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Hyster G005 (H70-110XL) Service Manual – PDF DOWNLOAD
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Description
Hyster G005 (H70-110XL) Service Manual – PDF DOWNLOAD
DESCRIPTION:
Hyster G005 (H70-110XL) Service Manual – PDF DOWNLOAD
SAFETY PRECAUTIONS MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly
fastened, and that the load being lifted is balanced. Make sure the crane, cables, and
chains have the capacity to support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair
on electric lift trucks.
• Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT
THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance
section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts
must meet or exceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before
using force to remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit whenmaking repairs,
or if the unit needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid PetroleumGas (LPG), Compressed Natural Gas (CNG), and Diesel fuel
are flammable. Be sure to follow the necessary safety precautions when handling these
fuels and when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks
away from the area. Make sure the area is well ventilated.
TABLE OF CONTENTS:
Hyster G005 (H70-110XL) Service Manual – PDF DOWNLOAD
22002..................................................................................................................... 1 General............................................................................................................... 3 Description........................................................................................................... 3 Alternator Repair..................................................................................................... 5 Alternator Type A................................................................................................. 5 Remove and Disassemble........................................................................................ 5 Clean......................................................................................................... 6 Assemble...................................................................................................... 6 Install....................................................................................................... 7 Alternator Type B................................................................................................. 10 Remove and Disassemble........................................................................................ 10 Clean......................................................................................................... 10 Assemble...................................................................................................... 11 Install....................................................................................................... 12 General Check and Adjustment.......................................................................................... 13 Low Output Check (Type A or Type B)................................................................................... 13 High Output Check (Type A or Type B).................................................................................. 15 Brushes Circuit Check................................................................................................. 16 Delco Alternators................................................................................................. 16 Motorola Alternators.............................................................................................. 17 Diodes Check.......................................................................................................... 18 Diodes Bridge Check................................................................................................... 18 Delco and Leece-Neville Alternators............................................................................... 18 Motorola Alternators.............................................................................................. 18 Rotor Field Winding Check............................................................................................. 19 Stator Windings Check................................................................................................. 20 Voltage Regulator Check............................................................................................... 20 Troubleshooting....................................................................................................... 21 100345.................................................................................................................... 23 THE FRAME............................................................................................................. 23 GENERAL........................................................................................................... 23 DESCRIPTION....................................................................................................... 23 REPAIRS........................................................................................................... 23 COUNTERWEIGHT..................................................................................................... 23 Removal....................................................................................................... 23 COUNTERWEIGHT..................................................................................................... 24 Installation.................................................................................................. 24 HOOD.............................................................................................................. 24 Removal....................................................................................................... 24 HOOD.............................................................................................................. 24 Installation.................................................................................................. 24 OVERHEAD GUARD.................................................................................................... 25 Removal....................................................................................................... 25 Installation.................................................................................................. 25 OPERATOR RESTRAINT SYSTEM......................................................................................... 25 RADIATOR.......................................................................................................... 25 Removal....................................................................................................... 25 Installation.................................................................................................. 26 EXHAUST SYSTEM.................................................................................................... 26 Muffler Replacement........................................................................................... 26 ENGINE............................................................................................................ 26 Removal....................................................................................................... 26 Installation.................................................................................................. 29 FUEL AND HYDRAULIC TANKS.......................................................................................... 30 Inspection.................................................................................................... 30 Repairs, Small Leaks.......................................................................................... 30 Repairs, Large Leaks.......................................................................................... 30 Cleaning...................................................................................................... 30 Other Methods Of Preparation For Repair....................................................................... 31 SAFETY LABELS..................................................................................................... 32 CAB........................................................................................................... 32 Cab Repalacement.............................................................................................. 32 Window Repalcement................................................................................................ 32 Windshield Wipers, Heater and Fan............................................................................. 35 Material Specifications For Cab Windows....................................................................... 35 Cab Heater Hoses.............................................................................................. 35 160054.................................................................................................................... 36 INTRODUCTION.......................................................................................................... 36 GENERAL........................................................................................................... 36 DESCRIPTION....................................................................................................... 36 OPERATION......................................................................................................... 36 REPAIRS............................................................................................................... 36 STEERING WHEEL AND COLUMN ASSEMBLY................................................................................ 36 TYPE "A" STEERING COLUMN ASSEMBLY................................................................................. 38 Removal And Disassembly....................................................................................... 38 Assembly And Installation..................................................................................... 38 TYPE "A" STEERING COLUMN.......................................................................................... 39 TYPE "A" STEERING COLUMN.......................................................................................... 40 TYPE "B" STEERING COLUMN.......................................................................................... 41 Removal And Disassembly....................................................................................... 41 Assembly And Installation..................................................................................... 41 TYPE "B" STEERING COLUMN.......................................................................................... 42 Disassembly of Steering Control Unit.......................................................................... 43 Cleaning of Steering Control Unit............................................................................. 43 Assembly of Steering Control Unit............................................................................. 45 CHECKS AND ADJUSTMENTS................................................................................................ 48 REMOVE AIR FROM THE SYSTEM........................................................................................ 48 TROUBLESHOOTING....................................................................................................... 49 190097.................................................................................................................... 50 INTRODUCTION.......................................................................................................... 50 DESCRIPTION....................................................................................................... 50 OPERATION......................................................................................................... 50 Flow Control Valve............................................................................................ 52 Relief Valve.................................................................................................. 52 REPAIRS............................................................................................................... 53 REMOVAL........................................................................................................... 53 DISASSEMBLY....................................................................................................... 53 CLEANING.......................................................................................................... 55 INSPECTION........................................................................................................ 55 ASSEMBLY.......................................................................................................... 56 INSTALLATION...................................................................................................... 57 CHECKS AND ADUSTMENTS................................................................................................. 58 CHECK THE OUTPUT OF THE PUMP...................................................................................... 58 CHECK FOR AIR IN THE HYDRAULIC SYSTEM............................................................................. 58 TROUBLESHOOTING....................................................................................................... 60 600412.................................................................................................................... 63 PERKINS DIESEL ENGINES, SERIES 1000................................................................................... 63 1.1 GENERAL....................................................................................................... 63 GENERAL SAFETY RULES.............................................................................................. 63 Viton Seals................................................................................................... 63 1.2 DESCRIPTION................................................................................................... 66 1.3 Engine Serial Number Codes................................................................................ 66 1.4 Engine Data............................................................................................... 66 1.5 1004–4 ENGINE............................................................................................. 67 1.6 1004–4T ENGINE............................................................................................ 67 1.7 1006–6 ENGINE............................................................................................. 67 1.8 1006–6T ENGINE............................................................................................ 67 1.9 REMOVAL AND INSTALLATION...................................................................................... 67 CYLINDER HEAD ASSEMBLY................................................................................................ 68 1.10 VALVE COVER.................................................................................................. 68 1.11 Removal.................................................................................................. 68 1.12 Installation............................................................................................. 68 1.13 ROCKER ARM ASSEMBLY.......................................................................................... 68 1.14 Removal.................................................................................................. 68 1.15 Installation............................................................................................. 68 1.16 Disassembly.............................................................................................. 69 1.17 Inspection............................................................................................... 69 1.18 Assembly................................................................................................. 69 1.19 VALVE CLEARANCE ADJUSTMENTS.................................................................................. 69 1.20 Four Cylinder Engines.................................................................................... 70 1.21 Six Cylinder Engines..................................................................................... 70 1.22 VALVE SPRINGS................................................................................................ 70 1.23 CYLINDER HEAD ASSEMBLY....................................................................................... 72 1.24 Removal.................................................................................................. 72 1.25 Installation............................................................................................. 73 1.26 VALVES AND VALVE SPRINGS..................................................................................... 76 1.27 Removal.................................................................................................. 76 1.28 Inspection............................................................................................... 77 1.29 Installation............................................................................................. 77 1.30 VALVE GUIDES................................................................................................. 77 1.31 Inspection............................................................................................... 77 1.32 Removal.................................................................................................. 