Hyster G005 (H3.50-5.00XL Europe) Service Manual – PDF DOWNLOAD

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Hyster G005 (H3.50-5.00XL Europe) Service Manual – PDF DOWNLOAD

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Hyster G005 (H3.50-5.00XL Europe) Service Manual – PDF DOWNLOAD

Language : English
Pages : 795
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TABLE OF CONTENTS:

Hyster G005 (H3.50-5.00XL Europe) Service Manual – PDF DOWNLOAD

22002...........................................................................................................................  1
	INTRODUCTION................................................................................................................  1
		GENERAL.................................................................................................................  1
		DESCRIPTION.............................................................................................................  1
	REPAIRS.....................................................................................................................  3
		GENERAL.................................................................................................................  3
		REMOVAL AND DISASSEMBLY (Type A)........................................................................................  3
		CLEANING................................................................................................................  3
		ASSEMBLY (Type A).......................................................................................................  4
		REMOVAL AND DISAASSEMBLY (Type B).......................................................................................  6
		CLEANING................................................................................................................  8
		ASSEMBLY (Type B).......................................................................................................  8
		INSTALLATION (Type A and Type B)........................................................................................  9
	CHECKS AND ADJUSTMENTS......................................................................................................  9
		GENERAL.................................................................................................................  9
		CHECK THE ALTERNATOR FOR LOW OUTPUT (Type A or Type B).................................................................. 10
		CHECK THE ALTERNATOR FOR HIGH OUTPUT (Type A or Type B)................................................................. 11
		CHECK THE CIRCUIT FOR THE BRUSHES....................................................................................... 13
			Delco Alternators................................................................................................... 13
			Motorola Alternators................................................................................................ 13
		CHECK THE DIODES........................................................................................................ 13
		CHECK THE DIODE BRIDGE.................................................................................................. 13
			Delco and Leece–Neville Alternators................................................................................. 13
			Motorola Alternators................................................................................................ 13
		CHECK THE FIELD WINDING FOR THE ROTOR................................................................................... 14
		CHECK THE WINDINGS IN THE STATOR........................................................................................ 14
		CHECK THE VOLTAGE REGULATOR............................................................................................. 15
	TROUBLESHOOTING............................................................................................................. 15
100345.......................................................................................................................... 16
	THE FRAME................................................................................................................... 16
		GENERAL................................................................................................................. 16
		DESCRIPTION............................................................................................................. 16
		REPAIRS................................................................................................................. 16
		COUNTERWEIGHT........................................................................................................... 16
			Removal............................................................................................................. 16
		COUNTERWEIGHT........................................................................................................... 17
			Installation........................................................................................................ 17
		HOOD.................................................................................................................... 17
			Removal............................................................................................................. 17
		HOOD.................................................................................................................... 17
			Installation........................................................................................................ 17
		OVERHEAD GUARD.......................................................................................................... 18
			Removal............................................................................................................. 18
			Installation........................................................................................................ 18
		OPERATOR RESTRAINT SYSTEM............................................................................................... 18
		RADIATOR................................................................................................................ 18
			Removal............................................................................................................. 18
			Installation........................................................................................................ 19
		EXHAUST SYSTEM.......................................................................................................... 19
			Muffler Replacement................................................................................................. 19
		ENGINE.................................................................................................................. 19
			Removal............................................................................................................. 19
			Installation........................................................................................................ 22
		FUEL AND HYDRAULIC TANKS................................................................................................ 23
			Inspection.......................................................................................................... 23
			Repairs, Small Leaks................................................................................................ 23
			Repairs, Large Leaks................................................................................................ 23
			Cleaning............................................................................................................ 23
			Other Methods Of Preparation For Repair............................................................................. 24
		SAFETY LABELS........................................................................................................... 25
			CAB................................................................................................................. 25
			Cab Repalacement.................................................................................................... 25
		Window Repalcement...................................................................................................... 25
			Windshield Wipers, Heater and Fan................................................................................... 28
			Material Specifications For Cab Windows............................................................................. 28
			Cab Heater Hoses.................................................................................................... 28
160054.......................................................................................................................... 29
	INTRODUCTION................................................................................................................ 29
		GENERAL................................................................................................................. 29
		DESCRIPTION............................................................................................................. 29
		OPERATION............................................................................................................... 29
	REPAIRS..................................................................................................................... 29
		STEERING WHEEL AND COLUMN ASSEMBLY...................................................................................... 29
		TYPE "A" STEERING COLUMN ASSEMBLY....................................................................................... 31
			Removal And Disassembly............................................................................................. 31
			Assembly And Installation........................................................................................... 31
		TYPE "A" STEERING COLUMN................................................................................................ 32
		TYPE "A" STEERING COLUMN................................................................................................ 33
		TYPE "B" STEERING COLUMN................................................................................................ 34
			Removal And Disassembly............................................................................................. 34
			Assembly And Installation........................................................................................... 34
		TYPE "B" STEERING COLUMN................................................................................................ 35
			Disassembly of Steering Control Unit................................................................................ 36
			Cleaning of Steering Control Unit................................................................................... 36
			Assembly of Steering Control Unit................................................................................... 38
	CHECKS AND ADJUSTMENTS...................................................................................................... 41
		REMOVE AIR FROM THE SYSTEM.............................................................................................. 41
	TROUBLESHOOTING............................................................................................................. 42
190097.......................................................................................................................... 43
	INTRODUCTION................................................................................................................ 43
		DESCRIPTION............................................................................................................. 43
		OPERATION............................................................................................................... 43
			Flow Control Valve.................................................................................................. 45
			Relief Valve........................................................................................................ 45
	REPAIRS..................................................................................................................... 46
		REMOVAL................................................................................................................. 46
		DISASSEMBLY............................................................................................................. 46
		CLEANING................................................................................................................ 48
		INSPECTION.............................................................................................................. 48
		ASSEMBLY................................................................................................................ 49
		INSTALLATION............................................................................................................ 50
	CHECKS AND ADUSTMENTS....................................................................................................... 51
		CHECK THE OUTPUT OF THE PUMP............................................................................................ 51
		CHECK FOR AIR IN THE HYDRAULIC SYSTEM................................................................................... 51
	TROUBLESHOOTING............................................................................................................. 53
200077.......................................................................................................................... 56
	INTRODUCTION................................................................................................................ 56
		GENERAL................................................................................................................. 56
		DESCRIPTION............................................................................................................. 56
		OPERATION............................................................................................................... 57
			Lift Section........................................................................................................ 58
			Tilt Section........................................................................................................ 58
			Relief Valve........................................................................................................ 60
		SOLENOID VALVE FOR AUXILIARY FUNCTION................................................................................... 61
			Operation........................................................................................................... 61
	REPAIRS..................................................................................................................... 61
		MAIN CONTROL VALVE...................................................................................................... 61
			Removal and Disassembly............................................................................................. 61
			Cleaning and Inspection............................................................................................. 62
			Assembly............................................................................................................ 62
			Installation........................................................................................................ 62
		SOLENOID VALVE FOR AUXILIARY FUNCTION................................................................................... 62
			Removal and Disassembly............................................................................................. 62
			Assembly and Installation........................................................................................... 64
	CHECKS AND ADJUSTMENTS...................................................................................................... 64
		PRESSURE RELIEF VALVES.................................................................................................. 64
			Primary Relief Valve................................................................................................ 64
			Seconday Relief Valve............................................................................................... 65
		CONTROL LEVER ARRANGEMENT............................................................................................... 65
	TROUBLESHOOTING............................................................................................................. 68
	SPECIFICATIONS.............................................................................................................. 70
600412.......................................................................................................................... 71
	PERKINS DIESEL ENGINES, SERIES 1000......................................................................................... 71
		1.1 GENERAL............................................................................................................. 71
		GENERAL SAFETY RULES.................................................................................................... 71
			Viton Seals......................................................................................................... 71
		1.2 DESCRIPTION......................................................................................................... 74
			1.3 Engine Serial Number Codes...................................................................................... 74
			1.4 Engine Data..................................................................................................... 74
			1.5 1004–4 ENGINE................................................................................................... 75
			1.6 1004–4T ENGINE.................................................................................................. 75
			1.7 1006–6 ENGINE................................................................................................... 75
			1.8 1006–6T ENGINE.................................................................................................. 75
		1.9 REMOVAL AND INSTALLATION............................................................................................ 75
	CYLINDER HEAD ASSEMBLY...................................................................................................... 76
		1.10 VALVE COVER........................................................................................................ 76
			1.11 Removal........................................................................................................ 76
			1.12 Installation................................................................................................... 76
		1.13 ROCKER ARM ASSEMBLY................................................................................................ 76
			1.14 Removal........................................................................................................ 76
			1.15 Installation................................................................................................... 76
			1.16 Disassembly.................................................................................................... 77
			1.17 Inspection..................................................................................................... 77
			1.18 Assembly....................................................................................................... 77
		1.19 VALVE CLEARANCE ADJUSTMENTS........................................................................................ 77
			1.20 Four Cylinder Engines.......................................................................................... 78
			1.21 Six Cylinder Engines........................................................................................... 78
		1.22 VALVE SPRINGS...................................................................................................... 78
		1.23 CYLINDER HEAD ASSEMBLY............................................................................................. 80
			1.24 Removal........................................................................................................ 80
			1.25 Installation................................................................................................... 81
		1.26 VALVES AND VALVE SPRINGS........................................................................................... 84
			1.27 Removal........................................................................................................ 84
			1.28 Inspection..................................................................................................... 85
			1.29 Installation................................................................................................... 85
		1.30 VALVE GUIDES....................................................................................................... 85
			1.31 Inspection..................................................................................................... 85
			1.32 Removal........................................................................................................ 86
			1.33 Installation................................................................................................... 86
		1.34 CYLINDER HEAD AND VALVE SEATS...................................................................................... 86
			1.35 Inspection..................................................................................................... 86
			1.36 Repair......................................................................................................... 87
			1.37 Installation Of New Valve Seats................................................................................ 87
	PISTON AND CONNECTING ROD ASSEMBLIES........................................................................................ 88
		1.38 ROD BEARINGS....................................................................................................... 88
			1.39 Removal........................................................................................................ 88
			1.40 Installation................................................................................................... 89
		1.41 PISTON AND CONNECTING ROD ASSEMBLY................................................................................. 89
			1.42 Service Note................................................................................................... 89
			1.43 Removal........................................................................................................ 89
			1.44 Installation................................................................................................... 90
		1.45 PISTON RINGS....................................................................................................... 91
			1.46 Removal........................................................................................................ 91
			1.47 Inspection..................................................................................................... 91
			1.48 Installation................................................................................................... 92
		1.49 PISTON AND CONNECTING ROD.......................................................................................... 93
			1.50 Disassembly.................................................................................................... 93
			1.51 Inspection..................................................................................................... 93
			1.52 Installation................................................................................................... 93
		1.53 PISTON COOLING JETS................................................................................................ 94
			1.54 Removal........................................................................................................ 94
			1.55 Installation................................................................................................... 94
	CRANKSHAFT ASSEMBLY......................................................................................................... 95
		1.56 GENERAL............................................................................................................ 95
		1.57 CRANKSHAFT PULLEY.................................................................................................. 95
