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Hyster G006 (H6.00-7.00XL) Service Manual – PDF DOWNLOAD
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Hyster G006 (H6.00-7.00XL) Service Manual – PDF DOWNLOAD
PART NO. 899784
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Description
Hyster G006 (H6.00-7.00XL) Service Manual – PDF DOWNLOAD
DESCRIPTION:
Hyster G006 (H6.00-7.00XL) Service Manual – PDF DOWNLOAD
SAFETY PRECAUTIONS MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly
fastened, and that the load being lifted is balanced. Make sure the crane, cables, and
chains have the capacity to support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair
on electric lift trucks.
• Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT
THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance
section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts
must meet or exceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before
using force to remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit whenmaking repairs,
or if the unit needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel
are flammable. Be sure to follow the necessary safety precautions when handling these
fuels and when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks
away from the area. Make sure the area is well ventilated.
PART NO. 899784
TABLE OF CONTENTS:
Hyster G006 (H6.00-7.00XL) Service Manual – PDF DOWNLOAD
alternador.............................................................................. 1 toc................................................................................. 1 Alternator with Regulator....................................................... 1 Safety Precautions Maintenance and Repair....................................... 2 General......................................................................... 5 Description..................................................................... 5 Alternator Repair............................................................... 7 Alternator Type A........................................................... 7 Remove and Disassemble.................................................. 7 Clean................................................................... 8 Assemble................................................................ 9 Install................................................................. 9 Alternator Type B........................................................... 12 Remove and Disassemble.................................................. 12 Clean................................................................... 12 Assemble................................................................ 13 Install................................................................. 14 General Check and Adjustment.................................................... 15 Low Output Check (Type A or Type B)............................................. 15 High Output Check (Type A or Type B)............................................ 17 Brushes Circuit Check........................................................... 18 Delco Alternators........................................................... 18 Motorola Alternators........................................................ 19 Diodes Check.................................................................... 20 Diode Bridge Check.............................................................. 20 Delco and Leece-Neville Alternators......................................... 20 Motorola Alternators........................................................ 20 Rotor Field Winding Check....................................................... 21 Stator Windings Check........................................................... 22 Voltage Regulator Check......................................................... 22 Troubleshooting................................................................. 22 Bomba hidraulica........................................................................ 27 toc................................................................................. 27 Hydraulic Gear Pumps............................................................ 27 Safety Precautions Maintenance and Repair....................................... 28 Description..................................................................... 31 Operation....................................................................... 32 Flow Control Valve.......................................................... 32 Relief Valve................................................................ 33 Hydraulic Gear Pump Repair...................................................... 33 Remove...................................................................... 33 Disassemble................................................................. 34 Clean....................................................................... 34 Inspect..................................................................... 35 Assemble.................................................................... 38 Install..................................................................... 40 Pump Output Check............................................................... 40 Method No. 1................................................................ 40 Method No. 2................................................................ 41 Hydraulic System Air Check...................................................... 42 Troubleshooting................................................................. 43 Buje delantero.......................................................................... 49 toc................................................................................. 49 Drive Axle...................................................................... 49 Safety Precautions Maintenance and Repair....................................... 50 General......................................................................... 53 Description..................................................................... 53 Drive Axle Repair............................................................... 54 Disassemble (Type 1 Shown).................................................. 54 Clean....................................................................... 57 Inspect..................................................................... 57 Assemble (Type 1 Shown)..................................................... 58 Torque Specifications........................................................... 61 Troubleshooting................................................................. 62 cilindro inclinacion.................................................................... 65 toc................................................................................. 65 Tilt Cylinders.................................................................. 65 Safety Precautions Maintenance and Repair....................................... 66 General......................................................................... 69 Description..................................................................... 69 Tilt Cylinder Repair............................................................ 69 Remove...................................................................... 69 Disassemble................................................................. 69 Clean....................................................................... 69 Assemble.................................................................... 70 Tilt Cylinders With O-Ring or Single-Lip Seals.......................... 70 Tilt Cylinders for XM and XMS Models.................................... 71 Tilt Cylinders for H700-800A and Early Model H700-920B.................. 72 Install..................................................................... 73 Tilt Cylinders Using Chevron Packing.................................... 73 Install............................................................. 75 Tilt Cylinder Leak Check........................................................ 77 Tilt Cylinder Stroke and Mast Tilt Angle Adjustment............................. 78 Torque Specifications........................................................... 79 Piston Rod Nut.............................................................. 79 Retainer.................................................................... 80 Troubleshooting................................................................. 81 tables.............................................................................. 65 Table 1. Movement Rates (Maximum) for Tilt Cylinders............................ 78 cilindros elevacion..................................................................... 85 toc................................................................................. 85 Lift Cylinders.................................................................. 85 Safety Precautions Maintenance and Repair....................................... 86 Safety Procedures When Working Near Mast........................................ 89 General......................................................................... 93 Description..................................................................... 93 Lowering Control Valve...................................................... 93 Cylinders (General)......................................................... 96 Cylinders (H520-620B, H700-800A)............................................ 96 Retainer, Install....................................................... 96 Cylinders (H360-460B)....................................................... 98 Cylinders (Two-Speed)....................................................... 100 Lift Cylinder Repair............................................................ 102 Lift Cylinder Removal Without Removing Mast................................. 102 Standard Masts With Main Lift Cylinder Fastened to Crossmember o........ 102 Standard and Full Free-Lift Masts With Lift Cylinder Fastened to........ 102 Masts That Have Two Cylinders, Main Lift Cylinder and Free-Lift ........ 102 Disassemble................................................................. 104 Assemble.................................................................... 104 Lift Cylinder Installation in Mast.......................................... 106 Standard Masts With Main Lift Cylinder Fastened to Crossmember o........ 106 Standard and Full Free-Lift Masts With Lift Cylinder Fastened to........ 106 Chevron-Style Packing....................................................... 106 Chevron-Style Packing Installation on Piston............................ 107 Chevron-Style Packing Installation in Packing Gland..................... 109 Lift Cylinders for VISTA® Masts................................................. 110 Description................................................................. 110 Lowering Control Valve.................................................. 110 Remove...................................................................... 112 Disassemble................................................................. 113 Assemble.................................................................... 114 Install..................................................................... 115 Main Lift Cylinders..................................................... 115 Free-Lift Cylinder...................................................... 115 Lift System Leak Check.......................................................... 116 Specifications.................................................................. 117 Troubleshooting................................................................. 118 tables.............................................................................. 85 Table 1. Lift Trucks with Two-Speed Lift Cylinders.............................. 101 Table 2. Cylinder Retainer Torque Specifications and Weight Guid................ 117 cooling system.......................................................................... 121 toc................................................................................. 121 Cooling System.................................................................. 121 Safety Precautions Maintenance and Repair....................................... 122 General......................................................................... 125 Description..................................................................... 126 Radiator.................................................................... 126 Radiator Cap................................................................ 126 Thermostat.................................................................. 126 Water Pump.................................................................. 127 Fan and Fan Shroud.......................................................... 127 Cooling System Checks........................................................... 127 Radiator.................................................................... 127 Thermostat.................................................................. 127 Water Pump.................................................................. 128 Exhaust Leaks............................................................... 128 Fan and Fan Shroud.......................................................... 128 Radiator Cleaning............................................................... 128 Drain....................................................................... 128 Clean....................................................................... 128 Fill........................................................................ 129 Troubleshooting................................................................. 130 diferencial............................................................................. 133 toc................................................................................. 133 Differential.................................................................... 133 Safety Precautions Maintenance and Repair....................................... 134 General......................................................................... 137 Description..................................................................... 137 Differential Repair............................................................. 137 Remove...................................................................... 137 Differential Carrier From Axle Housing, Remove.......................... 137 Differential and Ring Gear From Differential Carrier, Remove............ 141 Drive Pinion and Pinion Carrier From Differential Carrier, Remov........ 143 Disassemble................................................................. 144 Differential and Ring Gear Assembly, Disassemble........................ 144 Drive Pinion and Pinion Carrier, Disassemble............................ 146 Clean and Inspect........................................................... 148 Assemble.................................................................... 149 Pinion, Bearings, and Pinion Carrier, Assemble.......................... 149 Pinion Bearings, Adjust Preload......................................... 150 Press Method........................................................ 150 Yoke or Flange Method............................................... 150 Triple-Lip Seal, Install................................................ 151 Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion)............. 152 Differential and Ring Gear, Assemble.................................... 154 Differential Gears Rotating Torque, Check............................... 157 Differential and Ring Gear Assembly, Install............................ 158 Differential Bearings, Preload Adjust................................... 159 Ring Gear, Runout Check................................................. 160 Ring Gear Backlash, Adjust.............................................. 160 Gear Set, Tooth Contact Pattern Check................................... 162 Thrust Screw, Install and Adjust........................................ 164 Install..................................................................... 165 Differential Assembly Into Axle Housing, Install........................ 165 Specifications.................................................................. 167 Troubleshooting................................................................. 171 tables.............................................................................. 133 Table 1. Ring Gear Backlash Adjustment Specifications........................... 161 Table 2. Ring and Pinion Tooth Contact Adjustment............................... 163 Table 3. General Specifications................................................. 167 Table 4. Rivet Installation Pressure............................................ 167 Table 5. Pinion Adjustment...................................................... 167 Table 6. Pinion Preload Pressure................................................ 168 Table 7. Torque Specifications.................................................. 169 Table 8. Torque Specifications for Metric Hardware.............................. 170 Table 9. Torque Specifications for Metric (Fine) Hardware....................... 170 Distruibuidor hidraulico................................................................ 175 toc................................................................................. 175 Main Control Valve.............................................................. 175 Safety Precautions Maintenance and Repair....................................... 176 General......................................................................... 179 Description..................................................................... 179 Operation....................................................................... 182 Lift Spool.................................................................. 182 Tilt Spool.................................................................. 183 Tilt Backward........................................................... 183 Tilt Forward............................................................ 184 Single-Stage Relief Valve................................................... 186 Two-Stage Relief Valve...................................................... 187 Main Control Valve Repair....................................................... 188 Remove and Disassemble...................................................... 188 Clean and Inspect........................................................... 188 Assemble.................................................................... 188 Install..................................................................... 189 Single-Stage Relief Valve Adjustment............................................ 189 Two-Stage Relief Valve.......................................................... 190 Auxiliary Control Valve Relief Valve Adjustment (H60-110E Only)................. 190 Troubleshooting................................................................. 191 tables.............................................................................. 175 Table 1. Relief Pressures (Oil temperature at 55 to 66 C ( 131 t................ 189 ECU diagnosis........................................................................... 195 toc................................................................................. 195 Electronic Control Module (ECM) Diagnostic Troubleshooting...................... 195 Safety Precautions Maintenance and Repair....................................... 