 Assembly and Installation...........................................................................................1087 TRANSMISSION............................................................................................................1087 Removal, H6.00-7.00XL (H135-155XL)..................................................................................1087 Disassembly.........................................................................................................1088 Cleaning............................................................................................................1090 Inspection..........................................................................................................1090 Assembly............................................................................................................1091 Installation, H6.00-7.00XL (H135-155XL).............................................................................1095 CHECKS AND ADJUSTMENTS......................................................................................................1096 ADJUSTING THE CLUTCH PEDAL LINKAGE, H6.00-7.00XL (H135-155XL)...........................................................1096 TROUBLESHOOTING-OIL CLUTCH ASSEMBLY.........................................................................................1097 TROUBLESHOOTING-MANUAL TRANSMISSION.........................................................................................1099 910442-8000SRM0231-(12-2004)-UK-EN..............................................................................................1101 toc.........................................................................................................................1101 Metric and Inch (SAE) Fasteners.........................................................................................1101 Safety Precautions Maintenance and Repair...............................................................................1102 General.................................................................................................................1105 Threaded Fasteners..................................................................................................1105 Nomenclature, Threads...............................................................................................1105 Strength Identification.............................................................................................1106 Cotter (Split) Pins.................................................................................................1106 Fastener Torque Tables..............................................................................................1111 Conversion Table....................................................................................................1113 tables......................................................................................................................1101 Table 1. Bolts and Screws...............................................................................................1107 Table 2. Studs and Nuts.................................................................................................1108 Table 3. Torque Nuts....................................................................................................1109 Table 4. Torque Nuts With Nylon Insert..................................................................................1110 Table 5. Torque Values for Metric Fasteners*............................................................................1111 Table 6. Torque Values for Inch Fasteners*..............................................................................1112 Table 7. Conversion Table for Metric and English Units..................................................................1113 Table 8. Cotter Pin Dimensional Data....................................................................................1114 Table 9. Cotter Pin Dimensional Data....................................................................................1115 Table 10. Cotter Pin Dimensional Data...................................................................................1116 Table 11. Cotter Pin Dimensional Data...................................................................................1118 1455747-0600SRM0705-(03-2006)-UK-EN.............................................................................................1123 toc.........................................................................................................................1123 Perkins Diesel Engines..................................................................................................1123 Safety Precautions Maintenance and Repair...............................................................................1124 General.................................................................................................................1131 General Safety Rules................................................................................................1131 Description.............................................................................................................1132 Engine Serial Number Codes..........................................................................................1135 Engine Data.........................................................................................................1135 Engine Removal and Installation.........................................................................................1137 Lift Engine.........................................................................................................1137 Cylinder Head Assembly Repair...........................................................................................1137 Valve Cover.........................................................................................................1137 Remove..........................................................................................................1137 Install.........................................................................................................1138 Rocker Arm Assembly.................................................................................................1138 Remove..........................................................................................................1138 Install.........................................................................................................1138 Disassemble.....................................................................................................1138 Inspect.........................................................................................................1139 Assemble........................................................................................................1139 Valve Clearance Adjustments.........................................................................................1139 Four-Cylinder Engines...........................................................................................1140 Six-Cylinder Engines............................................................................................1140 Valve Springs.......................................................................................................1140 Cylinder Head Assembly..............................................................................................1142 Remove..........................................................................................................1142 Install.........................................................................................................1144 Valves and Valve Springs............................................................................................1148 Remove..........................................................................................................1148 Inspect.........................................................................................................1148 Install.........................................................................................................1149 Valve Guides........................................................................................................1149 Inspect.........................................................................................................1149 Remove..........................................................................................................1150 Install.........................................................................................................1150 Cylinder Head and Valve Seats.......................................................................................1150 Inspect.........................................................................................................1150 Repair..........................................................................................................1150 New Valve Seats, Install........................................................................................1150 Piston and Connecting Rod Assemblies Repair.............................................................................1152 Rod Bearings........................................................................................................1152 Remove..........................................................................................................1153 Install.........................................................................................................1153 Piston and Connecting Rod Assembly..................................................................................1154 Service Note....................................................................................................1154 Remove..........................................................................................................1154 Install.........................................................................................................1155 Piston Rings........................................................................................................1156 Remove..........................................................................................................1156 Inspect.........................................................................................................1156 