			1.58 Removal, Engines AA and AB..................................................................................... 95
			1.59 Installation, Engines AA and AB................................................................................ 95
			1.60 Removal, Engines YA and YB..................................................................................... 95
			1.61 Installation, Engines YA and YB................................................................................ 95
		1.62 REAR OIL SEAL...................................................................................................... 96
			1.63 Replacement.................................................................................................... 96
		1.64 MAIN BEARINGS...................................................................................................... 97
			1.65 Removal........................................................................................................ 97
			1.66 Installation................................................................................................... 97
		1.67 THRUST WASHERS..................................................................................................... 98
			1.68 Check The Axial Movement Of The Crankshaft..................................................................... 98
			1.69 Removal........................................................................................................ 99
			1.70 Installation................................................................................................... 99
		1.71 CRANKSHAFT......................................................................................................... 99
			1.72 Removal........................................................................................................ 99
			1.73 Inspection.....................................................................................................100
			1.74 Installation...................................................................................................100
	TIMING CASE AND TIMING GEARS................................................................................................102
		1.75 GENERAL............................................................................................................102
		1.76 TIMING CASE COVER..................................................................................................102
			1.77 Removal........................................................................................................102
			1.78 Installation...................................................................................................102
		1.79 FRONT OIL SEAL.....................................................................................................103
			1.80 Removal........................................................................................................103
			1.81 Installation...................................................................................................103
		1.82 IDLER GEAR AND HUB.................................................................................................103
			1.83 Removal........................................................................................................103
			1.84 Installation...................................................................................................104
		1.85 GEAR FOR THE FUEL INJECTION PUMP OR THE CAMSHAFT GEAR..............................................................105
			1.86 Removal........................................................................................................105
			1.87 Installation...................................................................................................105
		1.88 CRANKSHAFT GEAR....................................................................................................106
			1.89 Removal........................................................................................................106
			1.90 Installation...................................................................................................106
		1.91 TIMING CASE........................................................................................................106
			1.92 Removal........................................................................................................106
			1.93 Installation...................................................................................................106
		1.94 CAMSHAFT AND TAPPETS...............................................................................................107
			1.95 Removal........................................................................................................108
			1.96 Installation...................................................................................................108
	ENGINE BLOCK ASSEMBLY.......................................................................................................109
		1.97 DESCRIPTION........................................................................................................109
		1.98 ENGINE BLOCK.......................................................................................................109
			1.99 Disassembly....................................................................................................109
			1.100 Inspection....................................................................................................110
			1.101 Assembly......................................................................................................110
		1.102 CYLINDER LINER....................................................................................................110
			1.103 Inspection....................................................................................................110
			1.104 Hone..........................................................................................................111
			1.105 Removal.......................................................................................................111
			1.106 Installation..................................................................................................112
	TURBOCHARGER, ENGINES AB AND YB.............................................................................................113
		1.107 GENERAL...........................................................................................................113
			1.108 Removal.......................................................................................................113
			1.109 Installation..................................................................................................114
			1.110 Clean The Impeller And Compressor Housing.....................................................................114
	LUBRICATION SYSTEM..........................................................................................................115
		1.111 GENERAL...........................................................................................................115
		1.112 OIL FILTER, REPLACEMENT...........................................................................................115
		1.113 OIL SUMP..........................................................................................................116
			1.114 Removal.......................................................................................................116
			1.115 Installation..................................................................................................116
		1.116 OIL PUMP..........................................................................................................116
			1.117 Removal.......................................................................................................116
			1.118 Inspection....................................................................................................117
			1.119 Installation..................................................................................................117
		1.120 RELIEF VALVE......................................................................................................118
			1.121 Removal.......................................................................................................118
			1.122 Disassembly...................................................................................................118
			1.123 Inspection....................................................................................................119
			1.124 Installation..................................................................................................119
	FUEL SYSTEM.................................................................................................................119
		1.125 DESCRIPTION.......................................................................................................119
		1.126 CAV FUEL INJECTION PUMP...........................................................................................120
			1.127 Removal.......................................................................................................120
			1.128 Installation..................................................................................................120
		1.129 CAV FUEL INJECTION PUMP, CHECKS AND ADJUSTMENTS...................................................................121
			1.130 Timing Gear Marks.............................................................................................121
			1.131 How To Set Number 1 Piston To TDC On The Compression Stroke...................................................122
			1.132 Check The Valve Timing........................................................................................122
			1.133 Check The Timing Of The Fuel Injection Pump...................................................................123
			1.134 Check The Timing Mark Of The Fuel Injection Pump..............................................................123
			1.135 Check The Engine Timing Mark..................................................................................124
		1.136 REMOVE AIR FROM THE FUEL SYSTEM...................................................................................125
			1.137 Fuel Injection Pump With Vent Tube............................................................................125
			1.138 Fuel Injection Pump With Vent Screw...........................................................................126
		1.139 FUEL FILTER (REPLACEMENT).........................................................................................127
		1.140 FUEL INJECTORS....................................................................................................127
			1.141 Removal.......................................................................................................127
			1.142 Inspection....................................................................................................128
			1.143 Installation..................................................................................................129
		1.144 FUEL PUMP.........................................................................................................129
			1.145 Removal.......................................................................................................129
			1.146 Disassembly...................................................................................................129
			1.147 Assembly......................................................................................................130
			1.148 Installation..................................................................................................130
			1.149 Test..........................................................................................................131
	COOLING SYSTEM..............................................................................................................131
		1.150 GENERAL...........................................................................................................131
		1.151 THERMOSTAT........................................................................................................131
			1.152 Replacement...................................................................................................131
		1.153 COOLANT PUMP......................................................................................................132
			1.154 Removal.......................................................................................................132
			1.155 Disassembly...................................................................................................132
			1.156 Assembly......................................................................................................133
			1.157 Installation..................................................................................................133
		1.158 FAN AND FAN DRIVE.................................................................................................133
			1.159 Removal.......................................................................................................133
			1.160 Disassembly...................................................................................................133
			1.161 Assembly......................................................................................................134
			1.162 Installation..................................................................................................134
		1.163 OIL COOLER........................................................................................................134
			1.164 Removal, Engine AB............................................................................................134
			1.165 Removal, Engines YA and YB....................................................................................134
			1.166 Disassembly And Assembly......................................................................................135
			1.167 Installation, Engine AB.......................................................................................135
			1.168 Installation, Engines YA and YB...............................................................................136
			1.169 By–Pass Valve, Oil Cooler.....................................................................................136
	FLYWHEEL AND FLYWHEEL HOUSING...............................................................................................136
		1.170 GENERAL...........................................................................................................136
		1.171 FLYWHEEL..........................................................................................................136
			1.172 Removal.......................................................................................................136
			1.173 Ring Gear (Replacement).......................................................................................136
			1.174 Installation..................................................................................................136
		1.175 FLYWHEEL HOUSING..................................................................................................137
			1.176 Removal.......................................................................................................137
			1.177 Installation..................................................................................................137
	ELECTRICAL EQUIPMENT........................................................................................................138
		1.178 DRIVE BELTS.......................................................................................................138
		1.179 ALTERNATOR........................................................................................................139
		1.180 STARTER MOTOR.....................................................................................................139
			1.181 Removal.......................................................................................................139
			1.182 Installation..................................................................................................139
		1.183 COLD START AID....................................................................................................139
	AIR COMPRESSOR, ENGINES YA AND YB...........................................................................................139
		1.184 GENERAL...........................................................................................................139
			1.185 Air Compressor, Removal, WABCO................................................................................139
			1.186 Compressor Drive, Inspection..................................................................................140
			1.187 Air Compressor, Installation, WABCO...........................................................................140
			1.188 Compressor Drive, Disassembly, WABCO..........................................................................140
			1.189 Compressor Drive, Assembly, WABCO.............................................................................141
			1.190 Air Compressor, Removal, BENDIX...............................................................................141
			1.191 Air Compressor, Installation, BENDIX..........................................................................142
			1.192 Compressor Drive, Disassembly, BENDIX.........................................................................143
			1.193 Compressor Drive, Assembly, BENDIX............................................................................143
	ENGINE SPECIFICATIONS.......................................................................................................145
		1.194 CYLINDER HEAD ASSEMBLY............................................................................................145
			1.195 Cylinder Head.................................................................................................145
			1.196 Valve Guides..................................................................................................145
			1.197 Inlet Valves..................................................................................................146
			1.198 Exhaust Valves................................................................................................146
			1.199 Double Valve Springs To Outer.................................................................................146
			1.200 Double Valve Springs To Inner.................................................................................146
			1.201 Single Valve Springs..........................................................................................146
			1.202 Tappets.......................................................................................................146
			1.203 Rocker Arm Shaft..............................................................................................146
			1.204 Rocker Arms And Bushings......................................................................................147
		1.205 PISTON AND CONNECTING RODS........................................................................................147
			1.206 Pistons, Engines AA And YA....................................................................................147
			1.207 Pistons, Engines AB And YB....................................................................................147
			1.208 Piston Rings, Engines AA And YA...............................................................................147
			1.209 Piston Rings, Engines AB And YB...............................................................................147
			1.210 Connecting Rods, Engines AB And YB............................................................................148
			1.211 Connecting Rods, Engines AB And YB............................................................................148
			1.212 Piston Pins, Engines AA And YA................................................................................148
			1.213 Piston Pins, Engines AB and YB................................................................................148
			1.214 Small End Bushings, Engines AA And YA.........................................................................148
			1.215 Small End Bushings, Engines AB And YB.........................................................................148
			1.216 Connecting Rod Bearings, Engines AA And YA....................................................................149
			1.217 Connecting Rod Bearings, Engines AB And YB....................................................................149
			1.218 Piston Cooling Jets, Engines AB And YB........................................................................149
		1.219 CRANKSHAFT ASSEMBLY...............................................................................................149
			1.220 Crankshaft....................................................................................................149
			1.221 Crankshaft Heat Treatment.....................................................................................149
			1.222 Crankshaft Overhaul...........................................................................................149
			1.223 Main Bearings.................................................................................................151
			1.224 Crankshaft Thrust Washers.....................................................................................151
		1.225 TIMING CASE AND DRIVE ASSEMBLY....................................................................................151
			1.226 Camshaft......................................................................................................151
			1.227 Camshaft Thrust Washer........................................................................................151
			1.228 Camshaft Gear.................................................................................................152
			1.229 Gear For Fuel Injection Pump..................................................................................152
			1.230 Crankshaft Gear...............................................................................................152
			1.231 Idler Gear And Hub............................................................................................152
		1.232 ENGINE BLOCK ASSEMBLY.............................................................................................152
			1.233 Engine Block..................................................................................................152
			1.234 Cylinder Liners...............................................................................................152
		1.235 TURBOCHARGER......................................................................................................153
		1.236 LUBRICATION SYSTEM................................................................................................153
			1.237 Oil Pump, Engines AA And AB...................................................................................153
			1.238 Oil Pump, Engines YA And YB...................................................................................153
			1.239 Relief Valve..................................................................................................153
			1.240 Oil Filter....................................................................................................153
		1.241 FUEL SYSTEM.......................................................................................................153
			1.242 Cav Fuel Injection Pump.......................................................................................153
			1.243 FUEL INJECTORS................................................................................................154
			1.244 Fuel Pump, Engines AA And AB..................................................................................155
			1.245 Fuel Pump, Engines YA And YB..................................................................................155
			1.246 Fuel Filter...................................................................................................155
		1.247 COOLING SYSTEM....................................................................................................155
			1.248 Coolant Pump..................................................................................................155