78 1.33 Installation............................................................................................. 78 1.34 CYLINDER HEAD AND VALVE SEATS................................................................................ 78 1.35 Inspection............................................................................................... 78 1.36 Repair................................................................................................... 79 1.37 Installation Of New Valve Seats.......................................................................... 79 PISTON AND CONNECTING ROD ASSEMBLIES.................................................................................. 80 1.38 ROD BEARINGS................................................................................................. 80 1.39 Removal.................................................................................................. 80 1.40 Installation............................................................................................. 81 1.41 PISTON AND CONNECTING ROD ASSEMBLY........................................................................... 81 1.42 Service Note............................................................................................. 81 1.43 Removal.................................................................................................. 81 1.44 Installation............................................................................................. 82 1.45 PISTON RINGS................................................................................................. 83 1.46 Removal.................................................................................................. 83 1.47 Inspection............................................................................................... 83 1.48 Installation............................................................................................. 84 1.49 PISTON AND CONNECTING ROD.................................................................................... 85 1.50 Disassembly.............................................................................................. 85 1.51 Inspection............................................................................................... 85 1.52 Installation............................................................................................. 85 1.53 PISTON COOLING JETS.......................................................................................... 86 1.54 Removal.................................................................................................. 86 1.55 Installation............................................................................................. 86 CRANKSHAFT ASSEMBLY................................................................................................... 87 1.56 GENERAL...................................................................................................... 87 1.57 CRANKSHAFT PULLEY............................................................................................ 87 1.58 Removal, Engines AA and AB............................................................................... 87 1.59 Installation, Engines AA and AB.......................................................................... 87 1.60 Removal, Engines YA and YB............................................................................... 87 1.61 Installation, Engines YA and YB.......................................................................... 87 1.62 REAR OIL SEAL................................................................................................ 88 1.63 Replacement.............................................................................................. 88 1.64 MAIN BEARINGS................................................................................................ 89 1.65 Removal.................................................................................................. 89 1.66 Installation............................................................................................. 89 1.67 THRUST WASHERS............................................................................................... 90 1.68 Check The Axial Movement Of The Crankshaft............................................................... 90 1.69 Removal.................................................................................................. 91 1.70 Installation............................................................................................. 91 1.71 CRANKSHAFT................................................................................................... 91 1.72 Removal.................................................................................................. 91 1.73 Inspection............................................................................................... 92 1.74 Installation............................................................................................. 92 TIMING CASE AND TIMING GEARS.......................................................................................... 94 1.75 GENERAL...................................................................................................... 94 1.76 TIMING CASE COVER............................................................................................ 94 1.77 Removal.................................................................................................. 94 1.78 Installation............................................................................................. 94 1.79 FRONT OIL SEAL............................................................................................... 95 1.80 Removal.................................................................................................. 95 1.81 Installation............................................................................................. 95 1.82 IDLER GEAR AND HUB........................................................................................... 95 1.83 Removal.................................................................................................. 95 1.84 Installation............................................................................................. 96 1.85 GEAR FOR THE FUEL INJECTION PUMP OR THE CAMSHAFT GEAR........................................................ 97 1.86 Removal.................................................................................................. 97 1.87 Installation............................................................................................. 97 1.88 CRANKSHAFT GEAR.............................................................................................. 98 1.89 Removal.................................................................................................. 98 1.90 Installation............................................................................................. 98 1.91 TIMING CASE.................................................................................................. 98 1.92 Removal.................................................................................................. 98 1.93 Installation............................................................................................. 98 1.94 CAMSHAFT AND TAPPETS......................................................................................... 99 1.95 Removal..................................................................................................100 1.96 Installation.............................................................................................100 ENGINE BLOCK ASSEMBLY.................................................................................................101 1.97 DESCRIPTION..................................................................................................101 1.98 ENGINE BLOCK.................................................................................................101 1.99 Disassembly..............................................................................................101 1.100 Inspection..............................................................................................102 1.101 Assembly................................................................................................102 1.102 CYLINDER LINER..............................................................................................102 1.103 Inspection..............................................................................................102 1.104 Hone....................................................................................................103 1.105 Removal.................................................................................................103 1.106 Installation............................................................................................104 TURBOCHARGER, ENGINES AB AND YB.......................................................................................105 1.107 GENERAL.....................................................................................................105 1.108 Removal.................................................................................................105 1.109 Installation............................................................................................106 1.110 Clean The Impeller And Compressor Housing...............................................................106 LUBRICATION SYSTEM....................................................................................................107 1.111 GENERAL.....................................................................................................107 1.112 OIL FILTER, REPLACEMENT.....................................................................................107 1.113 OIL SUMP....................................................................................................108 1.114 Removal.................................................................................................108 1.115 Installation............................................................................................108 1.116 OIL PUMP....................................................................................................108 1.117 Removal.................................................................................................108 1.118 Inspection..............................................................................................109 1.119 Installation............................................................................................109 1.120 RELIEF VALVE................................................................................................110 1.121 Removal.................................................................................................110 1.122 Disassembly.............................................................................................110 1.123 Inspection..............................................................................................111 1.124 Installation............................................................................................111 FUEL SYSTEM...........................................................................................................111 1.125 DESCRIPTION.................................................................................................111 1.126 CAV FUEL INJECTION PUMP.....................................................................................112 1.127 Removal.................................................................................................112 1.128 Installation............................................................................................112 1.129 CAV FUEL INJECTION PUMP, CHECKS AND ADJUSTMENTS.............................................................113 1.130 Timing Gear Marks.......................................................................................113 1.131 How To Set Number 1 Piston To TDC On The Compression Stroke.............................................114 1.132 Check The Valve Timing..................................................................................114 1.133 Check The Timing Of The Fuel Injection Pump.............................................................115 1.134 Check The Timing Mark Of The Fuel Injection Pump........................................................115 1.135 Check The Engine Timing Mark............................................................................116 1.136 REMOVE AIR FROM THE FUEL SYSTEM.............................................................................117 1.137 Fuel Injection Pump With Vent Tube......................................................................117 1.138 Fuel Injection Pump With Vent Screw.....................................................................118 1.139 FUEL FILTER (REPLACEMENT)...................................................................................119 1.140 FUEL INJECTORS..............................................................................................119 1.141 Removal.................................................................................................119 1.142 Inspection..............................................................................................120 1.143 Installation............................................................................................121 1.144 FUEL PUMP...................................................................................................121 1.145 Removal.................................................................................................121 1.146 Disassembly.............................................................................................121 1.147 Assembly................................................................................................122 1.148 Installation............................................................................................122 1.149 Test....................................................................................................123 COOLING SYSTEM........................................................................................................123 1.150 GENERAL.....................................................................................................123 1.151 THERMOSTAT..................................................................................................123 1.152 Replacement.............................................................................................123 1.153 COOLANT PUMP................................................................................................124 1.154 Removal.................................................................................................124 1.155 Disassembly.............................................................................................124 1.156 Assembly................................................................................................125 1.157 Installation............................................................................................125 1.158 FAN AND FAN DRIVE...........................................................................................125 1.159 Removal.................................................................................................125 1.160 Disassembly.............................................................................................125 1.161 Assembly................................................................................................126 1.162 Installation............................................................................................126 1.163 OIL COOLER..................................................................................................126 1.164 Removal, Engine AB......................................................................................126 1.165 Removal, Engines YA and YB..............................................................................126 1.166 Disassembly And Assembly................................................................................127 1.167 Installation, Engine AB.................................................................................127 1.168 Installation, Engines YA and YB.........................................................................128 1.169 By–Pass Valve, Oil Cooler...............................................................................128 FLYWHEEL AND FLYWHEEL HOUSING.........................................................................................128 1.170 GENERAL.....................................................................................................128 1.171 FLYWHEEL....................................................................................................128 1.172 Removal.................................................................................................128 1.173 Ring Gear (Replacement).................................................................................128 1.174 Installation............................................................................................128 1.175 FLYWHEEL HOUSING............................................................................................129 1.176 Removal.................................................................................................129 1.177 Installation............................................................................................129 ELECTRICAL EQUIPMENT..................................................................................................130 1.178 DRIVE BELTS.................................................................................................130 1.179 