Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
Sale!
Hyster K005 (H3.50-5.50XM) Service Manual – PDF DOWNLOAD
Original price was: $89.95.$31.95Current price is: $31.95.
Hyster K005 (H3.50-5.50XM) Service Manual – PDF DOWNLOAD
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
Hyster K005 (H3.50-5.50XM) Service Manual – PDF DOWNLOAD
DESCRIPTION:
Hyster K005 (H3.50-5.50XM) Service Manual – PDF DOWNLOAD
SAFETY PRECAUTIONS MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly
fastened, and that the load being lifted is balanced. Make sure the crane, cables, and
chains have the capacity to support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair
on electric lift trucks. Disconnect the battery ground cable on internal combustion lift
trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT
THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance
section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts
must meet or exceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before
using force to remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit whenmaking repairs,
or if the unit needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel
are flammable. Be sure to follow the necessary safety precautions when handling these
fuels and when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks
away from the area. Make sure the area is well ventilated.
TABLE OF CONTENTS:
Hyster K005 (H3.50-5.50XM) Service Manual – PDF DOWNLOAD
0100SRM0726-1467898(06-2004)-UK-EN...................................................... 1 toc................................................................................. 1 Frame........................................................................... 1 Safety Precautions Maintenance and Repair....................................... 2 General......................................................................... 5 Description..................................................................... 5 Counterweight Repair............................................................ 5 Remove...................................................................... 5 Install..................................................................... 6 Hood Repair..................................................................... 6 Remove...................................................................... 6 Install..................................................................... 6 Overhead Guard Repair........................................................... 8 Remove...................................................................... 8 Inspect..................................................................... 8 Install..................................................................... 8 LED Backup and Brake Lights, Replace........................................ 8 Remove.................................................................. 8 Install................................................................. 8 Operator Restraint System Repair................................................ 9 Radiator Repair................................................................. 10 Remove...................................................................... 10 Install..................................................................... 10 Exhaust System Repair........................................................... 12 Muffler..................................................................... 12 Remove.................................................................. 12 Install................................................................. 12 LPG/Gas Engine Exhaust Pipe - Lift Trucks Without Low Emissions............. 12 Remove.................................................................. 12 Install................................................................. 15 EPA Compliant LPG/Gas Engine Exhaust System................................. 15 Remove.................................................................. 15 Install................................................................. 17 Diesel Engine Exhaust Pipe.................................................. 17 Remove.................................................................. 17 Install................................................................. 19 Engine Repair................................................................... 19 Remove...................................................................... 19 Install..................................................................... 21 Throttle Pedal Adjustment....................................................... 23 Perkins 1104C-44(RE) Diesel Engine.......................................... 23 Lift Trucks With an Accelerator Pedal................................... 23 Lift Trucks With a MONOTROL Pedal....................................... 24 Fuel and Hydraulic Tanks Repair................................................. 26 Inspect..................................................................... 26 Small Leaks, Repair......................................................... 26 Large Leaks, Repair......................................................... 26 Clean....................................................................... 26 Steam Method............................................................ 26 Chemical Solution Method................................................ 27 Other Preparation Methods for Repair........................................ 27 Safety Labels................................................................... 27 tables.............................................................................. 1 Table 1. Weight of Counterweights............................................... 5 0100SRM0778-1471864(06-2004)-UK-EN...................................................... 33 toc................................................................................. 33 Operators Cab................................................................... 33 Safety Precautions Maintenance and Repair....................................... 34 General......................................................................... 37 Cab Repair...................................................................... 38 Remove...................................................................... 38 Install..................................................................... 39 Switch Panel.................................................................... 39 Window Wipers Replacement....................................................... 40 Front Wiper Assembly........................................................ 40 Rear Wiper Assembly......................................................... 40 Door Handle Assembly............................................................ 42 Fuse Panel...................................................................... 43 Heater Assembly................................................................. 43 Remove...................................................................... 43 Install..................................................................... 43 Window Replacement.............................................................. 45 Options......................................................................... 47 Rear Strobe Lights.......................................................... 47 Heavy-Duty Air Cleaner...................................................... 47 Label Replacement............................................................... 48 Electrical Schematics........................................................... 48 tables.............................................................................. 33 Table 1. Material Specifications for Cab Windows................................ 45 0600SRM590-897800(11-2003)-EN........................................................... 53 toc................................................................................. 53 GM Engines...................................................................... 53 Safety Precautions Maintenance and Repair....................................... 54 General......................................................................... 57 Description..................................................................... 57 Engine Removal and Installation................................................. 58 Cylinder Head Repair............................................................ 58 Remove and Disassemble...................................................... 58 Clean and Inspect........................................................... 58 Valve Guides and Seats, Repairs............................................. 59 Valves, Repair.............................................................. 59 Valve Seats, Repair......................................................... 60 Valve Springs............................................................... 61 Rocker Arm Studs (Early Models)............................................. 61 Rocker Arm Studs (Late Models).............................................. 62 Assemble and Install........................................................ 62 Cylinder Block Cleaning and Inspection.......................................... 66 Piston Bore Preparation......................................................... 66 Engine Mounts Installation...................................................... 66 Lubrication System Repair....................................................... 67 Oil Pump, Remove and Disassemble............................................ 67 Clean and Inspect........................................................... 67 Oil Pump, Assemble and Install.............................................. 67 Oil Sump, Install........................................................... 68 Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters..................... 69 Timing Cover................................................................ 69 Remove.................................................................. 69 Install................................................................. 71 Timing Sprockets............................................................ 71 Remove.................................................................. 71 Install................................................................. 71 Camshaft.................................................................... 72 Remove.................................................................. 72 Inspect................................................................. 72 Install................................................................. 72 Balance Shaft............................................................... 73 Remove.................................................................. 73 Install................................................................. 74 Hydraulic Valve Lifters..................................................... 74 Remove.................................................................. 74 Disassemble............................................................. 75 Clean and Inspect....................................................... 75 Assemble................................................................ 75 Install................................................................. 76 Crankshaft Repair............................................................... 77 Remove...................................................................... 77 Inspect and Repair.......................................................... 77 How to Check Clearance Between Main Bearings and Their Journals............. 78 Install..................................................................... 79 Piston and Connecting Rod Assemblies Repair..................................... 80 Connecting Rod Bearings, Replace............................................ 80 Piston and Connecting Rod Assemblies, Remove................................ 81 Disassemble................................................................. 81 Piston, Clean and Inspect................................................... 82 Cylinder Bores, Inspect and Repair.......................................... 82 Piston Rings................................................................ 83 Assemble.................................................................... 84 Piston and Connecting Rod Assemblies, Install............................... 84 Flywheel and Flywheel Housing Repair............................................ 85 Flywheel, Repair............................................................ 85 Flywheel, Install........................................................... 85 H3.50-5.00XL (H70-110XL), S3.50-5.50XL (S70-120XL), S6.00-7.00XL........ 85 H6.00-7.00XL (H135-155XL)............................................... 85 Flywheel Housing H3.50-5.00XL (H70-110XL), H3.50-5.50XM (H70-120............ 85 Engine Adapter H6.00-7.00XL (H135-155XL).................................... 85 Coolant Pump Repair............................................................. 86 Thermostat Replacement.......................................................... 86 Fan Mount Repair (Early Models)................................................. 86 Fan Mount Assembly Repair (Late Models)......................................... 86 Drive Belt Installation......................................................... 88 Valve Clearance Adjustment (Early Models)....................................... 89 Valve Clearance Adjustment (New Models)......................................... 90 Compression Check............................................................... 90 Engine Specifications........................................................... 90 Engine Data................................................................. 90 Cylinder Head............................................................... 91 Hydraulic Valve Lifter...................................................... 91 Camshaft.................................................................... 91 Pistons..................................................................... 91 Crankshaft.................................................................. 92 Connecting Rods............................................................. 93 Balance Shaft............................................................... 93 Cooling System.............................................................. 93 Lubrication System.......................................................... 93 Torque Specifications........................................................... 94 Troubleshooting................................................................. 95 tables.............................................................................. 53 Table 1. Piston Rings Arrangement on Piston..................................... 84 0600SRM705-1455747(09-2003)-EN.......................................................... 101 toc................................................................................. 101 Perkins Diesel Engines.......................................................... 101 Safety Precautions Maintenance and Repair....................................... 102 General......................................................................... 109 General Safety Rules........................................................ 109 Description..................................................................... 110 Engine Serial Number Codes.................................................. 113 Engine Data................................................................. 113 Engine Removal and Installation................................................. 115 Lift Engine................................................................. 115 Cylinder Head Assembly Repair................................................... 115 Valve Cover................................................................. 115 Remove.................................................................. 115 Install................................................................. 116 Rocker Arm Assembly......................................................... 116 Remove.................................................................. 116 Install................................................................. 116 Disassemble............................................................. 