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Hyster Forklift H70XL H110XLF005 service manual – PDF DOWNLOAD
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Description
Hyster Forklift H70XL H110XLF005 service manual
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Hyster Forklift H70XL H110XLF005 service manual
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HYSTER FORKLIFT H70XL H110XLF005 SERVICE MANUAL – PDF DOWNLOAD:
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Hyster Forklift H70XL H110XLF005 service manual
- GENERAL This section has a description and the repair procedures for the alternator with a voltage regulator as part of the alternator. CAUTION When using an arc welder, always disconnect the ground lead from the lift truck battery to prevent alternator or battery damage. Attach the welding ground clamp as close to the weld area as possible to prevent welding current from damaging the bearings. The diodes and resistors in the electrical system can be damaged if the following cautions are not followed: •
- Do not disconnect the battery when the engine is running. The voltage surge can damage the diodes and resistors in the electrical system. • Do not disconnect an electric wire before the engine is stopped and the switches are “OFF”. • Do not cause a short–circuit by connecting the electric wires to the wrong terminals. Make sure a correct identification is made of the wire before it is connected. • Make sure a battery is the correct voltage and polarity before it is connected. • Do not check for current flow by making a spark because the electronic components can be damaged. NOTE: Information on alternators manufactured outside the United States is in the SRM (service repair manual) sections for lift trucks that use those alternators.
- DESCRIPTION (See FIGURE 1. and FIGURE 2.) NOTE: For this SRM section, the alternators are in two groups, Type A and Type B. The two types are very similar, but the Type A alternators have a set of three diodes (diode set) as well as the diode bridge. The Type B alternator has zener diodes as part of the diodes in the diode bridge. This alternator does not have a diode set, but does have an additional fan inside the rear housing. The basic operation of both types is very similar.
- The alternator generates an alternating current when the engine is running. The alternator is either ON or OFF. The alternator generates maximum current when it is ON and no current when it is OFF. The regulator switches the alternator between ON and OFF to get the average current needed to charge the battery. Alternator output is directly changed by engine speed and rotor field current. The alternating current is changed to a direct current by the diode bridge inside the alternator.
Table of Contents:
Hyster Forklift H70XL H110XLF005 service manual
INTRODUCTION................................................................................................................ 1 GENERAL................................................................................................................. 1 DESCRIPTION............................................................................................................. 1 REPAIRS..................................................................................................................... 3 GENERAL................................................................................................................. 3 REMOVAL AND DISASSEMBLY (Type A)........................................................................................ 3 CLEANING................................................................................................................ 3 ASSEMBLY (Type A)....................................................................................................... 4 REMOVAL AND DISAASSEMBLY (Type B)....................................................................................... 6 CLEANING................................................................................................................ 8 ASSEMBLY (Type B)....................................................................................................... 8 INSTALLATION (Type A and Type B)........................................................................................ 9 CHECKS AND ADJUSTMENTS...................................................................................................... 9 GENERAL................................................................................................................. 9 CHECK THE ALTERNATOR FOR LOW OUTPUT (Type A or Type B).................................................................. 10 CHECK THE ALTERNATOR FOR HIGH OUTPUT (Type A or Type B)................................................................. 11 CHECK THE CIRCUIT FOR THE BRUSHES....................................................................................... 13 Delco Alternators................................................................................................... 13 Motorola Alternators................................................................................................ 13 CHECK THE DIODES........................................................................................................ 13 CHECK THE DIODE BRIDGE.................................................................................................. 13 Delco and Leece–Neville Alternators................................................................................. 13 Motorola Alternators................................................................................................ 13 CHECK THE FIELD WINDING FOR THE ROTOR................................................................................... 14 CHECK THE WINDINGS IN THE STATOR........................................................................................ 14 CHECK THE VOLTAGE REGULATOR............................................................................................. 15 TROUBLESHOOTING............................................................................................................. 15 COOLING SYSTEM.............................................................................................................. 24 INTRODUCTION............................................................................................................ 24 DESCRIPTION............................................................................................................. 24 RADIATOR................................................................................................................ 24 RADIATOR CAP............................................................................................................ 24 THERMOSTAT.............................................................................................................. 24 WATER PUMP.............................................................................................................. 25 FAN AND FAN SHROUD ..................................................................................................... 25 REPAIRS..................................................................................................................... 25 COOLING SYSTEM CHECKS................................................................................................... 25 Exhaust Leaks....................................................................................................... 25 RADIATOR................................................................................................................ 25 Checks.............................................................................................................. 25 Cleaning The Radiator............................................................................................... 25 Drain The Cooling System............................................................................................ 27 Fill The Cooling System............................................................................................. 27 WATER PUMP.............................................................................................................. 27 Checks.............................................................................................................. 27 THERMOSTAT.............................................................................................................. 28 Checks.............................................................................................................. 28 FAN AND FAN SHROUD ..................................................................................................... 28 TROUBLESHOOTING............................................................................................................. 29 INTRODUCTION................................................................................................................ 30 GENERAL................................................................................................................. 30 DESCRIPTION............................................................................................................. 30 REPAIRS..................................................................................................................... 31 REMOVAL................................................................................................................. 31 Lift Trucks With A Manual Transmission.............................................................................. 31 Lift Trucks With A Powershift Transmission.......................................................................... 32 DISASSEMBLY............................................................................................................. 33 CLEANING................................................................................................................ 33 INSPECTION.............................................................................................................. 33 ASSEMBLY................................................................................................................ 33 INSTALLATION............................................................................................................ 34 Lift Trucks With A Manual Transmission.............................................................................. 34 Lift Trucks With A Powershift Transmission.......................................................................... 35 TROUBLESHOOTING............................................................................................................. 36 SPECIFICATIONS.............................................................................................................. 36 FIGURE 1. ELECTRICAL SCHEMATIC (GASOLINE/LPG, EARLY PRODUCTION)............................................................. 37 FIGURE 2. ELECTRICAL SCHEMATIC (GASOLINE/LPG, LATER PRODUCTION)............................................................. 39 FIGURE 3. ELECTRICAL SCHEMATIC (DIESEL, PERKINS 4.2482)..................................................................... 41 FIGURE 4. ELECTRICAL SCHEMATIC (DIESEL, PERKINS 1004-4, EARLY PRODUCTION)................................................... 43 FIGURE 5. ELECTRICAL SCHEMATIC (DIESEL, PERKINS 1004-4, LATER PRODUCTION)................................................... 45 FIGURE 6. HYDRAULIC SCHEMATIC............................................................................................... 47 FIGURE 7. HYDRAULIC SCHEMATIC, POWERSHIFT TRANSMISSION WITH MANUAL CONTROL.................................................. 48 FIGURE 8. HYDRAULIC SCHEMATIC, POWERSHIFT TRANSMISSION WITH MONTROL PEDAL................................................... 49 FIGURE 9. WIRING DIAGRAM, BACK-UP ALARM..................................................................................... 50 INTRODUCTION................................................................................................................ 51 GENERAL................................................................................................................. 51 DESCRIPTION AND OPERATION................................................................................................... 51 GENERAL................................................................................................................. 51 ECM (ELECTRONIC CONTROL MODULE)......................................................................................... 51 ALDL Connector...................................................................................................... 53 How The ECM Begins Operation........................................................................................ 53 ELECTRONIC ENGINE CONTROL............................................................................................... 54 What The ECM Does................................................................................................... 54 Pulse Generator, EST Distributor.................................................................................... 55 EST Module(See FIGURE 9.)........................................................................................... 56 When the Engine Is Being Started.................................................................................... 56 When the Engine Is Running.......................................................................................... 58 Electronic Control Module (ECM) With EST Distrubutor, Corrrections.................................................. 58 What The ECM Does................................................................................................... 58 FUEL CONTROL............................................................................................................ 59 Throttle Body Injection............................................................................................. 59 Fuel Injectors...................................................................................................... 60 Fuel Pressure Regulator............................................................................................. 60 Throttle Position Sensor............................................................................................ 60 Idle Air Control.................................................................................................... 60 Governor Motor And Throttle Drive Assembly.......................................................................... 61 Vacuum Ports........................................................................................................ 63 Fuel Pump........................................................................................................... 63 ECM SENSORS AND CONTROLLERS............................................................................................. 65 Manifold Absolute Pressure (MAP).................................................................................... 65 Coolant Temperature Sensor (CTS).................................................................................... 65 Initial Timing Connector (EST Distributor).......................................................................... 65 ELECTRONIC ENGINE CONTROL, TROUBLESHOOTING AND REPAIR....................................................................... 67 GENERAL................................................................................................................. 67 Engine Data......................................................................................................... 67 LIGHT BULB CHECK........................................................................................................ 67 SYSTEM CHECK............................................................................................................ 69 TROUBLESHOOTING WITH THE FAULT MONITOR SYSTEM IN THE ECM................................................................ 69 How To Clear A Code................................................................................................. 70 Fault In The ECM.................................................................................................... 70 Fault In The PROM................................................................................................... 71 CalPak Not Installed................................................................................................ 71 Fuel Control........................................................................................................ 71 Idle Air Control (IAC).............................................................................................. 71 Fuel Pump Circuit................................................................................................... 71 Coolant Temperature Sensor (CTS).................................................................................... 72 Manifold Absolute Pressuer Sensor (MAP)............................................................................. 72 Throttle Position Sensodr (TPS)..................................................................................... 72 Output Check, Throttle Position Sensor.............................................................................. 72 Electronic Spark Timing............................................................................................. 72 Engine Crank Signal................................................................................................. 73 Distributor Reference Signal........................................................................................ 73 TROUBLESHOOTING CHARTS...................................................................................................... 74 CHART A-1-No "Check Engine" Light....................................................................................... 74 Circuit Description, "Check Engine" Light........................................................................... 74 CHART A-1-No "Check Engine" Light....................................................................................... 75 CHART A-2-No ALDL Data Or No Code 12 From "Check Engine" Light. The "Check Engine" Light Is Continuosly Illuminated..... 76 Circuit Description, "Check Engine" Light........................................................................... 76 CHART A-2-No ALDL Data Or No Code 12 From "Check Engine" Light. The "Check Engine" Light Is Continuously Illuminated.... 