196 General......................................................................... 205 Description of ECM Based Diagnostics............................................ 205 Definition of Terms......................................................... 205 Diagnostics Overview of the Spectrum Fuel System............................ 205 Malfunction Indicator Lamp (MIL)............................................ 206 Spectrum Diagnostic Trouble Codes (DTC)..................................... 206 Using a Laptop Computer to Diagnose the Spectrum System..................... 206 Installing the Spectrum Diagnostic Software............................. 207 Connecting a Laptop Computer to the Spectrum System..................... 207 Diagnostic Communication Error.......................................... 207 Diagnostic Trouble Codes.................................................... 208 Checking Diagnostic Trouble Codes....................................... 208 Clearing Diagnostic Trouble Codes....................................... 208 DATA Stream................................................................. 209 Reading Sensor and Actuator Values...................................... 209 Graphing and Data Logging............................................... 210 Ignition System Test........................................................ 211 Disabling Ignition Outputs.............................................. 211 Injector Test............................................................... 212 Disabling Injectors..................................................... 212 Throttle Test............................................................... 212 Using a Diagnostic Jumper to Diagnose the ECI System.................... 213 On-Board Diagnostics System Check/Malfunction Indicator Lamp.................... 214 Circuit Description......................................................... 214 Preliminary and Intermittent Checks............................................. 217 GM 3.0L Wiring Schematics and Connectors........................................ 219 GM 3.0L Diagnostic Trouble Codes................................................ 233 DTC 111 - IAT High Voltage Motorola® TMAP................................... 233 Circuit Description..................................................... 233 Conditions for Setting the DTC.......................................... 233 DTC 112 - IAT Low Voltage Motorola® TMAP.................................... 236 Circuit Description..................................................... 236 Conditions for Setting the DTC.......................................... 236 DTC 113 - IAT Higher Than Expected 1 Motorola® TMAP......................... 238 Circuit Description..................................................... 238 Conditions for Setting the DTC.......................................... 238 Diagnostic Aids......................................................... 239 DTC 114 - IAT Higher Than Expected 2 Motorola® TMAP......................... 240 Circuit Description..................................................... 240 Conditions for Setting the DTC.......................................... 240 Diagnostic Aids......................................................... 240 DTC 115 - Oil Pressure Low.................................................. 241 Circuit Description..................................................... 241 Conditions for Setting the DTC.......................................... 241 DTC 121 - ECT Voltage High.................................................. 244 Circuit Description..................................................... 244 Conditions for Setting the DTC.......................................... 245 DTC 122 - ECT Voltage Low................................................... 248 Circuit Description..................................................... 248 Conditions for Setting the DTC.......................................... 248 DTC 123 - ECT Higher Than Expected 1........................................ 250 Circuit Description..................................................... 250 Conditions for Setting the DTC.......................................... 250 DTC 124 - ECT Higher Than Expected 2........................................ 252 Circuit Description..................................................... 252 Conditions for Setting the DTC.......................................... 252 DTC 131 - MAP High Pressure Motorola® TMAP.................................. 254 Circuit Description..................................................... 254 Conditions for Setting the DTC.......................................... 254 Diagnostic Aids......................................................... 254 DTC 132 - MAP Low Voltage Motorola® TMAP.................................... 257 Circuit Description..................................................... 257 Conditions for Setting the DTC.......................................... 257 DTC 134 - BP High Pressure Motorola® TMAP................................... 261 Circuit Description..................................................... 261 Conditions for Setting the DTC.......................................... 261 DTC 135 - BP Low Pressure Motorola® TMAP.................................... 262 Circuit Description..................................................... 262 Conditions for Setting the DTC.......................................... 262 DTC 142 - Crank Sync Noise.................................................. 266 Circuit Description..................................................... 266 Conditions for setting the DTC.......................................... 266 DTC 143 - Never Crank Synced At Start....................................... 270 Circuit Description..................................................... 270 Conditions for Setting the DTC.......................................... 270 DTC 144 - Camshaft Sensor Loss.............................................. 273 Circuit Description..................................................... 273 Conditions for Setting the DTC.......................................... 273 DTC 145 - Camshaft Sensor Noise............................................. 276 Circuit Description..................................................... 276 Conditions for Setting the DTC.......................................... 276 DTC 211 - Closed Loop Multiplier High (LPG)................................. 279 Circuit Description..................................................... 279 Conditions for Setting the DTC.......................................... 279 Diagnostic Aids......................................................... 279 DTC 212 - HO 2 S Open/Inactive.............................................. 282 Circuit Description..................................................... 282 Conditions for Setting the DTC.......................................... 282 DTC 221 - Closed Loop Multiplier High (Gasoline)............................ 284 Circuit Description..................................................... 284 Conditions for Setting the DTC.......................................... 284 Diagnostic Aids......................................................... 285 DTC 222 - Closed Loop Multiplier Low (Gasoline)............................. 288 Circuit Description..................................................... 288 Conditions for Setting the DTC.......................................... 288 Diagnostic Aids......................................................... 288 DTC 224 - Closed Loop Multiplier Low (LPG).................................. 290 Circuit Description..................................................... 290 Conditions for Setting the DTC.......................................... 290 Diagnostic Aids......................................................... 290 DTC 241 - Adaptive Lean Fault (High Limit-Gasoline)......................... 292 Circuit Description..................................................... 292 Conditions for Setting the DTC.......................................... 292 Diagnostic Aids......................................................... 292 DTC 242 - Adaptive Rich Fault (Low Limit-Gasoline).......................... 295 Circuit Description..................................................... 295 Conditions for Setting the DTC.......................................... 295 Diagnostic Aids......................................................... 295 DTC 243 - Adaptive Learn High (LPG)......................................... 298 Circuit Description..................................................... 298 Conditions for Setting the DTC.......................................... 298 Diagnostic Aids......................................................... 298 DTC 244 - Adaptive Learn Low (LPG).......................................... 301 Circuit Description..................................................... 301 Conditions for Setting the DTC.......................................... 301 Diagnostic Aids......................................................... 301 DTC 261 - System Voltage High............................................... 304 Circuit Description..................................................... 304 Conditions for Setting the DTC.......................................... 304 DTC 262 - System Voltage Low................................................ 306 Circuit Description..................................................... 306 Conditions for Setting the DTC.......................................... 306 DTC 411 - Injector Driver 1 Open............................................ 308 Circuit Description..................................................... 308 Conditions for Setting the DTC.......................................... 308 DTC 412 - Injector Driver 1 Shorted......................................... 311 Circuit Description..................................................... 311 Conditions for Setting the DTC.......................................... 311 DTC 511 - COP Failure....................................................... 314 Circuit Description..................................................... 314 Conditions for Setting the DTC.......................................... 314 DTC 512 - Invalid Interrupt................................................. 316 Circuit Description..................................................... 316 Conditions for Setting the DTC.......................................... 316 DTC 513 - A/D Loss.......................................................... 318 Circuit Description..................................................... 318 Conditions for Setting the DTC.......................................... 318 DTC 514 - RTI 1 Loss........................................................ 320 Circuit Description..................................................... 320 Conditions for Setting the DTC.......................................... 320 DTC 515 - Flash Checksum Invalid............................................ 322 Circuit Description..................................................... 322 Conditions for Setting the DTC.......................................... 322 DTC 516 - Ram Failure....................................................... 324 Circuit Description..................................................... 324 Conditions for Setting the DTC.......................................... 324 DTC 531 - External 5V Ref Lower Than Expected............................... 326 Circuit Description..................................................... 326 Conditions for Setting the DTC.......................................... 326 DTC 532 - External 5V Ref Higher Than Expected.............................. 328 Circuit Description..................................................... 328 Conditions for Setting the DTC.......................................... 328 DTC 555 - RTI 2 Loss........................................................ 330 Circuit Description..................................................... 330 Conditions for Setting the DTC.......................................... 330 DTC 556 - RTI 3 Loss........................................................ 332 Circuit Description..................................................... 332 Conditions for Setting the DTC.......................................... 332 DTC 611 - FPP High Voltage.................................................. 334 Circuit Description..................................................... 334 Conditions for Setting the DTC.......................................... 334 DTC 612 - FPP Low Voltage................................................... 338 Circuit Description..................................................... 338 Conditions for Setting the DTC.......................................... 338 DTC 631 - TPS1 Signal Voltage High.......................................... 342 Circuit Description..................................................... 342 Conditions for Setting the DTC.......................................... 342 DTC 632 - TPS1 Signal Voltage Low........................................... 345 Circuit Description..................................................... 345 Conditions for Setting the DTC.......................................... 345 DTC 638 - Throttle Unable To Close.......................................... 348 Circuit Description..................................................... 348 Conditions for Setting the DTC.......................................... 348 Diagnostic Aids......................................................... 349 DTC 651 - Maximum Govern Speed Override..................................... 351 Circuit Description..................................................... 351 Conditions for Setting the DTC.......................................... 351 Diagnostic Aids......................................................... 351 DTC 652 - Fuel Rev Limit.................................................... 354 Circuit Description..................................................... 354 Conditions for Setting the DTC.......................................... 354 Diagnostic Aids......................................................... 354 DTC 653 - Spark Rev Limit................................................... 356 Circuit Description..................................................... 356 Conditions for Setting the DTC.......................................... 356 Diagnostic Aids......................................................... 356 GM 4.3L Wiring Schematics and Connectors........................................ 360 GM 4.3L Diagnostic Trouble Codes................................................ 377 DTC 111 - IAT High Voltage Bosch® TMAP...................................... 377 Circuit Description..................................................... 377 Conditions for Setting the DTC.......................................... 377 DTC 111 - IAT High Voltage Motorola® TMAP................................... 380 Circuit Description..................................................... 380 Conditions for Setting the DTC.......................................... 380 DTC 112 - IAT Low Voltage Bosch® TMap....................................... 382 Circuit Description..................................................... 382 Conditions for Setting the DTC.......................................... 383 DTC 112 - IAT Low Voltage Motorola® TMAP.................................... 385 Circuit Description..................................................... 385 Conditions for Setting the DTC.......................................... 385 DTC 113 - IAT Higher Than Expected 1 Bosch® TMAP............................ 388 Circuit Description..................................................... 388 Conditions for Setting the DTC.......................................... 388 Diagnostic Aids......................................................... 388 DTC 113 - IAT Higher Than Expected 1 Motorola® TMAP......................... 389 Circuit Description..................................................... 389 Conditions for Setting the DTC.......................................... 389 Diagnostic Aids......................................................... 389 DTC 114 - IAT Higher Than Expected 2 Bosch® TMAP€........................... 390 Circuit Description..................................................... 390 Conditions for Setting the DTC.......................................... 390 Diagnostic Aids......................................................... 390 DTC 114 - IAT Higher Than Expected 2 Motorola® TMAP......................... 391 Circuit Description..................................................... 391 Conditions for Setting the DTC.......................................... 391 Diagnostic Aids......................................................... 391 DTC 115 - Oil Pressure Low.................................................. 392 Circuit Description..................................................... 392 Conditions for Setting the DTC.......................................... 392 DTC 121 - ECT Voltage High.................................................. 394 Circuit Description..................................................... 394 Conditions for Setting the DTC.......................................... 395 DTC 122 - ECT Voltage Low................................................... 398 Circuit Description..................................................... 398 Conditions for Setting the DTC.......................................... 398 DTC 123 - ECT Higher Than Expected 1........................................ 401 Circuit Description..................................................... 401 Conditions for Setting the DTC.......................................... 401 DTC 124 - ECT Higher Than Expected 2........................................ 403 Circuit Description..................................................... 403 Conditions for Setting the DTC.......................................... 403 DTC 131 - MAP High Pressure Bosch® TMAP..................................... 404 Circuit Description..................................................... 404 Conditions for Setting the DTC.......................................... 404 Diagnostic Aids......................................................... 404 DTC 131 - MAP High Pressure Motorola® TMAP.................................. 408 Circuit Description..................................................... 408 Conditions for Setting the DTC.......................................... 408 Diagnostic Aids......................................................... 408 DTC 132 - MAP Low Voltage Bosch® TMAP....................................... 411 Circuit Description..................................................... 411 Conditions for Setting the DTC.......................................... 411 DTC 132 - MAP Low Voltage Motorola® TMAP.................................... 414 Circuit Description..................................................... 414 Conditions for Setting the DTC.......................................... 414 DTC 134 - BP High Pressure Bosch® TMAP...................................... 419 Circuit Description..................................................... 419 Conditions for Setting the DTC.......................................... 419 DTC 134 - BP High Pressure Motorola® TMAP................................... 421 Circuit Description..................................................... 421 Conditions for Setting the DTC.......................................... 421 DTC 135 - BP Low Pressure Bosch® TMAP....................................... 423 Circuit Description..................................................... 