116 Inspect................................................................. 116 Assemble................................................................ 117 Valve Clearance Adjustments................................................. 117 Four-Cylinder Engines................................................... 118 Six-Cylinder Engines.................................................... 118 Valve Springs............................................................... 118 Cylinder Head Assembly...................................................... 120 Remove.................................................................. 120 Install................................................................. 122 Valves and Valve Springs.................................................... 126 Remove.................................................................. 126 Inspect................................................................. 126 Install................................................................. 127 Valve Guides................................................................ 127 Inspect................................................................. 127 Remove.................................................................. 128 Install................................................................. 128 Cylinder Head and Valve Seats............................................... 128 Inspect................................................................. 128 Repair.................................................................. 128 New Valve Seats, Install................................................ 128 Piston and Connecting Rod Assemblies Repair..................................... 130 Rod Bearings................................................................ 130 Remove.................................................................. 131 Install................................................................. 131 Piston and Connecting Rod Assembly.......................................... 132 Service Note............................................................ 132 Remove.................................................................. 132 Install................................................................. 133 Piston Rings................................................................ 134 Remove.................................................................. 134 Inspect................................................................. 134 Install................................................................. 134 Piston and Connecting Rod................................................... 135 Disassemble............................................................. 135 Inspect................................................................. 136 How to Select Correct Replacements...................................... 136 Install................................................................. 137 Piston Cooling Jets......................................................... 137 Remove.................................................................. 137 Install................................................................. 138 Crankshaft Assembly Repair...................................................... 138 General..................................................................... 138 Crankshaft Pulley........................................................... 139 Engine AR, Remove....................................................... 139 Engines YG and YH, Remove............................................... 139 Inspect................................................................. 140 Engine AR, Install...................................................... 140 Engines YG and YH, Install.............................................. 140 Rear Oil Seal............................................................... 141 Replace................................................................. 141 Main Bearings............................................................... 142 Remove.................................................................. 142 Inspect................................................................. 143 Install................................................................. 143 Thrust Washers.............................................................. 143 Crankshaft Axial Movement, Check........................................ 143 Remove.................................................................. 144 Install................................................................. 144 Crankshaft.................................................................. 145 Remove.................................................................. 145 Inspect................................................................. 145 Install................................................................. 145 Flywheel.................................................................... 147 Remove.................................................................. 147 Ring Gear, Replace...................................................... 147 Install................................................................. 147 Flywheel Housing............................................................ 148 Remove.................................................................. 148 Install................................................................. 148 Timing Case and Timing Gears Repair............................................. 149 General..................................................................... 149 Timing Case Cover........................................................... 149 Remove.................................................................. 149 Install................................................................. 150 Front Oil Seal.............................................................. 150 Remove.................................................................. 150 Install................................................................. 150 Crankshaft Pulley Wear Sleeve............................................... 151 Install................................................................. 151 Idler Gear and Hub.......................................................... 151 Remove.................................................................. 151 Install................................................................. 152 Air Compressor Drive, Bendix................................................ 153 Disassemble............................................................. 153 Assemble................................................................ 154 Fuel Injection Pump Gear.................................................... 154 Remove.................................................................. 155 Install................................................................. 155 Camshaft Gear............................................................... 156 Remove.................................................................. 156 Install................................................................. 156 Crankshaft Gear............................................................. 157 Remove.................................................................. 157 Install................................................................. 157 Timing Case................................................................. 157 Remove.................................................................. 157 Install................................................................. 158 Camshaft and Tappets........................................................ 159 Remove.................................................................. 159 Install................................................................. 159 Cylinder Block Assembly Repair.................................................. 160 Description................................................................. 160 Cylinder Block.............................................................. 160 Disassemble............................................................. 160 Inspect................................................................. 161 Assemble................................................................ 161 Cylinder Bore (Four-Cylinder Engines)....................................... 162 Cylinder Liner (Six-Cylinder Engines)....................................... 162 Inspect................................................................. 162 Cylinder Liner Condition, Check......................................... 162 Remove.................................................................. 163 Service Liner, Install.................................................. 164 Partially Finished Liner, Install....................................... 165 Engine Timing................................................................... 166 Description................................................................. 166 How to Set Number One Piston to TDC on Compression Stroke............... 167 How to Set Number One Piston to TDC on Compression Stroke (Alter........ 168 Valve Timing, Check..................................................... 168 Fuel Injection Pump Timing, Check....................................... 169 Turbocharger - Engine YH Repair................................................. 170 General..................................................................... 170 Remove.................................................................. 170 Install................................................................. 170 Impeller and Compressor Housing, Clean.................................. 171 Lubrication System Repair....................................................... 172 General..................................................................... 172 Oil Filter, Replace......................................................... 172 Filter Head................................................................. 173 Remove and Install...................................................... 173 Oil Sump.................................................................... 173 Remove.................................................................. 173 Install................................................................. 174 Oil Pump.................................................................... 174 Remove.................................................................. 174 Inspect................................................................. 174 Install................................................................. 175 Relief Valve................................................................ 175 Remove.................................................................. 175 Disassemble............................................................. 176 Inspect................................................................. 176 Assemble................................................................ 176 Install................................................................. 176 Idler Gear Shaft, Replace................................................... 177 Remove.................................................................. 177 Remove (Alternative).................................................... 177 Install................................................................. 178 Install (Alternative)................................................... 178 Install (Alternative for Four-Cylinder Engines Only).................... 179 Fuel System Repair.............................................................. 179 Description................................................................. 179 Fuel Injection Pump......................................................... 180 Remove.................................................................. 180 Install................................................................. 181 Check and Adjust........................................................ 182 Fuel System, Remove Air..................................................... 182 Fuel Filter, Replace........................................................ 183 Canister Type........................................................... 184 Quick Release Canister Type............................................. 184 Fuel Injectors.............................................................. 185 Remove.................................................................. 185 Inspect................................................................. 186 Install................................................................. 186 Fuel Pump................................................................... 187 Remove.................................................................. 187 Disassemble............................................................. 187 Assemble................................................................ 187 Install................................................................. 188 Test.................................................................... 188 Cooling System Repair........................................................... 189 General..................................................................... 189 Thermostat.................................................................. 189 Remove.................................................................. 189 Install................................................................. 189 Test.................................................................... 190 Coolant Pump................................................................ 190 Remove.................................................................. 190 Disassemble............................................................. 190 Assemble................................................................ 192 Install................................................................. 194 Fan and Fan Drive........................................................... 195 Remove.................................................................. 195 Install................................................................. 195 Oil Cooler (Six-Cylinder Engines)........................................... 196 Remove.................................................................. 196 Disassemble and Assemble................................................ 196 Install................................................................. 196 Oil Cooler By-Pass Valve................................................ 196 Electrical Equipment Repair..................................................... 197 Drive Belts................................................................. 197 Alternator.................................................................. 198 Remove.................................................................. 198 Install................................................................. 198 Starter Motor............................................................... 198 Remove.................................................................. 198 Install................................................................. 198 Cold Start Aid.............................................................. 198 Air Compressor - Engines YG and YH.............................................. 198 General..................................................................... 198 Repair...................................................................... 199 Remove.................................................................. 199 Install................................................................. 199 Rotary Exhauster Replacement.................................................... 200 Remove...................................................................... 200 Clean....................................................................... 200 Install..................................................................... 200 Engine Specifications........................................................... 201 Cylinder Head Assembly...................................................... 201 Piston and Connecting Rods.................................................. 204 Crankshaft Assembly......................................................... 207 Crankshaft Overhaul..................................................... 208 Timing Case and Drive Assembly.............................................. 