			1.249 Thermostat....................................................................................................156
			1.250 Fan Drive Housing.............................................................................................156
		1.251 FLYWHEEL AND HOUSING..............................................................................................156
			1.252 Limits for flywheel ''run out'' and alignment (total indicator reading).......................................156
		1.253 ELECTRICAL EQUIPMENT..............................................................................................156
			1.254 Alternator....................................................................................................156
			1.255 Starter Motor.................................................................................................156
			1.256 Cold Start Aid................................................................................................156
	TORQUE SPECIFICATIONS.......................................................................................................157
	SPECIAL TOOLS...............................................................................................................158
600590..........................................................................................................................162
	GM 4.3 LITRE V-6............................................................................................................162
		INTRODUCTION............................................................................................................162
		DESCRIPTION.............................................................................................................162
		ENGINE, REMOVAL AND INSTALLATION........................................................................................163
		CYLINDER HEAD...........................................................................................................163
			Removal And Disassembly.............................................................................................163
			Cleaning And Inspection.............................................................................................163
			Repairs, Valve Guides and Seats.....................................................................................163
			Repairs, Valves.....................................................................................................164
			Repairs, Valve Seats................................................................................................164
			Valve Springs.......................................................................................................165
			Studs For The Rocker Arms (Early Models)............................................................................166
			Studs For The Rocker Arms (Late Models).............................................................................167
			Assembly And Installation...........................................................................................167
		CYLINDER BLOCK, CLEANING AND INSPECTION.................................................................................169
		PISTON BORE PREPARATION.................................................................................................169
		ENGINE MOUNTS...........................................................................................................169
		LUBRICATION SYSTEM......................................................................................................169
			Oil Pump, Removal and Disassembly...................................................................................169
			Cleaning and Inspection.............................................................................................170
			Oil Pump, Assembly and Installation.................................................................................170
			Oil Sump, Installation..............................................................................................170
		TIMING COVER, TIMING SPROCKETS, CAMSHAFT AND VALVE LIFTERS..............................................................171
			Timing Cover, Removal...............................................................................................171
			Installation........................................................................................................172
			Timing Sprockets, Removal...........................................................................................173
			Timing Sprockets, Installation......................................................................................173
			Camshaft, Removal...................................................................................................173
			Camshaft, Inspection................................................................................................173
			Camshaft, Installation..............................................................................................173
			Balance Shaft, Removal..............................................................................................174
			Balance Shaft, Installation.........................................................................................175
			Hydraulic Valve Lifters, Removal....................................................................................176
			Hydraulic Valve Lifters, Disassembly................................................................................176
			Hydraulic Valve Lifters, Cleaning And Inspection....................................................................176
			Hydraulic Valve Lifters, Assembly...................................................................................177
			Hydraulic Valve Lifters, Installation...............................................................................177
		CRANKSHAFT..............................................................................................................178
			Removal.............................................................................................................178
			Inspection and Repair...............................................................................................178
			How To Check The Clearance Between The Main Bearings And Their Journals.............................................179
			Installation........................................................................................................180
		PISTON AND CONNECTING ROD ASSEMBLIES....................................................................................181
			Connecting Rod Bearings, Replacement................................................................................181
			Piston And Connecting Rod Assemblies, Removal.......................................................................182
			Disassembly.........................................................................................................182
			Piston, Cleaning And Inspection.....................................................................................182
			Cylinder Bores, Inspection And Repair...............................................................................183
			Piston Rings........................................................................................................184
			Assembly............................................................................................................184
			Piston And Connecting Rod Assemblies, Installation..................................................................185
		FLYWHEEL AND FLYWHEEL HOUSING...........................................................................................185
			Flywheel Repairs....................................................................................................185
			Flywheel, Installation..............................................................................................185
			Flywheel Housing....................................................................................................186
			Engine Adapter......................................................................................................186
		COOLANT PUMP............................................................................................................186
		THERMOSTAT..............................................................................................................186
		FAN MOUNT, EARLY MODELS.................................................................................................186
		FAN MOUNT ASSEMBLY, LATE MODELS.........................................................................................187
		DRIVE BELT, INSTALLATION................................................................................................188
	CHECKS AND ADJUSTMENTS......................................................................................................190
		VALVE CLEARANCE ADJUSTMENT, EARLY MODELS................................................................................190
		VALVE CLEARANCE ADJUSTMENT, NEW MODELS..................................................................................190
		CHECK THE COMPRESSION...................................................................................................190
	ENGINE SPECIFICATIONS.......................................................................................................191
		Engine Data.............................................................................................................191
		Cylinder head...........................................................................................................191
		Hydraulic Valve Lifter..................................................................................................191
		Camshaft................................................................................................................191
		Pistons.................................................................................................................191
		Crankshaft..............................................................................................................192
		Connecting Rods.........................................................................................................192
		Connecting Rods.........................................................................................................192
		Balance Shaft...........................................................................................................192
		Cooling System..........................................................................................................192
		Lubrication System......................................................................................................192
	TORQUE SPECIFICATIONS.......................................................................................................193
	TROUBLESHOOTING.............................................................................................................194
600705..........................................................................................................................197
	PERKINS DIESEL ENGINES, 1004-42 (AR), 1006-60 (YG), 1006-60T (YH) ..........................................................197
		GENERAL.................................................................................................................197
			General Safety Rules................................................................................................197
		DESCRIPTION.............................................................................................................199
			Engine Serial Number Codes..........................................................................................200
			Engine Data.........................................................................................................201
			1004-42 (AR) ENGINE (Low Governed Speed)............................................................................201
			1004-42 (AR) ENGINE (High Governed Speed)...........................................................................201
			1006-60 (YG) ENGINE.................................................................................................201
			1006-60T (YH) ENGINE................................................................................................201
		REMOVAL AND INSTALLATION................................................................................................202
			Lifting The Engine..................................................................................................202
	CYLINDER HEAD ASSEMBLY......................................................................................................202
		VALVE COVER.............................................................................................................202
			Removal.............................................................................................................202
			Installation........................................................................................................203
		ROCKER ARM ASSEMBLY.....................................................................................................203
			Removal.............................................................................................................203
			Installation........................................................................................................203
			Disassembly.........................................................................................................203
			Inspection..........................................................................................................204
			Assembly............................................................................................................204
		VALVE CLEARANCE ADJUSTMENTS.............................................................................................204
			Four Cylinder Engines...............................................................................................204
			Six Cylinder Engines................................................................................................205
		VALVE SPRINGS...........................................................................................................205
		CYLINDER HEAD ASSEMBLY..................................................................................................206
			Removal.............................................................................................................206
			Installation........................................................................................................209
		VALVE AND VALVE SPRINGS.................................................................................................213
			Removal.............................................................................................................213
			Inspection..........................................................................................................214
			Installation........................................................................................................214
		VALVE GUIDES............................................................................................................214
			Inspection..........................................................................................................214
			Removal.............................................................................................................215
			Installation........................................................................................................215
		CYLINDER HEAD AND VALVE SEATS...........................................................................................216
			Inspection..........................................................................................................216
			Repair..............................................................................................................216
			Installation Of New Valve Seats.....................................................................................217
	PISTON AND CONNECTING ROD ASSEMBLIES........................................................................................217
		ROD BEARINGS............................................................................................................218
			Removal.............................................................................................................218
			Installation........................................................................................................219
		PISTON AND CONNECTING ROD ASSEMBLY......................................................................................219
			Service Note........................................................................................................219
			Removal.............................................................................................................220
			Installation........................................................................................................220
		PISTON RINGS............................................................................................................221
			Removal.............................................................................................................221
			Inspection..........................................................................................................221
			Installation........................................................................................................222
		PISTON AND CONNECTING RODS..............................................................................................223
			Disassembly.........................................................................................................223
			Inspection..........................................................................................................224
			How To Select the Correct Replacements..............................................................................224
			Installation........................................................................................................225
		PISTON COOLING JETS.....................................................................................................225
			Removal.............................................................................................................225
			Installation........................................................................................................225
	CRANKSHAFT ASSEMBLY.........................................................................................................226
		GENERAL.................................................................................................................226
		CRANKSHAFT PULLEY.......................................................................................................227
			Removal, Engine AR..................................................................................................227
			Removal, Engines YG and YH..........................................................................................227
			Inspection..........................................................................................................227
			Installation, Engine AR ............................................................................................228
			Installation, Engine YG and YH......................................................................................228
		REAR OIL SEAL...........................................................................................................229
			Replacement.........................................................................................................229
		MAIN BEARINGS...........................................................................................................230
			Removal.............................................................................................................230
			Inspection..........................................................................................................230
			Installation........................................................................................................231
		THRUST WASHERS..........................................................................................................231
			Check The Axial Movement Of The Crankshaft..........................................................................231
			Removal.............................................................................................................232
			Installation........................................................................................................232
		CRANKSHAFT..............................................................................................................233
			Removal.............................................................................................................233
			Inspection..........................................................................................................233
			Installation........................................................................................................233
		FLYWHEEL................................................................................................................235
			Removal.............................................................................................................235
			Ring Gear (Replacement).............................................................................................235
			Installation........................................................................................................235
		FLYWHEEL HOUSING........................................................................................................236
			Removal.............................................................................................................236
			Installation........................................................................................................236
	TIMING CASE AND TIMING GEARS................................................................................................237
		GENERAL.................................................................................................................237
		TIMING CASE COVER.......................................................................................................237
			Removal.............................................................................................................237
			Installation........................................................................................................237
		FRONT OIL SEAL..........................................................................................................238
			Removal.............................................................................................................238
			Installation........................................................................................................238
		CRANKSHAFT PULLEY WEAR SLEEVE...........................................................................................239
			Installation........................................................................................................239
		IDLER GEAR AND HUB......................................................................................................239
			Removal.............................................................................................................239
			Installation........................................................................................................240
		AIR COMPRESSOR, DRIVE, BENDIX...........................................................................................241
			Disassembly.........................................................................................................241
			Compressor Drive, Assembly..........................................................................................242
		GEAR FOR THE FUEL INJECTION PUMP........................................................................................242
			Removal.............................................................................................................242
			Installation........................................................................................................243