77 CHART A-3-Starter Cranks The Engine, But Will Not Run................................................................... 78 Circuit Description................................................................................................. 79 CHART A-4-Fuel Injector Circuit......................................................................................... 80 Circuit Description................................................................................................. 80 CHART A-5-Fuel Pump Relay Circuit....................................................................................... 82 Circuit Description................................................................................................. 82 CHART A-6-Fuel System Pressure Test..................................................................................... 84 Circuit Description................................................................................................. 84 CHART A-7-MAP Output Check.............................................................................................. 86 Circuit Description................................................................................................. 86 CHART A-8-Engine Crank Signal Check..................................................................................... 88 Circuit Description................................................................................................. 88 CHART A-9-Ignition System Troubleshooting............................................................................... 89 CHART A-9 Ignition System Troubleshooting Chart......................................................................... 90 CHART A-10-Idle Air Control (IAC) System................................................................................ 92 Circuit Description................................................................................................. 92 FAULT CODES................................................................................................................. 94 CODE 14-Coolant Temperature Sensor Circuit (Indicates High Temperature)................................................. 94 Circuit Description................................................................................................. 94 CODE 15-Coolant Temperature Sensor Circuit (Indicates Low Temperature................................................... 96 Circuit Description................................................................................................. 96 CODE 21-Throttle Position Sensor Circuit (Signal Voltage High) ......................................................... 98 Circuit Description................................................................................................. 98 CODE 22-Throttle Position Sensor Circuit (Signal Voltage Low) ..........................................................100 Circuit Description.................................................................................................100 CODE 31-Engine Governor Circuit.........................................................................................102 Circuit Description.................................................................................................102 CODE 33-MAP Sensor Circuit, Signal Voltage High (Low Vacuum.............................................................104 Circuit Description.................................................................................................104 CODE 34-MAP Sensor Circuit, Signal Voltage Low (High Vacuum)............................................................106 Circuit Description.................................................................................................106 CODE 42-Electronic Spark Timing (EST)...................................................................................108 Circuit Description.................................................................................................108 CODE 54-Fuel Pump Circuit (Low Voltage).................................................................................110 Circuit Description.................................................................................................110 CODE 51-PROM In The ECM Has A Fault ....................................................................................112 CODE 52-Fuel CalPak Is Missing..........................................................................................112 CODE 55-ECM Has A Fault.................................................................................................112 TROUBLESHOOTING, POOR OPERATION.........................................................................................112 General.............................................................................................................112 Make A Careful Visual Check.........................................................................................112 FAULT: Fuel Usage Too High..........................................................................................112 FAULT: Codes Or Performance That Is Not Regular.....................................................................113 FAULT: "Dieseling"..................................................................................................113 FAULT: "Backfire"...................................................................................................113 FAULT: Rough Idle or Engine Stalls During Idle......................................................................113 FAULT: Smoke In The Exhaust Gases...................................................................................114 FAULT: Engine is Difficult To Start.................................................................................114 FAULT: Variation In Engine Power When The Throttle Is Held Steady...................................................115 FAULT: Decreased Engine Power.......................................................................................115 FAULT: "Detontion"..................................................................................................115 FAULT: Engine Momentarily Does Not Increase Power When Throttle Changes.............................................116 FAULT: One Cylinder In The Engine Does Not Operate Correctly. The Engine Does Not Idle Correctly....................116 REPAIRS, FUEL SYSTEM COMPONENTS ........................................................................................118 General.............................................................................................................118 Vacuum Ports........................................................................................................118 Throttle Body Injection (TBI) Unit..................................................................................118 TBI Unit, Removal...................................................................................................118 TBI Unit, Cleaning and Inspection...................................................................................119 TBI Unit, Installation..............................................................................................119 Cover For Fuel Meter Body, Replacement..............................................................................119 Fuel Injectors......................................................................................................120 Fuel Injectors, Removal.............................................................................................120 Fuel Injectors, Installation........................................................................................121 Pressure Regulator, Removal.........................................................................................121 Pressure Regulator, Inspection......................................................................................121 Pressure Regulator, Installation ...................................................................................121 Fuel Meter Body, Removal............................................................................................122 Fuel Meter Body, Installation.......................................................................................122 Throttle Position Sensor (TPS), Removal.............................................................................122 Throttle Position Sensor (TPS), Installation........................................................................122 Idle Air Control (IAC) Valve, Removal...............................................................................123 Cleaning and Inspection.............................................................................................123 Idle Air Control (IAC) Valve, Installation..........................................................................123 Governor Throttle Drive Assembly, Removal...........................................................................123 Governor Throttle Drive Assembly, Inspection........................................................................123 Cleaning and Lubrication............................................................................................124 Governor Throttle Drive Assembly, Installation......................................................................124 Governor Drive Motor, Removal.......................................................................................125 Governor Drive Motor, Cleaning and Lubrication......................................................................125 Governor Drive Motor, Installation..................................................................................126 Governor Drive Motor, Inspection....................................................................................126 Throttle Body, Removal and Disassembly..............................................................................126 Throttle Body, Inspection...........................................................................................126 Throttle Body, Assembly and Installation............................................................................126 Fuel Pump, Removal and Disassembly..................................................................................127 Fuel Pump, Inspection...............................................................................................127 REPAIRS, ELECTRICAL COMPONENTS..........................................................................................127 General.............................................................................................................127 Ignition Coil Test..................................................................................................127 Ignition Module Test................................................................................................128 Distributor, Removal................................................................................................128 Distributor, Disassembly............................................................................................129 Distributor, Assembly...............................................................................................129 Distributor, Installation...........................................................................................130 Firing Order........................................................................................................131 Ignition Timing.....................................................................................................131 Ignition Coil, Removal..............................................................................................132 Ignition Coil, Installation.........................................................................................132 Procedures For Spark Plugs, Spark Plug Wires And Boots .............................................................132 Troubleshooting of Spark Plugs......................................................................................133 Coolant Temperature Sensor (CTS), Replacement ......................................................................134 Manifold Absolute Pressure (MAP) Sensor, Replacement................................................................134 Oil Pressure Switch, Replacement....................................................................................135 Coolant Temperature Sender, Replacement.............................................................................135 Wire Harness........................................................................................................135 Connectors And Terminals............................................................................................135 Electronic Control Module (ECM).....................................................................................139 ECM CONNECTOR A-B IDENTIFICATION........................................................................................143 ECM CONNECTOR C-D IDENTIFICATION........................................................................................144 SPECIAL TOOLS...............................................................................................................145 INTRODUCTION................................................................................................................148 NOMENCLATURE, THREADS...................................................................................................148 STRENGTH IDENTIFICATION.................................................................................................149 TABLE 1. BOLTS AND SCREWS...................................................................................................149 TABLE 2. STUDS AND NUTS.....................................................................................................150 TABLE 3. TORQUE NUTS........................................................................................................151 TABLE 4. TORQUE NUTS WITH NYLON INSERT......................................................................................152 TABLE 5. TORQUE VALUES FOR INCH FASTENERS...................................................................................153 TABLE 6. TORQUE VALUES FOR METRIC FASTENERS.................................................................................154 THE FRAME...................................................................................................................157 GENERAL.................................................................................................................157 DESCRIPTION.............................................................................................................157 REPAIRS.................................................................................................................157 COUNTERWEIGHT...........................................................................................................157 Removal.............................................................................................................157 COUNTERWEIGHT...........................................................................................................158 Installation........................................................................................................158 HOOD....................................................................................................................158 Removal.............................................................................................................158 HOOD....................................................................................................................158 Installation........................................................................................................158 OVERHEAD GUARD..........................................................................................................159 Removal.............................................................................................................159 Installation........................................................................................................159 OPERATOR RESTRAINT SYSTEM...............................................................................................159 RADIATOR................................................................................................................159 Removal.............................................................................................................159 Installation........................................................................................................160 EXHAUST SYSTEM..........................................................................................................160 Muffler Replacement.................................................................................................160 ENGINE..................................................................................................................160 Removal.............................................................................................................160 Installation........................................................................................................163 FUEL AND HYDRAULIC TANKS................................................................................................164 Inspection..........................................................................................................164 Repairs, Small Leaks................................................................................................164 Repairs, Large Leaks................................................................................................164 Cleaning............................................................................................................164 Other Methods Of Preparation For Repair.............................................................................165 SAFETY LABELS...........................................................................................................166 CAB.................................................................................................................166 Cab Repalacement....................................................................................................166 Window Repalcement......................................................................................................166 Windshield