210 Engine Block Assembly....................................................... 211 Turbocharger................................................................ 214 Lubrication System.......................................................... 214 Fuel System................................................................. 216 Cooling System.............................................................. 218 Flywheel and Housing........................................................ 218 Electrical Equipment........................................................ 219 Torque Specifications........................................................... 220 Cylinder Head Assembly...................................................... 220 Piston and Connecting Rod Assemblies........................................ 220 Crankshaft Assembly......................................................... 220 Timing Case and Drive Assembly.............................................. 220 Turbocharger................................................................ 220 Lubrication System.......................................................... 220 Fuel System................................................................. 220 Cooling System.............................................................. 221 Flywheel.................................................................... 221 Auxiliary Equipment......................................................... 221 Special Torque Specifications................................................... 222 Flywheel and Housing........................................................ 222 Turbocharger................................................................ 222 Electrical Equipment........................................................ 222 Auxiliary Equipment......................................................... 222 Special Tools................................................................... 223 Troubleshooting................................................................. 227 tables.............................................................................. 101 Table 1. Cylinder Head.......................................................... 201 Table 2. Valve Guides........................................................... 201 Table 3. Inlet Valves........................................................... 202 Table 4. Exhaust Valves......................................................... 203 Table 5. Valve Springs.......................................................... 204 Table 6. Tappets................................................................ 204 Table 7. Rocker Arm Shaft....................................................... 204 Table 8. Rocker Arms and Bushings............................................... 204 Table 9. Pistons (Engine AR).................................................... 204 Table 10. Pistons (Engines YG and YH)........................................... 205 Table 11. Piston Rings (Engine AR).............................................. 205 Table 12. Piston Rings (Engines YG and YH)...................................... 206 Table 13. Piston Pins........................................................... 206 Table 14. Connecting Rods....................................................... 206 Table 15. Small End Bushings.................................................... 206 Table 16. Connecting Rod Bearings (Engines AR and YG)........................... 207 Table 17. Connecting Rod Bearings (Engine YH)................................... 207 Table 18. Piston Cooling Jets................................................... 207 Table 19. Crankshaft............................................................ 207 Table 20. Main Bearings......................................................... 208 Table 21. Crankshaft Thrust Washers............................................. 208 Table 22. Crankshaft Heat Treatment............................................. 208 Table 23. Crankshaft Overhaul Specifications.................................... 209 Table 24. Maximum Variation (Run-out)........................................... 210 Table 25. Camshaft.............................................................. 210 Table 26. Camshaft Thrust Washer................................................ 210 Table 27. Camshaft Gear......................................................... 211 Table 28. Gear for Fuel Injection Pump.......................................... 211 Table 29. Crankshaft Gear....................................................... 211 Table 30. Idler Gear and Hub.................................................... 211 Table 31. Cylinder Block (Engine AR)............................................ 212 Table 32. Cylinder Bore Specifications.......................................... 212 Table 33. Cylinder Block (Engines YG and YH).................................... 213 Table 34. Cylinder Liners (Engines YG and YH)................................... 213 Table 35. Cylinder Liner Specifications (Partially Finished).................... 214 Table 36. Oil Pump (Engine AR).................................................. 214 Table 37. Oil Pump (Engines YG and YH).......................................... 215 Table 38. Idler Gear for Oil Pump............................................... 215 Table 39. Relief Valve.......................................................... 215 Table 40. Oil Filter............................................................ 215 Table 41. Lucas Fuel Injection Pump............................................. 216 Table 42. Fuel Pump (Engine AR)................................................. 216 Table 43. Fuel Pump (Engines YG and YH)......................................... 216 Table 44. Fuel Filter........................................................... 216 Table 45. Fuel Injector Codes................................................... 217 Table 46. Coolant Pump.......................................................... 218 Table 47. Thermostat............................................................ 218 Table 48. Fan Drive Housing..................................................... 218 Table 49. Limits for Flywheel Run Out and Alignment (Total Indic................ 218 Table 50. Alternator............................................................ 219 Table 51. Starter Motor......................................................... 219 Table 52. Cold Start Aid........................................................ 219 Table 53. List of Possible Causes............................................... 228 0700SRM740-1466271(02-2004)-EN.......................................................... 233 toc................................................................................. 233 Cooling System.................................................................. 233 Safety Precautions Maintenance and Repair....................................... 234 General......................................................................... 237 Description..................................................................... 237 Radiator.................................................................... 237 Radiator Cap................................................................ 237 Thermostat.................................................................. 237 Water Pump.................................................................. 238 Fan and Fan Shroud.......................................................... 238 Drive Shaft................................................................. 238 Cooling System Checks........................................................... 238 Exhaust Leaks into Cooling System........................................... 238 Radiator Repair................................................................. 238 Checks...................................................................... 238 Clean....................................................................... 238 Cooling System.............................................................. 240 Drain................................................................... 240 Fill.................................................................... 240 Water Pump Repair............................................................... 240 Checks...................................................................... 240 Thermostat Repair............................................................... 241 Checks...................................................................... 241 Fan Assembly Repair............................................................. 241 Remove...................................................................... 241 Inspect..................................................................... 241 Install..................................................................... 241 Fan Belt Repair................................................................. 244 Remove...................................................................... 244 Install..................................................................... 244 Drive Shaft Repair.............................................................. 244 Remove...................................................................... 244 Install..................................................................... 244 Troubleshooting................................................................. 244 0900SRM745-1466265(09-2003)-EN.......................................................... 249 toc................................................................................. 249 LPG Fuel System................................................................. 249 Safety Precautions Maintenance and Repair....................................... 250 General......................................................................... 253 Description and Operation....................................................... 253 Fuel Tank................................................................... 253 Fuel Filter and Fuel Valve Unit............................................. 253 LPG Convertor Vaporizer (IMPCO)............................................. 253 LPG Controller (Dana EPIC/Teleflex-GFI)..................................... 257 Filter Section.......................................................... 257 Lock-Off Section........................................................ 257 Converter Section - Primary Regulation (Stage 1)........................ 257 Converter Section - Secondary Regulation (Stage 2)...................... 257 Carburetor.................................................................. 258 Governor.................................................................... 261 Two-Way Valves, Open-Loop System............................................ 261 Closed-Loop Fuel Control.................................................... 261 O.E. Tune Valve, Closed-Loop Fuel System.................................... 262 Oxygen Sensor, Closed-Loop Fuel System...................................... 262 LPG Tank Repair................................................................. 262 Remove...................................................................... 262 Install..................................................................... 262 Hydrostatic Relief Valve Repair................................................. 263 Remove and Install.......................................................... 263 Filter Unit Repair.............................................................. 264 Fuel Filter Element, Replace................................................ 264 Diaphragm and Fuel Valve, Replace........................................... 264 Hoses Replacement............................................................... 264 LPG Convertor Vaporizer (IMPCO) Repair.......................................... 266 Remove...................................................................... 266 Disassemble................................................................. 266 Clean....................................................................... 266 Inspect..................................................................... 266 Assemble.................................................................... 268 Install..................................................................... 272 LPG Controller (Dana EPIC/Teleflex-GFI) Repairs................................. 272 Remove...................................................................... 272 Disassemble................................................................. 272 Converter Section....................................................... 272 Filter Section.......................................................... 274 Lock-Off Section........................................................ 274 Clean....................................................................... 276 Inspect..................................................................... 276 LPG Controller Assembly..................................................... 276 Filter Section.......................................................... 276 Lock-Off Section........................................................ 276 Converter Section....................................................... 276 Carburetor Repair............................................................... 278 Remove...................................................................... 278 Disassemble................................................................. 278 Clean....................................................................... 278 Assemble.................................................................... 279 Install..................................................................... 279 Governor Assembly Repair........................................................ 280 Governor Motor Repair........................................................... 282 Remove...................................................................... 282 Install..................................................................... 282 Filter Unit Check............................................................... 282 Vaporizer Check................................................................. 283 Pressure Reducer Valve...................................................... 283 Vapor Valve................................................................. 283 Carburetor Adjustment........................................................... 283 Idle Mixture................................................................ 283 Idle Speed.................................................................. 283 Throttle Linkage Adjustment..................................................... 283 LPG Controller Adjustments (Dana EPIC/Teleflex-GFI)............................. 284 Filter and Lock-Off Sections Leak Check..................................... 284 Lock-Off Section Functional Check........................................... 285 Controller Pressure Test.................................................... 285 Adjustment of Secondary Lever............................................... 286 Final Adjustment Check...................................................... 286 Troubleshooting................................................................. 287 1300SRM727-1466259(06-2004)-UK-EN....................................................... 297 toc................................................................................. 297 Two-Speed Powershift Transmission............................................... 297 Safety Precautions Maintenance and Repair....................................... 298 General......................................................................... 301 Mechanical Description.......................................................... 301 Torque Converter............................................................ 302 Transmission Pump........................................................... 302 Shaft Assemblies............................................................ 302 Input (Reverse) Shaft....................................................... 302 Counter (Forward) Clutch Shafts............................................. 302 Clutch Assemblies........................................................... 302 Output Gear and Pinion...................................................... 