		CAMSHAFT GEAR...........................................................................................................244
			Removal.............................................................................................................244
			Installation........................................................................................................244
		CRANKSHAFT GEAR.........................................................................................................245
			Removal.............................................................................................................245
			Installation........................................................................................................245
		TIMING CASE.............................................................................................................245
			Removal.............................................................................................................245
			Installation........................................................................................................246
		CAMSHAFT AND TAPPETS....................................................................................................247
			Removal.............................................................................................................247
			Installation........................................................................................................247
	CYLINDER BLOCK ASSEMBLY.....................................................................................................248
		DESCRIPTION.............................................................................................................248
		CYLINDER BLOCK..........................................................................................................248
			Disassembly.........................................................................................................248
			Inspection..........................................................................................................249
			Assembly............................................................................................................249
		CYLINDER BORE (4-CYLINDER ENGINES)......................................................................................249
		CYLINDER LINER (6-CYLINDER ENGINES).....................................................................................250
			Inspection..........................................................................................................250
			To Check the Condition of a Cylinder Liner..........................................................................250
			Removal.............................................................................................................251
			Installation (Service Liner)........................................................................................252
			Installation (Partially Finished Liner).............................................................................253
	ENGINE TIMING...............................................................................................................254
		GENERAL DESCRIPTION.....................................................................................................254
			How To Set Number 1 Piston To TDC On The Compression Stroke.........................................................255
			How To Set Number 1 Piston To TDC On The Compression Stroke (Alternate Procedure)...................................256
			Check The Valve Timing..............................................................................................256
			Check The Timing Of The Fuel Injection Pump.........................................................................257
	TURBOCHARGER, ENGINE YH.....................................................................................................258
		GENERAL.................................................................................................................258
			Removal.............................................................................................................258
			Installation........................................................................................................258
			Clean The Impeller And Compressor Housing...........................................................................259
	LUBRICATION SYSTEM..........................................................................................................260
		GENERAL.................................................................................................................260
		OIL FILTER, REPLACEMENT.................................................................................................260
		FILTER HEAD.............................................................................................................261
			To Remove and to Install............................................................................................261
		OIL SUMP................................................................................................................261
			Removal.............................................................................................................261
			Installation........................................................................................................262
		OIL PUMP................................................................................................................262
			Removal.............................................................................................................262
			Inspection..........................................................................................................262
			Installation........................................................................................................263
		RELIEF VALVE............................................................................................................264
			Removal.............................................................................................................264
			Disassembly.........................................................................................................264
			Inspection..........................................................................................................265
			Assembly............................................................................................................265
			Installation........................................................................................................265
		IDLER GEAR SHAFT, REPLACEMENT...........................................................................................265
			Removal.............................................................................................................265
			Removal, Alternative ...............................................................................................266
			Installation........................................................................................................267
			Installation, Alternative...........................................................................................267
			Installation, Alternative For 4-Cylinder Engines Only...............................................................267
	FUEL SYSTEM.................................................................................................................268
		DESCRIPTION.............................................................................................................268
		FUEL INJECTION PUMP.....................................................................................................268
			Removal.............................................................................................................268
			Installation........................................................................................................269
		FUEL INJECTION PUMP, CHECKS AND ADJUSTMENTS.............................................................................270
		REMOVE AIR FROM THE FUEL CHECK..........................................................................................271
		FUEL FILTER (REPLACEMENT)...............................................................................................272
			Canister Type.......................................................................................................272
			Quick Release Canister Type.........................................................................................272
		FUEL INJECTORS..........................................................................................................273
			Removal.............................................................................................................273
			Inspection..........................................................................................................274
			Installation........................................................................................................274
		FUEL PUMP...............................................................................................................275
			Removal.............................................................................................................275
			Disassembly.........................................................................................................275
			Assembly............................................................................................................276
			Installation........................................................................................................276
			Test................................................................................................................277
	COOLING SYSTEM..............................................................................................................277
		GENERAL.................................................................................................................277
		THERMOSTAT..............................................................................................................277
			Thermostats.........................................................................................................277
			Remove..............................................................................................................277
			Install.............................................................................................................277
			Test................................................................................................................277
		COOLANT PUMP............................................................................................................278
			Removal.............................................................................................................278
			Disassembly.........................................................................................................279
			Assembly............................................................................................................280
			Installation........................................................................................................283
		FAN AND FAN DRIVE.......................................................................................................284
			Removal.............................................................................................................284
			Installation........................................................................................................284
		OIL COOLER (6-CYLINDER ENGINES).........................................................................................284
			Removal.............................................................................................................284
			Disassembly and Assembly............................................................................................284
			Installation........................................................................................................285
			By-Pass Valve, Oil Cooler...........................................................................................285
		ELECTRICAL EQUIPMENT....................................................................................................285
			DRIVE BELTS.........................................................................................................285
		ALTERNATOR..............................................................................................................286
			Removal.............................................................................................................286
			Installation........................................................................................................286
		STARTER MOTOR...........................................................................................................286
			Removal.............................................................................................................286
			Installation........................................................................................................287
		COLD START AID..........................................................................................................287
	AIR COMPRESSOR, ENGINES YG AND YH...........................................................................................287
		GENERAL.................................................................................................................287
			Air Compressor, Removal.............................................................................................287
			Air Compressor, Installation........................................................................................288
	ENGINE SPECIFICATIONS.......................................................................................................289
		CYLINDER HEAD ASSEMBLY..................................................................................................289
			Cylinder Head.......................................................................................................289
			Valve Guides........................................................................................................290
			Inlet Valves........................................................................................................290
			Exhaust Valves......................................................................................................291
			Valve Springs.......................................................................................................291
			Tappets.............................................................................................................291
			Rocker Arm Shaft....................................................................................................292
			Rocker Arms And Bushings............................................................................................292
		PISTON AND CONNECTIONG RODS.............................................................................................292
			Pistons (Engine AR).................................................................................................292
			Pistons (Engine YG and YH)..........................................................................................292
			Piston Rings (Engine AR)............................................................................................292
			Piston Rings (Engine YG and YH).....................................................................................293
			Piston Pins.........................................................................................................293
			Connecting Rods.....................................................................................................293
			Small End Bushings..................................................................................................294
			Connecting Rod Bearings, Engines AR and YG..........................................................................294
			Connecting Rod Bearings, Engine YH..................................................................................294
			Piston Cooling Jets.................................................................................................294
		CRANKSHAFT ASSEMBLY.....................................................................................................294
			Crankshaft..........................................................................................................294
			Main Bearings.......................................................................................................295
			Crankshaft Thrust Washers...........................................................................................295
			Crankshaft Heat Treatment...........................................................................................295
			Crankshaft Overhaul.................................................................................................295
		TIMING CASE AND DRIVE ASSEMBLY..........................................................................................297
			Camshaft............................................................................................................297
			Camshaft Thrust Washer..............................................................................................297
			Camshaft Gear.......................................................................................................297
			Gear For Fuel Injection Pump........................................................................................297
			Crankshaft Gear.....................................................................................................297
			Idler Gear And Hub..................................................................................................297
		ENGINE BLOCK ASSEMBLY...................................................................................................298
			Cylinder Block (Engine AR)..........................................................................................298
			Cylinder Bore Specifications (Engine AR)............................................................................298
			Cylinder Block (Engine YG And YH)...................................................................................299
			Cylinder Liner (Engine YG And YH)...................................................................................299
			Cylinder Liner Specifications (Partially Finished)..................................................................299
		TURBOCHARGER............................................................................................................300
		LUBRICATION SYSTEM......................................................................................................300
			Oil Pump, Engine AR.................................................................................................300
			Oil Pump, Engine YG And YH..........................................................................................300
			Idler Gear for Oil Pump.............................................................................................300
			Relief Valve........................................................................................................300
			Oil Filter..........................................................................................................301
		FUEL SYSTEM.............................................................................................................301
			Lucas Fuel Injection Pump...........................................................................................301
			Fuel Injector Codes.................................................................................................302
			Fuel Pump, Engine AR................................................................................................302
			Fuel Pump, Engine YG And YH.........................................................................................302
			Fuel Filter.........................................................................................................303
		COOLING SYSTEM..........................................................................................................303
			Coolant Pump........................................................................................................303
			Thermostat..........................................................................................................303
			Fan Drive Housing...................................................................................................303
		FLYWHEEL AND HOUSING....................................................................................................303
			Limits for Flywheel "Run Out" and Alignment (Total Indicator Reading)...............................................303
		ELECTRICAL EQUIPMENT....................................................................................................303
			Alternator..........................................................................................................303
			Starter Motor.......................................................................................................303
			Cold Start Aid......................................................................................................303
	TORQUE SPECIFICATIONS.......................................................................................................304
	SPECIAL TORQUE SPECIFICATIONS...............................................................................................306
	SPECIAL TOOLS...............................................................................................................307
	TROUBLESHOOTING.............................................................................................................311
		List of Possible Causes.................................................................................................312
700626..........................................................................................................................314
	COOLING SYSTEM..............................................................................................................314
		INTRODUCTION............................................................................................................314
		DESCRIPTION.............................................................................................................314
		RADIATOR................................................................................................................314
		RADIATOR CAP............................................................................................................314
		THERMOSTAT..............................................................................................................314
		WATER PUMP..............................................................................................................315
		FAN AND FAN SHROUD .....................................................................................................315
	REPAIRS.....................................................................................................................315
		COOLING SYSTEM CHECKS...................................................................................................315
			Exhaust Leaks.......................................................................................................315
		RADIATOR................................................................................................................315
			Checks..............................................................................................................315
			Cleaning The Radiator...............................................................................................315
			Drain The Cooling System............................................................................................317
			Fill The Cooling System.............................................................................................317
		WATER PUMP..............................................................................................................317
			Checks..............................................................................................................317