423 Conditions for Setting the DTC.......................................... 423 DTC 135 - BP Low Pressure Motorola® TMAP.................................... 427 Circuit Description..................................................... 427 Conditions for Setting the DTC.......................................... 427 DTC 142 - Crank Sync Noise.................................................. 430 Circuit Description..................................................... 430 Conditions for setting the DTC.......................................... 430 DTC 143 - Never Crank Synced At Start....................................... 434 Circuit Description..................................................... 434 Conditions for Setting the DTC.......................................... 434 DTC 144 - Camshaft Sensor Loss.............................................. 437 Circuit Description..................................................... 437 Conditions for Setting the DTC.......................................... 437 DTC 145 - Camshaft Sensor Noise............................................. 440 Circuit Description..................................................... 440 Conditions for Setting the DTC.......................................... 440 DTC 211 - Closed Loop Multiplier High (LPG)................................. 443 Circuit Description..................................................... 443 Conditions for Setting the DTC.......................................... 443 Diagnostic Aids......................................................... 444 DTC 212 - HO 2 S Open/Inactive.............................................. 446 Circuit Description..................................................... 446 Conditions for Setting the DTC.......................................... 446 DTC 221 - Closed Loop Multiplier High (Gasoline)............................ 449 Circuit Description..................................................... 449 Conditions for Setting the DTC.......................................... 449 Diagnostic Aids......................................................... 449 DTC 222 - Closed Loop Multiplier Low (Gasoline)............................. 452 Circuit Description..................................................... 452 Conditions for Setting the DTC.......................................... 452 Diagnostic Aids......................................................... 452 DTC 224 - Closed Loop Multiplier Low (LPG).................................. 454 Circuit Description..................................................... 454 Conditions for Setting the DTC.......................................... 454 Diagnostic Aids......................................................... 455 DTC 241 - Adaptive Lean Fault (High Limit-Gasoline)......................... 456 Circuit Description..................................................... 456 Conditions for Setting the DTC.......................................... 456 Diagnostic Aids......................................................... 456 DTC 242 - Adaptive Rich Fault (Low Limit-Gasoline).......................... 459 Circuit Description..................................................... 459 Conditions for Setting the DTC.......................................... 459 Diagnostic Aids......................................................... 459 DTC 243 - Adaptive Learn High (LPG)......................................... 462 Circuit Description..................................................... 462 Conditions for Setting the DTC.......................................... 462 Diagnostic Aids......................................................... 462 DTC 244 - Adaptive Learn Low (LPG).......................................... 465 Circuit Description..................................................... 465 Conditions for Setting the DTC.......................................... 465 Diagnostic Aids......................................................... 465 DTC 261 - System Voltage High............................................... 468 Circuit Description..................................................... 468 Conditions for Setting the DTC.......................................... 468 DTC 262 - System Voltage Low................................................ 470 Circuit Description..................................................... 470 Conditions for Setting the DTC.......................................... 470 DTC 511 - COP Failure....................................................... 472 Circuit Description..................................................... 472 Conditions for Setting the DTC.......................................... 472 DTC 512 - Invalid Interrupt................................................. 474 Circuit Description..................................................... 474 Conditions for Setting the DTC.......................................... 474 DTC 513 - A/D Loss.......................................................... 476 Circuit Description..................................................... 476 Conditions for Setting the DTC.......................................... 476 DTC 514 - RTI 1 Loss........................................................ 478 Circuit Description..................................................... 478 Conditions for Setting the DTC.......................................... 478 DTC 515 - Flash Checksum Invalid............................................ 480 Circuit Description..................................................... 480 Conditions for Setting the DTC.......................................... 480 DTC 516 - Ram Failure....................................................... 482 Circuit Description..................................................... 482 Conditions for Setting the DTC.......................................... 482 DTC 531 - External 5V Ref Lower Than Expected............................... 484 Circuit Description..................................................... 484 Conditions for Setting the DTC.......................................... 484 DTC 532 - External 5V Ref Higher Than Expected.............................. 486 Circuit Description..................................................... 486 Conditions for Setting the DTC.......................................... 486 DTC 555 - RTI 2 Loss........................................................ 488 Circuit Description..................................................... 488 Conditions for Setting the DTC.......................................... 488 DTC 556 - RTI 3 Loss........................................................ 490 Circuit Description..................................................... 490 Conditions for Setting the DTC.......................................... 490 DTC 611 - FPP High Voltage.................................................. 492 Circuit Description..................................................... 492 Conditions for Setting the DTC.......................................... 492 DTC 612 - FPP Low Voltage................................................... 496 Circuit Description..................................................... 496 Conditions for Setting the DTC.......................................... 496 DTC 631 - TPS1 Signal Voltage High.......................................... 500 Circuit Description..................................................... 500 Conditions for Setting the DTC.......................................... 500 DTC 632 - TPS1 Signal Voltage Low........................................... 503 Circuit Description..................................................... 503 Conditions for Setting the DTC.......................................... 503 DTC 638 - Throttle Unable To Close.......................................... 506 Circuit Description..................................................... 506 Conditions for Setting the DTC.......................................... 506 Diagnostic Aids......................................................... 507 DTC 651 - Maximum Govern Speed Override..................................... 509 Circuit Description..................................................... 509 Conditions for Setting the DTC.......................................... 509 Diagnostic Aids......................................................... 509 DTC 652 - Fuel Rev Limit.................................................... 512 Circuit Description..................................................... 512 Conditions for Setting the DTC.......................................... 512 Diagnostic Aids......................................................... 512 DTC 653 - Spark Rev Limit................................................... 514 Circuit Description..................................................... 514 Conditions for Setting the DTC.......................................... 514 Diagnostic Aids......................................................... 514 Wire Harness Repair............................................................. 517 On Vehicle Service Wiring Harness Repair.................................... 517 Connectors and Terminals.................................................... 518 Twisted/Shielded Cable Repair........................................... 518 Twisted Leads Repair.................................................... 519 Micro-Pack.............................................................. 520 Metri-Pack.............................................................. 520 Remove.............................................................. 520 Weather-Pack............................................................ 522 Weather-Pack Terminal Repair........................................ 523 tables.............................................................................. 195 Table 1. OBD System Check....................................................... 215 Table 2. Preliminary Checks..................................................... 217 Table 3. Intermittent Checks.................................................... 218 Table 4. Communication Port C002................................................ 219 Table 5. Coil Connector C003.................................................... 219 Table 6. Fuel System Interface C004............................................. 219 Table 7. Oil Pressure Connector C005............................................ 220 Table 8. Distributor Connector C006............................................. 220 Table 9. Magnetic Pickup Connector C007......................................... 220 Table 10. Heated Oxygen Sensor C008............................................. 220 Table 11. Throttle Position Sensor Connector C009............................... 221 Table 12. Foot Pedal Position Connector C010.................................... 221 Table 13. Governor Motor Connector C011......................................... 221 Table 14. TMAP Connector C012................................................... 221 Table 15. Starter Solenoid C013................................................. 222 Table 16. Engine Coolant Temperature C014....................................... 222 Table 17. Battery Connector C015................................................ 222 Table 18. Alternator Connection C016............................................ 222 Table 19. Battery Connector C017................................................ 222 Table 20. Alternator Connector C018............................................. 223 Table 21. Instrument Panel Connector C019....................................... 223 Table 22. Instrument Panel Connector C020....................................... 223 Table 23. Instrument Panel Connector C021....................................... 224 Table 24. Fuel Trim Valve Connector C022........................................ 224 Table 25. Fuel Lockoff Connector C023........................................... 224 Table 26. Pressure Trim Valve Connector C024.................................... 225 Table 27. Throttle Body Injector Connector C025................................. 225 Table 28. Relay and Fuse Center................................................. 225 Table 29. DTC 111 - IAT Voltage High (Motorola® TMAP)........................... 234 Table 30. DTC 112 - IAT Low Voltage (Motorola® TMAP)............................ 237 Table 31. DTC 115 - Oil Pressure Low............................................ 242 Table 32. Temperature Resistance................................................ 244 Table 33. DTC 121 - ECT VOLTAGE HIGH............................................ 245 Table 34. DTC 122 - ECT Voltage Low............................................. 249 Table 35. DTC 123 - ECT Higher Than Expected 1.................................. 251 Table 36. DTC 124 - ECT Higher Than Expected 2.................................. 253 Table 37. DTC 131 - MAP HIGH PRESSURE (Motorola® TMAP).......................... 255 Table 38. DTC 132 - MAP Low Voltage (Motorola® TMAP)............................ 258 Table 39. DTC 134 - BP High Pressure (Motorola® TMAP)........................... 261 Table 40. DTC 135 - BP Low Pressure (Motorola® TMAP)............................ 263 Table 41. DTC 142 - Crank Sync Noise............................................ 267 Table 42. DTC 143 - Never Crank Synced At Start................................. 270 Table 43. DTC 144 - Camshaft Sensor Loss........................................ 273 Table 44. DTC 145 - Camshaft Sensor Noise....................................... 276 Table 45. DTC 211 - Closed Loop Multiplier High (LPG)........................... 280 Table 46. DTC 212 - HO 2 S Open/Inactive........................................ 283 Table 47. DTC 221 - Closed Loop Multiplier High (Gasoline)...................... 286 Table 48. DTC 222 - Closed Loop Multiplier Low (Gasoline)....................... 289 Table 49. DTC 224 - Closed Loop Multiplier Low (LPG)............................ 291 Table 50. DTC 241 - Adaptive Lean Fault (High Limit-Gasoline)................... 293 Table 51. DTC 242 - Adaptive Rich Fault (Low Limit-Gasoline).................... 296 Table 52. DTC 243 - Adaptive Learn High (LPG)................................... 299 Table 53. DTC 244 - Adaptive Learn Low (LPG).................................... 302 Table 54. DTC 261 - System Voltage High......................................... 305 Table 55. DTC 262 - System Voltage Low.......................................... 306 Table 56. DTC 411 - Injector Driver 1 Open...................................... 309 Table 57. DTC 412 - Injector Driver 1 Shorted................................... 312 Table 58. DTC 511 - COP Failure................................................. 315 Table 59. DTC 512 - Invalid Interrupt........................................... 317 Table 60. DTC 513 - A/D Loss.................................................... 319 Table 61. DTC 514 - RTI 1 Loss.................................................. 321 Table 62. DTC 515 - Flash Checksum Invalid...................................... 323 Table 63. DTC 516 - Ram Failure................................................. 325 Table 64. DTC 531 - External 5V Ref Lower Than Expected......................... 327 Table 65. DTC 532 - External 5 V Ref Higher Than Expected....................... 329 Table 66. DTC 555 - RTI 2 Loss.................................................. 331 Table 67. DTC 556 - RTI 3 Loss.................................................. 333 Table 68. DTC 611 - FPP High Voltage............................................ 335 Table 69. DTC 612 - FPP Low Voltage............................................. 339 Table 70. DTC 631 - TPS1 Signal Voltage High.................................... 343 Table 71. DTC 632 - TPS1 Signal Voltage Low..................................... 346 Table 72. DTC 638 - Throttle Unable To Close.................................... 349 Table 73. DTC 651 - Maximum Govern Speed Override............................... 352 Table 74. DTC 652 - Fuel Rev Limit.............................................. 355 Table 75. DTC 653 - Spark Rev Limit............................................. 357 Table 76. Communication Port C002............................................... 360 Table 77. Injector Connector C003............................................... 360 Table 78. Injector Connector C004............................................... 360 Table 79. Oil Pressure Connector C005........................................... 361 Table 80. Throttle Position Sensor 1 Connector C006............................. 361 Table 81. Foot Pedal Position Connector C006A................................... 361 Table 82. Coil Connector C007................................................... 361 Table 83. Module Connector C008................................................. 362 Table 84. Crank Sensor Connector C009........................................... 362 Table 85. EGO Sensor Connector C010............................................. 362 Table 86. Cam Connector C011.................................................... 363 Table 87. Throttle Connector C012............................................... 363 Table 88. Bosch TMAP Connector C013 (Gasoline Fuel System Only)................. 363 Table 89. Motorola TMAP Connector C013 (LPG Fuel System Only)................... 364 Table 90. Starter Solenoid Connector C014....................................... 364 Table 91. ECT Connector C015.................................................... 364 Table 92. Starter Relay C016.................................................... 364 Table 93. Power Relay C017...................................................... 364 Table 94. Fuel Pump Relay C018.................................................. 364 Table 95. Battery Connector C019................................................ 365 Table 96. Alternator Connector C020............................................. 365 Table 97. Alternator Connector C021............................................. 365 Table 98. Instrument Panel Connector C022....................................... 365 Table 99. Instrument Panel Connector C023....................................... 366 Table 100. Instrument Panel Connector C024...................................... 366 Table 101. Fuel Trim Valve Connector C025....................................... 366 Table 102. Fuel Lockoff Connector C026.......................................... 367 Table 103. Pressure Trim Valve Connector C027................................... 367 Table 104. Injector 1 Connector C028............................................ 367 Table 105. Injector 2 Connector C029............................................ 368 Table 106. Injector 3 Connector C030............................................ 368 Table 107. Injector 4 Connector C031............................................ 368 Table 108. Injector 5 Connector C032............................................ 369 Table 109. Injector 6 Connector C033............................................ 369 Table 110. Relay and Fuse Center................................................ 369 Table 111. DTC 111 - IAT Voltage High (Bosch® TMAP)............................. 378 Table 112. DTC 111 - IAT Voltage High (Motorola® TMAP).......................... 381 Table 113. DTC 112 - IAT Low Voltage (Bosch® TMAP).............................. 383 Table 114. DTC 112 - IAT Low Voltage (Motorola® TMAP)........................... 386 Table 115. DTC 115 - Oil Pressure Low........................................... 392 Table 116. Temperature Resistance............................................... 