303 Electronic Control Unit..................................................... 303 Hydraulic Operation............................................................. 304 Torque Converter............................................................ 304 Seal Rings.................................................................. 305 Control Valve................................................................... 305 Clutch Pressure Regulator................................................... 305 Inching Spool Assembly...................................................... 305 Direction Spool............................................................. 307 Modulator Circuit........................................................... 307 Torque Converter Regulator.................................................. 307 MONOTROL® Pedal................................................................. 308 MONOTROL Pedal Start Circuit................................................ 308 Direction Control Lever......................................................... 309 Oil Flow Diagrams............................................................... 309 Neutral..................................................................... 309 Modulator Operation......................................................... 311 Forward-Low................................................................. 314 Forward-Low-Inching......................................................... 314 Reverse..................................................................... 318 1300SRM728-1466253(06-2004)-UK-EN....................................................... 325 toc................................................................................. 325 Two-Speed Powershift Transmission............................................... 325 Safety Precautions Maintenance and Repair....................................... 326 General......................................................................... 329 Transmission Repair............................................................. 329 Remove...................................................................... 329 Install..................................................................... 329 Clutch Packs Repair............................................................. 332 Remove and Disassemble...................................................... 332 Clutch Assemblies, Disassemble.......................................... 335 Inspect..................................................................... 337 Assemble and Install........................................................ 338 Clutch Assemblies, Assemble and Install................................. 338 Differential Repair............................................................. 346 Remove and Disassemble...................................................... 346 Inspect..................................................................... 347 Original Parts, Assemble and Install........................................ 347 New Parts, Assemble and Install............................................. 347 Adjustments With Original Shim Pack..................................... 348 Adjustments Without Original Shim Pack.................................. 349 Differential and Ring Gear Assembly, Assemble........................... 351 Control Valve Repair............................................................ 356 Remove and Disassemble...................................................... 356 Inspect..................................................................... 358 Assemble and Install........................................................ 358 MONOTROL® Pedal Repair.......................................................... 359 Remove and Disassemble...................................................... 359 Assemble and Install........................................................ 359 Direction Control Lever......................................................... 362 Remove and Disassemble...................................................... 362 Assemble and Install........................................................ 362 Stall Test...................................................................... 363 Inching/Brake Pedal Adjustment.................................................. 364 MONOTROL® Pedal Neutral Start Switch Adjustment................................. 366 MONOTROL® Pedal Neutral Start Switch Test....................................... 367 Test 1...................................................................... 367 Test 2...................................................................... 367 Electronic Control Unit Check................................................... 368 Oil Pressure Check.............................................................. 369 Transmission Pump Relief Valve, Test Port 1, Check.......................... 370 Input (Reverse) Clutch Pressure, Test Port 2, Check......................... 370 Counter (Forward) Clutch Pressure, Test Ports 3 and 4, Check................ 370 Torque Converter Regulator, Test Port 5, Check.............................. 370 Lubrication Circuit Oil Pressure, Test Port 6, Check........................ 370 Modulator Pressure, Test Port 7, Check...................................... 370 2-Speed Transmission Will Not Shift............................................. 371 Troubleshooting................................................................. 372 Troubleshooting - Pressure Tests................................................ 375 tables.............................................................................. 325 Table 1. Pinion Variation Numbers Examples...................................... 348 Table 2. Ring and Pinion Tooth Contact Adjustment............................... 354 Table 3. Stall Speeds (New Engines)............................................. 363 Table 4. Electronic Control Unit Connector...................................... 368 Table 5. Transmission Pressure Port Check....................................... 369 1300SRM800-1480352(03-2004)-EN.......................................................... 379 toc................................................................................. 379 Hydrostatic Transmission........................................................ 379 Safety Precautions Maintenance and Repair....................................... 380 General......................................................................... 383 Component Descriptions.......................................................... 383 Power Unit General Arrangement.............................................. 383 Hydrostatic Pump Mounting................................................... 384 Perkins 1004-42 and 1104C-44(RE) Diesel Engines......................... 384 GM 4.3L LPG Engine...................................................... 384 Hydrostatic Control Components.............................................. 384 Hydrostatic System Operation.................................................... 387 Hydrostatic Pump............................................................ 388 Drive Axle.................................................................. 388 Transmission Control Module (TCM)........................................... 390 Perkins 1004-42 Diesel Engine Trucks.................................... 390 Perkins 1104C-44(RE) Diesel and GM 4.3L LPG Engine Trucks............... 390 Transmission Control Inputs............................................. 393 Key Switch.......................................................... 393 Forward/Reverse Switches, Perkins 1004-42 Diesel Engine Trucks...... 393 Forward/Reverse Switches, Perkins 1104C-44(RE) Diesel and GM 4.3.... 393 Parking Brake Switches.............................................. 393 Engine Speed Sensor................................................. 393 Wheel Speed Sensors, Perkins 1104C-44(RE) Diesel and GM 4.3L LPG.... 396 Brake Pressure Sensor............................................... 396 Charge Pressure Sensor.............................................. 396 Transmission Oil Temperature Sensor................................. 396 Throttle Pedal Switch, Perkins 1004-42 Diesel Engine Trucks......... 396 Throttle Pedal Switch, Perkins 1104C-44(RE) Diesel and GM 4.3L L.... 396 Throttle Pedal Position Sensor, Perkins 1004-42 Diesel Engine Tr.... 396 Throttle Pedal Position Sensor, Perkins 1104C-44(RE) Diesel and .... 398 Transmission Control Outputs............................................ 398 Forward/Reverse Solenoid Enable, Perkins 1004-42 Diesel Engine T.... 398 Forward/Reverse Solenoid Enable, Perkins 1104C-44(RE) Diesel and.... 398 Forward/Reverse Solenoids, Perkins 1104C-44(RE) Diesel and GM 4..... 398 Engine Start Enable................................................. 398 Fuel Cutoff Relay................................................... 400 Retard Valve........................................................ 400 Pilot Solenoid Valve, Perkins 1004-42 Diesel Engine Trucks.......... 400 Pilot Solenoid Valve Enable, Perkins 1104C-44(RE) Diesel and GM .... 400 Transmission Fault Warning Light.................................... 400 Transmission Overspeed Warning Light................................ 400 Oil Temperature Warning Light....................................... 400 Throttle-Up Inputs...................................................... 401 Lift Lever Switch, Perkins 1004-42 Diesel Engine Trucks............. 401 Lift Lever Position Sensor, Perkins 1004-42 Diesel Engine Trucks.... 401 Lift Lever Switch, Perkins 1104C-44(RE) and GM 4.3L LPG Engine T.... 401 Lift Lever Position Sensor, Perkins 1104C-44(RE) and GM 4.3L LPG.... 401 Tilt/Auxiliary Lever Switches, Perkins 1004-42 Diesel Engine Tru.... 401 Tilt/Auxiliary Lever Switches, Perkins 1104C-44(RE) Diesel and G.... 401 Engine Throttle Position Sensor, Perkins 1004-42 Diesel Engine T.... 401 Throttle-Up Outputs, Perkins 1004-42 Diesel Engine Trucks............... 402 Throttle-Up Motor................................................... 402 Throttle Servo Motor - Perkins 1104C-44(RE) Diesel and GM 4.3L L........ 402 Transmission Control Module (TCM) Operation..................................... 403 How the TCM Begins Operation................................................ 403 TCM Operation on a Running Lift Truck....................................... 403 Lift Trucks With Perkins 1004-42 Diesel Engine.......................... 403 Lift Trucks With Perkins 1104C-44(RE) Diesel and GM 4.3L LPG Eng........ 403 Event and Fault Detection................................................... 403 Diagnostic Connector........................................................ 404 Hydrostatic Transmission Features............................................... 404 Travel Control.............................................................. 404 Lift Trucks With The Perkins 1004-42 Diesel Engine...................... 404 Lift Trucks With the Perkins 1104C-44(RE) Diesel and GM 4.3L LPG........ 404 Antistall................................................................... 405 Dynamic Braking............................................................. 405 Brake Inching............................................................... 405 Overspeed Control........................................................... 405 Hydraulic Retard............................................................ 406 Wheel Anti-spin............................................................. 406 Temperature Compensation.................................................... 406 Low Charge Pressure Compensation............................................ 407 Quick-Roll.................................................................. 408 Throttle-Up (Option)........................................................ 408 Perkins 1004-42 Diesel Engine Lift Trucks Only.......................... 408 Hydraulic Circuit............................................................... 408 Loop Circuit................................................................ 408 Charge Circuit.............................................................. 411 Pilot Supply Circuit........................................................ 411 Pilot Control Circuit....................................................... 411 Retard Circuit.............................................................. 412 Cooling Oil Supply Circuit.................................................. 412 Cooling Circuit............................................................. 412 tables.............................................................................. 379 Table 1. Electronic Transmission Control System - Perkins 1004-4................ 386 Table 2. Electronic Transmission Control System - Perkins 1104C-................ 386 1300SRM801-1480353(03-2004)-EN.......................................................... 415 toc................................................................................. 415 Hydrostatic Transmission........................................................ 415 Safety Precautions Maintenance and Repair....................................... 416 General......................................................................... 421 TransLink™ User Interface Software.......................................... 421 Connecting PC to TCM.................................................... 421 Transmission Fluid.......................................................... 422 Startup and Calibration......................................................... 424 Startup Procedure Following Service or Repairs.............................. 424 Throttle System Calibration................................................. 425 Perkins 1004-42 Diesel Engine........................................... 425 Perkins 1104C-44(RE) Diesel Engine and GM 4.3L LPG Engine............... 426 Throttle System Calibration Checks.......................................... 426 Perkins 1104C-44(RE) Diesel Engine and GM 4.3L LPG Engine Lift T........ 426 Hydrostatic Pump Repair......................................................... 427 Remove...................................................................... 427 Install..................................................................... 429 Charge Pump Repair.............................................................. 431 Remove...................................................................... 431 Inspect..................................................................... 431 Install..................................................................... 431 Pump Control Valve Repair....................................................... 433 Remove...................................................................... 433 Inspect..................................................................... 433 Install..................................................................... 433 Replace Pilot Solenoid...................................................... 433 Replace Directional Solenoid Pair........................................... 433 Clean or Replace Pilot Supply Filter Disk................................... 433 Replace Loop Relief Cartridges.............................................. 434 Replace Filter Cartridge.................................................... 434 Replace Filter Head......................................................... 435 Drive Axle Repair............................................................... 435 Remove and Disassemble...................................................... 435 Inspect..................................................................... 438 Assemble and Install........................................................ 438 Wheel Speed Sensors, Replace................................................ 439 Lift Trucks With Perkins 1104C-44(RE) Diesel Engine and GM 4.3L ........ 439 Axle Valve Repair............................................................... 439 Remove...................................................................... 439 Inspect..................................................................... 439 Install..................................................................... 439 Replace Pressure Reducing Valve............................................. 439 Replace Shuttle Valve....................................................... 440 Replace Charge Supply Regulator............................................. 440 Replace Retard Valve........................................................ 