		THERMOSTAT..............................................................................................................318
			Checks..............................................................................................................318
		FAN AND FAN SHROUD .....................................................................................................318
	TROUBLESHOOTING.............................................................................................................319
900348..........................................................................................................................320
	INTRODUCTION................................................................................................................320
		GENERAL.................................................................................................................320
		DESCRIPTION AND OPERATION...............................................................................................320
			Fuel Tank...........................................................................................................321
			Fuel Filter and Fuel Valve Unit.....................................................................................321
			Vaporizer...........................................................................................................322
			Carburetor..........................................................................................................323
			Governor............................................................................................................324
	REPAIRS.....................................................................................................................326
		LPG TANK................................................................................................................326
			Removal.............................................................................................................326
			Installation........................................................................................................326
		HYDROSTATIC RELIEF VALVE................................................................................................326
			Removal and Installation............................................................................................326
		FILTER UNIT.............................................................................................................328
			Replacement Of The Fuel Filter Element..............................................................................328
			Replacement of the Diaphragm and Fuel Valve ........................................................................328
		REPLACEMENT OF THE HOSES................................................................................................328
		VAPORIZER...............................................................................................................328
			Removal.............................................................................................................328
			Vaporizer Disassembly...............................................................................................330
			Cleaning............................................................................................................330
			Inspection..........................................................................................................330
			Vaporizer Assembly..................................................................................................330
			Installation........................................................................................................332
		CARBURETOR..............................................................................................................332
			Removal.............................................................................................................332
			Disassembly.........................................................................................................332
			Cleaning............................................................................................................333
			Assembly............................................................................................................333
			Installation........................................................................................................333
		GOVERNOR................................................................................................................333
	CHECKS AND ADJUSTMENTS......................................................................................................334
		CHECK THE FILTER UNIT...................................................................................................334
		CHECK THE VAPORIZER.....................................................................................................334
			Pressure Reducer Valve..............................................................................................334
			Vapor Valve.........................................................................................................334
		ADJUST THE CARBURETOR...................................................................................................335
			Idle Mixture........................................................................................................335
			Idle Speed .........................................................................................................335
			Power Mixture.......................................................................................................335
		ADJUST THE THROTTLE LINKAGE.............................................................................................335
	TROUBLESHOOTING.............................................................................................................336
1200334.........................................................................................................................339
	INTRODUCTION................................................................................................................339
		General.................................................................................................................339
		Description.............................................................................................................339
	REPAIRS.....................................................................................................................341
		Removal and Disassembly.................................................................................................341
		Cleaning and Inspection.................................................................................................342
		Assembly and Installation...............................................................................................343
	CHECKS AND ADJUSTMENTS......................................................................................................345
		Adjusting the Clutch Pedal and Linkage..................................................................................345
		Adjusting the By-pass Valve for Cold Oil................................................................................345
	TROUBLESHOOTING.............................................................................................................346
1300335.........................................................................................................................348
	INTRODUCTION................................................................................................................348
		General.................................................................................................................348
		Description.............................................................................................................348
		Operation...............................................................................................................348
	REPAIRS.....................................................................................................................350
		Removal.................................................................................................................350
		Disassembly.............................................................................................................351
		Cleaning................................................................................................................353
		Inspection..............................................................................................................354
		Assembly................................................................................................................354
		Installation............................................................................................................365
	CHECKS AND ADJUSTMENTS......................................................................................................366
		Adjusting The Shift Linkage H3.50-5.00XL (H70-110XL)....................................................................366
		Adjusting The Shift Linkage S6.00-7.00XL (S135-155XL)...................................................................368
		Adjusting The Clutch Pedal And Linkage..................................................................................368
	TROUBLESHOOTING.............................................................................................................370
	SPECIFICATIONS..............................................................................................................372
1300336.........................................................................................................................373
	DESCRIPTION.................................................................................................................373
		GENERAL.................................................................................................................373
	MECHANICAL DESCRIPTION......................................................................................................373
		TORQUE CONVERTER........................................................................................................373
		OIL LAMP................................................................................................................374
		SHAFT AND CLUTCH ASSEMBLIES.............................................................................................374
			Input Shaft.........................................................................................................375
			Forward Clutch Shaft................................................................................................375
			Clutch Assemblies...................................................................................................375
			Output Gear.........................................................................................................376
	HYDRAULIC OPERATION.........................................................................................................376
		TORQUE CONVERTER........................................................................................................376
		SHAFT ASSEMBLIES........................................................................................................377
		CONTROL VALVE...........................................................................................................379
			General.............................................................................................................379
			System Regulator....................................................................................................379
			Clutch Pressure Regulator...........................................................................................379
			Torque Converter Regulator..........................................................................................380
			Inching Spool.......................................................................................................380
			Direction Spool, Manual Control.....................................................................................380
			Drain Spool.........................................................................................................381
			Accumulator.........................................................................................................381
			Modulation Spool....................................................................................................382
		LUBRICATION CIRCUIT.....................................................................................................383
		MONOTROL PEDAL..........................................................................................................383
		OIL FLOW DIAGRAMS.......................................................................................................383
			Neutral.............................................................................................................383
			Forward.............................................................................................................383
			Forward-Inching.....................................................................................................383
			Reverse.............................................................................................................384
1300337.........................................................................................................................389
	REPAIRS ....................................................................................................................389
		GENERAL.................................................................................................................389
		REMOVAL.................................................................................................................389
		TRANSMISSION, DISASSEMBLY...............................................................................................391
			Input Shaft, Disassembly............................................................................................392
			Forward Shaft, Disassembly..........................................................................................394
			Cleaning and Inspection.............................................................................................395
		TRANSMISSION, ASSEMBLY..................................................................................................396
			Forward Shaft, Assembly.............................................................................................396
			Input Shaft, Assembly...............................................................................................398
			Assembly............................................................................................................400
			Installation........................................................................................................403
		CONTROL VALVE...........................................................................................................404
			Removal.............................................................................................................404
			Disassembly.........................................................................................................405
			Assembly............................................................................................................405
			Installation........................................................................................................407
		THROTTLE PEDAL..........................................................................................................407
		MONOTROL PEDAL..........................................................................................................407
			Removal and Disassembly.............................................................................................407
			Assembly and Installation...........................................................................................407
	CHECKS AND ADJUSTMENTS......................................................................................................410
		STALL TEST..............................................................................................................410
		ADJUST THE LINKAGE FOR THE INCHING PEDAL................................................................................411
			Linkage For Models With An Inching Pedal And A Brake Pedal..........................................................411
			Linkage For ModelsWith One Inching/Brake Pedal......................................................................413
		ADJUST THE LINKAGE FOR THE DIRECTION CONTROL LEVER......................................................................414
			Earlier Production..................................................................................................414
			Later Production....................................................................................................415
		CHECK THE OIL PRESSURE FOR THE TRANSMISSION.............................................................................416
			System Pressure Check Port..........................................................................................417
			Torque Converter Check Port.........................................................................................417
			Clutch Pressure Check Port..........................................................................................418
			Inching Pressure....................................................................................................418
			Solenoid Check Ports (Monotrol Control Only)........................................................................418
			Lubrication Pressure Check Ports....................................................................................418
	TROUBLESHOOTING.............................................................................................................419
1300346.........................................................................................................................422
	INTRODUCTION................................................................................................................422
		GENERAL.................................................................................................................422
		DESCRIPTION.............................................................................................................422
	REPAIRS.....................................................................................................................422
		REMOVAL.................................................................................................................422
		DISASSEMBLY.............................................................................................................422
		CLEANING................................................................................................................425
		INSPECTION..............................................................................................................425
		ASSEMBLY................................................................................................................425
			Pinion Assembly.....................................................................................................425
			Differential........................................................................................................426
		INSTALLATION............................................................................................................432
	TROUBLESHOOTING.............................................................................................................433
	SPECIFICATIONS..............................................................................................................434
1400361.........................................................................................................................435
	INTRODUCTION................................................................................................................435
		GENERAL.................................................................................................................435
		DESCRIPTION.............................................................................................................435
	REPAIRS.....................................................................................................................436
		REMOVAL.................................................................................................................436
			Lift Trucks With A Manual Transmission..............................................................................436
			Lift Trucks With A Powershift Transmission..........................................................................437
		DISASSEMBLY.............................................................................................................438
		CLEANING................................................................................................................438
		INSPECTION..............................................................................................................438
		ASSEMBLY................................................................................................................438
		INSTALLATION............................................................................................................439
			Lift Trucks With A Manual Transmission..............................................................................439
			Lift Trucks With A Powershift Transmission..........................................................................440
	TROUBLESHOOTING.............................................................................................................441
	SPECIFICATIONS..............................................................................................................441
1600326.........................................................................................................................442
	INTRODUCTION................................................................................................................442
		GENERAL.................................................................................................................442
		DESCRIPTION.............................................................................................................442
	REPAIRS.....................................................................................................................443
		STEERING AXLE, H3.50-5.00XL (H70-110XL) and S/E 3.50-5.50XL (S/E 70-120XL)..............................................443
			Removal.............................................................................................................443
			Installation........................................................................................................443
		STEERING AXLE, H6.00-7.00XL (H135-155XL) H8.00-16.00XL (H165-360XL).....................................................444
			Removal.............................................................................................................444
			Installation........................................................................................................445
		WHEELS AND HUBS, ALL UNITS..............................................................................................445
			Removal and Disassembly.............................................................................................445
			Cleaning............................................................................................................445
			Assembly and Installation...........................................................................................445
		SPINDLES AND BEARINGS, ALL UNITS........................................................................................446
			Removal.............................................................................................................446
			Cleaning............................................................................................................447
			Assembly and Installation...........................................................................................447