395 Table 117. DTC 121 - ECT VOLTAGE HIGH........................................... 396 Table 118. DTC 122 - ECT Voltage Low............................................ 399 Table 119. DTC 123 - ECT Higher Than Expected 1................................. 402 Table 120. DTC 124 - ECT Higher Than Expected 2................................. 404 Table 121. DTC 131 - MAP High Pressure (Bosch® TMAP)............................ 405 Table 122. DTC 131 - MAP HIGH PRESSURE (Motorola® TMAP)......................... 409 Table 123. DTC 132 - MAP Low Voltage (Bosch® TMAP).............................. 412 Table 124. DTC 132 - MAP Low Voltage (Motorola® TMAP)........................... 415 Table 125. DTC 134 - BP High Pressure (Bosch® TMAP)............................. 420 Table 126. DTC 134 - BP High Pressure (Motorola® TMAP).......................... 422 Table 127. DTC 135 - BP Low Pressure (Bosch® TMAP).............................. 423 Table 128. DTC 135 - BP Low Pressure (Motorola® TMAP)........................... 427 Table 129. DTC 142 - Crank Sync Noise........................................... 431 Table 130. DTC 143 - Never Crank Synced At Start................................ 434 Table 131. DTC 144 - Camshaft Sensor Loss....................................... 437 Table 132. DTC 145 - Camshaft Sensor Noise...................................... 440 Table 133. DTC 211 - Closed Loop Multiplier High (LPG).......................... 444 Table 134. DTC 212 - HO 2 S Open/Inactive....................................... 447 Table 135. DTC 221 - Closed Loop Multiplier High (Gasoline)..................... 450 Table 136. DTC 222 - Closed Loop Multiplier Low (Gasoline)...................... 453 Table 137. DTC 224 - Closed Loop Multiplier Low (LPG)........................... 455 Table 138. DTC 241 - Adaptive Lean Fault (High Limit-Gasoline).................. 457 Table 139. DTC 242 - Adaptive Rich Fault (Low Limit-Gasoline)................... 460 Table 140. DTC 243 - Adaptive Learn High (LPG).................................. 463 Table 141. DTC 244 - Adaptive Learn Low (LPG)................................... 466 Table 142. DTC 261 - System Voltage High........................................ 469 Table 143. DTC 262 - System Voltage Low......................................... 470 Table 144. DTC 511 - COP Failure................................................ 473 Table 145. DTC 512 - Invalid Interrupt.......................................... 475 Table 146. DTC 513 - A/D Loss................................................... 477 Table 147. DTC 514 - RTI 1 Loss................................................. 479 Table 148. DTC 515 - Flash Checksum Invalid..................................... 481 Table 149. DTC 516 - Ram Failure................................................ 483 Table 150. DTC 531 - External 5V Ref Lower Than Expected........................ 485 Table 151. DTC 532 - External 5 V Ref Higher Than Expected...................... 487 Table 152. DTC 555 - RTI 2 Loss................................................. 489 Table 153. DTC 556 - RTI 3 Loss................................................. 491 Table 154. DTC 611 - FPP High Voltage........................................... 493 Table 155. DTC 612 - FPP Low Voltage............................................ 496 Table 156. DTC 631 - TPS1 Signal Voltage High................................... 501 Table 157. DTC 632 - TPS1 Signal Voltage Low.................................... 504 Table 158. DTC 638 - Throttle Unable To Close................................... 507 Table 159. DTC 651 - Maximum Govern Speed Override.............................. 510 Table 160. DTC 652 - Fuel Rev Limit............................................. 513 Table 161. DTC 653 - Spark Rev Limit............................................ 516 Eje direccion........................................................................... 527 toc................................................................................. 527 Steering Axle................................................................... 527 Safety Precautions Maintenance and Repair....................................... 528 General......................................................................... 531 Description..................................................................... 531 Steering Axle Assembly Repair................................................... 535 Steering Axle H3.50-5.00XL (H70-110XL) (G005), S3.50-5.50XL (S70............ 535 Remove.................................................................. 535 Install................................................................. 536 Steering Axle H6.00-7.00XL (H135-155XL, H135-155XL 2 ) (F006, G0............ 536 Remove.................................................................. 536 Install................................................................. 537 Wheels and Hubs Repair (All Units).............................................. 537 Remove and Disassemble...................................................... 537 Clean....................................................................... 537 Inspect..................................................................... 537 Assemble and Install........................................................ 538 Spindles and Bearings Repair (All Units)........................................ 539 Remove...................................................................... 539 Clean....................................................................... 539 Assemble and Install........................................................ 539 Tie Rods Repair (All Units)..................................................... 540 Remove...................................................................... 540 Clean....................................................................... 540 Install..................................................................... 540 Steering Cylinder Repair........................................................ 543 Remove and Disassemble...................................................... 543 Clean and Inspect........................................................... 543 Assemble and Install........................................................ 543 Troubleshooting................................................................. 544 especificaciones y capacidades.......................................................... 549 toc................................................................................. 549 Capacities and Specifications................................................... 549 Safety Precautions Maintenance and Repair....................................... 550 Lift Truck Weights.............................................................. 553 Capacities...................................................................... 553 Tire Sizes...................................................................... 554 Tire Pressure................................................................... 554 Electrical System............................................................... 554 Wheel Nut Torque................................................................ 554 Engine Specifications........................................................... 555 Hydraulic System................................................................ 555 Mast Speeds..................................................................... 556 Transmission Oil Pressures...................................................... 556 Torque Specifications........................................................... 557 Engine - GM 4.3L V-6........................................................ 557 Engine - Perkins 4.2482..................................................... 557 Engine - Perkins 1004.4..................................................... 557 Clutch...................................................................... 557 Manual Transmission......................................................... 558 Powershift Transmission..................................................... 558 Speed Reducer............................................................... 558 Drive Axle.................................................................. 558 Steering System............................................................. 558 Brake System................................................................ 558 Hydraulic System............................................................ 559 Tilt Cylinder............................................................... 559 Mast........................................................................ 559 esquemas................................................................................ 563 toc................................................................................. 563 Diagrams........................................................................ 563 Safety Precautions Maintenance and Repair....................................... 564 frame................................................................................... 625 toc................................................................................. 625 Frame........................................................................... 625 Safety Precautions Maintenance and Repair....................................... 626 General......................................................................... 629 Description..................................................................... 629 Counterweight Repair............................................................ 630 Remove...................................................................... 630 Install..................................................................... 630 Hood Repair..................................................................... 631 Remove...................................................................... 631 Install..................................................................... 631 Overhead Guard Repair........................................................... 631 Remove...................................................................... 631 Install..................................................................... 631 Operator Restraint System Repair................................................ 632 Hydraulic Tank Repair........................................................... 633 Remove...................................................................... 633 Inspect..................................................................... 633 Small Leaks Repair.......................................................... 633 Large Leaks Repair.......................................................... 633 Clean....................................................................... 633 Steam Method............................................................ 634 Chemical Solution Method................................................ 634 Other Methods of Preparation for Repair..................................... 634 Install..................................................................... 634 Fuel Tank Repair................................................................ 635 Remove...................................................................... 635 Repair...................................................................... 635 Install..................................................................... 635 Radiator Repair................................................................. 635 Remove...................................................................... 635 Install..................................................................... 635 Engine Repair................................................................... 636 Remove...................................................................... 636 Install..................................................................... 636 Throttle Pedal Adjustment....................................................... 638 Perkins 1104C-44(RE) Diesel Engine.......................................... 638 Safety Labels................................................................... 639 Cab Repair...................................................................... 641 Cab, Replace................................................................ 641 Window, Replace............................................................. 641 Windshield Wipers and Heater................................................ 641 tables.............................................................................. 625 Table 1. Material Specifications for Cab Windows................................ 643 GM V6 4.3litros......................................................................... 647 toc................................................................................. 647 GM Engines...................................................................... 647 Safety Precautions Maintenance and Repair....................................... 648 General......................................................................... 651 Description..................................................................... 651 Engine Removal and Installation................................................. 652 Cylinder Head Repair............................................................ 652 Remove and Disassemble...................................................... 652 Clean and Inspect........................................................... 652 Valve Guides and Seats, Repairs............................................. 653 Valves, Repair.............................................................. 653 Valve Seats, Repair......................................................... 654 Valve Springs............................................................... 655 Rocker Arm Studs (Early Models)............................................. 655 Rocker Arm Studs (Late Models).............................................. 656 Assemble and Install........................................................ 656 Cylinder Block Cleaning and Inspection.......................................... 660 Piston Bore Preparation......................................................... 660 Engine Mounts Installation...................................................... 660 Lubrication System Repair....................................................... 661 Oil Pump, Remove and Disassemble............................................ 661 Clean and Inspect........................................................... 661 Oil Pump, Assemble and Install.............................................. 661 Oil Sump, Install........................................................... 662 Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters..................... 663 Timing Cover................................................................ 663 Remove.................................................................. 663 Install................................................................. 665 Timing Sprockets............................................................ 665 Remove.................................................................. 665 Install................................................................. 665 Camshaft.................................................................... 666 Remove.................................................................. 666 Inspect................................................................. 666 Install................................................................. 666 Balance Shaft............................................................... 667 Remove.................................................................. 667 Install................................................................. 668 Hydraulic Valve Lifters..................................................... 668 Remove.................................................................. 668 Disassemble............................................................. 669 Clean and Inspect....................................................... 669 Assemble................................................................ 669 Install................................................................. 670 Crankshaft Repair............................................................... 671 Remove...................................................................... 671 Inspect and Repair.......................................................... 671 How to Check Clearance Between Main Bearings and Their Journals............. 672 Install..................................................................... 673 Piston and Connecting Rod Assemblies Repair..................................... 674 Connecting Rod Bearings, Replace............................................ 674 Piston and Connecting Rod Assemblies, Remove................................ 675 Disassemble................................................................. 675 Piston, Clean and Inspect................................................... 676 Cylinder Bores, Inspect and Repair.......................................... 676 Piston Rings................................................................ 677 Assemble.................................................................... 678 Piston and Connecting Rod Assemblies, Install............................... 678 Flywheel and Flywheel Housing Repair............................................ 679 Flywheel, Repair............................................................ 679 Flywheel, Install........................................................... 679 H3.50-5.00XL (H70-110XL), S3.50-5.50XL (S70-120XL), S6.00-7.00XL........ 679 H6.00-7.00XL (H135-155XL)............................................... 679 Flywheel Housing H3.50-5.00XL (H70-110XL), H3.50-5.50XM (H70-120............ 679 Engine Adapter H6.00-7.00XL (H135-155XL).................................... 679 Coolant Pump Repair............................................................. 680 Thermostat Replacement.......................................................... 680 Fan Mount Repair (Early Models)................................................. 680 Fan Mount Assembly Repair (Late Models)......................................... 680 Drive Belt Installation......................................................... 682 Valve Clearance Adjustment (Early Models)....................................... 683 Valve Clearance Adjustment (New Models)......................................... 684 Compression Check............................................................... 684 Engine Specifications........................................................... 684 Engine Data................................................................. 684 Cylinder Head............................................................... 685 Hydraulic Valve Lifter...................................................... 685 Camshaft.................................................................... 685 Pistons..................................................................... 685 Crankshaft.................................................................. 686 Connecting Rods............................................................. 687 Balance Shaft............................................................... 687 Cooling System.............................................................. 687 Lubrication System.......................................................... 687 Torque Specifications........................................................... 