440 Replace Temperature Sensor.................................................. 440 Transmission Control Module (TCM) Replacement................................... 441 Throttle Pedal/ MONOTROL® Pedal Repair.......................................... 441 Remove Standard Throttle Pedal.............................................. 441 Install Standard Throttle Pedal............................................. 441 Lift Trucks With Perkins 1004-42 Diesel Engine.......................... 441 Lift Trucks With Perkins 1104C-44 (RE) Diesel Engine and GM 4.3L........ 442 Remove and Disassemble MONOTROL Pedal....................................... 442 Assemble and Install MONOTROL Pedal......................................... 442 Replace Throttle Pedal Position Sensor...................................... 444 Replace Throttle Pedal Switch............................................... 445 Throttle-Up Assembly Replace - Perkins 1004-42 Diesel Engine.................... 446 Remove...................................................................... 446 Inspect..................................................................... 446 Install..................................................................... 446 Replace Throttle Motor...................................................... 447 Replace Engine Throttle Position Sensor..................................... 447 Throttle Servo Motor Replace - Perkins 1104C-44(RE) Diesel and G................ 447 Remove...................................................................... 447 Perkins 1104C-44(RE) Diesel Engine...................................... 447 GM 4.3L LPG Engine...................................................... 447 Inspect..................................................................... 449 Install..................................................................... 449 Perkins 1104C-44(RE) Diesel Engine...................................... 449 GM 4.3L LPG Engine...................................................... 449 Throttle-Up Switch Assembly Repair.............................................. 451 Remove...................................................................... 451 Install..................................................................... 451 Replace Lift Lever Position Sensor.......................................... 451 Replace Throttle-Up Switches................................................ 451 Hydrostatic Drive Checks and Adjustments........................................ 452 Swashplate Positioning Cylinder............................................. 452 Truck Travel Speed Limit Adjustment......................................... 453 Perkins 1004-42 Diesel Engine........................................... 453 Perkins 1104C-44(RE) Diesel Engine and GM 4.3L LPG Engine............... 453 Charge Pressure............................................................. 453 Pilot Supply Pressure....................................................... 454 Pilot Pressure.............................................................. 454 POR Pressure................................................................ 454 Loop Pressure............................................................... 454 Throttle Pedal/ MONOTROL Pedal Checks and Adjustments........................... 455 Throttle Cable.............................................................. 455 Perkins 1004-42 Diesel Engine Trucks.................................... 455 Pedal Stop.................................................................. 455 Standard Throttle Pedal................................................. 455 Perkins 1004-42 Diesel Engine Trucks................................ 455 Perkins 1104C-44(RE) Diesel and GM 4.3L LPG Engine Trucks........... 455 MONOTROL Pedal.......................................................... 455 Perkins 1004-42 Diesel Engine Trucks................................ 455 Perkins 1104C-44(RE) Diesel and GM 4.3L LPG Engine Trucks........... 455 MONOTROL Pedal Operation.................................................... 455 Throttle Pedal Position Sensor.............................................. 455 Throttle Pedal Switch....................................................... 456 MONOTROL Pedal Switch....................................................... 457 Throttle-Up Assembly Checks and Adjustments..................................... 458 Engine Throttle Position Sensor............................................. 458 Throttle-Up Motor........................................................... 459 Throttle Servo Motor Checks and Adjustments..................................... 459 Throttle Servo Motor Position Sensor........................................ 459 Throttle Servo Motor........................................................ 460 Throttle-Up Switch Assembly Checks and Adjustments.............................. 461 Throttle-Up Switches........................................................ 461 Lift Lever Position Sensor.................................................. 461 Sensor Checks................................................................... 462 Charge Pressure Sensor...................................................... 462 Brake Pressure Sensor....................................................... 462 Oil Temperature Sensor...................................................... 463 Engine Speed Sensor......................................................... 463 Left Speed Sensor....................................................... 464 Right Speed Sensor...................................................... 465 Event Codes..................................................................... 465 Perkins 1004-42 Diesel Engine Trucks........................................ 465 Event Code Descriptions - Perkins 1004-42 Diesel Engine Trucks.............. 466 Perkins 1104C-44(RE) Diesel Engine and GM 4.3L LPG Trucks................... 472 Event Code Descriptions - Perkins 1104C-44(RE) Diesel and GM 4.3............ 473 Troubleshooting................................................................. 482 Perkins 1004-42 diesel engine trucks only................................... 486 Perkins 1004-42 diesel engine trucks only................................... 487 Perkins 1104C-44(RE) diesel and GM 4.3L LPG engine trucks................... 487 Perkins 1104C-44(RE) diesel and GM 4.3L LPG engine trucks................... 487 tables.............................................................................. 415 Table 1. Charge and Brake Sensor Outputs........................................ 463 Table 2. Oil Temperature Sensor Outputs......................................... 463 Table 3. Engine Speed Sensor Outputs............................................ 464 Table 4. Wheel Speed Sensor Outputs - Perkins 1104C-44(RE) Diese................ 464 1400SRM731-1466247(09-2003)-EN.......................................................... 493 toc................................................................................. 493 Drive Axle...................................................................... 493 Safety Precautions Maintenance and Repair....................................... 494 General......................................................................... 497 Description..................................................................... 497 Drive Axle Repair............................................................... 497 Remove and Disassemble...................................................... 497 Clean and Inspect........................................................... 499 Assemble and Install........................................................ 499 Troubleshooting................................................................. 501 1600SRM732-1466241(10-2003)-EN.......................................................... 505 toc................................................................................. 505 Steering Control Unit........................................................... 505 Safety Precautions Maintenance and Repair....................................... 506 General......................................................................... 509 Description..................................................................... 509 Operation....................................................................... 509 Steering Wheel and Column Assembly Repair....................................... 511 Remove and Disassemble...................................................... 511 Assemble and Install........................................................ 511 Steering Control Unit....................................................... 514 Disassemble............................................................. 514 Clean................................................................... 516 Assemble................................................................ 517 System Air Removal.............................................................. 520 Troubleshooting................................................................. 520 1600SRM733-1466235(09-2003)-EN.......................................................... 525 toc................................................................................. 525 Steering Axle................................................................... 525 Safety Precautions Maintenance and Repair....................................... 526 General......................................................................... 529 Description..................................................................... 529 Steering Axle Assembly Repair................................................... 530 Remove...................................................................... 530 Install..................................................................... 530 Wheels and Hub Repair........................................................... 531 Remove and Disassemble...................................................... 531 Clean....................................................................... 531 Inspect..................................................................... 531 Assemble and Install........................................................ 531 Spindles and Bearings Repair.................................................... 532 Remove...................................................................... 532 Clean....................................................................... 532 Inspect..................................................................... 532 Assemble and Install........................................................ 532 Tie Rods Repair................................................................. 533 Remove...................................................................... 533 Clean....................................................................... 533 Inspect..................................................................... 533 Install..................................................................... 533 Steering Cylinder Repair........................................................ 533 Remove and Disassemble...................................................... 533 Clean and Inspect........................................................... 534 Assemble and Install........................................................ 534 Troubleshooting................................................................. 535 1800SRM734-1466229(03-2004)-EN.......................................................... 539 toc................................................................................. 539 Brake System.................................................................... 539 Safety Precautions Maintenance and Repair....................................... 540 General......................................................................... 543 Description and Operation....................................................... 543 Brake Booster and Master Cylinder........................................... 543 Service Brake Assembly...................................................... 543 Parking Brake............................................................... 544 Brake Shoe Assemblies Repair.................................................... 544 Remove and Disassemble...................................................... 544 Clean....................................................................... 547 Inspect..................................................................... 547 Assemble and Install........................................................ 547 Brake Booster and Master Cylinder Repair........................................ 549 Remove...................................................................... 549 Disassemble................................................................. 549 Clean and Inspect........................................................... 549 Assemble.................................................................... 549 Install..................................................................... 551 Brake Booster Filter, Replace............................................... 552 Parking Brake Repair............................................................ 552 Remove and Disassemble...................................................... 552 Assemble and Install........................................................ 552 Brake System Air Removal........................................................ 552 Brake Pedal Adjustment.......................................................... 553 Parking Brake Adjustment........................................................ 553 Parking Brake Not Applied Switch Test........................................... 554 Parking Brake Switch Test ( MONOTROL® Pedal Only)............................... 554 Brake Shoes Adjustment.......................................................... 555 Troubleshooting................................................................. 555 1900SRM743-1466217(10-2003)-EN.......................................................... 561 toc................................................................................. 561 Hydraulic System................................................................ 561 Safety Precautions Maintenance and Repair....................................... 562 General......................................................................... 565 Description..................................................................... 565 Operation....................................................................... 567 Hydraulic Pump H3.50-5.50XM (H70-120XM)..................................... 567 Hydraulic Pump S3.50-5.50XM (S70-120XM)..................................... 567 Main Control Valve.......................................................... 568 Steering Control Unit....................................................... 568 Specifications.................................................................. 569 Hydraulic System Capacity................................................... 569 Hydraulic Tank Capacity..................................................... 569 Relief Pressures @ 2200 rpm, 50 to 80 C ( 120 to 180 F)..................... 569 Hydraulic Pump Flow to Valve................................................ 569 Steering Priority Flow...................................................... 569 Troubleshooting................................................................. 570 Lift, Lower and Tilt Circuit................................................ 570 Steering Circuit............................................................ 571 1900SRM753-1466223(09-2003)-EN.......................................................... 575 toc................................................................................. 575 Hydraulic Gear Pump............................................................. 575 Safety Precautions Maintenance and Repair....................................... 576 General......................................................................... 579 Description..................................................................... 579 Operation....................................................................... 579 Hydraulic Gear Pump Repair...................................................... 580 Remove...................................................................... 580 Disassemble................................................................. 