		TIE RODS, ALL UNITS.....................................................................................................447
			Removal.............................................................................................................447
			Cleaning............................................................................................................447
			Installation........................................................................................................448
		STEERING CYLINDER.......................................................................................................449
			Removal and Disassembly.............................................................................................449
			Cleaning and Inspection.............................................................................................449
			Assembly and Installation...........................................................................................449
	TROUBLESHOOTING.............................................................................................................450
1800338.........................................................................................................................451
	INTRODUCTION................................................................................................................451
		GENERAL.................................................................................................................451
		DESCRIPTION AND OPERATION...............................................................................................451
		BRAKE BOOSTER AND MASTER CYLINDER.......................................................................................451
		MASTER CYLINDER.........................................................................................................451
		SERVICE BRAKE ASSEMBLY..................................................................................................453
		PARKING BRAKE...........................................................................................................454
	REPAIRS.....................................................................................................................454
		BRAKE SHOE ASSEMBLIES...................................................................................................454
			Removal and Disassembly.............................................................................................454
			Cleaning and Inspection.............................................................................................455
			Assembly and Installation...........................................................................................457
		MASTER CYLINDER.........................................................................................................460
		S3.50-5.50XL (S70-120XL) and H3.50-5.00XL (H70-110XL....................................................................460
			Removal ............................................................................................................460
			Disassembly.........................................................................................................460
			Assembly............................................................................................................461
			Installation........................................................................................................461
		MASTER CYLINDER, E3.50-5.50XL (E70-120XL)...............................................................................461
			Removal and Disassebly..............................................................................................461
			Cleaning and Inspection.............................................................................................462
			Assembly and Installation...........................................................................................462
		BRAKE BOOSTER...........................................................................................................462
			Removal.............................................................................................................462
			Disassembly.........................................................................................................462
			Cleaning and Inspection.............................................................................................463
			Assembly............................................................................................................463
			Installation........................................................................................................464
	CHECKS AND ADJUSTMENTS......................................................................................................464
		REMOVE THE AIR FROM THE BRAKE SYSTEM....................................................................................464
		ADJUST THE BRAKE PEDAL..................................................................................................464
		ADJUST THE BRAKE SHOES..................................................................................................465
		ADJUST THE PARKING BRAKE................................................................................................466
		CHECK THE RELIEF VALVE ON THE PARKING BOOSTER...........................................................................466
	TROUBLESHOOTING.............................................................................................................466
1900333.........................................................................................................................468
	INTRODUCTION................................................................................................................468
		GENERAL.................................................................................................................468
		DESCRIPTION AND OPERATION...............................................................................................468
			Hydraulic Pump......................................................................................................468
			Main Control Valve..................................................................................................469
			Steering Control Unit...............................................................................................471
			Brake Booster.......................................................................................................471
	REPAIRS.....................................................................................................................471
		HYDRAULIC PUMP..........................................................................................................471
			Removal.............................................................................................................471
			Disassembly.........................................................................................................472
			Cleaning and Inspection.............................................................................................472
			Assembly............................................................................................................472
			Installation........................................................................................................473
			Adjust the Flow Divider.............................................................................................473
	SPECIFICATIONS..............................................................................................................473
	TROUBLESHOOTING.............................................................................................................474
1900339.........................................................................................................................476
	INTRODUCTION................................................................................................................476
		GENERAL.................................................................................................................476
		DESCRIPTION.............................................................................................................476
	REPAIRS.....................................................................................................................478
		REMOVAL AND DISASSEMBLY.................................................................................................478
		CLEANING................................................................................................................478
		INSPECTION..............................................................................................................478
		ASSEMBLY AND INSTALLATION...............................................................................................479
	TROUBLESHOOTING.............................................................................................................480
		GENERAL.................................................................................................................480
2100103.........................................................................................................................481
	INTRODUCTION................................................................................................................484
		GENERAL.................................................................................................................484
		DESCRIPTION.............................................................................................................484
	REPAIRS.....................................................................................................................484
		REMOVAL.................................................................................................................484
		DISASSEMBLY.............................................................................................................484
		CLEANING................................................................................................................484
		ASSEMBLY................................................................................................................484
			Tilt Cylinders for the XM and XMS Models............................................................................484
			Tilt Cylinders with O-Ring or Single Lip Seals......................................................................486
			Tilt Cylinders for H700-800A and Early Model H700-920B..............................................................486
		INSTALLATION............................................................................................................486
			Tilt Cylinders with Chevron Packing.................................................................................486
	CHECKS AND ADJUSTMENTS......................................................................................................490
		CHECK THE TILT CYLINDERS FOR LEAKS......................................................................................490
		ADJUST THE TILT CYLINDER STROKE AND THE MAST TILT ANGLE.................................................................490
	TROUBLESHOOTING.............................................................................................................493
2200106.........................................................................................................................496
	INTRODUCTION................................................................................................................496
		GENERAL.................................................................................................................496
		DESCRIPTION AND OPERATION...............................................................................................496
	REPAIRS.....................................................................................................................498
		REMOVAL.................................................................................................................498
		DISSASEMBLY.............................................................................................................498
		CLEANING................................................................................................................499
		ASSEMBLY................................................................................................................499
		INSTALLATION............................................................................................................499
	CHECKS AND ADJUSTMENTS......................................................................................................500
		GENERAL.................................................................................................................500
	TROUBLESHOOTING.............................................................................................................502
2200143.........................................................................................................................504
	INTRODUCTION................................................................................................................504
		GENERAL.................................................................................................................504
	DESCRIPTION.................................................................................................................504
		GENERAL.................................................................................................................504
		STEERING COLUMN GAUGES, METERS AND INDICATORS...........................................................................507
		LED DISPLAY PANEL.......................................................................................................507
			Battery Discharge Indicators .......................................................................................507
			Brush Wear Indicators...............................................................................................508
			Motor Temperature Indicators........................................................................................509
		"LX" SERIES INSTRUMENT PANEL DISPLAY....................................................................................510
			Hourmeter Functions.................................................................................................511
			Battery Indicator Function..........................................................................................511
			Status Code Function................................................................................................511
	CHECKS AND ADJUSTMENTS......................................................................................................511
		GENERAL.................................................................................................................511
	REPLACEMENT.................................................................................................................512
		GENERAL.................................................................................................................512
		METER REPLACEMENT.......................................................................................................512
		SENDER REPLACEMENT......................................................................................................513
			Fuel Level Sender...................................................................................................513
			Pressure And Temperature Sender.....................................................................................514
		I.T.W. DISPLAY PANEL....................................................................................................514
			Removal.............................................................................................................514
	SPECIFICATIONS..............................................................................................................515
	TROUBLESHOOTING.............................................................................................................516
2200144.........................................................................................................................517
	ELECTRICAL WARNING DEVICES..................................................................................................517
		GENERAL.................................................................................................................517
		DESCRIPTION.............................................................................................................517
			Operator Controlled Horns...........................................................................................517
			System Warning Lights, Buzzers and Bells............................................................................517
			Reverse Warning Horns...............................................................................................518
			Warning Lights......................................................................................................518
		REPLACEMENT.............................................................................................................519
			General.............................................................................................................519
			Replacing Horns or Bells............................................................................................519
			Replacing Horn Relay or Buzzer......................................................................................519
			Replacing Warning Lights............................................................................................519
			Light Assemblies....................................................................................................520
			Replacing Flashing Units............................................................................................520
2200463.........................................................................................................................521
	MICROPROCESSOR SPARK TIMING SYSTEM (MSTS)...................................................................................521
		GENERAL.................................................................................................................521
		DESCRIPTION.............................................................................................................521
			What MSTS Does......................................................................................................523
			How MSTS Begins Operation...........................................................................................523
		OPERATION...............................................................................................................523
			Pulse Generator.....................................................................................................523
			HEI Module..........................................................................................................524
			When the Engine Is Being Started....................................................................................524
			When the Engine Is Running..........................................................................................526
			Manifold Absolute Pressure (MAP)....................................................................................526
			Coolant Temperature Sensor (CTS)....................................................................................526
			Electronic Control Module (ECM), Corrections........................................................................527
			The Initial Timing Connector........................................................................................527
			Gasoline and LPG Conversions........................................................................................528
	TROUBLESHOOTING.............................................................................................................530
		GENERAL.................................................................................................................530
		TOOLS AND TEST EQUIPMENT................................................................................................530
		MSTS TROUBLESHOOTING....................................................................................................531
			Test Description....................................................................................................531
		IGNITION SYSTEM TROUBLESHOOTING.........................................................................................533
			Test Description....................................................................................................533
		ELECTRONIC SPARK TIMING (EST) TROUBLESHOOTING...........................................................................536
			Circuit Description.................................................................................................536
			Test Description....................................................................................................536
		MANIFOLD ABSOLUTE PRESSURE (MAP) TROUBLESHOOTING........................................................................539
			Circuit Description.................................................................................................539
			Test Description....................................................................................................539
		COOLANT TEMPERATURE SENSOR (CTS) TROUBLESHOOTING........................................................................542
			Circuit Description.................................................................................................542
			Test Description....................................................................................................542
	REPAIRS.....................................................................................................................544
		DISTRIBUTOR.............................................................................................................544
			Removal.............................................................................................................544
			Disassembly.........................................................................................................545
			Inspection..........................................................................................................545
			Assembly............................................................................................................546
			Installation........................................................................................................546
			Igntion Timing......................................................................................................546
		HEI MODULE..............................................................................................................547
			Test For A Fault....................................................................................................547
			HEI Module Replacement..............................................................................................547
		SENSING COIL............................................................................................................548
			Test For A Fault....................................................................................................548
			Sensing Coil Replacement............................................................................................548
		IGNITION COIL...........................................................................................................548
			Test For A Fault....................................................................................................548
		ELECTRONIC CONTROL MODULE (ECM).........................................................................................549
			Removal.............................................................................................................549
			Installation........................................................................................................549
		COOLANT TEMPERATURE SENSOR (CTS)........................................................................................549