Wipers, Heater and Fan...................................................................................169 Material Specifications For Cab Windows.............................................................................169 Cab Heater Hoses....................................................................................................169 INTRODUCTION................................................................................................................170 DESCRIPTION.............................................................................................................170 OPERATION...............................................................................................................170 Flow Control Valve..................................................................................................172 Relief Valve........................................................................................................172 REPAIRS.....................................................................................................................173 REMOVAL.................................................................................................................173 DISASSEMBLY.............................................................................................................173 CLEANING................................................................................................................175 INSPECTION..............................................................................................................175 ASSEMBLY................................................................................................................176 INSTALLATION............................................................................................................177 CHECKS AND ADUSTMENTS.......................................................................................................178 CHECK THE OUTPUT OF THE PUMP............................................................................................178 CHECK FOR AIR IN THE HYDRAULIC SYSTEM...................................................................................178 TROUBLESHOOTING.............................................................................................................180 WEBER CARBURETOR WITH GOVERNOR..............................................................................................182 GENERAL.................................................................................................................182 DESCRIPTION.............................................................................................................182 Carburetor..........................................................................................................182 Governor............................................................................................................182 OPERATION...............................................................................................................183 Carburetor, Float System............................................................................................183 Carburetor, Idle System.............................................................................................183 Carburetor, Main Metering System....................................................................................183 Carburetor, Power System............................................................................................184 Carburetor, Accelerator Pump System.................................................................................184 Carburetor, Choke System............................................................................................185 GOVERNOR................................................................................................................186 REPAIRS.....................................................................................................................187 CARBURETOR..............................................................................................................187 Removal.............................................................................................................187 Disassembly.........................................................................................................187 Cleaning............................................................................................................187 Assembly............................................................................................................187 Installation........................................................................................................188 GOVERNOR................................................................................................................188 CHECKS AND ADJUSTMENTS......................................................................................................189 GENERAL.................................................................................................................189 CHOKE SYSTEM............................................................................................................189 ELECTRIC CHOKE..........................................................................................................189 IDLE MIXTURE ADJUSTMENT.................................................................................................190 IDLE SPEED ADJUSTMENT...................................................................................................190 THROTTLE LINKAGE ADJUSTMENT.............................................................................................191 TROUBLESHOOTING.........................................................................................................192 GM 4.3 LITRE V-6............................................................................................................193 INTRODUCTION............................................................................................................193 DESCRIPTION.............................................................................................................193 ENGINE, REMOVAL AND INSTALLATION........................................................................................194 CYLINDER HEAD...........................................................................................................194 Removal And Disassembly.............................................................................................194 Cleaning And Inspection.............................................................................................194 Repairs, Valve Guides and Seats.....................................................................................194 Repairs, Valves.....................................................................................................195 Repairs, Valve Seats................................................................................................195 Valve Springs.......................................................................................................196 Studs For The Rocker Arms (Early Models)............................................................................197 Studs For The Rocker Arms (Late Models).............................................................................198 Assembly And Installation...........................................................................................198 CYLINDER BLOCK, CLEANING AND INSPECTION.................................................................................200 PISTON BORE PREPARATION.................................................................................................200 ENGINE MOUNTS...........................................................................................................200 LUBRICATION SYSTEM......................................................................................................200 Oil Pump, Removal and Disassembly...................................................................................200 Cleaning and Inspection.............................................................................................201 Oil Pump, Assembly and Installation.................................................................................201 Oil Sump, Installation..............................................................................................201 TIMING COVER, TIMING SPROCKETS, CAMSHAFT AND VALVE LIFTERS..............................................................202 Timing Cover, Removal...............................................................................................202 Installation........................................................................................................203 Timing Sprockets, Removal...........................................................................................204 Timing Sprockets, Installation......................................................................................204 Camshaft, Removal...................................................................................................204 Camshaft, Inspection................................................................................................204 Camshaft, Installation..............................................................................................204 Balance Shaft, Removal..............................................................................................205 Balance Shaft, Installation.........................................................................................206 Hydraulic Valve Lifters, Removal....................................................................................207 Hydraulic Valve Lifters, Disassembly................................................................................207 Hydraulic Valve Lifters, Cleaning And Inspection....................................................................207 Hydraulic Valve Lifters, Assembly...................................................................................208 Hydraulic Valve Lifters, Installation...............................................................................208 CRANKSHAFT..............................................................................................................209 Removal.............................................................................................................209 Inspection and Repair...............................................................................................209 How To Check The Clearance Between The Main Bearings And Their Journals.............................................210 Installation........................................................................................................211 PISTON AND CONNECTING ROD ASSEMBLIES....................................................................................212 Connecting Rod Bearings, Replacement................................................................................212 Piston And Connecting Rod Assemblies, Removal.......................................................................213 Disassembly.........................................................................................................213 Piston, Cleaning And Inspection.....................................................................................213 Cylinder Bores, Inspection And Repair...............................................................................214 Piston Rings........................................................................................................215 Assembly............................................................................................................215 Piston And Connecting Rod Assemblies, Installation..................................................................216 FLYWHEEL AND FLYWHEEL HOUSING...........................................................................................216 Flywheel Repairs....................................................................................................216 Flywheel, Installation..............................................................................................216 Flywheel Housing....................................................................................................217 Engine Adapter......................................................................................................217 COOLANT PUMP............................................................................................................217 THERMOSTAT..............................................................................................................217 FAN MOUNT, EARLY MODELS.................................................................................................217 FAN MOUNT ASSEMBLY, LATE MODELS.........................................................................................218 DRIVE BELT, INSTALLATION................................................................................................219 CHECKS AND ADJUSTMENTS......................................................................................................221 VALVE CLEARANCE ADJUSTMENT, EARLY MODELS................................................................................221 VALVE CLEARANCE ADJUSTMENT, NEW MODELS..................................................................................221 CHECK THE COMPRESSION...................................................................................................221 ENGINE SPECIFICATIONS.......................................................................................................222 Engine Data.............................................................................................................222 Cylinder head...........................................................................................................222 Hydraulic Valve Lifter..................................................................................................222 Camshaft................................................................................................................222 Pistons.................................................................................................................222 Crankshaft..............................................................................................................223 Connecting Rods.........................................................................................................223 Connecting Rods.........................................................................................................223 Balance Shaft...........................................................................................................223 Cooling System..........................................................................................................223 Lubrication System......................................................................................................223 TORQUE SPECIFICATIONS.......................................................................................................224 TROUBLESHOOTING.............................................................................................................225 HIGH ENERGY IGNITION (HEI)..................................................................................................228 DESCRIPTION.............................................................................................................228 REPAIRS.....................................................................................................................230 DISTRIBUTOR.............................................................................................................230 Removal.............................................................................................................230 Disassembly.........................................................................................................230 Assembly............................................................................................................235 INSTALLATION, IF THE CRANKSHAFT WAS NOT ROTATED WHEN DISTRIBUTOR WAS REMOVED............................................236 INSTALLATION, IF THE CRANKSHAFT WAS ROTATED WHEN THE DISTRIBUTOR WAS REMOVED............................................237 IGNITION COIL...........................................................................................................237 Removal, Some 4 and 6 Cylinder Models...............................................................................237 Installation, Some 4 and 6 Cylinder Models..........................................................................238 Removal, V8, Some 4 and 6 Cylinder Models...........................................................................238 Installation, V8, Some 4 and 6 Cylinder Models......................................................................239 ELECTRONIC MODULE.......................................................................................................240 Removal.............................................................................................................240 Installation........................................................................................................240 SENSING COIL............................................................................................................241 Removal.............................................................................................................241 Installation........................................................................................................241 SPARK PLUGS.............................................................................................................241 Removal.............................................................................................................241 Installation........................................................................................................242 CHECKS AND ADJUSTMENTS..................................................................................................242 Visual Checks.......................................................................................................242 Check The High Voltage Wires........................................................................................242 Checking The