580 Clean....................................................................... 580 Inspect..................................................................... 582 Assemble.................................................................... 582 Install..................................................................... 583 Pump Output Check............................................................... 584 Method No. 1................................................................ 584 Method No. 2................................................................ 585 Hydraulic System Air Check...................................................... 586 Troubleshooting................................................................. 586 2000SRM754-1466211(12-2003)-EN.......................................................... 591 toc................................................................................. 591 Main Control Valve.............................................................. 591 Safety Precautions Maintenance and Repair....................................... 592 General......................................................................... 595 Description..................................................................... 595 Operation....................................................................... 595 Lift Section................................................................ 595 Tilt and Auxiliary Sections................................................. 599 Reattaching the Clevis End of the Tilt Spool............................ 600 Relief Valve................................................................ 600 Main Control Valve Repair....................................................... 600 Remove and Disassemble...................................................... 600 Clean and Inspect........................................................... 602 Assemble.................................................................... 604 Install..................................................................... 604 Pressure Relief Valve Check and Adjustment...................................... 605 Main Relief Valve (Lift).................................................... 605 Steering Relief Valve....................................................... 605 Secondary Relief Valve (Tilt and Auxiliary)................................. 608 Specifications.................................................................. 609 Troubleshooting................................................................. 609 2100SRM735-1466205(09-2003)-EN.......................................................... 615 toc................................................................................. 615 Tilt Cylinders.................................................................. 615 Safety Precautions Maintenance and Repair....................................... 616 General......................................................................... 619 Description..................................................................... 619 Tilt Cylinder Repair............................................................ 619 Remove...................................................................... 619 Disassemble................................................................. 620 Clean....................................................................... 621 Inspect..................................................................... 621 Assemble.................................................................... 621 Install..................................................................... 621 Tilt Cylinder Leak Check........................................................ 622 Tilt Cylinder Stroke and Mast Tilt Angle Adjustment............................. 622 Troubleshooting................................................................. 622 2200SRM002-899784(10-2003)-EN........................................................... 627 toc................................................................................. 627 Alternator with Regulator....................................................... 627 Safety Precautions Maintenance and Repair....................................... 628 General......................................................................... 631 Description..................................................................... 631 Alternator Repair............................................................... 633 Alternator Type A........................................................... 633 Remove and Disassemble.................................................. 633 Clean................................................................... 634 Assemble................................................................ 635 Install................................................................. 635 Alternator Type B........................................................... 638 Remove and Disassemble.................................................. 638 Clean................................................................... 638 Assemble................................................................ 639 Install................................................................. 640 General Check and Adjustment.................................................... 641 Low Output Check (Type A or Type B)............................................. 641 High Output Check (Type A or Type B)............................................ 643 Brushes Circuit Check........................................................... 644 Delco Alternators........................................................... 644 Motorola Alternators........................................................ 645 Diodes Check.................................................................... 646 Diode Bridge Check.............................................................. 646 Delco and Leece-Neville Alternators......................................... 646 Motorola Alternators........................................................ 646 Rotor Field Winding Check....................................................... 647 Stator Windings Check........................................................... 648 Voltage Regulator Check......................................................... 648 Troubleshooting................................................................. 648 2200SRM107-899788(03-2002)-EN........................................................... 653 toc................................................................................. 653 High Energy Ignition (HEI) System............................................... 653 Safety Precautions Maintenance and Repair....................................... 654 Description..................................................................... 657 Distributor Repair.............................................................. 659 Remove...................................................................... 659 Disassemble................................................................. 659 Assemble.................................................................... 664 Install, If Crankshaft WAS NOT Rotated when Distributor was Remo............ 665 Install, If Crankshaft WAS Rotated when Distributor was Removed............. 665 Ignition Coil Replacement....................................................... 666 Some Four- and Six-Cylinder Models.......................................... 666 Remove.................................................................. 666 Install................................................................. 667 V8, Some Four- and Six-Cylinder Models...................................... 667 Remove.................................................................. 667 Install................................................................. 668 Electronic Module Replacement................................................... 669 Remove...................................................................... 669 Install..................................................................... 669 Sensing Coil Replacement........................................................ 670 Remove...................................................................... 670 Install..................................................................... 670 Spark Plugs Replacement......................................................... 670 Remove...................................................................... 670 Install..................................................................... 671 Visual Check.................................................................... 671 High Voltage Wires Check........................................................ 671 Ignition Coil Check............................................................. 672 Coil in Distributor Cap Design.............................................. 672 Separate Coil Design........................................................ 672 Sensing Coil, Check......................................................... 673 Electronic Module Check......................................................... 673 Ignition Timing Adjustment...................................................... 673 GM V8-366 (6-liter) Ignition System Check....................................... 675 GM V6-LPG (4.3 liter) GM V6-LPG (4.3 liter) Ignition Timing and ................ 675 Specifications.................................................................. 675 Troubleshooting................................................................. 676 2200SRM744-1466175(09-2003)-EN.......................................................... 681 toc................................................................................. 681 Carbureted Engine Management System (CEMS)...................................... 681 Safety Precautions Maintenance and Repair....................................... 682 Description..................................................................... 685 Ignition Control System......................................................... 686 Setting Timing Reference.................................................... 686 Idle Speed Control System................................................... 686 Curb Idle Setting Procedure................................................. 687 Governor Control System......................................................... 687 Closed-Loop Fuel System......................................................... 688 Closed-Loop Fuel Control.................................................... 688 Entering Closed-Loop Control................................................ 688 Normal Closed-Loop Operation................................................ 688 Closed-Loop Diagnostics..................................................... 688 O.E. Tune Valve Action at Engine Shutdown................................... 688 Diagnostic System............................................................... 689 Closed-Loop Diagnostic Troubleshooting...................................... 690 Diagnostic Troubleshooting.................................................. 690 tables.............................................................................. 681 Table 1. Diagnostic Codes....................................................... 689 Table 2. Diagnostic Troubleshooting............................................. 690 2200SRM755-1466193(11-2001)-EN.......................................................... 699 toc................................................................................. 699 Starter......................................................................... 699 Safety Precautions Maintenance and Repair....................................... 700 General......................................................................... 703 Description..................................................................... 703 Yoke Assembly............................................................... 704 Armature Assembly........................................................... 704 Clutch Assembly............................................................. 704 Magnetic Switch Assembly.................................................... 704 Operation....................................................................... 704 Starter Repair.................................................................. 705 Remove...................................................................... 705 Disassemble................................................................. 706 Clean....................................................................... 709 Assemble.................................................................... 710 Install..................................................................... 713 General Checks and Adjustments.................................................. 713 Armature Tests.................................................................. 714 Armature Short Circuit Test................................................. 714 Armature Winding Ground Test................................................ 714 Commutator Run-Out Test..................................................... 714 Yoke Test....................................................................... 715 Brush and Brush Holder Check.................................................... 715 Brush Holder Insulation Test................................................ 715 Clutch Test................................................................. 715 Magnetic Switch Test............................................................ 716 Pull-In Test................................................................ 716 Hold-In Test................................................................ 716 Return Test................................................................. 716 Performance Tests............................................................... 717 No-Load Test................................................................ 717 Troubleshooting................................................................. 717 2200SRM756-1468474(11-2003)-EN.......................................................... 723 toc................................................................................. 723 Instrument Panel Indicators and Senders......................................... 723 Safety Precautions Maintenance and Repair....................................... 724 General......................................................................... 727 Description..................................................................... 727 Instruments and Senders..................................................... 727 Password Function........................................................... 734 Supervisor Password Function............................................ 734 Entering Operator Passwords......................................... 734 Deleting Operator Passwords......................................... 735 Retrieve the Most Recent Operator Password Used to Enable the Tr.... 735 Display All Operator Passwords Programmed Into the System........... 735 Enable and Disable Operator Passwords Function...................... 735 Allow Supervisor Password to Enable the Truck to Start.............. 735 Operator Passwords Function............................................. 735 Component Replacement - General Information..................................... 736 Sender Replacement.............................................................. 736 Fuel Level Sender........................................................... 736 Pressure and Temperature Sender............................................. 737 Display Panel Replacement....................................................... 738 Specifications.................................................................. 740 Troubleshooting................................................................. 741 tables.............................................................................. 723 Table 1. Instrument Panel Description........................................... 728 Table 2. Sender Description..................................................... 733 Table 3. Meter and Sender Specifications........................................ 