			Removal.............................................................................................................549
			Installation........................................................................................................550
		MANIFOLD ABSOLUTE PRESSURE (MAP)........................................................................................550
			Removal.............................................................................................................550
			Installation........................................................................................................550
			PRESSURE CONVERSION CHART...........................................................................................551
2200468.........................................................................................................................552
	ELECTRONIC ENGINE CONTROL, TROUBLESHOOTING AND REPAIR.......................................................................552
		GENERAL.................................................................................................................552
			Engine Data.........................................................................................................552
		LIGHT BULB CHECK........................................................................................................552
		SYSTEM CHECK............................................................................................................554
		TROUBLESHOOTING WITH THE FAULT MONITOR SYSTEM IN THE ECM................................................................554
			How To Clear A Code.................................................................................................555
			Fault In The ECM....................................................................................................555
			Fault In The PROM...................................................................................................556
			CalPak Not Installed................................................................................................556
			Fuel Control........................................................................................................556
			Idle Air Control (IAC)..............................................................................................556
			Fuel Pump Circuit...................................................................................................556
			Coolant Temperature Sensor (CTS)....................................................................................557
			Manifold Absolute Pressuer Sensor (MAP).............................................................................557
			Throttle Position Sensodr (TPS).....................................................................................557
			Output Check, Throttle Position Sensor..............................................................................557
			Electronic Spark Timing.............................................................................................557
			Engine Crank Signal.................................................................................................558
			Distributor Reference Signal........................................................................................558
	TROUBLESHOOTING CHARTS......................................................................................................559
		CHART A-1-No "Check Engine" Light.......................................................................................559
			Circuit Description, "Check Engine" Light...........................................................................559
		CHART A-1-No "Check Engine" Light.......................................................................................560
		CHART A-2-No ALDL Data Or No Code 12 From "Check Engine" Light. The "Check Engine" Light Is Continuosly Illuminated.....561
			Circuit Description, "Check Engine" Light...........................................................................561
		CHART A-2-No ALDL Data Or No Code 12 From "Check Engine" Light. The "Check Engine" Light Is Continuously Illuminated....562
		CHART A-3-Starter Cranks The Engine, But Will Not Run...................................................................563
			Circuit Description.................................................................................................564
		CHART A-4-Fuel Injector Circuit.........................................................................................565
			Circuit Description.................................................................................................565
		CHART A-5-Fuel Pump Relay Circuit.......................................................................................567
			Circuit Description.................................................................................................567
		CHART A-6-Fuel System Pressure Test.....................................................................................569
			Circuit Description.................................................................................................569
		CHART A-7-MAP Output Check..............................................................................................571
			Circuit Description.................................................................................................571
		CHART A-8-Engine Crank Signal Check.....................................................................................573
			Circuit Description.................................................................................................573
		CHART A-9-Ignition System Troubleshooting...............................................................................574
		CHART A-9 Ignition System Troubleshooting Chart.........................................................................575
		CHART A-10-Idle Air Control (IAC) System................................................................................577
			Circuit Description.................................................................................................577
	FAULT CODES.................................................................................................................579
		CODE 14-Coolant Temperature Sensor Circuit (Indicates High Temperature).................................................579
			Circuit Description.................................................................................................579
		CODE 15-Coolant Temperature Sensor Circuit (Indicates Low Temperature...................................................581
			Circuit Description.................................................................................................581
		CODE 21-Throttle Position Sensor Circuit (Signal Voltage High) .........................................................583
			Circuit Description.................................................................................................583
		CODE 22-Throttle Position Sensor Circuit (Signal Voltage Low) ..........................................................585
			Circuit Description.................................................................................................585
		CODE 31-Engine Governor Circuit.........................................................................................587
			Circuit Description.................................................................................................587
		CODE 33-MAP Sensor Circuit, Signal Voltage High (Low Vacuum.............................................................589
			Circuit Description.................................................................................................589
		CODE 34-MAP Sensor Circuit, Signal Voltage Low (High Vacuum)............................................................591
			Circuit Description.................................................................................................591
		CODE 42-Electronic Spark Timing (EST)...................................................................................593
			Circuit Description.................................................................................................593
		CODE 54-Fuel Pump Circuit (Low Voltage).................................................................................595
			Circuit Description.................................................................................................595
		CODE 51-PROM In The ECM Has A Fault ....................................................................................597
		CODE 52-Fuel CalPak Is Missing..........................................................................................597
		CODE 55-ECM Has A Fault.................................................................................................597
		TROUBLESHOOTING, POOR OPERATION.........................................................................................597
			General.............................................................................................................597
			Make A Careful Visual Check.........................................................................................597
			FAULT: Fuel Usage Too High..........................................................................................597
			FAULT: Codes Or Performance That Is Not Regular.....................................................................598
			FAULT: "Dieseling"..................................................................................................598
			FAULT: "Backfire"...................................................................................................598
			FAULT: Rough Idle or Engine Stalls During Idle......................................................................598
			FAULT: Smoke In The Exhaust Gases...................................................................................599
			FAULT: Engine is Difficult To Start.................................................................................599
			FAULT: Variation In Engine Power When The Throttle Is Held Steady...................................................600
			FAULT: Decreased Engine Power.......................................................................................600
			FAULT: "Detontion"..................................................................................................600
			FAULT: Engine Momentarily Does Not Increase Power When Throttle Changes.............................................601
			FAULT: One Cylinder In The Engine Does Not Operate Correctly. The Engine Does Not Idle Correctly....................601
		REPAIRS, FUEL SYSTEM COMPONENTS ........................................................................................603
			General.............................................................................................................603
			Vacuum Ports........................................................................................................603
			Throttle Body Injection (TBI) Unit..................................................................................603
			TBI Unit, Removal...................................................................................................603
			TBI Unit, Cleaning and Inspection...................................................................................604
			TBI Unit, Installation..............................................................................................604
			Cover For Fuel Meter Body, Replacement..............................................................................604
			Fuel Injectors......................................................................................................605
			Fuel Injectors, Removal.............................................................................................605
			Fuel Injectors, Installation........................................................................................606
			Pressure Regulator, Removal.........................................................................................606
			Pressure Regulator, Inspection......................................................................................606
			Pressure Regulator, Installation ...................................................................................606
			Fuel Meter Body, Removal............................................................................................607
			Fuel Meter Body, Installation.......................................................................................607
			Throttle Position Sensor (TPS), Removal.............................................................................607
			Throttle Position Sensor (TPS), Installation........................................................................607
			Idle Air Control (IAC) Valve, Removal...............................................................................608
			Cleaning and Inspection.............................................................................................608
			Idle Air Control (IAC) Valve, Installation..........................................................................608
			Governor Throttle Drive Assembly, Removal...........................................................................608
			Governor Throttle Drive Assembly, Inspection........................................................................608
			Cleaning and Lubrication............................................................................................609
			Governor Throttle Drive Assembly, Installation......................................................................609
			Governor Drive Motor, Removal.......................................................................................610
			Governor Drive Motor, Cleaning and Lubrication......................................................................610
			Governor Drive Motor, Installation..................................................................................611
			Governor Drive Motor, Inspection....................................................................................611
			Throttle Body, Removal and Disassembly..............................................................................611
			Throttle Body, Inspection...........................................................................................611
			Throttle Body, Assembly and Installation............................................................................611
			Fuel Pump, Removal and Disassembly..................................................................................612
			Fuel Pump, Inspection...............................................................................................612
		REPAIRS, ELECTRICAL COMPONENTS..........................................................................................612
			General.............................................................................................................612
			Ignition Coil Test..................................................................................................612
			Ignition Module Test................................................................................................613
			Distributor, Removal................................................................................................613
			Distributor, Disassembly............................................................................................614
			Distributor, Assembly...............................................................................................614
			Distributor, Installation...........................................................................................615
			Firing Order........................................................................................................616
			Ignition Timing.....................................................................................................616
			Ignition Coil, Removal..............................................................................................617
			Ignition Coil, Installation.........................................................................................617
			Procedures For Spark Plugs, Spark Plug Wires And Boots .............................................................617
			Troubleshooting of Spark Plugs......................................................................................618
			Coolant Temperature Sensor (CTS), Replacement ......................................................................619
			Manifold Absolute Pressure (MAP) Sensor, Replacement................................................................619
			Oil Pressure Switch, Replacement....................................................................................620
			Coolant Temperature Sender, Replacement.............................................................................620
			Wire Harness........................................................................................................620
			Connectors And Terminals............................................................................................620
			Electronic Control Module (ECM).....................................................................................624
		ECM CONNECTOR A-B IDENTIFICATION........................................................................................628
		ECM CONNECTOR C-D IDENTIFICATION........................................................................................629
	SPECIAL TOOLS...............................................................................................................630
2200473.........................................................................................................................633
	INTRODUCTION................................................................................................................633
		GENERAL.................................................................................................................633
	DESCRIPTION AND OPERATION...................................................................................................633
		GENERAL.................................................................................................................633
		ECM (ELECTRONIC CONTROL MODULE).........................................................................................633
			ALDL Connector......................................................................................................635
			How The ECM Begins Operation........................................................................................635
		ELECTRONIC ENGINE CONTROL...............................................................................................636
			What The ECM Does...................................................................................................636
			Pulse Generator, EST Distributor....................................................................................637
			EST Module(See FIGURE 9.)...........................................................................................638
			When the Engine Is Being Started....................................................................................638
			When the Engine Is Running..........................................................................................640
			Electronic Control Module (ECM) With EST Distrubutor, Corrrections..................................................640
			What The ECM Does...................................................................................................640
		FUEL CONTROL............................................................................................................641
			Throttle Body Injection.............................................................................................641
			Fuel Injectors......................................................................................................642
			Fuel Pressure Regulator.............................................................................................642
			Throttle Position Sensor............................................................................................642
			Idle Air Control....................................................................................................642
			Governor Motor And Throttle Drive Assembly..........................................................................643
			Vacuum Ports........................................................................................................645
			Fuel Pump...........................................................................................................645
		ECM SENSORS AND CONTROLLERS.............................................................................................647
			Manifold Absolute Pressure (MAP)....................................................................................647
			Coolant Temperature Sensor (CTS)....................................................................................647
			Initial Timing Connector (EST Distributor)..........................................................................647
4000135.........................................................................................................................649
	SAFETY PROCEDURES WHEN WORKING NEAR THE MAST................................................................................649
		SAFETY PROCEDURES WHEN WORKING NEAR THE MAST............................................................................649
	LIFT CYLINDERS..............................................................................................................652
		GENERAL.................................................................................................................652
		DESCRIPTION.............................................................................................................652
			Lowering Control Valve..............................................................................................652
			Cylinders (General).................................................................................................655
			Cylinders (H520-620B,H700-800A).....................................................................................657
			Cylinders (H360-460B)...............................................................................................658
			Cylinders (Two-Speed)...............................................................................................658
	REPAIRS.....................................................................................................................659
		REMOVAL OF THE LIFT CYLINDER WITHOUT REMOVING THE MAST..................................................................659
			Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast............................659
			Standard and Full Free-Lift Masts with the Lift Cylinder to a Crosshead.............................................663
			Masts that have Two Cylinders, A Main Lift Cylinder  and a Free-Lift Cylinder.......................................661
		DISASSEMBLY.............................................................................................................661
		ASSEMBLY................................................................................................................663
		INSTALLATION OF THE LIFT CYLINDER IN THE MAST...........................................................................663
			Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast............................663
			Standard and Full-Free-Lift Masts with the Lift Cylinder Fastened to a Crosshead....................................663
		CHEVRON PACKING.........................................................................................................664
	LIFT CYLINDERS FOR VISTA MASTS..............................................................................................667
		DESCRIPTION.............................................................................................................667
			Lowering Control Valve..............................................................................................669
		REMOVAL.................................................................................................................670
		DISASSEMBLY.............................................................................................................670