ALTERNATOR..................................................................................................131 1.180 STARTER MOTOR...............................................................................................131 1.181 Removal.................................................................................................131 1.182 Installation............................................................................................131 1.183 COLD START AID..............................................................................................131 AIR COMPRESSOR, ENGINES YA AND YB.....................................................................................131 1.184 GENERAL.....................................................................................................131 1.185 Air Compressor, Removal, WABCO..........................................................................131 1.186 Compressor Drive, Inspection............................................................................132 1.187 Air Compressor, Installation, WABCO.....................................................................132 1.188 Compressor Drive, Disassembly, WABCO....................................................................132 1.189 Compressor Drive, Assembly, WABCO.......................................................................133 1.190 Air Compressor, Removal, BENDIX.........................................................................133 1.191 Air Compressor, Installation, BENDIX....................................................................134 1.192 Compressor Drive, Disassembly, BENDIX...................................................................135 1.193 Compressor Drive, Assembly, BENDIX......................................................................135 ENGINE SPECIFICATIONS.................................................................................................137 1.194 CYLINDER HEAD ASSEMBLY......................................................................................137 1.195 Cylinder Head...........................................................................................137 1.196 Valve Guides............................................................................................137 1.197 Inlet Valves............................................................................................138 1.198 Exhaust Valves..........................................................................................138 1.199 Double Valve Springs To Outer...........................................................................138 1.200 Double Valve Springs To Inner...........................................................................138 1.201 Single Valve Springs....................................................................................138 1.202 Tappets.................................................................................................138 1.203 Rocker Arm Shaft........................................................................................138 1.204 Rocker Arms And Bushings................................................................................139 1.205 PISTON AND CONNECTING RODS..................................................................................139 1.206 Pistons, Engines AA And YA..............................................................................139 1.207 Pistons, Engines AB And YB..............................................................................139 1.208 Piston Rings, Engines AA And YA.........................................................................139 1.209 Piston Rings, Engines AB And YB.........................................................................139 1.210 Connecting Rods, Engines AB And YB......................................................................140 1.211 Connecting Rods, Engines AB And YB......................................................................140 1.212 Piston Pins, Engines AA And YA..........................................................................140 1.213 Piston Pins, Engines AB and YB..........................................................................140 1.214 Small End Bushings, Engines AA And YA...................................................................140 1.215 Small End Bushings, Engines AB And YB...................................................................140 1.216 Connecting Rod Bearings, Engines AA And YA..............................................................141 1.217 Connecting Rod Bearings, Engines AB And YB..............................................................141 1.218 Piston Cooling Jets, Engines AB And YB..................................................................141 1.219 CRANKSHAFT ASSEMBLY.........................................................................................141 1.220 Crankshaft..............................................................................................141 1.221 Crankshaft Heat Treatment...............................................................................141 1.222 Crankshaft Overhaul.....................................................................................141 1.223 Main Bearings...........................................................................................143 1.224 Crankshaft Thrust Washers...............................................................................143 1.225 TIMING CASE AND DRIVE ASSEMBLY..............................................................................143 1.226 Camshaft................................................................................................143 1.227 Camshaft Thrust Washer..................................................................................143 1.228 Camshaft Gear...........................................................................................144 1.229 Gear For Fuel Injection Pump............................................................................144 1.230 Crankshaft Gear.........................................................................................144 1.231 Idler Gear And Hub......................................................................................144 1.232 ENGINE BLOCK ASSEMBLY.......................................................................................144 1.233 Engine Block............................................................................................144 1.234 Cylinder Liners.........................................................................................144 1.235 TURBOCHARGER................................................................................................145 1.236 LUBRICATION SYSTEM..........................................................................................145 1.237 Oil Pump, Engines AA And AB.............................................................................145 1.238 Oil Pump, Engines YA And YB.............................................................................145 1.239 Relief Valve............................................................................................145 1.240 Oil Filter..............................................................................................145 1.241 FUEL SYSTEM.................................................................................................145 1.242 Cav Fuel Injection Pump.................................................................................145 1.243 FUEL INJECTORS..........................................................................................146 1.244 Fuel Pump, Engines AA And AB............................................................................147 1.245 Fuel Pump, Engines YA And YB............................................................................147 1.246 Fuel Filter.............................................................................................147 1.247 COOLING SYSTEM..............................................................................................147 1.248 Coolant Pump............................................................................................147 1.249 Thermostat..............................................................................................148 1.250 Fan Drive Housing.......................................................................................148 1.251 FLYWHEEL AND HOUSING........................................................................................148 1.252 Limits for flywheel ''run out'' and alignment (total indicator reading).................................148 1.253 ELECTRICAL EQUIPMENT........................................................................................148 1.254 Alternator..............................................................................................148 1.255 Starter Motor...........................................................................................148 1.256 Cold Start Aid..........................................................................................148 TORQUE SPECIFICATIONS.................................................................................................149 SPECIAL TOOLS.........................................................................................................150 600590....................................................................................................................154 GM 4.3 LITRE V-6......................................................................................................154 INTRODUCTION......................................................................................................154 DESCRIPTION.......................................................................................................154 ENGINE, REMOVAL AND INSTALLATION .................................................................................155 CYLINDER HEAD.....................................................................................................155 Removal And Disassembly.......................................................................................155 Cleaning And Inspection.......................................................................................155 Repairs, Valve Guides and Seats...............................................................................155 Repairs, Valves ..............................................................................................156 Repairs, Valve Seats..........................................................................................156 Valve Springs.................................................................................................157 Studs For The Rocker Arms (Early Models)......................................................................158 Studs For The Rocker Arms (Late Models).......................................................................159 Assembly And Installation.....................................................................................159 CYLINDER BLOCK, CLEANING AND INSPECTION...........................................................................161 PISTON BORE PREPARATION...........................................................................................161 ENGINE MOUNTS.....................................................................................................161 LUBRICATION SYSTEM................................................................................................161 Oil Pump, Removal and Disassembly.............................................................................161 Cleaning and Inspection.......................................................................................162 Oil Pump, Assembly and Installation...........................................................................162 Oil Sump, Installation........................................................................................162 TIMING COVER, TIMING SPROCKETS, CAMSHAFT AND VALVE LIFTERS........................................................163 Timing Cover, Removal.........................................................................................163 Installation..................................................................................................164 Timing Sprockets, Removal.....................................................................................165 Timing Sprockets, Installation................................................................................165 Camshaft, Removal.............................................................................................165 Camshaft, Inspection..........................................................................................165 Camshaft, Installation........................................................................................165 Balance Shaft, Removal........................................................................................166 Balance Shaft, Installation...................................................................................167 Hydraulic Valve Lifters, Removal..............................................................................168 Hydraulic Valve Lifters, Disassembly..........................................................................168 Hydraulic Valve Lifters, Cleaning And Inspection..............................................................168 Hydraulic Valve Lifters, Assembly.............................................................................169 Hydraulic Valve Lifters, Installation.........................................................................169 CRANKSHAFT........................................................................................................170 Removal.......................................................................................................170 Inspection and Repair.........................................................................................170 How To Check The Clearance Between The Main Bearings And Their Journals.......................................171 Installation..................................................................................................172 PISTON AND CONNECTING ROD ASSEMBLIES..............................................................................173 Connecting Rod Bearings, Replacement..........................................................................173 Piston And Connecting Rod Assemblies, Removal.................................................................174 Disassembly...................................................................................................174 Piston, Cleaning And Inspection...............................................................................174 Cylinder Bores, Inspection And Repair.........................................................................175 Piston Rings..................................................................................................176 Assembly......................................................................................................176 Piston And Connecting Rod Assemblies, Installation............................................................177 FLYWHEEL AND FLYWHEEL HOUSING.....................................................................................177 Flywheel Repairs..............................................................................................177 Flywheel, Installation .......................................................................................177 Flywheel Housing..............................................................................................178 Engine Adapter................................................................................................178 COOLANT PUMP......................................................................................................178 THERMOSTAT........................................................................................................178 FAN MOUNT, EARLY MODELS...........................................................................................178 FAN MOUNT ASSEMBLY, LATE MODELS...................................................................................179 DRIVE BELT, INSTALLATION..........................................................................................180 CHECKS AND ADJUSTMENTS................................................................................................182 VALVE CLEARANCE ADJUSTMENT, EARLY MODELS..........................................................................182 VALVE CLEARANCE ADJUSTMENT, NEW MODELS............................................................................182 CHECK THE COMPRESSION.............................................................................................182 ENGINE SPECIFICATIONS.................................................................................................183 Engine Data.......................................................................................................183 Engine Data...................................................................................................183 Cylinder head.................................................................................................183 Hydraulic Valve Lifter........................................................................................183 Camshaft......................................................................................................183 Pistons.......................................................................................................183 Crankshaft....................................................................................................184 Connecting Rods...............................................................................................184 