Ignition Coil..........................................................................................242 Coil In Distributor Cap Design......................................................................................242 Separate Coil Design................................................................................................243 Checking The Sensing Coil...........................................................................................243 Check The Electronic Module.........................................................................................244 Ignition Timing Adjustment..........................................................................................244 Ignition System, GM V8-366 (6-litre)................................................................................245 Ignition Timing and Idle Speed Adjustment, GM V6-LPG (4.3-litre)....................................................245 SPECIFICATIONS..............................................................................................................245 TROUBLESHOOTING.............................................................................................................246 INTRODUCTION................................................................................................................247 GENERAL.................................................................................................................247 DESCRIPTION AND OPERATION...............................................................................................247 BRAKE BOOSTER AND MASTER CYLINDER.......................................................................................247 MASTER CYLINDER.........................................................................................................247 SERVICE BRAKE ASSEMBLY..................................................................................................249 PARKING BRAKE...........................................................................................................250 REPAIRS.....................................................................................................................250 BRAKE SHOE ASSEMBLIES...................................................................................................250 Removal and Disassembly.............................................................................................250 Cleaning and Inspection.............................................................................................251 Assembly and Installation...........................................................................................253 MASTER CYLINDER.........................................................................................................256 S3.50-5.50XL (S70-120XL) and H3.50-5.00XL (H70-110XL....................................................................256 Removal ............................................................................................................256 Disassembly.........................................................................................................256 Assembly............................................................................................................257 Installation........................................................................................................257 MASTER CYLINDER, E3.50-5.50XL (E70-120XL)...............................................................................257 Removal and Disassebly..............................................................................................257 Cleaning and Inspection.............................................................................................258 Assembly and Installation...........................................................................................258 BRAKE BOOSTER...........................................................................................................258 Removal.............................................................................................................258 Disassembly.........................................................................................................258 Cleaning and Inspection.............................................................................................259 Assembly............................................................................................................259 Installation........................................................................................................260 CHECKS AND ADJUSTMENTS......................................................................................................260 REMOVE THE AIR FROM THE BRAKE SYSTEM....................................................................................260 ADJUST THE BRAKE PEDAL..................................................................................................260 ADJUST THE BRAKE SHOES..................................................................................................261 ADJUST THE PARKING BRAKE................................................................................................262 CHECK THE RELIEF VALVE ON THE PARKING BOOSTER...........................................................................262 TROUBLESHOOTING.............................................................................................................262 INTRODUCTION................................................................................................................264 GENERAL.................................................................................................................264 DESCRIPTION.............................................................................................................264 REPAIRS.....................................................................................................................266 REMOVAL AND DISASSEMBLY.................................................................................................266 CLEANING................................................................................................................266 INSPECTION..............................................................................................................266 ASSEMBLY AND INSTALLATION...............................................................................................267 TROUBLESHOOTING.............................................................................................................268 GENERAL.................................................................................................................268 INTRODUCTION................................................................................................................269 GENERAL.................................................................................................................269 DESCRIPTION AND OPERATION...............................................................................................269 Hydraulic Pump......................................................................................................269 Main Control Valve..................................................................................................270 Steering Control Unit...............................................................................................272 Brake Booster.......................................................................................................272 REPAIRS.....................................................................................................................272 HYDRAULIC PUMP..........................................................................................................272 Removal.............................................................................................................272 Disassembly.........................................................................................................273 Cleaning and Inspection.............................................................................................273 Assembly............................................................................................................273 Installation........................................................................................................274 Adjust the Flow Divider.............................................................................................274 SPECIFICATIONS..............................................................................................................274 TROUBLESHOOTING.............................................................................................................275 INTRODUCTION................................................................................................................277 GENERAL.................................................................................................................277 DESCRIPTION AND OPERATION...............................................................................................277 Fuel Tank...........................................................................................................278 Fuel Filter and Fuel Valve Unit.....................................................................................278 Vaporizer...........................................................................................................279 Carburetor..........................................................................................................280 Governor............................................................................................................281 REPAIRS.....................................................................................................................283 LPG TANK................................................................................................................283 Removal.............................................................................................................283 Installation........................................................................................................283 HYDROSTATIC RELIEF VALVE................................................................................................283 Removal and Installation............................................................................................283 FILTER UNIT.............................................................................................................285 Replacement Of The Fuel Filter Element..............................................................................285 Replacement of the Diaphragm and Fuel Valve ........................................................................285 REPLACEMENT OF THE HOSES................................................................................................285 VAPORIZER...............................................................................................................285 Removal.............................................................................................................285 Vaporizer Disassembly...............................................................................................287 Cleaning............................................................................................................287 Inspection..........................................................................................................287 Vaporizer Assembly..................................................................................................287 Installation........................................................................................................289 CARBURETOR..............................................................................................................289 Removal.............................................................................................................289 Disassembly.........................................................................................................289 Cleaning............................................................................................................290 Assembly............................................................................................................290 Installation........................................................................................................290 GOVERNOR................................................................................................................290 CHECKS AND ADJUSTMENTS......................................................................................................291 CHECK THE FILTER UNIT...................................................................................................291 CHECK THE VAPORIZER.....................................................................................................291 Pressure Reducer Valve..............................................................................................291 Vapor Valve.........................................................................................................291 ADJUST THE CARBURETOR...................................................................................................292 Idle Mixture........................................................................................................292 Idle Speed .........................................................................................................292 Power Mixture.......................................................................................................292 ADJUST THE THROTTLE LINKAGE.............................................................................................292 TROUBLESHOOTING.............................................................................................................293 INTRODUCTION................................................................................................................296 GENERAL.................................................................................................................296 DESCRIPTION.............................................................................................................296 OPERATION...............................................................................................................297 Lift Section........................................................................................................298 Tilt Section........................................................................................................298 Relief Valve........................................................................................................300 SOLENOID VALVE FOR AUXILIARY FUNCTION...................................................................................301 Operation...........................................................................................................301 REPAIRS.....................................................................................................................301 MAIN CONTROL VALVE......................................................................................................301 Removal and Disassembly.............................................................................................301 Cleaning and Inspection.............................................................................................302 Assembly............................................................................................................302 Installation........................................................................................................302 SOLENOID VALVE FOR AUXILIARY FUNCTION...................................................................................302 Removal and Disassembly.............................................................................................302 Assembly and Installation...........................................................................................304 CHECKS AND ADJUSTMENTS......................................................................................................304 PRESSURE RELIEF VALVES..................................................................................................304 Primary Relief Valve................................................................................................304 Seconday Relief Valve...............................................................................................305 CONTROL LEVER ARRANGEMENT...............................................................................................305 TROUBLESHOOTING.............................................................................................................308 SPECIFICATIONS..............................................................................................................310 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST................................................................................311 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST............................................................................311 LIFT CYLINDERS..............................................................................................................314 GENERAL.................................................................................................................314 DESCRIPTION.............................................................................................................314 Lowering Control Valve..............................................................................................314 Cylinders (General).................................................................................................317 Cylinders (H520-620B,H700-800A).....................................................................................319 Cylinders (H360-460B)...............................................................................................320 Cylinders (Two-Speed)...............................................................................................320 REPAIRS.....................................................................................................................321 REMOVAL OF THE LIFT CYLINDER WITHOUT REMOVING THE MAST..................................................................321 Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast............................321 