688 Troubleshooting................................................................. 689 tables.............................................................................. 647 Table 1. Piston Rings Arrangement on Piston..................................... 678 GM v6 high voltage swich................................................................ 695 toc................................................................................. 695 High Voltage Switch (HVS) Ignition.............................................. 695 Safety Precautions Maintenance and Repair....................................... 696 Description..................................................................... 699 Distributor Ignition (DI) System............................................ 699 Crankshaft Position (CKP) Sensor............................................ 699 Camshaft Position (CMP) Sensor.............................................. 699 Ignition Coil and Ignition Control Module (ICM)............................. 699 Secondary Ignition Components............................................... 699 Spark Plugs and Wires........................................................... 699 Spark Plug Wire Inspection.................................................. 699 Spark Plug Wire Replacement................................................. 699 Remove.................................................................. 699 Install................................................................. 700 Spark Plug Inspection....................................................... 700 Usage................................................................... 700 Inspection.............................................................. 700 Visual Inspection....................................................... 702 Spark Plug Replacement...................................................... 702 Remove.................................................................. 702 Install................................................................. 702 Distributor Repair.............................................................. 703 Inspect..................................................................... 703 Overhaul.................................................................... 703 Disassemble............................................................. 703 Assemble................................................................ 706 Replace..................................................................... 706 Remove.................................................................. 706 Install Procedure 1..................................................... 708 Install Procedure 2..................................................... 709 Ignition Coil Replacement....................................................... 711 Remove...................................................................... 711 Install..................................................................... 711 Ignition Control Module Replacement............................................. 712 Remove...................................................................... 712 Install..................................................................... 712 Camshaft Position (CMP) Sensor Replacement...................................... 712 Remove...................................................................... 712 Install..................................................................... 714 Crankshaft Position (CKP) Sensor Replacement.................................... 714 Remove...................................................................... 714 Install..................................................................... 714 Wire Harness Repair............................................................. 716 On Vehicle Service Wiring Harness Repair.................................... 716 Connectors and Terminals.................................................... 716 Twisted/Shielded Cable Repair........................................... 717 Twisted Leads Repair.................................................... 718 Micro-Pack.............................................................. 718 Metri-Pack.............................................................. 718 Remove.............................................................. 719 Weather-Pack............................................................ 720 Weather-Pack Terminal Repair........................................ 721 Specifications and Special Tools................................................ 722 System Diagnosis................................................................ 724 tables.............................................................................. 695 Table 1. Ignition System Specifications......................................... 722 Table 2. Fastener Tightening Specifications..................................... 722 Table 3. Special Tools.......................................................... 723 Table 4. Distributor Ignition (DI).............................................. 724 indicadores del panel y sensores........................................................ 731 toc................................................................................. 731 Instrument Panel Indicators and Senders......................................... 731 Safety Precautions Maintenance and Repair....................................... 732 General......................................................................... 735 Description..................................................................... 736 Steering Column Gauges, Meters, and Indicators.............................. 736 LED Display Panel........................................................... 736 Battery Discharge Indicators............................................ 736 Brush Wear Indicators................................................... 743 Motor Temperature Indicators............................................ 743 LX Series Display Panel..................................................... 745 Hourmeter Functions..................................................... 745 Battery Indicator Function.............................................. 746 Status Code Function.................................................... 747 ZX Series Display Panels.................................................... 747 Display Panel........................................................... 747 Basic Display Panels.................................................... 747 Performance Display..................................................... 750 Brush Wear Indicators................................................... 753 Adjustments - General........................................................... 754 Replacement - General Information............................................... 754 Meter Replacement............................................................... 755 Sender Replacement.............................................................. 756 Fuel Level Sender........................................................... 756 Pressure and Temperature Sender............................................. 756 ITW Display Panel Replacement................................................... 757 Remove...................................................................... 757 Column Mount Display Panel (EV-100/200ZX Motor Controllers) Repl................ 758 Remove...................................................................... 758 Display Panel Assembly, Replace............................................. 758 Indicator LEDs.............................................................. 759 Battery Indicators.......................................................... 759 Digital Display (Performance Display Panel Only)............................ 759 Status Code or Performance Level Switches and Indicator LEDs (Pe............ 759 Basic Display Panel, Replace Parts.......................................... 759 Performance Display Panel, Replace Parts.................................... 761 Dash Mount Display Panel (EV100/200ZX Motor Controllers) Replace................ 762 Remove and Replace.......................................................... 762 Specifications.................................................................. 762 Meter Specifications........................................................ 762 Sender Specifications....................................................... 763 Troubleshooting................................................................. 763 Meter....................................................................... 763 LPG electronic control.................................................................. 767 toc................................................................................. 767 Electronic Controlled LPG/Gasoline Fuel System.................................. 767 Safety Precautions Maintenance and Repair....................................... 768 General......................................................................... 773 Fuel System Warnings and Cautions........................................... 773 Glossary........................................................................ 774 Description and Operation of LPG Fuel System.................................... 778 Propane Fuel System......................................................... 778 LPG Fuel Tank............................................................... 778 Service Line................................................................ 778 Fuel Filter................................................................. 780 Low Pressure Lock-Off (LPL)................................................. 780 Low Pressure Regulator (LPR)................................................ 781 Air Fuel Mixer.............................................................. 781 Throttle Control Device..................................................... 782 Drive By Cable.......................................................... 782 Three-Way Catalytic (TWC) Muffler........................................... 783 Electronic Control Module (ECM)............................................. 783 Heated Exhaust Gas Oxygen (HEGO) Sensor..................................... 784 Description and Operation of Gasoline Fuel System............................... 786 Gasoline Fuel System Throttle Body Injection (TBI), 3.0L Engine ............ 786 Gasoline Multi-Point Fuel Injection (MPFI) System, 4.3L Only................ 786 Gasoline Fuel Storage Tank.................................................. 786 Gasoline Fuel Pump.......................................................... 786 Fuel Filter................................................................. 786 Fuel Pressure Regulator, 3.0L Only.......................................... 789 Fuel Rail and Pressure Regulator, 4.3L Only................................. 790 Fuel Injector............................................................... 790 Throttle Control Device..................................................... 790 Drive By Cable.......................................................... 790 Three-Way Catalytic Muffler................................................. 791 Electronic Control Module (ECM)............................................. 791 Heated Exhaust Gas Oxygen (HEGO) Sensor..................................... 793 LPG Fuel System Repair.......................................................... 793 Propane Fuel System Pressure Relief......................................... 793 Propane Fuel System Leak Test............................................... 793 Propane Fuel Filter Replacement............................................. 794 Remove.................................................................. 794 Install................................................................. 794 Low Pressure Lock-Off (LPL) Replacement..................................... 794 Remove.................................................................. 794 Install................................................................. 794 Pressure Trim Valve (PTV) Replacement....................................... 796 Remove.................................................................. 796 Install................................................................. 796 Low Pressure Regulator...................................................... 796 Remove.................................................................. 796 Install................................................................. 797 Fuel Trim Valve (FTV) Solenoid Replacement.................................. 797 Remove.................................................................. 797 Install................................................................. 797 Temperature Manifold Absolute Pressure (TMAP)............................... 799 Remove.................................................................. 799 Install................................................................. 799 Throttle Body Replacement................................................... 799 Remove.................................................................. 799 Install................................................................. 801 Mixer Replacement........................................................... 801 Remove.................................................................. 801 Install................................................................. 802 Coolant Hose Replacement.................................................... 802 Remove.................................................................. 802 Install................................................................. 802 Vapor Hose Replacement...................................................... 802 Remove.................................................................. 802 Install................................................................. 802 Balance Line Hose Replacement............................................... 802 Remove.................................................................. 802 Install................................................................. 803 PTV Hose Replacement........................................................ 803 Remove.................................................................. 803 Install................................................................. 803 FTV Hose Replacement........................................................ 803 Remove.................................................................. 803 Install................................................................. 803 Throttle Position Sensor (TPS) Replacement.................................. 803 Foot Pedal Position (FPP) Sensor Replacement................................ 806 Electronic Control Module (ECM) Replacement................................. 809 Remove.................................................................. 809 Install................................................................. 809 Heated Exhaust Gas Oxygen (HEGO) Sensor Replacement......................... 810 Remove.................................................................. 810 Install................................................................. 810 Three-Way Catalytic Muffler (TWC) Replacement............................... 810 Remove.................................................................. 810 Install................................................................. 810 Restricted Exhaust System Diagnosis......................................... 810 Exhaust System Description.............................................. 810 Tools Required...................................................... 810 Diagnostic Tool..................................................... 810 Check at Heated Exhaust Gas Oxygen Sensor (HEGO)........................ 810 Gasoline Fuel System Repair..................................................... 811 Gasoline MPFI and TBI Fuel System Pressure Relief........................... 811 Gasoline Fuel System Leak Test.............................................. 812 Throttle Body Injector (TBI) Assembly Replacement, 3.0L Only................ 812 Remove.................................................................. 812 Install................................................................. 812 Throttle Body Assembly Replacement, 3.0L Only............................... 814 Remove.................................................................. 814 Install................................................................. 814 Throttle Body Assembly Replacement, 4.3L Only............................... 814 Remove.................................................................. 814 Install................................................................. 815 Fuel Rail Replacement, Gasoline 4.3L Only................................... 815 Remove.................................................................. 815 Install................................................................. 817 Injector Replacement, Gasoline 4.3L Only.................................... 817 Remove.................................................................. 817 Install................................................................. 817 Injector Replacement, Gasoline 3.0L Only.................................... 817 Remove.................................................................. 817 Install................................................................. 818 Temperature Manifold Absolute Pressure (TMAP) Replacement................... 818 Remove.................................................................. 818 Install................................................................. 818 Throttle Position Sensor (TPS) Replacement.................................. 818 Foot Pedal Position (FPP) Sensor Replacement................................ 822 Electronic Control Module (ECM) Replacement................................. 824 Remove.................................................................. 824 Install................................................................. 824 Heated Exhaust Gas Oxygen (HEGO) Sensor Replacement......................... 824 Remove.................................................................. 824 Install................................................................. 825 Three-Way Catalytic Muffler (TWC) Replacement............................... 825 Remove.................................................................. 825 Install................................................................. 825 Restricted Exhaust System Diagnosis......................................... 825 Exhaust System Description.............................................. 825 Tools Required...................................................... 825 Diagnostic Tool..................................................... 825 Check at Heated Exhaust Gas Oxygen Sensor (HEGO)........................ 825 LPG System Diagnosis............................................................ 826 Fuel System Description..................................................... 826 Diagnostic Aids............................................................. 827 Tools Required.......................................................... 827 Duty Cycle Monitoring Tool.............................................. 827 Diagnostic Tool......................................................... 827 Pressure Gauges......................................................... 827 Test Description........................................................ 