Install.........................................................................................................1156 Piston and Connecting Rod...........................................................................................1157 Disassemble.....................................................................................................1157 Inspect.........................................................................................................1158 How to Select Correct Replacements..............................................................................1158 Install.........................................................................................................1159 Piston Cooling Jets.................................................................................................1159 Remove..........................................................................................................1159 Install.........................................................................................................1160 Crankshaft Assembly Repair..............................................................................................1160 General.............................................................................................................1160 Crankshaft Pulley...................................................................................................1161 Engine AR, Remove...............................................................................................1161 Engines YG and YH, Remove.......................................................................................1161 Inspect.........................................................................................................1162 Engine AR, Install..............................................................................................1162 Engines YG and YH, Install......................................................................................1162 Rear Oil Seal.......................................................................................................1163 Replace.........................................................................................................1163 Main Bearings.......................................................................................................1164 Remove..........................................................................................................1164 Inspect.........................................................................................................1165 Install.........................................................................................................1165 Thrust Washers......................................................................................................1165 Crankshaft Axial Movement, Check................................................................................1165 Remove..........................................................................................................1166 Install.........................................................................................................1166 Crankshaft..........................................................................................................1167 Remove..........................................................................................................1167 Inspect.........................................................................................................1167 Install.........................................................................................................1167 Flywheel............................................................................................................1169 Remove..........................................................................................................1169 Ring Gear, Replace..............................................................................................1169 Install.........................................................................................................1169 Flywheel Housing....................................................................................................1170 Remove..........................................................................................................1170 Install.........................................................................................................1170 Timing Case and Timing Gears Repair.....................................................................................1171 General.............................................................................................................1171 Timing Case Cover...................................................................................................1171 Remove..........................................................................................................1171 Install.........................................................................................................1172 Front Oil Seal......................................................................................................1172 Remove..........................................................................................................1172 Install.........................................................................................................1172 Crankshaft Pulley Wear Sleeve.......................................................................................1173 Install.........................................................................................................1173 Idler Gear and Hub..................................................................................................1173 Remove..........................................................................................................1173 Install.........................................................................................................1174 Air Compressor Drive, Bendix........................................................................................1175 Disassemble.....................................................................................................1175 Assemble........................................................................................................1176 Fuel Injection Pump Gear............................................................................................1176 Remove..........................................................................................................1177 Install.........................................................................................................1177 Camshaft Gear.......................................................................................................1178 Remove..........................................................................................................1178 Install.........................................................................................................1178 Crankshaft Gear.....................................................................................................1179 Remove..........................................................................................................1179 Install.........................................................................................................1179 Timing Case.........................................................................................................1179 Remove..........................................................................................................1179 Install.........................................................................................................1180 Camshaft and Tappets................................................................................................1181 Remove..........................................................................................................1181 Install.........................................................................................................1181 Cylinder Block Assembly Repair..........................................................................................1182 Description.........................................................................................................1182 Cylinder Block......................................................................................................1182 Disassemble.....................................................................................................1182 Inspect.........................................................................................................1183 Assemble........................................................................................................1183 Cylinder Bore (Four-Cylinder Engines)...............................................................................1184 Cylinder Liner (Six-Cylinder Engines)...............................................................................1184 Inspect.........................................................................................................1184 Cylinder Liner Condition, Check.................................................................................1184 Remove..........................................................................................................1185 Service Liner, Install..........................................................................................1186 Partially Finished Liner, Install...............................................................................1187 Engine Timing...........................................................................................................1188 Description.........................................................................................................1188 How to Set Number One Piston to TDC on Compression Stroke.......................................................1189 How to Set Number One Piston to TDC on Compression Stroke (Alter................................................1190 Valve Timing, Check.............................................................................................1190 Fuel Injection Pump Timing, Check...............................................................................1191 Turbocharger - Engine YH