Standard and Full Free-Lift Masts with the Lift Cylinder to a Crosshead.............................................325 Masts that have Two Cylinders, A Main Lift Cylinder and a Free-Lift Cylinder.......................................323 DISASSEMBLY.............................................................................................................323 ASSEMBLY................................................................................................................325 INSTALLATION OF THE LIFT CYLINDER IN THE MAST...........................................................................325 Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast............................325 Standard and Full-Free-Lift Masts with the Lift Cylinder Fastened to a Crosshead....................................325 CHEVRON PACKING.........................................................................................................326 LIFT CYLINDERS FOR VISTA MASTS..............................................................................................329 DESCRIPTION.............................................................................................................329 Lowering Control Valve..............................................................................................331 REMOVAL.................................................................................................................332 DISASSEMBLY.............................................................................................................332 ASSEMBLY................................................................................................................332 INSTALLATION............................................................................................................333 Main Lift Cylinders.................................................................................................333 Free-Lift Cylinders.................................................................................................333 CHECKS AND ADJUSTMENTS......................................................................................................334 CHECK FOR LEAKS IN LIFT SYSTEM..........................................................................................334 TROUBLESHOOTING.............................................................................................................335 SPECIFICATIONS..............................................................................................................336 VISTA® MASTS................................................................................................................337 GENERAL.................................................................................................................337 DESCRIPTION AND OPERATION...............................................................................................337 CARRIAGES...............................................................................................................337 TWO-STAGE MAST WITH LIMITED FREE-LIFT...................................................................................337 TWO-STAGE MAST WITH FULL FREE-LIFT MAST.................................................................................338 THREE-STAGE MAST WITH FULL FREE-LIFT....................................................................................339 REPAIRS.....................................................................................................................341 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST (1 OF 2)...................................................................341 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST (2 OF 2)...................................................................342 FORKS...................................................................................................................342 Forks, Removal And Installation.....................................................................................342 CARRIAGE................................................................................................................344 Removal.............................................................................................................344 SIDE-SHIFT CARRIAGE (EARLIER DESIGNS)...................................................................................345 Disassembly, Side Shift Carriage....................................................................................345 Assembly, Side Shift Carriage.......................................................................................347 Installation........................................................................................................348 SIDE-SHIFT CARRIAGE (1993 AND LATER DESIGN).............................................................................348 Removal.............................................................................................................348 Repairs.............................................................................................................349 Installation........................................................................................................350 TABLE 1. WEIGHT OF MAST PARTS...........................................................................................350 TWO-STAGE MAST WITH LIMITED FREE-LIFT...................................................................................351 Removal.............................................................................................................351 Disassembly.........................................................................................................351 Cleaning and Inspection.............................................................................................353 Assembly............................................................................................................353 Installation........................................................................................................354 TWO-STAGE MAST WITH FULL FREE-LIFT......................................................................................354 Removal.............................................................................................................354 Disassembly.........................................................................................................354 Cleaning and Inspection.............................................................................................355 Assembly............................................................................................................355 Installation........................................................................................................355 THREE-STAGE MAST WITH FULL FREE LIFT....................................................................................356 Removal.............................................................................................................356 Disassembly.........................................................................................................356 Cleaning and Inspection.............................................................................................357 Assembly............................................................................................................357 Installation........................................................................................................359 CHECKS AND ADJUSTMENTS......................................................................................................361 CHECK THE OPERATION OF THE MAST.........................................................................................361 CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM.............................................................................361 Lift System.........................................................................................................361 Tilt System.........................................................................................................361 ADJUST THE TILT CYLINDER STROKE AND THE BACKWARD TILT ANGLE.............................................................362 LIFT CHAIN ADJUSTMENTS..................................................................................................362 MAST ADJUSTMENTS........................................................................................................363 CARRIAGE ADJUSTMENT.....................................................................................................364 TROUBLESHOOTING.............................................................................................................367 MICROPROCESSOR SPARK TIMING SYSTEM (MSTS)...................................................................................369 GENERAL.................................................................................................................369 DESCRIPTION.............................................................................................................369 What MSTS Does......................................................................................................371 How MSTS Begins Operation...........................................................................................371 OPERATION...............................................................................................................371 Pulse Generator.....................................................................................................371 HEI Module..........................................................................................................372 When the Engine Is Being Started....................................................................................372 When the Engine Is Running..........................................................................................374 Manifold Absolute Pressure (MAP)....................................................................................374 Coolant Temperature Sensor (CTS)....................................................................................374 Electronic Control Module (ECM), Corrections........................................................................375 The Initial Timing Connector........................................................................................375 Gasoline and LPG Conversions........................................................................................376 TROUBLESHOOTING.............................................................................................................378 GENERAL.................................................................................................................378 TOOLS AND TEST EQUIPMENT................................................................................................378 MSTS TROUBLESHOOTING....................................................................................................379 Test Description....................................................................................................379 IGNITION SYSTEM TROUBLESHOOTING.........................................................................................381 Test Description....................................................................................................381 ELECTRONIC SPARK TIMING (EST) TROUBLESHOOTING...........................................................................384 Circuit Description.................................................................................................384 Test Description....................................................................................................384 MANIFOLD ABSOLUTE PRESSURE (MAP) TROUBLESHOOTING........................................................................387 Circuit Description.................................................................................................387 Test Description....................................................................................................387 COOLANT TEMPERATURE SENSOR (CTS) TROUBLESHOOTING........................................................................390 Circuit Description.................................................................................................390 Test Description....................................................................................................390 REPAIRS.....................................................................................................................392 DISTRIBUTOR.............................................................................................................392 Removal.............................................................................................................392 Disassembly.........................................................................................................393 Inspection..........................................................................................................393 Assembly............................................................................................................394 Installation........................................................................................................394 Igntion Timing......................................................................................................394 HEI MODULE..............................................................................................................395 Test For A Fault....................................................................................................395 HEI Module Replacement..............................................................................................395 SENSING COIL............................................................................................................396 Test For A Fault....................................................................................................396 Sensing Coil Replacement............................................................................................396 IGNITION COIL...........................................................................................................396 Test For A Fault....................................................................................................396 ELECTRONIC CONTROL MODULE (ECM).........................................................................................397 Removal.............................................................................................................397 Installation........................................................................................................397 COOLANT TEMPERATURE SENSOR (CTS)........................................................................................397 Removal.............................................................................................................397 Installation........................................................................................................398 MANIFOLD ABSOLUTE PRESSURE (MAP)........................................................................................398 Removal.............................................................................................................398 Installation........................................................................................................398 PRESSURE CONVERSION CHART...........................................................................................399 INTRODUCTION................................................................................................................400 General.................................................................................................................400 Description.............................................................................................................400 REPAIRS.....................................................................................................................402 Removal and Disassembly.................................................................................................402 Cleaning and Inspection.................................................................................................403 Assembly and Installation...............................................................................................404 CHECKS AND ADJUSTMENTS......................................................................................................406 Adjusting the Clutch Pedal and Linkage..................................................................................406 Adjusting the By-pass Valve for Cold Oil................................................................................406 TROUBLESHOOTING.............................................................................................................407 PERIODIC MAINTENANCE........................................................................................................409 GENERAL.................................................................................................................409 SERIAL NUMBER DATA......................................................................................................409 HOW TO MOVE A DISABLED LIFT TRUCK.......................................................................................409 How To Tow the Lift Truck...........................................................................................409 HOW TO PUT A LIFT TRUCK ON BLOCKS.......................................................................................410 How To Raise the Drive Tires........................................................................................410 How To Raise the Steering Tires.....................................................................................410 MAINTENANCE SCHEDULE........................................................................................................412 MAINTENANCE PROCEDURES......................................................................................................415 EVERY 8 HOURS OR DAILY......................................................................................................415 HOW TO MAKE THE CHECKS WITH THE ENGINE STOPPED..........................................................................415 Hydraulic System Oil................................................................................................415 