827 Gasoline System Diagnosis....................................................... 835 Fuel System Description, 3.0L Only.......................................... 835 Fuel System Description, 4.3L Only.......................................... 835 Diagnostic Aids............................................................. 836 Tools Required.......................................................... 836 Diagnostic Tool......................................................... 836 Test Description........................................................ 836 LPG Symptom Diagnosis........................................................... 843 Gasoline Symptom Diagnosis...................................................... 856 Wire Harness Repair............................................................. 866 On Vehicle Service Wiring Harness Repair.................................... 866 Connectors and Terminals.................................................... 867 Twisted/Shielded Cable Repair........................................... 867 Twisted Leads Repair.................................................... 868 Micro-Pack.............................................................. 869 Metri-Pack.............................................................. 869 Remove.............................................................. 869 Weather-Pack............................................................ 871 Weather-Pack Terminal Repair........................................ 872 tables.............................................................................. 767 Table 1. TPS Replacement Procedure.............................................. 804 Table 2. FPP Replacement Procedure.............................................. 807 Table 3. TPS Replacement Procedure.............................................. 819 Table 4. FPP Replacement Procedure.............................................. 822 Table 5. LPG Fuel System Diagnosis.............................................. 827 Table 6. Fuel Control Diagnosis................................................. 831 Table 7. Gasoline Fuel System Diagnosis, 3.0L Only.............................. 837 Table 8. Gasoline Fuel System Diagnosis, 4.3L Only.............................. 840 Table 9. Preliminary Checks..................................................... 843 Table 10. Intermittent ......................................................... 844 Table 11. No Start.............................................................. 845 Table 12. Hard Start............................................................ 847 Table 13. Cuts Out or Misses.................................................... 848 Table 14. Hesitation, Sag, or Stumble........................................... 849 Table 15. Backfire.............................................................. 850 Table 16. Lack of Power, Sluggishness, or Sponginess............................ 851 Table 17. Poor Fuel Economy..................................................... 852 Table 18. Rough, Unstable, Incorrect Idle, or Stalling.......................... 853 Table 19. Surges or Chuggles.................................................... 855 Table 20. Preliminary Checks.................................................... 856 Table 21. Intermittent.......................................................... 857 Table 22. No Start.............................................................. 858 Table 23. Hard Start............................................................ 859 Table 24. Cuts Out or Misses.................................................... 860 Table 25. Hesitation, Sag, or Stumble........................................... 861 Table 26. Backfire.............................................................. 862 Table 27. Lack of Power, Sluggishness, or Sponginess............................ 863 Table 28. Poor Fuel Economy..................................................... 864 Table 29. Rough, Unstable, Incorrect Idle, or Stalling.......................... 865 Table 30. Surges or Chuggles.................................................... 866 mastil.................................................................................. 877 toc................................................................................. 877 Masts........................................................................... 877 Safety Precautions Maintenance and Repair....................................... 878 General......................................................................... 881 Description and Operation....................................................... 881 General..................................................................... 881 Safety Procedures When Working Near Mast.................................... 882 Two-Stage Mast.............................................................. 882 Three-Stage Mast............................................................ 884 Carriage Repair................................................................. 886 Remove...................................................................... 886 Sideshift Carriage, Disassemble............................................. 886 Sideshift Carriage, Assemble................................................ 887 Install..................................................................... 887 Two-Stage Mast Repair........................................................... 889 Remove...................................................................... 889 Disassemble................................................................. 890 Clean and Inspect........................................................... 891 Assemble.................................................................... 892 Install..................................................................... 892 Three-Stage Mast Repair......................................................... 894 Remove...................................................................... 894 Disassemble................................................................. 894 Clean and Inspect........................................................... 894 Assemble.................................................................... 894 Install..................................................................... 896 Mast Operation Check............................................................ 896 Lift and Tilt System Leaks Check................................................ 897 Lift System................................................................. 897 Tilt System................................................................. 897 Tilt Cylinder Stroke and Backward Tilt Angle Adjustment......................... 898 Lift Chain Adjustments.......................................................... 898 Mast Adjustments................................................................ 901 Carriage Adjustment............................................................. 901 Troubleshooting................................................................. 903 tables.............................................................................. 877 Table 1. Mast Parts Weight...................................................... 890 Table 2. Hook-Type Carriage Chain Adjustment.................................... 899 Table 3. Pin-Type Carriage Chain Adjustment..................................... 899 metrica-pulgada......................................................................... 907 toc................................................................................. 907 Metric and Inch (SAE) Fasteners................................................. 907 Safety Precautions Maintenance and Repair....................................... 908 General......................................................................... 911 Threaded Fasteners.......................................................... 911 Nomenclature, Threads....................................................... 911 Strength Identification..................................................... 912 Cotter (Split) Pins......................................................... 912 Fastener Torque Tables...................................................... 917 Conversion Table............................................................ 919 tables.............................................................................. 907 Table 1. Bolts and Screws....................................................... 913 Table 2. Studs and Nuts......................................................... 914 Table 3. Torque Nuts............................................................ 915 Table 4. Torque Nuts With Nylon Insert.......................................... 916 Table 5. Torque Values for Metric Fasteners*.................................... 917 Table 6. Torque Values for Inch Fasteners*...................................... 918 Table 7. Conversion Table for Metric and English Units.......................... 919 Table 8. Cotter Pin Dimensional Data............................................ 920 Table 9. Cotter Pin Dimensional Data............................................ 921 Table 10. Cotter Pin Dimensional Data........................................... 922 Table 11. Cotter Pin Dimensional Data........................................... 924 motor arranque.......................................................................... 927 General............................................................................. 930 Description and Operation........................................................... 930 Starter Repair...................................................................... 932 Remove.......................................................................... 932 Disassemble..................................................................... 932 Clean........................................................................... 933 Assemble........................................................................ 933 Install......................................................................... 934 General Checks and Adjustments...................................................... 934 Troubleshooting..................................................................... 937 orbitrol direccion...................................................................... 940 toc................................................................................. 940 Steering Control Unit........................................................... 940 Safety Precautions Maintenance and Repair....................................... 941 General......................................................................... 944 Description..................................................................... 944 Operation....................................................................... 944 Steering Wheel and Column Assembly Repair....................................... 946 Steering Column Assembly Repair................................................. 946 Type A Steering Column Assembly............................................. 946 Remove and Disassemble.................................................. 946 Assemble and Install.................................................... 948 Type B Steering Column Assembly............................................. 950 Remove and Disassemble.................................................. 950 Assemble and Install.................................................... 950 Steering Control Unit................................................... 953 Disassemble......................................................... 953 Clean............................................................... 956 Assemble............................................................ 957 System Air Removal.............................................................. 962 Troubleshooting................................................................. 962 periodos mantenimiento.................................................................. 966 toc................................................................................. 966 Periodic Maintenance............................................................ 966 Safety Precautions Maintenance and Repair....................................... 967 General......................................................................... 972 Serial Number Data.......................................................... 972 How to Move Disabled Truck.................................................. 972 How to Tow Lift Truck................................................... 972 How to Put Lift Truck on Blocks............................................. 973 How to Raise Drive Tires................................................ 973 How to Raise Steering Tires............................................. 973 Maintenance Schedule............................................................ 974 Maintenance Procedures Every 8 Hours or Daily................................... 990 How to Make Checks With Engine Stopped...................................... 990 Hydraulic System Oil.................................................... 991 Engine Oil.............................................................. 991 Drive Belts............................................................. 992 Intake Manifold Rubber Cap.............................................. 992 Cooling System.......................................................... 992 Air Filter.............................................................. 993 Fuel System............................................................. 993 Primary Fuel Filter, Diesel Engine...................................... 994 Battery................................................................. 994 Tires and Wheels........................................................ 994 Forks................................................................... 995 Adjust.............................................................. 995 Remove and Install.................................................. 995 Forks, Mast, and Lift Chains, Inspect................................... 998 Operator Restraint System............................................... 999 Safety Labels...........................................................1000 How to Make Checks With Engine Running......................................1000 Gauges, Lights, Horn, and Fuses.........................................1000 Oil Level, Powershift Transmission......................................1002 Oil Level, Oil Clutch System, H3.50-5.00XL (H70-110XL)..................1002 Control Levers and Pedals...............................................1002 Lift System Operation...................................................1002 Inching/Brake Pedal.....................................................1003 Service Brakes..........................................................1003 Parking Brake...........................................................1003 Steering System.........................................................1003 Maintenance Procedures Every 250 Hours or 6 Weeks...............................1004 Engine Oil and Filter, GM V-6 Engine........................................1004 Lift Chains, Lubrication....................................................1004 Drive Shafts................................................................1004 Mast Lubrication............................................................1005 Crankcase Breather, GM V-6..................................................1005 Air Filter, GM V-6 EPA Compliant Engine ....................................1005 Maintenance Procedures Every 350 Hours or 2 Months..............................1006 Engine Oil and Filter, Perkins 4.2482 Diesel Engine.........................1006 Drive Belts.................................................................1006 Perkins Diesel Engine...................................................1006 GM V-6 Engine (Early Models)............................................1007 GM V-6 Engine (Late Models).............................................1007 Brake Fluid.................................................................1009 Lift Chains Wear Check......................................................1009 Forks Wear and Damage Check.................................................1010 Steering Axle Lubrication...................................................1010 Fuel System, Checks and Adjustments.........................................1010 Diesel Fuel System......................................................1010 LPG Carburetor (Early Models)...........................................1010 Gasoline Carburetor (Early Models)......................................1011 Fuel Injection (Late Models)............................................1011 Crankcase Breather, Perkins 4.2482 Diesel Engine............................1011 Hydraulic Tank Breather.....................................................1011 Cooling System, Clean Debris from Radiator Core.............................1011 Maintenance Procedures Every 500 Hours or 3 Months..............................1012 Engine Oil and Filter, Perkins Diesel Engine................................1012 Crankcase Breather, Perkins Diesel Engine...................................1012 PCV Valve, GM V-6...........................................................1012 Maintenance Procedures Every 1000 Hours or 6 Months.............................1013 Manifold Heat Valve, GM V-6 (Early Models)..................................1013 Ignition System, GM V-6.....................................................1013 Valve Clearance Adjustment..................................................1013 Fuel Filter, Replace (Diesel Engine)........................................1013 Fuel System Air Removal (Perkins 1004-4 Diesel Engine)......................1013 Fuel Injection Pump With Vent Tube......................................1014 Fuel Injection Pump With Vent Screw.....................................1014 Fuel System Air Removal (Perkins 4.2482 Diesel Engine)......................1016 Oil Level Check in Transmission.............................................1016 Manual Transmission, H3.50-5.00XL (H70-110XL)...........................1016 Speed Reducer for Powershift Transmission, H3.50-5.00XL (H70-110........1016 Manual Transmission, H6.00-7.00XL (H135-155XL)..........................1016 Differential and Drive Axle for Powershift Transmission, H6.00-7........1016 Differential, Speed Reducer, and Drive Axle for Manual Transmiss........1017 Control Levers and Pedals, Lubricate........................................1017 Crankcase Breather, Replace.................................................1017 Cooling System, GM V-6 EPA Compliant Engine.................................1017 Spark Plug Replacement......................................................1017 Remove..................................................................1017 Install.................................................................1018 LPG Fuel Filter GM V-6 EPA Compliant Engine, Replace........................1018 Inspect Engine Electrical System, Connectors, and FCVS Connectio............1019 Maintenance Procedures Every 2000 Hours or Yearly...............................1019 Hydraulic System............................................................1019 Hydraulic Oil and Filter, H3.50-5.00XL (H70-110XL), Replace.............1019 Hydraulic Oil and Filter, H6.00-7.00XL (H135-155XL, H135-155XL 2........1020 Oil Change and Oil Filter Replacement, Powershift