		ASSEMBLY................................................................................................................670
		INSTALLATION............................................................................................................671
			Main Lift Cylinders.................................................................................................671
			Free-Lift Cylinders.................................................................................................671
	CHECKS AND ADJUSTMENTS......................................................................................................672
		CHECK FOR LEAKS IN LIFT SYSTEM..........................................................................................672
	TROUBLESHOOTING.............................................................................................................673
	SPECIFICATIONS..............................................................................................................674
4000340.........................................................................................................................675
	VISTA® MASTS................................................................................................................675
		GENERAL.................................................................................................................675
		DESCRIPTION AND OPERATION...............................................................................................675
		CARRIAGES...............................................................................................................675
		TWO-STAGE MAST WITH LIMITED FREE-LIFT...................................................................................675
		TWO-STAGE MAST WITH FULL FREE-LIFT MAST.................................................................................676
		THREE-STAGE MAST WITH FULL FREE-LIFT....................................................................................677
	REPAIRS.....................................................................................................................679
		SAFETY PROCEDURES WHEN WORKING NEAR THE MAST (1 OF 2)...................................................................679
		SAFETY PROCEDURES WHEN WORKING NEAR THE MAST (2 OF 2)...................................................................680
		FORKS...................................................................................................................680
			Forks, Removal And Installation.....................................................................................680
		CARRIAGE................................................................................................................682
			Removal.............................................................................................................682
		SIDE-SHIFT CARRIAGE (EARLIER DESIGNS)...................................................................................683
			Disassembly, Side Shift Carriage....................................................................................683
			Assembly, Side Shift Carriage.......................................................................................685
			Installation........................................................................................................686
		SIDE-SHIFT CARRIAGE (1993 AND LATER DESIGN).............................................................................686
			Removal.............................................................................................................686
			Repairs.............................................................................................................687
			Installation........................................................................................................688
		TABLE 1. WEIGHT OF MAST PARTS...........................................................................................688
		TWO-STAGE MAST WITH LIMITED FREE-LIFT...................................................................................689
			Removal.............................................................................................................689
			Disassembly.........................................................................................................689
			Cleaning and Inspection.............................................................................................691
			Assembly............................................................................................................691
			Installation........................................................................................................692
		TWO-STAGE MAST WITH FULL FREE-LIFT......................................................................................692
			Removal.............................................................................................................692
			Disassembly.........................................................................................................692
			Cleaning and Inspection.............................................................................................693
			Assembly............................................................................................................693
			Installation........................................................................................................693
		THREE-STAGE MAST WITH FULL FREE LIFT....................................................................................694
			Removal.............................................................................................................694
			Disassembly.........................................................................................................694
			Cleaning and Inspection.............................................................................................695
			Assembly............................................................................................................695
			Installation........................................................................................................697
	CHECKS AND ADJUSTMENTS......................................................................................................699
		CHECK THE OPERATION OF THE MAST.........................................................................................699
		CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM.............................................................................699
			Lift System.........................................................................................................699
			Tilt System.........................................................................................................699
		ADJUST THE TILT CYLINDER STROKE AND THE BACKWARD TILT ANGLE.............................................................700
		LIFT CHAIN ADJUSTMENTS..................................................................................................700
		MAST ADJUSTMENTS........................................................................................................701
		CARRIAGE ADJUSTMENT.....................................................................................................702
	TROUBLESHOOTING.............................................................................................................705
8000231.........................................................................................................................707
	INTRODUCTION................................................................................................................707
		NOMENCLATURE, THREADS...................................................................................................707
		STRENGTH IDENTIFICATION.................................................................................................708
	TABLE 1. BOLTS AND SCREWS...................................................................................................708
	TABLE 2. STUDS AND NUTS.....................................................................................................709
	TABLE 3. TORQUE NUTS........................................................................................................710
	TABLE 4. TORQUE NUTS WITH NYLON INSERT......................................................................................711
	TABLE 5. TORQUE VALUES FOR INCH FASTENERS...................................................................................712
	TABLE 6. TORQUE VALUES FOR METRIC FASTENERS.................................................................................713
8000341.........................................................................................................................716
	PERIODIC MAINTENANCE........................................................................................................716
		GENERAL.................................................................................................................716
		SERIAL NUMBER DATA......................................................................................................716
		HOW TO MOVE A DISABLED LIFT TRUCK.......................................................................................716
			How To Tow the Lift Truck...........................................................................................716
		HOW TO PUT A LIFT TRUCK ON BLOCKS.......................................................................................717
			How To Raise the Drive Tires........................................................................................717
			How To Raise the Steering Tires.....................................................................................717
	MAINTENANCE SCHEDULE........................................................................................................719
	MAINTENANCE PROCEDURES......................................................................................................722
	EVERY 8 HOURS OR DAILY......................................................................................................722
		HOW TO MAKE THE CHECKS WITH THE ENGINE STOPPED..........................................................................722
			Hydraulic System Oil................................................................................................722
			Engine Oil..........................................................................................................724
			Drive Belts.........................................................................................................724
			Cooling System......................................................................................................724
			Air Filter..........................................................................................................724
			Fuel System.........................................................................................................725
			Primary Fuel Filter, Diesel Engine..................................................................................725
			Battery.............................................................................................................725
			Tires and Wheels....................................................................................................725
			Forks...............................................................................................................726
			Forks, Adjustment...................................................................................................726
			Forks, Removal And Installation.....................................................................................726
			Inspection of Forks, Mast, And Lift Chains..........................................................................727
			Operator Restraint System...........................................................................................729
			Safety Labels.......................................................................................................730
		HOW TO MAKE THE CHECKS WITH THE ENGINE RUNNING..........................................................................730
			Gauges, Lights, Horn, and Fuses.....................................................................................730
			Oil Level, Powershift Transmission..................................................................................730
			Oil Level, Oil Clutch System, H3.50-5.00XL (H70-110XL)..............................................................731
			Control Levers and Pedals...........................................................................................731
			Lift System Operation...............................................................................................731
			Inching/Brake Pedal.................................................................................................732
			Service Brakes......................................................................................................732
			Parking Brake.......................................................................................................732
			Steering System.....................................................................................................732
	EVRY 150 HOURS OR MONTHLY...................................................................................................732
		THRUST SCREW FOR THE DIFFERENTIAL, H6.00-7.00XL (H135-155XL)............................................................732
		LIFT CHAINS, LUBRICATION................................................................................................732
		DRIVE SHAFTS............................................................................................................733
	EVERY 350 HOURS OR TWO MONTHS...............................................................................................733
		ENGINE OIL AND FILTER...................................................................................................733
		DRIVE BELTS.............................................................................................................734
			Perkins Diesel Engine...............................................................................................734
			GM V-6 Engine (Early Models)........................................................................................734
			GM V-6 Engine (Later Models)........................................................................................735
		HYDRAULIC TANK BREATHER, CLEAN AND CHECK................................................................................736
		BRAKE FLUID.............................................................................................................736
		LIFT CHAINS, CHECK FOR WEAR.............................................................................................736
		FORKS, CHECK FOR WEAR AND DAMAGE........................................................................................737
		MAST, LUBRICATION.......................................................................................................737
		CONTROL LEVERS AND PEDALS, LUBRICATION..................................................................................737
		STEERING AXLE, LUBRICATION..............................................................................................738
		FUEL SYSTEM, CHECKS AND ADJUSTMENTS.....................................................................................738
			Diesel Fuel System..................................................................................................738
			LPG Carburetor (Early Models).......................................................................................738
			Gasoline Carburetor (Early Models)..................................................................................739
			Fuel Injection (Late Models)........................................................................................739
	EVERY 1000 HOURS OR SIX MONTHS..............................................................................................739
		PCV VALVE, GM V-6.......................................................................................................739
		MANIFOLD HEAT VALVE, GM V-6 (EARLY MODELS)..............................................................................739
		CRANKCASE BREATHER, GM-V6...............................................................................................739
		IGNITION SYSTEM (GM V-6)................................................................................................739
		VALVE CLEARANCE ADJUSTMENT..............................................................................................740
		FUEL FILTER (REPLACEMENT), DIESEL ENGINE................................................................................740
		REMOVE AIR FROM THE FUEL SYSTEM: PERKINS 1004-4 DIESEL ENGINE...........................................................740
			Fuel Injection Pump With A Vent Tube................................................................................740
			Fuel Injection Pump With A Vent Screw...............................................................................741
		REMOVE AIR FROM THE FUEL SYSTEM: PERKINS 4.2482 DIESEL ENGINE...........................................................742
		CHECK THE OIL LEVEL IN THE TRANSMISSION.................................................................................742
			Manual Transmission, H3.50-5.00XL (H70-110XL).......................................................................742
			Speed Reducer For The Powershift Transmission, H3.50-5.00XL (H70-110XL).............................................743
			Manual Transmission, H6.00-7.00XL (H135-155XL)......................................................................743
			Differential And Drive Axle For The Powershift Transmission, H6.00-7.00XL (H135-155XL...............................743
			Differential, Speed Reducer, And Drive Axle For The Manual Transmission, H6.00-7.00XL (H135-155XL)..................743
	EVERY 2000 HOURS OR YEARLY..................................................................................................743
		HYDRAULIC SYSTEM........................................................................................................743
			Replace the Hydraulic Oil and Filter, H3.50-5.00XL (H70-110XL)......................................................743
			Replace the Hydraulic Oil and Filter, H6.00-7.00XL (H135-155XL).....................................................744
		CHANGE THE OIL AND REPLACE THE OIL FILTER, POWERSHIFT TRANSMISSION, ALL UNITS...........................................744
		CHANGE THE OIL, MANUAL TRANSMISSION, H3.50-5.00XL (H70-110XL)...........................................................744
		CHANGE THE OIL, MANUAL TRANSMISSION, H6.00-7.00XL (H135-155XL)..........................................................744
		CHANGE THE OIL, SPEED REDUCER, POWERSHIFT TRANSMISSION, H3.50-5.00XL (H70-110XL)........................................745
		CHANGE THE OIL AND FILTER, OIL CLUTCH SYSTEM, H3.50-5.00XL (H70-110XL)..................................................745
		CHANGE THE OIL, DIFFERENTIAL AND DRIVE AXLE FOR THE POWERSHIFT TRANSMISSION, H6.00-7.00XL (H135-155XL)..................745
		CHANGE THE OIL, DIFFERENTIAL, SPEED REDUCER, AND DRIVE AXLE FOR MANUAL TRANSMISSION, H6.00-7.00XL (H135-155XL)..........745
		COOLING SYSTEM..........................................................................................................746
		WHEEL BEARINGS..........................................................................................................746
			Steering Wheels, lubrication........................................................................................746
			Drive Wheels, Lubrication...........................................................................................746
		PCV VALVE, GM V-6.......................................................................................................746
		SERVICE BRAKES..........................................................................................................746
		LPG FILTER, REPLACEMENT.................................................................................................747
		GASOLINE FUEL FILTER, REPLACEMENT.......................................................................................747
		CHECK THE HOOD LATCH, H3.50-5.00XL (H70-110XL)..........................................................................747
	GENERAL PROCEDURES..........................................................................................................748
		SAFETY PROCEDURES WHEN WORKING NEAR THE MAST............................................................................748
		LIFT CHAIN ADJUSTMENTS..................................................................................................750
		FUEL INJECTORS..........................................................................................................750
		CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM.............................................................................751
			Check the Lift Cylinder for Leaks...................................................................................751
			Check the Tilt Cylinder for Leaks...................................................................................751
		WELDING REPAIRS.........................................................................................................751
		CHANGES TO THE OVERHEAD GUARD...........................................................................................752
		WHEELS AND TIRES........................................................................................................753
			Remove The Wheels From The Lift Truck...............................................................................753
			Remove The Wheel From The Tire......................................................................................753
			Install The Wheel In The Tire.......................................................................................755
			Pneumatic Tires, Add Air To The Tires...............................................................................756
			Install the Wheels..................................................................................................756
		SOLID RUBBER TIRES......................................................................................................757
			Remove The Tire From The Wheel......................................................................................757
			Install The Tire On The Wheel.......................................................................................758
	REFERENCE TABLE.............................................................................................................759
8000342.........................................................................................................................760
8000343.........................................................................................................................768
	FIGURE 1. ELECTRICAL SCHEMATIC (GASOLINE/LPG, EARLY PRODUCTION).............................................................768
	FIGURE 2. ELECTRICAL SCHEMATIC (GASOLINE/LPG, LATER PRODUCTION).............................................................770
	FIGURE 3. ELECTRICAL SCHEMATIC (DIESEL, PERKINS 4.2482).....................................................................772
	FIGURE 4. ELECTRICAL SCHEMATIC (DIESEL, PERKINS 1004-4, EARLY PRODUCTION)...................................................774
	FIGURE 5. ELECTRICAL SCHEMATIC (DIESEL, PERKINS 1004-4, LATER PRODUCTION)...................................................776
	FIGURE 6. HYDRAULIC SCHEMATIC...............................................................................................778
	FIGURE 7. HYDRAULIC SCHEMATIC, POWERSHIFT TRANSMISSION WITH MANUAL CONTROL..................................................779
	FIGURE 8. HYDRAULIC SCHEMATIC, POWERSHIFT TRANSMISSION WITH MONTROL PEDAL...................................................780
	FIGURE 9. WIRING DIAGRAM, BACK-UP ALARM.....................................................................................781
8000494.........................................................................................................................782

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