Engine Oil..........................................................................................................417 Drive Belts.........................................................................................................417 Cooling System......................................................................................................417 Air Filter..........................................................................................................417 Fuel System.........................................................................................................418 Primary Fuel Filter, Diesel Engine..................................................................................418 Battery.............................................................................................................418 Tires and Wheels....................................................................................................418 Forks...............................................................................................................419 Forks, Adjustment...................................................................................................419 Forks, Removal And Installation.....................................................................................419 Inspection of Forks, Mast, And Lift Chains..........................................................................420 Operator Restraint System...........................................................................................422 Safety Labels.......................................................................................................423 HOW TO MAKE THE CHECKS WITH THE ENGINE RUNNING..........................................................................423 Gauges, Lights, Horn, and Fuses.....................................................................................423 Oil Level, Powershift Transmission..................................................................................423 Oil Level, Oil Clutch System, H3.50-5.00XL (H70-110XL)..............................................................424 Control Levers and Pedals...........................................................................................424 Lift System Operation...............................................................................................424 Inching/Brake Pedal.................................................................................................425 Service Brakes......................................................................................................425 Parking Brake.......................................................................................................425 Steering System.....................................................................................................425 EVRY 150 HOURS OR MONTHLY...................................................................................................425 THRUST SCREW FOR THE DIFFERENTIAL, H6.00-7.00XL (H135-155XL)............................................................425 LIFT CHAINS, LUBRICATION................................................................................................425 DRIVE SHAFTS............................................................................................................426 EVERY 350 HOURS OR TWO MONTHS...............................................................................................426 ENGINE OIL AND FILTER...................................................................................................426 DRIVE BELTS.............................................................................................................427 Perkins Diesel Engine...............................................................................................427 GM V-6 Engine (Early Models)........................................................................................427 GM V-6 Engine (Later Models)........................................................................................428 HYDRAULIC TANK BREATHER, CLEAN AND CHECK................................................................................429 BRAKE FLUID.............................................................................................................429 LIFT CHAINS, CHECK FOR WEAR.............................................................................................429 FORKS, CHECK FOR WEAR AND DAMAGE........................................................................................430 MAST, LUBRICATION.......................................................................................................430 CONTROL LEVERS AND PEDALS, LUBRICATION..................................................................................430 STEERING AXLE, LUBRICATION..............................................................................................431 FUEL SYSTEM, CHECKS AND ADJUSTMENTS.....................................................................................431 Diesel Fuel System..................................................................................................431 LPG Carburetor (Early Models).......................................................................................431 Gasoline Carburetor (Early Models)..................................................................................432 Fuel Injection (Late Models)........................................................................................432 EVERY 1000 HOURS OR SIX MONTHS..............................................................................................432 PCV VALVE, GM V-6.......................................................................................................432 MANIFOLD HEAT VALVE, GM V-6 (EARLY MODELS)..............................................................................432 CRANKCASE BREATHER, GM-V6...............................................................................................432 IGNITION SYSTEM (GM V-6)................................................................................................432 VALVE CLEARANCE ADJUSTMENT..............................................................................................433 FUEL FILTER (REPLACEMENT), DIESEL ENGINE................................................................................433 REMOVE AIR FROM THE FUEL SYSTEM: PERKINS 1004-4 DIESEL ENGINE...........................................................433 Fuel Injection Pump With A Vent Tube................................................................................433 Fuel Injection Pump With A Vent Screw...............................................................................434 REMOVE AIR FROM THE FUEL SYSTEM: PERKINS 4.2482 DIESEL ENGINE...........................................................435 CHECK THE OIL LEVEL IN THE TRANSMISSION.................................................................................435 Manual Transmission, H3.50-5.00XL (H70-110XL).......................................................................435 Speed Reducer For The Powershift Transmission, H3.50-5.00XL (H70-110XL).............................................436 Manual Transmission, H6.00-7.00XL (H135-155XL)......................................................................436 Differential And Drive Axle For The Powershift Transmission, H6.00-7.00XL (H135-155XL...............................436 Differential, Speed Reducer, And Drive Axle For The Manual Transmission, H6.00-7.00XL (H135-155XL)..................436 EVERY 2000 HOURS OR YEARLY..................................................................................................436 HYDRAULIC SYSTEM........................................................................................................436 Replace the Hydraulic Oil and Filter, H3.50-5.00XL (H70-110XL)......................................................436 Replace the Hydraulic Oil and Filter, H6.00-7.00XL (H135-155XL).....................................................437 CHANGE THE OIL AND REPLACE THE OIL FILTER, POWERSHIFT TRANSMISSION, ALL UNITS...........................................437 CHANGE THE OIL, MANUAL TRANSMISSION, H3.50-5.00XL (H70-110XL)...........................................................437 CHANGE THE OIL, MANUAL TRANSMISSION, H6.00-7.00XL (H135-155XL)..........................................................437 CHANGE THE OIL, SPEED REDUCER, POWERSHIFT TRANSMISSION, H3.50-5.00XL (H70-110XL)........................................438 CHANGE THE OIL AND FILTER, OIL CLUTCH SYSTEM, H3.50-5.00XL (H70-110XL)..................................................438 CHANGE THE OIL, DIFFERENTIAL AND DRIVE AXLE FOR THE POWERSHIFT TRANSMISSION, H6.00-7.00XL (H135-155XL)..................438 CHANGE THE OIL, DIFFERENTIAL, SPEED REDUCER, AND DRIVE AXLE FOR MANUAL TRANSMISSION, H6.00-7.00XL (H135-155XL)..........438 COOLING SYSTEM..........................................................................................................439 WHEEL BEARINGS..........................................................................................................439 Steering Wheels, lubrication........................................................................................439 Drive Wheels, Lubrication...........................................................................................439 PCV VALVE, GM V-6.......................................................................................................439 SERVICE BRAKES..........................................................................................................439 LPG FILTER, REPLACEMENT.................................................................................................440 GASOLINE FUEL FILTER, REPLACEMENT.......................................................................................440 CHECK THE HOOD LATCH, H3.50-5.00XL (H70-110XL)..........................................................................440 GENERAL PROCEDURES..........................................................................................................441 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST............................................................................441 LIFT CHAIN ADJUSTMENTS..................................................................................................443 FUEL INJECTORS..........................................................................................................443 CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM.............................................................................444 Check the Lift Cylinder for Leaks...................................................................................444 Check the Tilt Cylinder for Leaks...................................................................................444 WELDING REPAIRS.........................................................................................................444 CHANGES TO THE OVERHEAD GUARD...........................................................................................445 WHEELS AND TIRES........................................................................................................446 Remove The Wheels From The Lift Truck...............................................................................446 Remove The Wheel From The Tire......................................................................................446 Install The Wheel In The Tire.......................................................................................448 Pneumatic Tires, Add Air To The Tires...............................................................................449 Install the Wheels..................................................................................................449 SOLID RUBBER TIRES......................................................................................................450 Remove The Tire From The Wheel......................................................................................450 Install The Tire On The Wheel.......................................................................................451 REFERENCE TABLE.............................................................................................................452 INTRODUCTION................................................................................................................453 GENERAL.................................................................................................................453 DESCRIPTION.............................................................................................................453 ENGINE SERIAL NUMBER CODES..............................................................................................454 REMOVAL AND INSTALLATION................................................................................................454 ENGINE......................................................................................................................454 CYLINDER HEAD...........................................................................................................454 Removal.............................................................................................................454 Installation........................................................................................................455 Cylinder Head Repairs...............................................................................................456 OIL PUMP................................................................................................................458 Removal.............................................................................................................458 Disassembly.........................................................................................................458 Inspection..........................................................................................................458 Assembly............................................................................................................459 Installation........................................................................................................459 RELIEF VALVE............................................................................................................460 TIMING GEAR CASE AND TIMING GEARS.......................................................................................460 Removal.............................................................................................................460 Installation........................................................................................................461 PISTONS AND CONNECTING RODS.............................................................................................462 Removal.............................................................................................................462 Disassembly.........................................................................................................462 Inspection..........................................................................................................463 Assembly............................................................................................................464 Installation........................................................................................................464 CRANKSHAFT AND MAIN BEARINGS............................................................................................465 Removal.............................................................................................................465 Inspection..........................................................................................................465 Assembly............................................................................................................466 CAMSHAFT AND CAM FOLLOWERS..............................................................................................467 Removal.............................................................................................................467 Inspection..........................................................................................................468 Assembly............................................................................................................468 FLYWHEEL AND FLYWHEEL HOUSING...........................................................................................469 Removal.............................................................................................................469 Repairs.............................................................................................................469 Installation........................................................................................................469 STEERING PUMP DRIVE.....................................................................................................469 Removal.............................................................................................................469 Installation........................................................................................................470 PCV VALVE...............................................................................................................470 FUEL SYSTEM.................................................................................................................470 FUEL PUMP...............................................................................................................470 Removal.............................................................................................................470 Disassembly.........................................................................................................470 Assembly............................................................................................................470 Installation........................................................................................................471 FUEL INJECTION PUMP.....................................................................................................471 Removal.............................................................................................................471 Repairs.............................................................................................................471 