740 2200SRM765-1473385(11-2001)-EN.......................................................... 745 toc................................................................................. 745 Microprocessor Spark Timing System (MSTS)....................................... 745 Safety Precautions Maintenance and Repair....................................... 746 General......................................................................... 749 Description..................................................................... 750 What MSTS Does.............................................................. 750 How MSTS Begins Operation................................................... 750 Operation....................................................................... 751 Distributor................................................................. 751 Ignition Coil............................................................... 751 Ignition Module............................................................. 751 When Engine Is Being Started................................................ 752 When Engine Is Running...................................................... 753 Manifold Absolute Pressure (MAP) Sensor..................................... 754 Engine Coolant Temperature (ECT) Sensor..................................... 754 MSTS Module Corrections..................................................... 755 Troubleshooting................................................................. 756 General..................................................................... 756 Tools and Test Equipment.................................................... 758 MSTS........................................................................ 759 Troubleshooting Procedure................................................... 759 Where to Start.......................................................... 759 Visual/Physical Inspection.............................................. 759 Knowledge/Tools Required................................................ 759 Damage from Static Discharge (Static Electricity)....................... 759 Troubleshooting Information................................................. 760 Malfunction Indicator Lamp (MIL)........................................ 760 Connecting CodeMate Tester.............................................. 760 Reading Diagnostic Trouble Codes (DTC).................................. 761 Clearing Diagnostic Trouble Codes (DTC's)............................... 762 On-Board Diagnostic (OBD) System Check...................................... 762 Test Description........................................................ 762 No Malfunction Indicator Lamp................................................... 764 Circuit Description......................................................... 764 Test Description............................................................ 764 No DTC-12, Malfunction Indicator Lamp ON........................................ 766 Circuit Description......................................................... 766 Test Description............................................................ 766 Starter Rotates Engine, Engine Does Not Run..................................... 767 Test Description............................................................ 767 DTC-14 Engine Coolant Temperature (ECT) (Low Temperature Indicat................ 771 Circuit Description......................................................... 771 Test Description............................................................ 771 DTC-15 Engine Coolant Temperature Sensor (ECT) (High Temperature................ 773 Circuit Description......................................................... 773 Test Description............................................................ 773 DTC-34 Manifold Absolute Pressure (MAP) Sensor.................................. 775 Circuit Description......................................................... 775 Test Description............................................................ 775 DTC-41 Electronic Spark Timing (EST) Open Circuit............................... 778 Circuit Description......................................................... 778 Test Description............................................................ 778 DTC-42 Electronic Spark Timing (EST) Grounded Circuit........................... 780 Circuit Description......................................................... 780 Test Description............................................................ 780 DTC-51 MSTS Failure............................................................. 782 Circuit Description......................................................... 782 Distributor Repair.............................................................. 782 Remove...................................................................... 782 Disassemble................................................................. 783 Inspect..................................................................... 783 Assemble.................................................................... 783 Install..................................................................... 784 Ignition Timing............................................................. 784 Ignition Module Repair.......................................................... 785 Test For Fault.............................................................. 785 Replace..................................................................... 786 Sensing Coil Repair............................................................. 786 Test For Fault.............................................................. 786 Replace..................................................................... 786 Ignition Coil Repair............................................................ 787 Test For Fault.............................................................. 787 Remove...................................................................... 787 Install..................................................................... 787 MSTS Module Repair.............................................................. 788 Remove...................................................................... 788 Install..................................................................... 788 ECT Sensor Replacement.......................................................... 788 MAP Sensor Replacement.......................................................... 789 tables.............................................................................. 745 Table 1. MSTS Module Connections................................................ 757 Table 2. Pressure Conversion Chart.............................................. 758 Table 3. MSTS Diagnostic Codes.................................................. 760 2200SRM781-1474823(11-2001)-EN.......................................................... 793 toc................................................................................. 793 Electronic Engine Control....................................................... 793 Safety Precautions Maintenance and Repair....................................... 794 General......................................................................... 797 Description and Operation....................................................... 797 General..................................................................... 797 Electronic Control Module (ECM)............................................. 797 Diagnostic Connector.................................................... 797 How ECM Begins Operation................................................ 801 Electronic Engine Control................................................... 802 What ECM Does........................................................... 802 Distributor............................................................. 803 Ignition Module......................................................... 804 When Engine Is Being Started............................................ 804 When Engine Is Running.................................................. 805 Electronic Control Module (ECM) with Ignition Module Distributor........ 806 Fuel Control................................................................ 807 Throttle Body Injection (TBI)........................................... 807 Fuel Injectors.......................................................... 808 Fuel Pressure Regulator................................................. 808 Throttle Position Sensor (TPS).......................................... 808 Idle Air Control (IAC).................................................. 809 GM 4.3L Engine Governor System.......................................... 809 GM 3.0L Engine Governor System.......................................... 810 Vacuum Ports............................................................ 812 Fuel Pump............................................................... 812 ECM Sensors and Controllers................................................. 814 Manifold Absolute Pressure (MAP)........................................ 814 Engine Coolant Temperature (ECT) Sensor................................. 815 2200SRM782-1474824(11-2001)-EN.......................................................... 819 toc................................................................................. 819 Electronic Engine Control....................................................... 819 Safety Precautions Maintenance and Repair....................................... 820 General......................................................................... 825 Troubleshooting Procedure................................................... 825 How This Section Is Arranged................................................ 825 Where Do I Start?........................................................... 825 Visual/Physical Inspection.................................................. 825 Knowledge/Tools Required.................................................... 825 Damage From Static Discharge (Static Electricity)........................... 825 Troubleshooting Information................................................. 826 Malfunction Indicator Lamp (MIL)........................................ 826 Reading Diagnostic Trouble Codes (DTC).................................. 826 Clearing Diagnostic Trouble Codes (DTCs)................................ 830 ECM Diagnostic Codes Available.............................................. 831 Diagnostic Mode......................................................... 831 Field Service Mode...................................................... 831 ECM Learning Ability.................................................... 831 SCAN Tool Information....................................................... 832 On-Board Diagnostic (OBD) System Check...................................... 833 Test Description........................................................ 833 Troubleshooting Charts.......................................................... 835 General..................................................................... 835 Tools and Test Equipment................................................ 835 Troubleshooting Chart Description Summary................................... 836 A-1 - No Malfunction Indicator Lamp............................................. 836 Circuit Description......................................................... 836 Test Description............................................................ 837 Other Troubleshooting Checks................................................ 837 A-2 - No Scan Data, No DTC 12, Malfunction Indicator Lamp ON.................... 839 Circuit Description......................................................... 839 Test Description............................................................ 840 A-3 - Starter Rotates Engine, Engine Will Not Run............................... 842 Circuit Description......................................................... 842 Test Description............................................................ 842 Other Troubleshooting Checks................................................ 842 A-4 - Fuel Injector Circuit..................................................... 844 Test Description............................................................ 844 A-5 - Fuel Pump Relay Circuit................................................... 846 Circuit Description......................................................... 846 Test Description............................................................ 846 Other Troubleshooting Checks................................................ 846 A-6 - Fuel System Troubleshooting............................................... 848 Circuit Description......................................................... 848 Test Description............................................................ 848 Other Troubleshooting Checks................................................ 849 Test Description............................................................ 849 Fuel Pressure Check......................................................... 849 A-7 - Ignition System Troubleshooting........................................... 853 Test Description............................................................ 853 DTC 14 Engine Coolant Temperature Sensor Circuit (Low Temperatur................ 857 Circuit Description......................................................... 857 Test Description............................................................ 857 Other Troubleshooting Checks................................................ 857 DTC 15 Engine Coolant Temperature Sensor Circuit (High Temperatu................ 859 Circuit Description......................................................... 859 Test Description............................................................ 859 Other Troubleshooting Checks................................................ 860 DTC 21 Throttle Position Sensor Circuit (Signal Voltage High)................... 862 Circuit Description......................................................... 862 Test Description............................................................ 862 Other Troubleshooting Checks................................................ 862 DTC 22 Throttle Position Sensor Circuit (Signal Voltage Low).................... 864 Circuit Description......................................................... 864 Test Description............................................................ 864 Other Troubleshooting Checks................................................ 864 DTC 31 Engine Governor Circuit.................................................. 866 Circuit Description......................................................... 866 Test Description............................................................ 866 Other Troubleshooting Checks................................................ 866 DTC 33 MAP Sensor Circuit (Signal Voltage High - Low Vacuum).................... 868 Circuit Description......................................................... 868 Test Description............................................................ 868 Other Troubleshooting Checks................................................ 868 DTC 34 MAP Sensor Circuit (Signal Voltage Low - High Vacuum).................... 870 Circuit Description......................................................... 870 Test Description............................................................ 870 Other Troubleshooting Checks................................................ 870 DTC 41 Electronic Spark Timing (EST) - Open EST Circuit......................... 872 Circuit Description......................................................... 872 Test Description............................................................ 872 Other Troubleshooting Checks................................................ 872 DTC 42 EST - Grounded EST Circuit, Open or Grounded Bypass Circu................ 874 Circuit Description......................................................... 874 Test Description............................................................ 874 Other Troubleshooting Checks................................................ 875 DTC 51 ECM Failure.............................................................. 877 Circuit Description......................................................... 877 Other Troubleshooting Checks................................................ 877 Troubleshooting, Poor Operation................................................. 