Repair.........................................................................................1192 General.............................................................................................................1192 Remove..........................................................................................................1192 Install.........................................................................................................1192 Impeller and Compressor Housing, Clean..........................................................................1193 Lubrication System Repair...............................................................................................1194 General.............................................................................................................1194 Oil Filter, Replace.................................................................................................1194 Filter Head.........................................................................................................1195 Remove and Install..............................................................................................1195 Oil Sump............................................................................................................1195 Remove..........................................................................................................1195 Install.........................................................................................................1196 Oil Pump............................................................................................................1196 Remove..........................................................................................................1196 Inspect.........................................................................................................1196 Install.........................................................................................................1197 Relief Valve........................................................................................................1197 Remove..........................................................................................................1197 Disassemble.....................................................................................................1198 Inspect.........................................................................................................1198 Assemble........................................................................................................1198 Install.........................................................................................................1199 Idler Gear Shaft, Replace...........................................................................................1199 Remove..........................................................................................................1199 Remove (Alternative)............................................................................................1199 Install.........................................................................................................1200 Install (Alternative)...........................................................................................1200 Install (Alternative for Four-Cylinder Engines Only)............................................................1201 Fuel System Repair......................................................................................................1201 Description.........................................................................................................1201 Fuel Injection Pump.................................................................................................1202 Remove..........................................................................................................1202 Install.........................................................................................................1203 Check and Adjust................................................................................................1204 Fuel System Air Removal.............................................................................................1204 Fuel Filter, Replace................................................................................................1205 Canister Type...................................................................................................1206 Quick Release Canister Type.....................................................................................1206 Fuel Injectors......................................................................................................1207 Remove..........................................................................................................1207 Inspect.........................................................................................................1208 Install.........................................................................................................1208 Fuel Pump...........................................................................................................1209 Remove..........................................................................................................1209 Disassemble.....................................................................................................1209 Assemble........................................................................................................1209 Install.........................................................................................................1210 Test............................................................................................................1210 Cooling System Repair...................................................................................................1211 General.............................................................................................................1211 Thermostat..........................................................................................................1211 Remove..........................................................................................................1211 Install.........................................................................................................1211 Test............................................................................................................1212 Coolant Pump........................................................................................................1212 Remove..........................................................................................................1212 Disassemble.....................................................................................................1212 Assemble........................................................................................................1214 Install.........................................................................................................1216 Fan and Fan Drive...................................................................................................1217 Remove..........................................................................................................1217 Install.........................................................................................................1217 Oil Cooler (Six-Cylinder Engines)...................................................................................1218 Remove..........................................................................................................1218 Disassemble and Assemble........................................................................................1218 Install.........................................................................................................1218 Oil Cooler Bypass Valve.........................................................................................1218 Electrical Equipment Repair.............................................................................................1219 Drive Belts.........................................................................................................1219 Adjustment......................................................................................................1219 Remove..........................................................................................................1220 Install.........................................................................................................1220 Alternator..........................................................................................................1220 Remove..........................................................................................................1220 Install.........................................................................................................1220 Starter Motor.......................................................................................................1220 Remove..........................................................................................................1220 Install.........................................................................................................1220 Cold Start Aid......................................................................................................1220 Air Compressor - Engines YG and YH......................................................................................1221 General.............................................................................................................1221 Repair..............................................................................................................1221 Remove..........................................................................................................1221 Install.........................................................................................................1221 Rotary Exhauster Replacement............................................................................................1223 Remove..............................................................................................................1223 Clean...............................................................................................................1223 Install.............................................................................................................1223 