Transmission, ............1020 Oil Change, Manual Transmission, H3.50-5.00XL (H70-110XL)...................1020 Oil Change, Manual Transmission, H6.00-7.00XL (H135-155XL)..................1020 Oil Change, Speed Reducer, Powershift Transmission, H3.50-5.00XL............1020 Oil and Filter Change, Oil Clutch System, H3.50-5.00XL (H70-110X............1021 Oil Change, Differential and Drive Axle, Powershift Transmission............1021 Oil Change, Differential, Speed Reducer, and Drive Axle, Manual ............1021 Cooling System..............................................................1021 PCV Valve, GM V-6...........................................................1021 Service Brakes..............................................................1022 LPG Filter, Replace.........................................................1022 Gasoline Fuel Filter, Replace...............................................1023 Hood Latch Check, H3.50-5.00XL (H70-110XL)..................................1023 Air Filter Element, GM V-6 EPA Compliant Engine.............................1023 Oxygen Sensor GM V-6 EPA Compliant Engine...................................1023 Inspect Low Pressure Regulator (LPR) for Oil Buildup and Leaks..............1024 Check Throttle Shaft for Sticking...........................................1025 Inspect Exhaust Manifold and Piping for Leaks...............................1025 Test LPG/GAS Regulator Pressure.............................................1025 Safety Procedures When Working Near Mast........................................1025 Lift Chain Adjustments..........................................................1027 Fuel Injectors Repair...........................................................1029 Lift and Tilt System Leak Check.................................................1029 Lift Cylinders, Leak Check..................................................1029 Tilt Cylinders, Leak Check..................................................1030 Welding Repairs.................................................................1030 Overhead Guard Changes..........................................................1031 Wheel and Tire Replacement......................................................1032 Remove Wheels From Lift Truck...............................................1032 Remove Wheels From Tire.....................................................1032 Remove Tire From Two-Piece Wheel........................................1033 Remove Tire From Three- and Four-Piece Wheels...........................1035 Install Wheel in Tire.......................................................1036 Install Three- or Four-Piece Wheel in Tire..............................1037 Install Two-Piece Wheel in Tire.........................................1038 Add Air to Pneumatic Tires..................................................1039 Wheels, Install.............................................................1039 Solid Rubber Tires Repair.......................................................1040 Wheel, Tire Remove..........................................................1040 Wheel, Tire Install.........................................................1042 SIT Tire, Change for H3.50-5.00XL (G005), and H6.00-7.00XL (F006............1043 Remove SIT Solid Tire From Wheel........................................1044 Install SIT Solid Tire on Wheel.........................................1045 Adhesives and Sealants..........................................................1046 Hydraulic Oil, Lubricant, and Coolant Specifications............................1047 tables.............................................................................. 966 Table 1. Maintenance Schedule................................................... 976 Table 2. Hook-Type Carriage Chain Adjustment....................................1028 Table 3. Pin-Type Carriage Chain Adjustment.....................................1028 perkins 1104 manual.....................................................................1050 toc.................................................................................1050 Perkins Diesel Engines..........................................................1050 Safety Precautions Maintenance and Repair.......................................1051 General.........................................................................1058 General Safety Rules........................................................1058 Description.....................................................................1059 Engine Serial Number Codes..................................................1059 Engine Data.................................................................1061 Engine Removal and Installation.................................................1062 Cylinder Head Assembly Repair...................................................1062 Engine Breather.............................................................1062 Remove..................................................................1062 Install.................................................................1062 Valve Cover.................................................................1063 Remove..................................................................1063 Install.................................................................1063 Rocker Arm Assembly.........................................................1065 Remove..................................................................1065 Disassemble.............................................................1065 Inspect.................................................................1065 Assemble................................................................1065 Install.................................................................1066 Valve Clearance Adjustments.................................................1066 Valve Springs...............................................................1067 Cylinder Head Assembly......................................................1068 Remove..................................................................1068 Inspect.................................................................1069 Install.................................................................1070 Valves and Valve Springs....................................................1071 Remove..................................................................1071 Inspect.................................................................1072 Install.................................................................1072 Valve Guides................................................................1073 Inspect.................................................................1073 Remove..................................................................1073 Install.................................................................1073 Valve Seats.................................................................1075 Inspect.................................................................1075 Repair..................................................................1075 New Valve Seats, Install................................................1076 Piston and Connecting Rod Assemblies Repair.....................................1076 General.....................................................................1076 Rod Bearings................................................................1077 Remove..................................................................1077 Install.................................................................1077 Piston and Connecting Rod Assembly..........................................1078 Service Note............................................................1078 Remove..................................................................1078 Disassemble.............................................................1079 Inspect.................................................................1079 How to Select Correct Replacements......................................1080 Assemble................................................................1081 Install.................................................................1082 Piston Cooling Jets.........................................................1083 Remove..................................................................1083 Install.................................................................1084 Crankshaft Assembly Repair......................................................1084 General.....................................................................1084 Crankshaft Pulley...........................................................1084 Remove..................................................................1084 Inspect.................................................................1084 Install.................................................................1085 Rear Oil Seal...............................................................1085 Remove..................................................................1085 Install.................................................................1085 Crankshaft Flange Wear Sleeve...............................................1087 Remove..................................................................1087 Install.................................................................1087 Main Bearings...............................................................1088 Remove..................................................................1088 Inspect.................................................................1088 Install.................................................................1089 Thrust Washers..............................................................1090 Crankshaft Axle Movement, Check.........................................1090 Remove..................................................................1090 Install.................................................................1091 Crankshaft..................................................................1091 Remove..................................................................1091 Inspect.................................................................1092 Install.................................................................1092 Crankshaft Timing Ring......................................................1094 Remove..................................................................1094 Install.................................................................1094 Flywheel....................................................................1094 Remove..................................................................1094 Ring Gear, Replace......................................................1095 Install.................................................................1095 Flywheel Housing............................................................1095 Remove..................................................................1095 Install.................................................................1096 Timing Case and Timing Gears Repair.............................................1096 General.....................................................................1096 Timing Case Cover...........................................................1096 Remove..................................................................1096 Install.................................................................1097 Front Oil Seal..............................................................1098 Remove, With Timing Case Installed......................................1098 Install, With Timing Case Installed.....................................1098 Remove, With Timing Case Removed........................................1099 Install, With Timing Case Removed.......................................1099 Crankshaft Pulley Wear Sleeve, Install......................................1100 Fuel Pump Gear..............................................................1100 Remove..................................................................1100 Install.................................................................1102 Idler Gear and Hub..........................................................1103 Remove..................................................................1103 Disassemble.............................................................1104 Standard Idler Gear and Hub Assembly................................1104 Heavy Duty Idler Gear and Hub Assembly..............................1104 Assemble................................................................1104 Standard Idler Gear and Hub Assembly................................1104 Heavy Duty Idler Gear and Hub Assembly..............................1105 Install.................................................................1105 Camshaft Gear...............................................................1106 Remove..................................................................1106 Install.................................................................1106 Crankshaft Gear.............................................................1107 Remove..................................................................1107 Install.................................................................1107 Timing Case.................................................................1107 Remove..................................................................1107 Install.................................................................1108 Power Take-Off (PTO) Adaptor................................................1109 Remove..................................................................1109 Disassemble.............................................................1110 Assemble................................................................1110 Install.................................................................1110 Camshaft and Tappets........................................................1110 Remove..................................................................1110 Install.................................................................1111 Cylinder Block Assembly Repair..................................................1111 General.....................................................................1111 Cylinder Block..............................................................1112 Disassemble.............................................................1112 Inspect.................................................................1112 Assemble................................................................1112 Cylinder Bore...............................................................1113 Inspect.................................................................1113 Cylinder Liner Condition Check..........................................1113 Engine Timing...................................................................1113 General.....................................................................1113 How to Set Number One Piston to TDC on Compression Stroke...................1113 Fuel Injection Pump Timing, Check...........................................1115 Fuel Injection Pump Timing, Adjust..........................................1116 Lubrication System Repair.......................................................1117 General.....................................................................1117 Oil Filter, Replace.........................................................1117 Oil Filter Head.............................................................1118 Remove..................................................................1118 Install.................................................................1118 Oil Sump....................................................................1119 Remove..................................................................1119 Install.................................................................1119 Oil Pump....................................................................1120 Remove..................................................................1120 Inspect.................................................................1120 Install.................................................................1121 Oil Strainer and Suction Pipe...............................................1122 Remove..................................................................1122 Install.................................................................1122 Relief Valve................................................................1122 Remove..................................................................1122 Install.................................................................1122 Dipstick Tube...............................................................1123 Remove and Install......................................................1123 Fuel System Repair..............................................................1123 General.....................................................................1123 Cold Start Advance Unit (KSB)...............................................1124 Typical Fuel System.........................................................1125 Fuel Filter.................................................................1126 Remove..................................................................1126 Install.................................................................1126 Fuel Injectors..............................................................1127 Remove..................................................................1127 Install.................................................................1128 Fuel System Air Removal.....................................................1129 Bosch EVPE Fuel Injection Pump..............................................1129 General.................................................................1129 Remove..................................................................1130 Install.................................................................1131 Cooling System Repair...........................................................1131 General.....................................................................1131 Thermostat..................................................................1133 Remove..................................................................1133 Install.................................................................1133 Test....................................................................1134 Coolant Pump................................................................1134 Remove..................................................................1134 Disassemble.............................................................1135 Assemble................................................................1136 Install.................................................................1137 Fan.........................................................................1137 Remove and Install......................................................1137 Fan Drive...................................................................1138 Remove..................................................................1138 Install.................................................................1138 Oil Cooler..................................................................1138 Remove..................................................................1138 Disassemble and Assemble................................................1138 Install.................................................................1139 