Connecting Rods...............................................................................................184 Balance Shaft.................................................................................................184 Cooling System................................................................................................184 Lubrication System............................................................................................184 TORQUE SPECIFICATIONS.................................................................................................185 TROUBLESHOOTING.......................................................................................................186 600705....................................................................................................................189 General...............................................................................................................191 General Safety Rules..............................................................................................191 Description...........................................................................................................192 Engine Serial Number Codes........................................................................................195 Engine Data.......................................................................................................195 Engine Removal and Installation.......................................................................................197 Lift Engine.......................................................................................................197 Cylinder Head Assembly Repair.........................................................................................197 Valve Cover.......................................................................................................197 Remove........................................................................................................197 Install.......................................................................................................198 Rocker Arm Assembly...............................................................................................198 Remove........................................................................................................198 Install.......................................................................................................198 Disassemble...................................................................................................198 Inspect.......................................................................................................198 Assemble......................................................................................................199 Valve Clearance Adjustments.......................................................................................199 Four-Cylinder Engines.........................................................................................200 Six-Cylinder Engines..........................................................................................200 Valve Springs.....................................................................................................200 Cylinder Head Assembly............................................................................................202 Remove........................................................................................................202 Install.......................................................................................................204 Valves and Valve Springs..........................................................................................208 Remove........................................................................................................208 Inspect.......................................................................................................208 Install.......................................................................................................209 Valve Guides......................................................................................................209 Inspect.......................................................................................................209 Remove........................................................................................................210 Install.......................................................................................................210 Cylinder Head and Valve Seats.....................................................................................210 Inspect.......................................................................................................210 Repair........................................................................................................210 New Valve Seat, Install.......................................................................................210 Piston and Connecting Rod Assemblies Repair...........................................................................212 Rod Bearings......................................................................................................212 Remove........................................................................................................213 Install.......................................................................................................213 Piston and Connecting Rod Assembly................................................................................214 Service Note..................................................................................................214 Remove........................................................................................................214 Install.......................................................................................................215 Piston Rings......................................................................................................216 Remove........................................................................................................216 Inspect.......................................................................................................216 Install.......................................................................................................216 Piston and Connecting Rod.........................................................................................217 Disassemble...................................................................................................217 Inspect.......................................................................................................218 How to Select Correct Replacements............................................................................218 Install.......................................................................................................219 Piston Cooling Jets...............................................................................................219 Remove........................................................................................................219 Install.......................................................................................................220 Crankshaft Assembly Repair............................................................................................220 General...........................................................................................................220 Crankshaft Pulley.................................................................................................221 Engine AR, Remove.............................................................................................221 Engine YG and YH, Remove......................................................................................221 Inspect.......................................................................................................222 Engine AR, Install............................................................................................222 Engines YG and YH, Install....................................................................................222 Rear Oil Seal.....................................................................................................223 Replace.......................................................................................................223 Main Bearings.....................................................................................................224 Remove........................................................................................................224 Inspect.......................................................................................................225 Install.......................................................................................................225 Thrust Washers....................................................................................................225 Crankshaft Axial Movement, Check..............................................................................225 Remove........................................................................................................226 Install.......................................................................................................226 Crankshaft........................................................................................................227 Remove........................................................................................................227 Inspect.......................................................................................................227 Install.......................................................................................................227 Flywheel..........................................................................................................229 Remove........................................................................................................229 Ring Gear, Replace............................................................................................229 Install.......................................................................................................229 Flywheel Housing..................................................................................................230 Remove........................................................................................................230 Install.......................................................................................................230 Timing Case and Timing Gears Repair...................................................................................231 General...........................................................................................................231 Timing Case Cover.................................................................................................231 Remove........................................................................................................231 Install.......................................................................................................232 Front Oil Seal....................................................................................................232 Remove........................................................................................................232 Install.......................................................................................................232 Crankshaft Pulley Wear Sleeve.....................................................................................233 Install.......................................................................................................233 Idler Gear and Hub................................................................................................233 Remove........................................................................................................233 Install.......................................................................................................234 Air Compressor Drive, Bendix......................................................................................235 Disassemble...................................................................................................235 Assemble......................................................................................................236 Fuel Injection Pump Gear..........................................................................................236 Remove........................................................................................................237 Install.......................................................................................................237 Camshaft Gear.....................................................................................................238 Remove........................................................................................................238 Install.......................................................................................................238 Crankshaft Gear...................................................................................................239 Remove........................................................................................................239 Install.......................................................................................................239 Timing Case.......................................................................................................239 Remove........................................................................................................239 Install.......................................................................................................240 Camshaft and Tappets..............................................................................................241 Remove........................................................................................................241 Install.......................................................................................................241 Cylinder Block Assembly Repair........................................................................................242 Description.......................................................................................................242 Cylinder Block....................................................................................................242 Disassemble...................................................................................................242 Inspect.......................................................................................................243 Assemble......................................................................................................243 Cylinder Bore (Four-Cylinder Engines).............................................................................244 Cylinder Liner (Six-Cylinder Engines).............................................................................244 Inspect.......................................................................................................244 Cylinder Liner Condition, Check...............................................................................244 Remove........................................................................................................245 Service Liner, Install........................................................................................246 Partially Finished Liner, Install.............................................................................247 Engine Timing.........................................................................................................248 Description.......................................................................................................248 How to Set Number One Piston to TDC on Compression Stroke.....................................................249 How to Set Number One Piston to TDC on Compression Stroke (Alternate Procedure)...............................250 Valve Timing, Check...........................................................................................250 Fuel Injection Pump Timing, Check.............................................................................251 Turbocharger - Engine YH Repair.......................................................................................252 General...........................................................................................................252 Remove........................................................................................................252 Install.......................................................................................................252 Impeller and Compressor Housing, Clean........................................................................253 Lubrication System Repair.............................................................................................254 General...........................................................................................................254 Oil Filter, Replace...............................................................................................254 Filter Head...................................................................................................255 Remove and Install........................................................................................255 Oil Sump......................................................................................................255 Remove....................................................................................................255 Install...................................................................................................256 Oil Pump......................................................................................................256 