Engine Specifications...................................................................................................1224 Cylinder Head Assembly..............................................................................................1224 Piston and Connecting Rods..........................................................................................1227 Crankshaft Assembly.................................................................................................1230 Crankshaft Overhaul.............................................................................................1232 Timing Case and Drive Assembly......................................................................................1234 Engine Block Assembly...............................................................................................1235 Turbocharger........................................................................................................1238 Lubrication System..................................................................................................1238 Fuel System.........................................................................................................1239 Cooling System......................................................................................................1241 Flywheel and Housing................................................................................................1241 Electrical Equipment................................................................................................1242 Torque Specifications...................................................................................................1242 Cylinder Head Assembly..............................................................................................1242 Piston and Connecting Rod Assemblies................................................................................1242 Crankshaft Assembly.................................................................................................1242 Timing Case and Drive Assembly......................................................................................1243 Turbocharger........................................................................................................1243 Lubrication System..................................................................................................1243 Fuel System.........................................................................................................1243 Cooling System......................................................................................................1243 Flywheel............................................................................................................1243 Auxiliary Equipment.................................................................................................1243 Special Torque Specifications...........................................................................................1244 Flywheel and Housing................................................................................................1244 Turbocharger........................................................................................................1244 Electrical Equipment................................................................................................1244 Auxiliary Equipment.................................................................................................1244 Special Tools*..........................................................................................................1245 Troubleshooting.........................................................................................................1250 tables......................................................................................................................1123 Table 1. Cylinder Head..................................................................................................1224 Table 2. Valve Guides...................................................................................................1224 Table 3. Inlet Valves...................................................................................................1224 Table 4. Exhaust Valves.................................................................................................1225 Table 5. Valve Springs..................................................................................................1227 Table 6. Tappets........................................................................................................1227 Table 7. Rocker Arm Shaft...............................................................................................1227 Table 8. Rocker Arms and Bushings.......................................................................................1227 Table 9. Pistons (Engine AR)............................................................................................1227 Table 10. Pistons (Engines YG and YH)...................................................................................1227 Table 11. Piston Rings (Engine AR)......................................................................................1228 Table 12. Piston Rings (Engines YG and YH)..............................................................................1228 Table 13. Piston Pins...................................................................................................1229 Table 14. Connecting Rods...............................................................................................1229 Table 15. Small End Bushings............................................................................................1229 Table 16. Connecting Rod Bearings (Engines AR and YG)...................................................................1229 Table 17. Connecting Rod Bearings (Engine YH)...........................................................................1229 Table 18. Piston Cooling Jets...........................................................................................1230 Table 19. Crankshaft....................................................................................................1230 Table 20. Main Bearings.................................................................................................1231 Table 21. Crankshaft Thrust Washers.....................................................................................1231 Table 22. Crankshaft Heat Treatment.....................................................................................1231 Table 23. Crankshaft Overhaul Specifications............................................................................1232 Table 24. Maximum Variation (Run-out)...................................................................................1234 Table 25. Camshaft......................................................................................................1234 Table 26. Camshaft Thrust Washer........................................................................................1234 Table 27. Camshaft Gear.................................................................................................1234 Table 28. Gear for Fuel Injection Pump..................................................................................1235 Table 29. Crankshaft Gear...............................................................................................1235 Table 30. Idler Gear and Hub............................................................................................1235 Table 31. Cylinder Block (Engine AR)....................................................................................1235 Table 32. Cylinder Bore Specifications..................................................................................1236 Table 33. Cylinder Block (Engines YG and YH)............................................................................1237 Table 34. Cylinder Liners (Engines YG and YH)...........................................................................1237 Table 35. Cylinder Liner Specifications (Partially Finished)............................................................1237 Table 36. Oil Pump (Engine AR)..........................................................................................1238 Table 37. Oil Pump (Engines YG and YH)..................................................................................1238 Table 38. Idler Gear for Oil Pump.......................................................................................1239 Table 39. Relief Valve..................................................................................................1239 Table 40. Oil Filter....................................................................................................1239 Table 41. Lucas Fuel Injection Pump.....................................................................................1239 Table 42. Fuel Injector Codes...........................................................................................1240 Table 43. Fuel Pump (Engine AR).........................................................................................1241 Table 44. Fuel Pump (Engines YG and YH).................................................................................1241 Table 45. Fuel Filter...................................................................................................1241 Table 46. Coolant Pump..................................................................................................1241 Table 47. Thermostat....................................................................................................1241 Table 48. Fan Drive Housing.............................................................................................1241 Table 49. Limits for Flywheel Run Out and Alignment (Total Indic........................................................1242 Table 50. Alternator....................................................................................................1242 Table 51. Starter Motor.................................................................................................1242 Table 52. Cold Start Aid................................................................................................1242 Table 53. List of Possible