Installation........................................................................................................471 FUEL INJECTORS..........................................................................................................471 Removal.............................................................................................................471 Repairs.............................................................................................................472 Installation........................................................................................................472 COLD START AID..........................................................................................................472 Description.........................................................................................................472 Removal.............................................................................................................472 Installation........................................................................................................472 COOLING SYSTEM..............................................................................................................473 THERMOSTAT..............................................................................................................473 Removal.............................................................................................................473 Inspection..........................................................................................................473 Installation........................................................................................................473 WATER PUMP..............................................................................................................473 Removal.............................................................................................................473 Disassembly.........................................................................................................473 Assembly............................................................................................................473 Installation........................................................................................................473 CHECKS AND ADJUSTMENTS......................................................................................................473 CHECKING THE INJECTORS..................................................................................................473 Repairs.............................................................................................................474 Installation........................................................................................................474 REMOVING AIR FROM THE FUEL SYSTEM.......................................................................................474 CHECKING THE TIMING MARKS...............................................................................................475 Method A............................................................................................................475 Method B............................................................................................................476 CHECKING THE TIMING ANGLE OF THE FUEL INJECTION PUMP WITH THE SPECIAL TOOL..............................................477 VALVE CLEARANCE ADJUSTMENT..............................................................................................478 ADJUSTING THE THROTTLE LINKAGE..........................................................................................478 TROUBLESHOOTING.............................................................................................................480 SPECIFICATIONS..............................................................................................................481 TORQUE SPECIFICATIONS.......................................................................................................484 PERKINS DIESEL ENGINES, SERIES 1000.........................................................................................485 1.1 GENERAL.............................................................................................................485 GENERAL SAFETY RULES....................................................................................................485 Viton Seals.........................................................................................................485 1.2 DESCRIPTION.........................................................................................................488 1.3 Engine Serial Number Codes......................................................................................488 1.4 Engine Data.....................................................................................................488 1.5 1004–4 ENGINE...................................................................................................489 1.6 1004–4T ENGINE..................................................................................................489 1.7 1006–6 ENGINE...................................................................................................489 1.8 1006–6T ENGINE..................................................................................................489 1.9 REMOVAL AND INSTALLATION............................................................................................489 CYLINDER HEAD ASSEMBLY......................................................................................................490 1.10 VALVE COVER........................................................................................................490 1.11 Removal........................................................................................................490 1.12 Installation...................................................................................................490 1.13 ROCKER ARM ASSEMBLY................................................................................................490 1.14 Removal........................................................................................................490 1.15 Installation...................................................................................................490 1.16 Disassembly....................................................................................................491 1.17 Inspection.....................................................................................................491 1.18 Assembly.......................................................................................................491 1.19 VALVE CLEARANCE ADJUSTMENTS........................................................................................491 1.20 Four Cylinder Engines..........................................................................................492 1.21 Six Cylinder Engines...........................................................................................492 1.22 VALVE SPRINGS......................................................................................................492 1.23 CYLINDER HEAD ASSEMBLY.............................................................................................494 1.24 Removal........................................................................................................494 1.25 Installation...................................................................................................495 1.26 VALVES AND VALVE SPRINGS...........................................................................................498 1.27 Removal........................................................................................................498 1.28 Inspection.....................................................................................................499 1.29 Installation...................................................................................................499 1.30 VALVE GUIDES.......................................................................................................499 1.31 Inspection.....................................................................................................499 1.32 Removal........................................................................................................500 1.33 Installation...................................................................................................500 1.34 CYLINDER HEAD AND VALVE SEATS......................................................................................500 1.35 Inspection.....................................................................................................500 1.36 Repair.........................................................................................................501 1.37 Installation Of New Valve Seats................................................................................501 PISTON AND CONNECTING ROD ASSEMBLIES........................................................................................502 1.38 ROD BEARINGS.......................................................................................................502 1.39 Removal........................................................................................................502 1.40 Installation...................................................................................................503 1.41 PISTON AND CONNECTING ROD ASSEMBLY.................................................................................503 1.42 Service Note...................................................................................................503 1.43 Removal........................................................................................................503 1.44 Installation...................................................................................................504 1.45 PISTON RINGS.......................................................................................................505 1.46 Removal........................................................................................................505 1.47 Inspection.....................................................................................................505 1.48 Installation...................................................................................................506 1.49 PISTON AND CONNECTING ROD..........................................................................................507 1.50 Disassembly....................................................................................................507 1.51 Inspection.....................................................................................................507 1.52 Installation...................................................................................................507 1.53 PISTON COOLING JETS................................................................................................508 1.54 Removal........................................................................................................508 1.55 Installation...................................................................................................508 CRANKSHAFT ASSEMBLY.........................................................................................................509 1.56 GENERAL............................................................................................................509 1.57 CRANKSHAFT PULLEY..................................................................................................509 1.58 Removal, Engines AA and AB.....................................................................................509 1.59 Installation, Engines AA and AB................................................................................509 1.60 Removal, Engines YA and YB.....................................................................................509 1.61 Installation, Engines YA and YB................................................................................509 1.62 REAR OIL SEAL......................................................................................................510 1.63 Replacement....................................................................................................510 1.64 MAIN BEARINGS......................................................................................................511 1.65 Removal........................................................................................................511 1.66 Installation...................................................................................................511 1.67 THRUST WASHERS.....................................................................................................512 1.68 Check The Axial Movement Of The Crankshaft.....................................................................512 1.69 Removal........................................................................................................513 1.70 Installation...................................................................................................513 1.71 CRANKSHAFT.........................................................................................................513 1.72 Removal........................................................................................................513 1.73 Inspection.....................................................................................................514 1.74 Installation...................................................................................................514 TIMING CASE AND TIMING GEARS................................................................................................516 1.75 GENERAL............................................................................................................516 1.76 TIMING CASE COVER..................................................................................................516 1.77 Removal........................................................................................................516 1.78 Installation...................................................................................................516 1.79 FRONT OIL SEAL.....................................................................................................517 1.80 Removal........................................................................................................517 1.81 Installation...................................................................................................517 1.82 IDLER GEAR AND HUB.................................................................................................517 1.83 Removal........................................................................................................517 1.84 Installation...................................................................................................518 1.85 GEAR FOR THE FUEL INJECTION PUMP OR THE CAMSHAFT GEAR..............................................................519 1.86 Removal........................................................................................................519 1.87 Installation...................................................................................................519 1.88 CRANKSHAFT GEAR....................................................................................................520 1.89 Removal........................................................................................................520 1.90 Installation...................................................................................................520 1.91 TIMING CASE........................................................................................................520 1.92 Removal........................................................................................................520 1.93 Installation...................................................................................................520 1.94 CAMSHAFT AND TAPPETS...............................................................................................521 1.95 Removal........................................................................................................522 1.96 Installation...................................................................................................522 ENGINE BLOCK ASSEMBLY.......................................................................................................523 1.97 DESCRIPTION........................................................................................................523 1.98 ENGINE BLOCK.......................................................................................................523 1.99 Disassembly....................................................................................................523 1.100 Inspection....................................................................................................524 1.101 Assembly......................................................................................................524 1.102 CYLINDER LINER....................................................................................................524 1.103 Inspection....................................................................................................524 1.104 Hone..........................................................................................................525 1.105 Removal.......................................................................................................525 1.106 Installation..................................................................................................526 TURBOCHARGER, ENGINES AB AND YB.............................................................................................527 1.107 GENERAL...........................................................................................................527 1.108 Removal.......................................................................................................527 1.109 Installation..................................................................................................528 1.110 Clean The Impeller And Compressor Housing.....................................................................528 LUBRICATION SYSTEM..........................................................................................................529 1.111 GENERAL...........................................................................................................529 