Remove....................................................................................................256 Inspect...................................................................................................256 Install...................................................................................................257 Relief Valve..................................................................................................257 Remove....................................................................................................257 Disassemble...............................................................................................258 Inspect...................................................................................................258 Assemble..................................................................................................258 Install...................................................................................................258 Idler Gear Shaft, Replace.....................................................................................259 Remove....................................................................................................259 Remove (Alternative)......................................................................................259 Install...................................................................................................260 Install (Alternative).....................................................................................260 Install (Alternative for Four-Cylinder Engines Only)......................................................261 Fuel System Repair....................................................................................................261 Description.......................................................................................................261 Fuel Injection Pump...............................................................................................262 Remove........................................................................................................262 Install.......................................................................................................263 Check and Adjust..............................................................................................264 Fuel System, Remove Air...........................................................................................264 Fuel Filter, Replace..............................................................................................265 Canister Type.................................................................................................266 Quick Release Canister Type...................................................................................266 Fuel Injectors....................................................................................................267 Remove........................................................................................................267 Inspect.......................................................................................................268 Install.......................................................................................................268 Fuel Pump.........................................................................................................269 Remove........................................................................................................269 Disassemble...................................................................................................269 Assemble......................................................................................................269 Install.......................................................................................................270 Test..........................................................................................................270 Cooling System Repair.................................................................................................271 General...........................................................................................................271 Thermostat........................................................................................................271 Remove........................................................................................................271 Install.......................................................................................................271 Test..........................................................................................................272 Coolant Pump......................................................................................................272 Remove........................................................................................................272 Disassemble...................................................................................................272 Assemble......................................................................................................274 Install.......................................................................................................276 Fan and Fan Drive.................................................................................................277 Remove........................................................................................................277 Install.......................................................................................................277 Oil Cooler (Six-Cylinder Engines).................................................................................278 Remove........................................................................................................278 Disassemble and Assemble......................................................................................278 Install.......................................................................................................278 Oil Cooler By-Pass Valve......................................................................................278 Electrical Equipment Repair...........................................................................................279 Drive Belts.......................................................................................................279 Alternator........................................................................................................280 Remove........................................................................................................280 Install.......................................................................................................280 Starter Motor.....................................................................................................280 Remove........................................................................................................280 Install.......................................................................................................280 Cold Start Aid....................................................................................................280 Air Compressor - Engines YG and YH....................................................................................280 General...........................................................................................................280 Repair............................................................................................................281 Remove........................................................................................................281 Install.......................................................................................................281 Engine Specifications.................................................................................................283 Cylinder Head Assembly............................................................................................283 Piston and Connecting Rods........................................................................................287 Crankshaft Assembly...............................................................................................289 Crankshaft Overhaul...........................................................................................291 Timing Case and Drive Assembly....................................................................................293 Engine Block Assembly.............................................................................................294 Turbocharger......................................................................................................297 Lubrication System................................................................................................297 Fuel System.......................................................................................................298 Cooling System....................................................................................................300 Flywheel and Housing..............................................................................................300 Electrical Equipment..............................................................................................300 Torque Specifications.................................................................................................301 Cylinder Head Assembly............................................................................................301 Piston and Connecting Rod Assemblies..............................................................................301 Crankshaft Assembly...............................................................................................301 Timing Case and Drive Assembly....................................................................................301 Turbocharger......................................................................................................301 Lubrication System................................................................................................301 Fuel System.......................................................................................................302 Cooling System....................................................................................................302 Flywheel .........................................................................................................302 Auxiliary Equipment...............................................................................................302 Special Torque Specifications.........................................................................................303 Flywheel and Housing..............................................................................................303 Turbocharger......................................................................................................303 Electrical Equipment..............................................................................................303 Auxiliary Equipment...............................................................................................303 Special Tools.........................................................................................................303 Troubleshooting.......................................................................................................308 700626....................................................................................................................312 General...............................................................................................................314 Description...........................................................................................................315 Radiator..........................................................................................................315 Radiator Cap......................................................................................................315 Thermostat........................................................................................................315 Water Pump........................................................................................................316 Fan and Fan Shroud................................................................................................316 Cooling System Checks.................................................................................................316 Radiator..........................................................................................................316 Thermostat........................................................................................................316 Water Pump........................................................................................................317 Exhaust Leaks.....................................................................................................317 Fan and Fan Shroud................................................................................................317 Radiator Cleaning.....................................................................................................317 Drain.............................................................................................................317 Clean.............................................................................................................317 Fill..............................................................................................................318 Troubleshooting.......................................................................................................319 900348....................................................................................................................321 INTRODUCTION..........................................................................................................321 GENERAL...........................................................................................................321 DESCRIPTION AND OPERATION.........................................................................................321 Fuel Tank.....................................................................................................322 Fuel Filter and Fuel Valve Unit...............................................................................322 Vaporizer.....................................................................................................323 Carburetor....................................................................................................324 Governor......................................................................................................325 REPAIRS...............................................................................................................327 LPG TANK..........................................................................................................327 Removal.......................................................................................................327 Installation..................................................................................................327 HYDROSTATIC RELIEF VALVE..........................................................................................327 Removal and Installation......................................................................................327 FILTER UNIT.......................................................................................................329 Replacement Of The Fuel Filter Element........................................................................329 Replacement of the Diaphragm and Fuel Valve ..................................................................329 REPLACEMENT OF THE HOSES..........................................................................................329 VAPORIZER.........................................................................................................329 Removal.......................................................................................................329 Vaporizer Disassembly.........................................................................................331 Cleaning......................................................................................................331 Inspection....................................................................................................331 Vaporizer Assembly............................................................................................331 Installation..................................................................................................333 CARBURETOR........................................................................................................333 Removal.......................................................................................................333 Disassembly...................................................................................................333 Cleaning......................................................................................................334 Assembly......................................................................................................334 Installation..................................................................................................334 GOVERNOR..........................................................................................................334 CHECKS AND ADJUSTMENTS................................................................................................335 CHECK THE FILTER UNIT.............................................................................................335 CHECK THE VAPORIZER...............................................................................................335 Pressure Reducer