Causes.......................................................................................1250 1473385-2200SRM0765-(11-2001)-UK-EN.............................................................................................1255 toc.........................................................................................................................1255 Microprocessor Spark Timing System (MSTS)...............................................................................1255 Safety Precautions Maintenance and Repair...............................................................................1256 General.................................................................................................................1259 Description.............................................................................................................1260 What MSTS Does......................................................................................................1260 How MSTS Begins Operation...........................................................................................1260 Operation...............................................................................................................1261 Distributor.........................................................................................................1261 Ignition Coil.......................................................................................................1261 Ignition Module.....................................................................................................1261 When Engine Is Being Started........................................................................................1262 When Engine Is Running..............................................................................................1263 Manifold Absolute Pressure (MAP) Sensor.............................................................................1264 Engine Coolant Temperature (ECT) Sensor.............................................................................1264 MSTS Module Corrections.............................................................................................1265 Troubleshooting.........................................................................................................1266 General.............................................................................................................1266 Tools and Test Equipment............................................................................................1268 MSTS................................................................................................................1269 Troubleshooting Procedure...........................................................................................1269 Where to Start..................................................................................................1269 Visual/Physical Inspection......................................................................................1269 Knowledge/Tools Required........................................................................................1269 Damage from Static Discharge (Static Electricity)...............................................................1269 Troubleshooting Information.........................................................................................1270 Malfunction Indicator Lamp (MIL)................................................................................1270 Connecting CodeMate Tester......................................................................................1270 Reading Diagnostic Trouble Codes (DTC)..........................................................................1271 Clearing Diagnostic Trouble Codes (DTC's).......................................................................1272 On-Board Diagnostic (OBD) System Check..............................................................................1272 Test Description................................................................................................1272 No Malfunction Indicator Lamp...........................................................................................1274 Circuit Description.................................................................................................1274 Test Description....................................................................................................1274 No DTC-12, Malfunction Indicator Lamp ON................................................................................1276 Circuit Description.................................................................................................1276 Test Description....................................................................................................1276 Starter Rotates Engine, Engine Does Not Run.............................................................................1277 Test Description....................................................................................................1277 DTC-14 Engine Coolant Temperature (ECT) (Low Temperature Indicat........................................................1281 Circuit Description.................................................................................................1281 Test Description....................................................................................................1281 DTC-15 Engine Coolant Temperature Sensor (ECT) (High Temperature........................................................1283 Circuit Description.................................................................................................1283 Test Description....................................................................................................1283 DTC-34 Manifold Absolute Pressure (MAP) Sensor..........................................................................1285 Circuit Description.................................................................................................1285 Test Description....................................................................................................1285 DTC-41 Electronic Spark Timing (EST) Open Circuit.......................................................................1288 Circuit Description.................................................................................................1288 Test Description....................................................................................................1288 DTC-42 Electronic Spark Timing (EST) Grounded Circuit...................................................................1290 Circuit Description.................................................................................................1290 Test Description....................................................................................................1290 DTC-51 MSTS Failure.....................................................................................................1292 Circuit Description.................................................................................................1292 Distributor Repair......................................................................................................1292 Remove..............................................................................................................1292 Disassemble.........................................................................................................1293 Inspect.............................................................................................................1293 Assemble............................................................................................................1293 Install.............................................................................................................1294 Ignition Timing.....................................................................................................1294 Ignition Module Repair..................................................................................................1295 Test For Fault......................................................................................................1295 Replace.............................................................................................................1296 Sensing Coil Repair.....................................................................................................1296 Test For Fault......................................................................................................1296 Replace.............................................................................................................1296 Ignition Coil Repair....................................................................................................1297 Test For Fault......................................................................................................1297 Remove..............................................................................................................1297 Install.............................................................................................................1297 MSTS Module Repair......................................................................................................1298 Remove..............................................................................................................1298 Install.............................................................................................................1298 ECT Sensor Replacement..................................................................................................1298 MAP Sensor Replacement..................................................................................................1299 tables......................................................................................................................1255 Table 1. MSTS Module Connections........................................................................................1267 Table 2. Pressure Conversion Chart......................................................................................1268 Table 3. MSTS Diagnostic Codes..........................................................................................1270
HYSTER F006 (H6.00-7.00XL EUROPE) SERVICE MANUAL – PDF DOWNLOAD:
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