1.112 OIL FILTER, REPLACEMENT...........................................................................................529 1.113 OIL SUMP..........................................................................................................530 1.114 Removal.......................................................................................................530 1.115 Installation..................................................................................................530 1.116 OIL PUMP..........................................................................................................530 1.117 Removal.......................................................................................................530 1.118 Inspection....................................................................................................531 1.119 Installation..................................................................................................531 1.120 RELIEF VALVE......................................................................................................532 1.121 Removal.......................................................................................................532 1.122 Disassembly...................................................................................................532 1.123 Inspection....................................................................................................533 1.124 Installation..................................................................................................533 FUEL SYSTEM.................................................................................................................533 1.125 DESCRIPTION.......................................................................................................533 1.126 CAV FUEL INJECTION PUMP...........................................................................................534 1.127 Removal.......................................................................................................534 1.128 Installation..................................................................................................534 1.129 CAV FUEL INJECTION PUMP, CHECKS AND ADJUSTMENTS...................................................................535 1.130 Timing Gear Marks.............................................................................................535 1.131 How To Set Number 1 Piston To TDC On The Compression Stroke...................................................536 1.132 Check The Valve Timing........................................................................................536 1.133 Check The Timing Of The Fuel Injection Pump...................................................................537 1.134 Check The Timing Mark Of The Fuel Injection Pump..............................................................537 1.135 Check The Engine Timing Mark..................................................................................538 1.136 REMOVE AIR FROM THE FUEL SYSTEM...................................................................................539 1.137 Fuel Injection Pump With Vent Tube............................................................................539 1.138 Fuel Injection Pump With Vent Screw...........................................................................540 1.139 FUEL FILTER (REPLACEMENT).........................................................................................541 1.140 FUEL INJECTORS....................................................................................................541 1.141 Removal.......................................................................................................541 1.142 Inspection....................................................................................................542 1.143 Installation..................................................................................................543 1.144 FUEL PUMP.........................................................................................................543 1.145 Removal.......................................................................................................543 1.146 Disassembly...................................................................................................543 1.147 Assembly......................................................................................................544 1.148 Installation..................................................................................................544 1.149 Test..........................................................................................................545 COOLING SYSTEM..............................................................................................................545 1.150 GENERAL...........................................................................................................545 1.151 THERMOSTAT........................................................................................................545 1.152 Replacement...................................................................................................545 1.153 COOLANT PUMP......................................................................................................546 1.154 Removal.......................................................................................................546 1.155 Disassembly...................................................................................................546 1.156 Assembly......................................................................................................547 1.157 Installation..................................................................................................547 1.158 FAN AND FAN DRIVE.................................................................................................547 1.159 Removal.......................................................................................................547 1.160 Disassembly...................................................................................................547 1.161 Assembly......................................................................................................548 1.162 Installation..................................................................................................548 1.163 OIL COOLER........................................................................................................548 1.164 Removal, Engine AB............................................................................................548 1.165 Removal, Engines YA and YB....................................................................................548 1.166 Disassembly And Assembly......................................................................................549 1.167 Installation, Engine AB.......................................................................................549 1.168 Installation, Engines YA and YB...............................................................................550 1.169 By–Pass Valve, Oil Cooler.....................................................................................550 FLYWHEEL AND FLYWHEEL HOUSING...............................................................................................550 1.170 GENERAL...........................................................................................................550 1.171 FLYWHEEL..........................................................................................................550 1.172 Removal.......................................................................................................550 1.173 Ring Gear (Replacement).......................................................................................550 1.174 Installation..................................................................................................550 1.175 FLYWHEEL HOUSING..................................................................................................551 1.176 Removal.......................................................................................................551 1.177 Installation..................................................................................................551 ELECTRICAL EQUIPMENT........................................................................................................552 1.178 DRIVE BELTS.......................................................................................................552 1.179 ALTERNATOR........................................................................................................553 1.180 STARTER MOTOR.....................................................................................................553 1.181 Removal.......................................................................................................553 1.182 Installation..................................................................................................553 1.183 COLD START AID....................................................................................................553 AIR COMPRESSOR, ENGINES YA AND YB...........................................................................................553 1.184 GENERAL...........................................................................................................553 1.185 Air Compressor, Removal, WABCO................................................................................553 1.186 Compressor Drive, Inspection..................................................................................554 1.187 Air Compressor, Installation, WABCO...........................................................................554 1.188 Compressor Drive, Disassembly, WABCO..........................................................................554 1.189 Compressor Drive, Assembly, WABCO.............................................................................555 1.190 Air Compressor, Removal, BENDIX...............................................................................555 1.191 Air Compressor, Installation, BENDIX..........................................................................556 1.192 Compressor Drive, Disassembly, BENDIX.........................................................................557 1.193 Compressor Drive, Assembly, BENDIX............................................................................557 ENGINE SPECIFICATIONS.......................................................................................................559 1.194 CYLINDER HEAD ASSEMBLY............................................................................................559 1.195 Cylinder Head.................................................................................................559 1.196 Valve Guides..................................................................................................559 1.197 Inlet Valves..................................................................................................560 1.198 Exhaust Valves................................................................................................560 1.199 Double Valve Springs To Outer.................................................................................560 1.200 Double Valve Springs To Inner.................................................................................560 1.201 Single Valve Springs..........................................................................................560 1.202 Tappets.......................................................................................................560 1.203 Rocker Arm Shaft..............................................................................................560 1.204 Rocker Arms And Bushings......................................................................................561 1.205 PISTON AND CONNECTING RODS........................................................................................561 1.206 Pistons, Engines AA And YA....................................................................................561 1.207 Pistons, Engines AB And YB....................................................................................561 1.208 Piston Rings, Engines AA And YA...............................................................................561 1.209 Piston Rings, Engines AB And YB...............................................................................561 1.210 Connecting Rods, Engines AB And YB............................................................................562 1.211 Connecting Rods, Engines AB And YB............................................................................562 1.212 Piston Pins, Engines AA And YA................................................................................562 1.213 Piston Pins, Engines AB and YB................................................................................562 1.214 Small End Bushings, Engines AA And YA.........................................................................562 1.215 Small End Bushings, Engines AB And YB.........................................................................562 1.216 Connecting Rod Bearings, Engines AA And YA....................................................................563 1.217 Connecting Rod Bearings, Engines AB And YB....................................................................563 1.218 Piston Cooling Jets, Engines AB And YB........................................................................563 1.219 CRANKSHAFT ASSEMBLY...............................................................................................563 1.220 Crankshaft....................................................................................................563 1.221 Crankshaft Heat Treatment.....................................................................................563 1.222 Crankshaft Overhaul...........................................................................................563 1.223 Main Bearings.................................................................................................565 1.224 Crankshaft Thrust Washers.....................................................................................565 1.225 TIMING CASE AND DRIVE ASSEMBLY....................................................................................565 1.226 Camshaft......................................................................................................565 1.227 Camshaft Thrust Washer........................................................................................565 1.228 Camshaft Gear.................................................................................................566 1.229 Gear For Fuel Injection Pump..................................................................................566 1.230 Crankshaft Gear...............................................................................................566 1.231 Idler Gear And Hub............................................................................................566 1.232 ENGINE BLOCK ASSEMBLY.............................................................................................566 1.233 Engine Block..................................................................................................566 1.234 Cylinder Liners...............................................................................................566 1.235 TURBOCHARGER......................................................................................................567 1.236 LUBRICATION SYSTEM................................................................................................567 1.237 Oil Pump, Engines AA And AB...................................................................................567 1.238 Oil Pump, Engines YA And YB...................................................................................567 1.239 Relief Valve..................................................................................................567 1.240 Oil Filter....................................................................................................567 1.241 FUEL SYSTEM.......................................................................................................567 1.242 Cav Fuel Injection Pump.......................................................................................567 1.243 FUEL INJECTORS................................................................................................568 1.244 Fuel Pump, Engines AA And AB..................................................................................569 1.245 Fuel Pump, Engines YA And YB..................................................................................569 1.246 Fuel Filter...................................................................................................569 1.247 COOLING SYSTEM....................................................................................................569 1.248 Coolant Pump..................................................................................................569 1.249 Thermostat....................................................................................................570 1.250 Fan Drive Housing.............................................................................................570 1.251 FLYWHEEL AND HOUSING..............................................................................................570 1.252 Limits for flywheel ''run out'' and alignment (total indicator reading).......................................570 1.253 ELECTRICAL EQUIPMENT..............................................................................................570 1.254 Alternator....................................................................................................570 1.255 Starter Motor.................................................................................................570 1.256 Cold Start Aid................................................................................................570 TORQUE SPECIFICATIONS.......................................................................................................571 SPECIAL TOOLS...............................................................................................................572
Please Note:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
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