Valve........................................................................................335 Vapor Valve...................................................................................................335 ADJUST THE CARBURETOR.............................................................................................336 Idle Mixture..................................................................................................336 Idle Speed ...................................................................................................336 Power Mixture.................................................................................................336 ADJUST THE THROTTLE LINKAGE.......................................................................................336 TROUBLESHOOTING.......................................................................................................337 1200334...................................................................................................................340 INTRODUCTION..........................................................................................................340 General...........................................................................................................340 Description.......................................................................................................340 REPAIRS...............................................................................................................342 Removal and Disassembly...........................................................................................342 Cleaning and Inspection...........................................................................................343 Assembly and Installation.........................................................................................344 CHECKS AND ADJUSTMENTS................................................................................................346 Adjusting the Clutch Pedal and Linkage............................................................................346 Adjusting the By-pass Valve for Cold Oil..........................................................................346 TROUBLESHOOTING.......................................................................................................347 1300335...................................................................................................................349 INTRODUCTION..........................................................................................................349 General...........................................................................................................349 Description.......................................................................................................349 Operation.........................................................................................................349 REPAIRS...............................................................................................................351 Removal...........................................................................................................351 Disassembly.......................................................................................................352 Cleaning..........................................................................................................354 Inspection........................................................................................................355 Assembly..........................................................................................................355 Installation......................................................................................................366 CHECKS AND ADJUSTMENTS................................................................................................367 Adjusting The Shift Linkage H3.50-5.00XL (H70-110XL)..............................................................367 Adjusting The Shift Linkage S6.00-7.00XL (S135-155XL).............................................................369 Adjusting The Clutch Pedal And Linkage............................................................................369 TROUBLESHOOTING.......................................................................................................371 SPECIFICATIONS........................................................................................................373 1300336...................................................................................................................374 DESCRIPTION...........................................................................................................374 GENERAL...........................................................................................................374 MECHANICAL DESCRIPTION................................................................................................374 TORQUE CONVERTER..................................................................................................374 OIL LAMP..........................................................................................................375 SHAFT AND CLUTCH ASSEMBLIES.......................................................................................375 Input Shaft...................................................................................................376 Forward Clutch Shaft..........................................................................................376 Clutch Assemblies.............................................................................................376 Output Gear...................................................................................................377 HYDRAULIC OPERATION...................................................................................................377 TORQUE CONVERTER..................................................................................................377 SHAFT ASSEMBLIES..................................................................................................378 CONTROL VALVE.....................................................................................................380 General.......................................................................................................380 System Regulator..............................................................................................380 Clutch Pressure Regulator.....................................................................................380 Torque Converter Regulator....................................................................................381 Inching Spool.................................................................................................381 Direction Spool, Manual Control...............................................................................381 Drain Spool...................................................................................................382 Accumulator...................................................................................................382 Modulation Spool..............................................................................................383 LUBRICATION CIRCUIT...............................................................................................384 MONOTROL PEDAL....................................................................................................384 OIL FLOW DIAGRAMS.................................................................................................384 Neutral.......................................................................................................384 Forward.......................................................................................................384 Forward-Inching...............................................................................................384 Reverse.......................................................................................................385 1300337...................................................................................................................390 REPAIRS ..............................................................................................................390 GENERAL...........................................................................................................390 REMOVAL...........................................................................................................390 TRANSMISSION, DISASSEMBLY.........................................................................................392 Input Shaft, Disassembly......................................................................................393 Forward Shaft, Disassembly....................................................................................395 Cleaning and Inspection.......................................................................................396 TRANSMISSION, ASSEMBLY............................................................................................397 Forward Shaft, Assembly.......................................................................................397 Input Shaft, Assembly.........................................................................................399 Assembly......................................................................................................401 Installation..................................................................................................404 CONTROL VALVE.....................................................................................................405 Removal.......................................................................................................405 Disassembly...................................................................................................406 Assembly......................................................................................................406 Installation..................................................................................................408 THROTTLE PEDAL....................................................................................................408 MONOTROL PEDAL....................................................................................................408 Removal and Disassembly.......................................................................................408 Assembly and Installation.....................................................................................408 CHECKS AND ADJUSTMENTS................................................................................................411 STALL TEST........................................................................................................411 ADJUST THE LINKAGE FOR THE INCHING PEDAL..........................................................................412 Linkage For Models With An Inching Pedal And A Brake Pedal....................................................412 Linkage For ModelsWith One Inching/Brake Pedal................................................................414 ADJUST THE LINKAGE FOR THE DIRECTION CONTROL LEVER................................................................415 Earlier Production............................................................................................415 Later Production..............................................................................................416 CHECK THE OIL PRESSURE FOR THE TRANSMISSION.......................................................................417 System Pressure Check Port....................................................................................418 Torque Converter Check Port...................................................................................418 Clutch Pressure Check Port....................................................................................419 Inching Pressure..............................................................................................419 Solenoid Check Ports (Monotrol Control Only)..................................................................419 Lubrication Pressure Check Ports..............................................................................419 TROUBLESHOOTING.......................................................................................................420 1300346...................................................................................................................423 INTRODUCTION..........................................................................................................423 GENERAL...........................................................................................................423 DESCRIPTION.......................................................................................................423 REPAIRS...............................................................................................................423 REMOVAL...........................................................................................................423 DISASSEMBLY.......................................................................................................423 CLEANING..........................................................................................................426 INSPECTION........................................................................................................426 ASSEMBLY..........................................................................................................426 Pinion Assembly...............................................................................................426 Differential..................................................................................................427 INSTALLATION......................................................................................................433 TROUBLESHOOTING.......................................................................................................434 SPECIFICATIONS........................................................................................................435 1400361...................................................................................................................436 INTRODUCTION..........................................................................................................436 GENERAL...........................................................................................................436 DESCRIPTION.......................................................................................................436 REPAIRS...............................................................................................................437 REMOVAL...........................................................................................................437 Lift Trucks With A Manual Transmission........................................................................437 Lift Trucks With A Powershift Transmission....................................................................438 DISASSEMBLY.......................................................................................................439 CLEANING..........................................................................................................439 INSPECTION........................................................................................................439 ASSEMBLY..........................................................................................................439 INSTALLATION......................................................................................................440 Lift Trucks With A Manual Transmission........................................................................440 Lift Trucks With A Powershift Transmission....................................................................441 TROUBLESHOOTING.......................................................................................................442 SPECIFICATIONS........................................................................................................442 1600326...................................................................................................................443 General...............................................................................................................445 Description...........................................................................................................445 Steering Axle Assembly Repair.........................................................................................445 Steering Axle H3.50-5.00XL (H70-110XL) and S/E3.50-5.50XL (S/E70-120XL)...........................................445 Remove........................................................................................................445 Install.......................................................................................................446 Steering Axle H6.00-7.00XL (H135-155XL), H8.00-16.00XL (H165-360XL), and H8.00-16.00XM (H170-360HD)...............447 Remove........................................................................................................447 Install.......................................................................................................448 Wheels and Hubs Repair (All Units)....................................................................................449 Remove and Disassemble............................................................................................449 Clean.............................................................................................................449 Assembly and Install..............................................................................................449 Spindles and Bearings Repair (All Units)..............................................................................451 