Coolant By-Pass Hose........................................................1139 Removal.................................................................1139 Install.................................................................1139 Electrical Equipment Repair.....................................................1139 Drive Belt..................................................................1139 Check...................................................................1139 Adjust..................................................................1140 Remove..................................................................1140 Install.................................................................1140 Alternator..................................................................1140 Remove..................................................................1140 Install.................................................................1140 Fault Diagnosis.........................................................1141 Normal Operation:...................................................1141 If the warning lamp is not illuminated when the ignition switch ....1141 If the Warning Light Continues to be Illuminated When the Altern....1142 Starter Motor...............................................................1142 Remove..................................................................1142 Install.................................................................1143 Test....................................................................1143 Starting Aid................................................................1143 Remove..................................................................1143 Install.................................................................1143 Check...................................................................1144 Power Supply Continuity.............................................1144 Operation...........................................................1144 Pressure Sensor.............................................................1145 Remove..................................................................1145 Install.................................................................1146 Temperature Sensor..........................................................1146 Remove..................................................................1146 Install.................................................................1146 Engine Specifications...........................................................1147 Cylinder Head Assembly......................................................1147 Piston and Connecting Rods..................................................1150 Crankshaft Assembly.........................................................1151 Crankshaft Overhaul.....................................................1151 Timing Case and Drive Assembly..............................................1153 Engine Block Assembly.......................................................1154 Lubrication System..........................................................1155 Fuel System.................................................................1155 Cooling System..............................................................1156 Flywheel and Housing........................................................1157 Electrical Equipment........................................................1157 Torque Specifications...........................................................1157 Special Torque Specifications...................................................1158 Cylinder Head Assembly......................................................1158 Piston and Connecting Rod Assemblies........................................1158 Crankshaft Assembly.........................................................1158 Timing Case and Drive Assembly..............................................1158 Cylinder block..............................................................1158 Fuel System.................................................................1158 Lubrication System..........................................................1158 Cooling System..............................................................1159 Flywheel and Housing........................................................1159 Electrical Equipment........................................................1159 Special Tools...................................................................1160 Troubleshooting.................................................................1163 tables..............................................................................1050 Table 1. Cylinder Head..........................................................1147 Table 2. Valve Guides...........................................................1147 Table 3. Inlet Valves...........................................................1148 Table 4. Exhaust Valves.........................................................1148 Table 5. Valve Springs..........................................................1149 Table 6. Tappets................................................................1149 Table 7. Rocker Arm Shaft.......................................................1149 Table 8. Rocker Arms and Bushings...............................................1150 Table 9. Pistons................................................................1150 Table 10. Piston Rings..........................................................1150 Table 11. Piston Pins...........................................................1150 Table 12. Connecting Rods.......................................................1150 Table 13. Small End Bushings....................................................1151 Table 14. Connecting Rod Bearings...............................................1151 Table 15. Piston Cooling Jets...................................................1151 Table 16. Crankshaft Overhaul Specifications....................................1152 Table 17. Maximum Variation (Run-out)...........................................1153 Table 18. Camshaft..............................................................1153 Table 19. Camshaft Thrust Washer................................................1153 Table 20. Camshaft Gear.........................................................1153 Table 21. Gear for Fuel Pump....................................................1153 Table 22. Crankshaft Gear.......................................................1153 Table 23. Idler Gear and Hub....................................................1154 Table 24. Timing Gear Backlash Values...........................................1154 Table 25. Cylinder Block........................................................1154 Table 26. Oil Pump..............................................................1155 Table 27. Idler Gear for Oil Pump...............................................1155 Table 28. Relief Valve..........................................................1155 Table 29. Oil Filter............................................................1155 Table 30. Bosch Fuel Injection Pump.............................................1155 Table 31. Fuel Injector Settings................................................1156 Table 32. Fuel Pump.............................................................1156 Table 33. Fuel Filter...........................................................1156 Table 34. Coolant Pump..........................................................1156 Table 35. Thermostat............................................................1156 Table 36. Fan Drive Housing.....................................................1157 Table 37. Limits for Flywheel Run Out and Alignment (Total Indic................1157 Table 38. Alternator............................................................1157 Table 39. Starter Motor.........................................................1157 Table 40. Starting Aids.........................................................1157 Table 41. List of Possible Causes...............................................1164 sistema frenos..........................................................................1168 toc.................................................................................1168 Brake System....................................................................1168 Safety Precautions Maintenance and Repair.......................................1169 General.........................................................................1172 Description.....................................................................1172 Operation.......................................................................1173 Brake Booster and Master Cylinder...........................................1173 Brake Booster...........................................................1173 Master Cylinder.........................................................1174 Service Brake Assembly......................................................1175 Parking Brake...............................................................1176 Brake Shoe Assemblies Repair....................................................1177 Remove and Disassemble......................................................1177 Clean and Inspect...........................................................1178 Cleaning Procedures.....................................................1178 Inspect.................................................................1178 Assemble and Install........................................................1179 Master Cylinder Repair..........................................................1180 Remove......................................................................1180 Disassemble.................................................................1180 Assemble....................................................................1182 Install.....................................................................1182 Brake Booster Repair............................................................1182 Remove......................................................................1182 Disassemble.................................................................1182 Clean and Inspect...........................................................1184 Assemble....................................................................1184 Install.....................................................................1184 Brake System Air Removal........................................................1184 Brake Pedal Adjustment..........................................................1185 Brake Shoes Adjustment..........................................................1186 Parking Brake Adjustment........................................................1186 Parking Brake Switch Adjustment.................................................1186 Brake Booster Relief Valve Check................................................1186 Troubleshooting.................................................................1187 sistema hidraulico......................................................................1192 toc.................................................................................1192 Hydraulic System................................................................1192 Safety Precautions Maintenance and Repair.......................................1193 General.........................................................................1196 Description and Operation.......................................................1196 Hydraulic Pumps.............................................................1198 Main Control Valve..........................................................1198 Control Valve Lever.........................................................1199 Steering Control Unit.......................................................1199 Brake Valve.................................................................1199 Oil Clutch, H6.00-7.00XL (H135-155XL) (F006)................................1200 Troubleshooting.................................................................1200 Lift, Lower, and Tilt Circuit...............................................1201 Steering, Brake, and Oil Clutch System......................................1202 transmision 2 velocidades (2)...........................................................1206 toc.................................................................................1206 Two-Speed Powershift Transmission...............................................1206 Safety Precautions Maintenance and Repair.......................................1207 General.........................................................................1210 Mechanical Description..........................................................1210 Torque Converter............................................................1210 Transmission Pump...........................................................1211 Shaft Assemblies............................................................1211 Input Shaft.................................................................1212 Forward Clutch Shaft........................................................1212 Clutch Assemblies...........................................................1212 Countershaft................................................................1219 Output Shaft................................................................1219 Hydraulic Operation.............................................................1220 Torque Converter............................................................1220 Seal Rings..................................................................1221 Control Valve...................................................................1221 System Pressure Regulator...................................................1224 Clutch Pressure Regulator...................................................1224 Torque Converter Regulator..................................................1225 Inching Spool...............................................................1225 Direction Spool, Direction Control Lever....................................1225 Direction Spool, MONOTROL Pedal.............................................1226 Range Spool.................................................................1226 Drain Spool.................................................................1227 Accumulator.................................................................1227 Modulator Spool.............................................................1227 Operation...................................................................1227 Lubrication Circuit.............................................................1228 MONOTROL Pedal..................................................................1228 Oil Flow Diagrams...............................................................1230 Neutral.....................................................................1230 Forward-Low.................................................................1231 Forward-Low-Inching.........................................................1232 Reverse-Low.................................................................1233 transmision 2 velocidades...............................................................1236 toc.................................................................................1236 Two-Speed Powershift Transmission...............................................1236 Safety Precautions Maintenance and Repair.......................................1237 General.........................................................................1240 Transmission Repair.............................................................1240 Transmission and Torque Converter, Remove...................................1240 Transmission, Disassemble...................................................1242 Reverse-Low Clutch, Disassemble.............................................1245 Reverse-High Clutch, Disassemble............................................1248 Forward-Low Clutch, Disassemble.............................................1251 Forward-High Clutch, Disassemble............................................1254 Clean and Inspect...........................................................1256 Forward Low and High Clutches Assembly..........................................1257 Forward Clutches, Assemble..................................................1259 Reverse-Low Clutch, Assemble................................................1265 Reverse Clutches, Assemble..................................................1267 Transmission, Assemble......................................................1274 Torque Converter, Install...................................................1281 Control Valve Repair............................................................1282 Remove......................................................................1282 Disassemble.................................................................1283 Assemble....................................................................1284 Install.....................................................................1286 MONOTROL Pedal..................................................................1286 Remove and Disassemble......................................................1286 Assemble and Install........................................................1286 Stall Test......................................................................1289 Linkage Adjustments.............................................................1290 Linkage for Inching Pedal H6.00-7.00XL (H135-155XL, H135-155XL 2............1290 Linkage for Inching Pedal S6.00-7.00XL (S135-155XL, S135-155XL 2............1293 Linkage for Range Lever - Early Model H6.00-7.00XL (H135-155XL) ............1296 Linkage for Direction Control Lever - Early Model H6.00-7.00XL (............1296 Linkage for Range Lever - Later Model H6.00-7.00XL (H135-155XL, ............1298 Linkage for Direction Control Lever - Later Model H6.00-7.00XL (............1300 Linkage for Range Lever S6.00-7.00XL (S135-155XL, S135-155XL 2 )............1302 Linkage for Direction Control Lever S6.00-7.00XL (S135-155XL, S1............1302 Oil Pressure Check..............................................................1304 System Pressure Check Port..................................................1304 Torque Converter Check Port.................................................1304 Clutch Pressure Check Port..................................................1304 Inching Pressure............................................................1305 Solenoid Check Ports (MONOTROL Control Only)................................1305 Lubrication Pressure Check Ports............................................1305 Specifications..................................................................1306 Troubleshooting.................................................................1306 Correct System Pressure: 1300 ±124 kPa ( 189 ±18 psi).......................1309 Correct Clutch Pressure: 924 ±69 kPa ( 134 ±10 psi).........................1310 Correct Solenoid Pressure (MONOTROL Only): 965 ±138 kPa ( 140 ±2............1311 Torque Converter Pressure: 834 ±69 kPa ( 121 ±10 psi).......................1311 Lubrication Pressure: 83 ±21 kPa ( 12 ±3 psi)...............................1311 tables..............................................................................1236 Table 1. Stall Speed Specifications.............................................1289
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