Remove............................................................................................................451 Clean.............................................................................................................451 Assemble and Install..............................................................................................451 Tie Rods Repair (All Units)...........................................................................................452 Remove............................................................................................................452 Clean.............................................................................................................452 Install...........................................................................................................452 Steering Cylinder Repair..............................................................................................454 Remove and Disassemble............................................................................................454 Clean and Inspect.................................................................................................454 Assemble and Install..............................................................................................454 Troubleshooting.......................................................................................................455 1800338...................................................................................................................458 ......................................................................................................................458 ......................................................................................................................459 ......................................................................................................................460 ......................................................................................................................461 ......................................................................................................................462 ......................................................................................................................463 ......................................................................................................................464 ......................................................................................................................465 ......................................................................................................................466 ......................................................................................................................467 ......................................................................................................................468 ......................................................................................................................469 ......................................................................................................................470 ......................................................................................................................471 ......................................................................................................................472 ......................................................................................................................473 ......................................................................................................................474 ......................................................................................................................475 ......................................................................................................................476 ......................................................................................................................477 ......................................................................................................................478 ......................................................................................................................479 ......................................................................................................................480 ......................................................................................................................481 1900333...................................................................................................................482 INTRODUCTION..........................................................................................................482 GENERAL...........................................................................................................482 DESCRIPTION AND OPERATION.........................................................................................482 Hydraulic Pump................................................................................................482 Main Control Valve............................................................................................483 Steering Control Unit.........................................................................................485 Brake Booster.................................................................................................485 REPAIRS...............................................................................................................485 HYDRAULIC PUMP....................................................................................................485 Removal.......................................................................................................485 Disassembly...................................................................................................486 Cleaning and Inspection.......................................................................................486 Assembly......................................................................................................486 Installation..................................................................................................487 Adjust the Flow Divider.......................................................................................487 SPECIFICATIONS........................................................................................................487 TROUBLESHOOTING.......................................................................................................488 1900339...................................................................................................................490 INTRODUCTION..........................................................................................................490 GENERAL...........................................................................................................490 DESCRIPTION.......................................................................................................490 REPAIRS...............................................................................................................492 REMOVAL AND DISASSEMBLY...........................................................................................492 CLEANING..........................................................................................................492 INSPECTION........................................................................................................492 ASSEMBLY AND INSTALLATION.........................................................................................493 TROUBLESHOOTING.......................................................................................................494 GENERAL...........................................................................................................494 2200106...................................................................................................................495 General...............................................................................................................497 Description and Operation.............................................................................................497 Starter Repair........................................................................................................499 Remove............................................................................................................499 Disassemble.......................................................................................................499 Clean.............................................................................................................500 Assemble..........................................................................................................500 Install...........................................................................................................501 General Checks and Adjustments........................................................................................501 Troubleshooting.......................................................................................................504 2200143...................................................................................................................508 INTRODUCTION..........................................................................................................508 GENERAL...........................................................................................................508 DESCRIPTION...........................................................................................................508 GENERAL...........................................................................................................508 STEERING COLUMN GAUGES, METERS AND INDICATORS.....................................................................511 LED DISPLAY PANEL.................................................................................................511 Battery Discharge Indicators..................................................................................511 Brush Wear Indicators.........................................................................................512 Motor Temperature Indicators..................................................................................513 "LX" SERIES DISPLAY PANEL.........................................................................................514 Hourmeter Functions...........................................................................................515 Battery Indicator Function....................................................................................515 Status Code Function..........................................................................................515 "ZX" SERIES DISPLAY PANELS........................................................................................515 Display Panel.................................................................................................516 Basic Display Panels..........................................................................................516 Performance Display...........................................................................................518 Brush Wear Indicators.........................................................................................521 CHECKS AND ADJUSTMENTS................................................................................................521 GENERAL...........................................................................................................521 REPLACEMENT...........................................................................................................522 GENERAL...........................................................................................................522 METER REPLACEMENT.................................................................................................522 SENDER REPLACEMENT................................................................................................523 Fuel Level Sender.............................................................................................523 Pressure And Temperature Sender...............................................................................523 I.T.W. DISPLAY PANEL..............................................................................................524 Removal.......................................................................................................524 DISPLAY PANELS FOR THE EV - 100/200ZX MOTOR CONTROLLERS, COLUMN MOUNT.............................................525 Removal.......................................................................................................525 Replacing Display Panel Assembly..............................................................................525 Indicator LEDs................................................................................................525 Battery Indicators............................................................................................525 Digital Display (Performance Disply Panel Only)...............................................................525 Status Code Or Performance Level Switches And Indicator LEDs (Performance Display Panel Only).................525 Replacing Parts Of The Basic Display Panel....................................................................526 Replacing Parts Of The Performance Display Panel..............................................................528 DISPLAY PANELS FOR THE EV-100/200ZX MOTOR CONTROLLERS, DASH MOUNT.................................................528 Removal And Replacement.......................................................................................528 SPECIFICATIONS........................................................................................................529 TROUBLESHOOTING.......................................................................................................530 2200144...................................................................................................................531 ELECTRICAL WARNING DEVICES............................................................................................531 GENERAL...........................................................................................................531 DESCRIPTION.......................................................................................................531 Operator Controlled Horns.....................................................................................531 System Warning Lights, Buzzers and Bells......................................................................531 Reverse Warning Horns.........................................................................................532 Warning Lights................................................................................................532 REPLACEMENT.......................................................................................................533 General.......................................................................................................533 Replacing Horns or Bells......................................................................................533 Replacing Horn Relay or Buzzer................................................................................533 Replacing Warning Lights......................................................................................533 Light Assemblies..............................................................................................534 Replacing Flashing Units......................................................................................534 2200463...................................................................................................................535 ......................................................................................................................535 ......................................................................................................................536 ......................................................................................................................537 ......................................................................................................................538 ......................................................................................................................539 ......................................................................................................................540 ......................................................................................................................541 ......................................................................................................................542 ......................................................................................................................543 ......................................................................................................................544 ......................................................................................................................545 ......................................................................................................................546 ......................................................................................................................547 ......................................................................................................................548 ......................................................................................................................549 ......................................................................................................................550 ......................................................................................................................551 ......................................................................................................................552 ......................................................................................................................553 ......................................................................................................................554 ......................................................................................................................555 ......................................................................................................................556 ......................................................................................................................557 ......................................................................................................................558 ......................................................................................................................559 ......................................................................................................................560 ......................................................................................................................561 ......................................................................................................................562 ......................................................................................................................563 ......................................................................................................................564 ......................................................................................................................565 ......................................................................................................................566 ......................................................................................................................567 ......................................................................................................................568 ......................................................................................................................569 ......................................................................................................................570 8000231...................................................................................................................571 General...............................................................................................................573 Nomenclature, Threads.............................................................................................573 Strength Identification...........................................................................................574 Fastener Torque Tables............................................................................................578 Conversion Table..................................................................................................580 8000341...................................................................................................................582 PERIODIC MAINTENANCE..................................................................................................582 GENERAL...........................................................................................................582 SERIAL NUMBER DATA................................................................................................582 HOW TO MOVE A DISABLED LIFT TRUCK ..............................................................................582 How To Tow the Lift Truck.....................................................................................582 HOW TO PUT A LIFT TRUCK ON BLOCKS.................................................................................583 How To Raise the Drive Tires..................................................................................583 How To Raise the Steering Tires...............................................................................583 MAINTENANCE SCHEDULE..................................................................................................585 MAINTENANCE PROCEDURES EVERY 8 HOURS OR DAILY.........................................................................588 HOW TO MAKE CHECKS WITH THE ENGINE STOPPED........................................................................588 Hydraulic System Oil..........................................................................................588 Engine Oil....................................................................................................590 Drive Belts...................................................................................................590 Cooling System................................................................................................590 Air Filter....................................................................................................590 Fuel System...................................................................................................591 Primary Fuel Filter, Diesel Engine............................................................................591 Battery.......................................................................................................591 Tires and Wheels..............................................................................................591 Forks.........................................................................................................592 Forks, Adjustment.............................................................................................592 Forks, Removal And Installation...............................................................................592 Inspection Of Forks, Mast, and Lift Chains....................................................................593 Operator Restraint System.....................................................................................595 Safety Labels.................................................................................................596 HOW TO MAKE THE CHECKS WITH THE ENGINE RUNNING....................................................................596 Gauges, Lights, Horns, and Fuses..............................................................................596 Oil Level, Powershift Transmission............................................................................596 Oil Level, Oil Clutch System, H3.50-5.00Xl (H70-110XL)........................................................597 Control Levers and Pedals.....................................................................................597 Lift System Operation.........................................................................................597 Inching/Brake Pedal...........................................................................................598 Service Brakes................................................................................................598 Parking Brake.................................................................................................598 Steering System...............................................................................................598 EVERY 150 HOURS OR MONTHLY............................................................................................598 THRUST SCREW FOR THE DIFFERENTIAL, H6.00-7.00XL (H135-155XL)......................................................598 LIFT CHAINS, LUBRICATION..........................................................................................598 DRIVE SHAFTS......................................................................................................599 EVERY 350 HOURS OR TWO MONTHS.........................................................................................599 ENGINE OIL AND FILTER.............................................................................................599 DRIVE BELTS.......................................................................................................600 Perkins Diesel Engine.........................................................................................600 GM V-6 Engine (Early Models)..................................................................................600 GM V-6 Engine (Late Models)...................................................................................601 HYDRAULIC TANK BREATHER, CLEAN AND CHECK..........................................................................602 BRAKE FLUID.......................................................................................................602 LIFT CHAINS, CHECK FOR WEAR.......................................................................................602 FORKS, CHECK FOR WEAR AND DAMAGE..................................................................................603 MAST, LUBRICATION.................................................................................................603 CONTROL LEVERS AND PEDALS, LUBRICATION............................................................................603 STEERING AXLE, LUBRICATION........................................................................................604 FUEL SYSTEM, CHECKS AND ADJUSTMENT................................................................................604 Diesel Fuel System............................................................................................604 LPG Carburetor (Early Models).................................................................................604 Gasoline Carburetor (Early Models)............................................................................605 Fuel Injection (Late Models)..................................................................................605 EVERY 1000 HOURS OR SIX MONTHS........................................................................................605 PCV VALVE, GM V-6.................................................................................................605 MANIFOLD HEAT VALVE, GM V-6 (EARLY MODELS)........................................................................605 CRANKCASE BREATHER, GM-V6.........................................................................................605 IGNITION SYSTEM (GM V-6)..........................................................................................605 VALVE CLEARANCE ADJUSTMENT........................................................................................606 FUEL FILTER (REPLACEMENT), DIESEL ENGINE..........................................................................606 REMOVE AIR FROM THE FUEL SYSTEM: PERKINS 1004-4 DIESEL ENGINE.....................................................606 Fuel Injection Pump With A Vent Tube..........................................................................606 Fuel Injection Pump With A Vent Screw.........................................................................607 REMOVE THE AIR FROM THE FUEL SYSTEM: PERKINS 4.2482 DIESEL ENGINE.................................................608 CHECK THE OIL LEVEL IN THE TRANSMISSION...........................................................................608 Manual Transmission, H3.50-5.00XL (H70-110Xl).................................................................608 Speed Reducer For The Powershift Transmission, H3.50-5.00XL (H70-110XL).......................................609 Manual Transmission, H6.00-7.00XL (H135-155XL)................................................................609 Differential And Drive Axle For The Powershift Transmission, H6.00-7.00Xl (H135-155XL)........................609 Differential, Speed Reducer, And Drive Axle For The Manual Transmission, H6.00-7.00Xl (H135-155XL) ...........609 EVERY 2000 HOURS OR YEARLY............................................................................................609 HYDRAULIC SYSTEM..................................................................................................609 Replace the Hydraulic Oil and Filter, H3.50-5.00XL (H70-110XL) ...............................................609 Replace the Hydraulic Oil and Filter, H6.00-7.00XL (H135-155XL) ..............................................610 CHANGE THE OIL AND REPLACE THE OIL FILTER, POWERSHIFT TRANSMISSION, ALL UNITS ....................................610 CHANGE THE OIL, MANUAL TRANSMISSION, H3.50-5.00XL (H70-110XL).....................................................610 CHANGE THE OIL, MANUAL TRANSMISSION, H6.00-7.00XL (H135-155XL)....................................................610 CHANGE THE OIL, SPEED REDUCER, POWERSHIFT TRANSMISSION, H3.50-5.00XL (H70-110XL)..................................611 CHANGE THE OIL AND FILTER, OIL CLUTCH SYSTEM, H3.50-5.00XL (H70-110XL)............................................611 CHANGE THE OIL, DIFFERENTIAL AND DRIVE AXLE FOR THE POWERSHIFT TRANSMISSION, H6.00-7.00XL (H135-155XL)............611 CHANGE THE OIL, DIFFERENTIAL, SPEED REDUCER, AND DRIVE AXLE FOR MANUAL TRANSMISSION, H6.00-7.00XL (H135-155XL)....611 COOLING SYSTEM....................................................................................................612 WHEEL BEARINGS....................................................................................................612 Steering Wheel, lubrication...................................................................................612 Drive Wheels, Lubrication.....................................................................................612 PCV VALVE, GM V-6.................................................................................................612 SERVICE BRAKES....................................................................................................612 LPG FILTER, REPLACEMENT...........................................................................................613 GASOLINE FUEL FILTER, REPLACEMENT.................................................................................613 CHECK THE HOOD LATCH, H3.50-5.00XL (H70-110XL)....................................................................613 GENERAL PROCEDURES....................................................................................................614 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST......................................................................614 LIFT CHAIN ADJUSTMENTS............................................................................................616 FUEL INJECTORS....................................................................................................616 CHECKS FOR LEAKS IN THE LIFT AND TILT SYSTEM .....................................................................617 Check the Lift Cylinders for Leaks............................................................................617 Check the Tilt Cylinders for Leaks............................................................................617 WELDING REPAIRS...................................................................................................617 CHANGES TO THE OVERHEAD GUARD.....................................................................................618 WHEELS AND TIRES..................................................................................................619 Remove The Wheels From The Lift Truck.........................................................................619 Remove The Wheel From The Tire................................................................................619 Install The Wheel In The Tire.................................................................................621 Pneumatic Tires, Add Air To The Tires.........................................................................622 Install the Wheels ...........................................................................................622 SOLID RUBBER TIRES................................................................................................623 Remove The Tire From The Wheel................................................................................623 Install The Tire On The Wheel.................................................................................624 REFERENCE TABLE.......................................................................................................625 8000342...................................................................................................................627 8000343...................................................................................................................635 FIGURE 1. ELECTRICAL SCHEMATIC (GASOLINE/LPG, EARLY PRODUCTION).......................................................635 FIGURE 2. ELECTRICAL SCHEMATIC (GASOLINE/LPG, LATER PRODUCTION).......................................................637 FIGURE 3. ELECTRICAL SCHEMATIC (DIESEL, PERKINS 4.2482)...............................................................639 FIGURE 4. ELECTRICAL SCHEMATIC (DIESEL, PERKINS 1004-4, EARLY PRODUCTION).............................................641 FIGURE 5. ELECTRICAL SCHEMATIC (DIESEL, PERKINS 1004-4, LATER PRODUCTION).............................................643 FIGURE 6. HYDRAULIC SCHEMATIC.........................................................................................645 FIGURE 7. HYDRAULIC SCHEMATIC, POWERSHIFT TRANSMISSION WITH MANUAL CONTROL............................................646 FIGURE 8. HYDRAULIC SCHEMATIC, POWERSHIFT TRANSMISSION WITH MONTROL PEDAL.............................................647 FIGURE 9. WIRING DIAGRAM, BACK-UP ALARM...............................................................................648 8000494...................................................................................................................649
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