878 General..................................................................... 878 Make a Careful Visual Check................................................. 878 FAULT: Codes or Performance That Is Not Regular............................. 878 FAULT: Loss of Diagnostic Trouble Code (DTC) Memory......................... 878 FAULT: Engine Quits While Driving........................................... 878 Additional Checks....................................................... 878 FAULT: Engine Is Difficult to Start......................................... 878 FAULT: Variation in Engine Power When Throttle Is Held Steady............... 879 FAULT: Decreased Engine Power............................................... 879 FAULT: Detonation........................................................... 880 FAULT: Engine Momentarily Does Not Increase Power When Throttle ............ 880 FAULT: One or More Cylinders Do Not Operate Correctly - Engine D............ 881 FAULT: Rough Idle or Engine Stalls During Idle.............................. 881 FAULT: Fuel Usage Too High.................................................. 882 FAULT: Dieseling............................................................ 882 FAULT: Backfire............................................................. 882 System Test Charts.............................................................. 883 General..................................................................... 883 Engine Coolant Temperature (ECT) Sensor Test................................ 883 Throttle Position (TP) Sensor Check......................................... 883 Minimum Idle Speed.......................................................... 884 Adjustment.............................................................. 884 B-1 - Idle Air Control (IAC) System Check....................................... 885 Circuit Description......................................................... 885 Other Troubleshooting Checks................................................ 885 B-2 - Manifold Absolute Pressure (MAP) Sensor Output Test....................... 886 Circuit Description......................................................... 886 Test Description............................................................ 886 B-3 - Check Governor System..................................................... 889 Governor System Not Operating Correctly..................................... 889 Check Function of Governor System........................................... 889 Check PCV System............................................................ 889 Fuel System Components Repair................................................... 890 General..................................................................... 890 Fuel Pressure Relief Procedure.............................................. 890 Fuel Pump Replacement....................................................... 890 Throttle Body Injection Unit (TBI).......................................... 891 Remove.................................................................. 891 Clean and Inspect....................................................... 892 Install................................................................. 892 Fuel Meter Body............................................................. 892 Remove.................................................................. 892 Install................................................................. 892 Fuel Injector............................................................... 895 Remove.................................................................. 895 Install................................................................. 895 Pressure Regulator.......................................................... 896 Remove.................................................................. 896 Inspect................................................................. 896 Install................................................................. 896 Throttle Position Sensor (TPS).............................................. 896 Remove.................................................................. 896 Install................................................................. 897 Idle Air Control (IAC) Valve................................................ 897 Remove.................................................................. 897 Clean and Inspect....................................................... 897 Install................................................................. 897 Governor System 3.0L Engine Repair.............................................. 898 Governor Module, Replace.................................................... 898 Governor Motor, Replace..................................................... 898 Throttle Cables, Install and Adjust......................................... 898 MONOTROL® Pedal, Check...................................................... 899 Governor System 4.3L Engine Repair.............................................. 900 Governor Throttle Drive Assembly............................................ 900 Remove.................................................................. 900 Inspect................................................................. 901 Install................................................................. 901 Governor Drive Motor........................................................ 901 Remove.................................................................. 901 Clean and Lubricate..................................................... 902 Install................................................................. 902 Inspect................................................................. 903 Ignition System Components Repair............................................... 903 ECM Replacement............................................................. 903 Function Check.............................................................. 903 Distributor................................................................. 903 Remove.................................................................. 903 Disassemble............................................................. 904 Inspect................................................................. 904 Assemble................................................................ 904 Install................................................................. 904 Firing Order............................................................ 905 Ignition Timing......................................................... 905 Ignition Module Repair.......................................................... 905 Test For Fault.............................................................. 905 Replace..................................................................... 906 Sensing Coil................................................................ 907 Test.................................................................... 907 Replace................................................................. 907 Ignition Coil............................................................... 907 Test.................................................................... 907 Remove.................................................................. 908 Install................................................................. 908 Sensors Repair.................................................................. 908 Engine Coolant Temperature (ECT) Sensor, Replace............................ 908 MAP Sensor, Replace......................................................... 908 PCV System Repair............................................................... 909 Replace..................................................................... 909 Wiring.......................................................................... 909 Connectors and Terminals.................................................... 909 Procedures for Spark Plugs, Spark Plug Wires, and Boots..................... 913 Wiring Diagram.............................................................. 913 Spark Plugs Troubleshooting..................................................... 917 Special Tools................................................................... 918 tables.............................................................................. 819 Table 1. ECM Diagnostic Codes Available......................................... 831 Table 2. SCAN Tool Information.................................................. 832 Table 3. Troubleshooting Chart Description Summary.............................. 836 Table 4. ECT Sensor - Temperature vs Resistance................................. 860 Table 5. ECT Sensor - Temperature vs Resistance................................. 883 Table 6. ECM Connector J1 Identification........................................ 915 Table 7. ECM Connector J2 Identification........................................ 916 4000SRM223-910435(01-1997)-EN........................................................... 923 VISTA MAST, REPAIR.................................................................. 923 GENERAL......................................................................... 923 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST.................................... 923 FORKS........................................................................... 924 Forks, Removal And Installation............................................. 924 CARRIAGE........................................................................ 925 Removal..................................................................... 925 Installation................................................................ 926 MASTS........................................................................... 926 Removal..................................................................... 926 Disassembly................................................................. 927 Cleaning and Inspection..................................................... 932 Assembly.................................................................... 932 Installation................................................................ 936 SIDE-SHIFT CARRIAGE (EARLIER DESIGN)............................................ 937 Removal..................................................................... 937 Repairs..................................................................... 937 Installation................................................................ 937 SIDE-SHIFT CARRIAGE (1993 AND LATER DESIGN)..................................... 938 Removal..................................................................... 938 Repairs..................................................................... 938 Installation................................................................ 939 CHECKS AND ADJUSTMENTS.............................................................. 940 CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM..................................... 940 ADJUST THE TILT CYLINDER STROKE AND THE BACKWARD TILT ANGLE..................... 941 LIFT CHAIN ADJUSTMENTS.......................................................... 942 MAST ADJUSTMENTS................................................................ 942 CARRIAGE ADJUSTMENT............................................................. 944 HEADER HOSE ARRANGEMENTS........................................................ 944 Two-Stage Header Hose....................................................... 945 Header Hoses For Free-Lift, Three-Stage, and Four Stage Masts............... 945 TROUBLESHOOTING..................................................................... 950 4000SRM318-897100(12-1996)-EN........................................................... 951 INTRODUCTION........................................................................ 951 GENERAL......................................................................... 951 REPAIRS............................................................................. 951 FORKS........................................................................... 951 CARRIAGE........................................................................ 951 Removal..................................................................... 951 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST.................................... 952 Installation................................................................ 953 MAST............................................................................ 954 Removal..................................................................... 954 Disassembly................................................................. 955 Cleaning.................................................................... 958 Inspection, Forks, Mast, And Lift Chains.................................... 958 Assembly, Mast Components................................................... 959 Installation................................................................ 960 CHECKS AND ADJUSTMENTS.............................................................. 961 CHECK FOR LEAKS IN THE LIFT SYSTEM.............................................. 961 Check the Lift Cylinders for Leaks.......................................... 961 Check The Tilt Cylinders For Leaks.......................................... 961 ADJUST THE TILT CYLINDER STROKE AND BACKWARD TILT ANGLE......................... 961 LIFT CHAIN ADJUSTMENTS.......................................................... 962 MAST ADJUSTMENTS................................................................ 962 CARRIAGE ADJUSTMENTS............................................................ 964 TROUBLESHOOTING..................................................................... 965 4000SRM736-1466163(10-2003)-EN.......................................................... 966 toc................................................................................. 966 Masts........................................................................... 966 Safety Precautions Maintenance and Repair....................................... 967 General......................................................................... 970 Description and Operation....................................................... 970 Carriages................................................................... 970 Two-Stage Mast With Limited Free-Lift....................................... 970 Two-Stage Mast With Full Free-Lift.......................................... 971 Three-Stage Mast With Full Free-Lift........................................ 972 Safety Procedures When Working Near Mast........................................ 974 Fork Replacement................................................................ 976 Remove...................................................................... 977 Install..................................................................... 977 Carriage Repair................................................................. 978 Remove...................................................................... 978 Sideshift Carriage Repair....................................................... 979 Remove...................................................................... 979 Disassemble................................................................. 979 Assemble.................................................................... 979 Install..................................................................... 980 Two-Stage Mast With Limited Free-Lift Repair.................................... 981 Remove - H3.50-5.50XM (H70-120XM) Model Lift Trucks......................... 981 Remove - S3.50-5.50XM (S70-120XM) and E3.50-5.50XL 3 (E70-120XL ............ 981 Disassemble................................................................. 981 Clean and Inspect........................................................... 985 Assemble.................................................................... 986 Install - H3.50-5.50XM (H70-120XM) Lift Truck Models........................ 987 Install - S3.50-5.50XM (S70-120XM) and E3.50-5.50XL 3 (E70-120XL............ 989 Two-Stage Mast With Full Free-Lift Repair....................................... 991 Remove...................................................................... 991 Disassemble................................................................. 991 Clean and Inspect........................................................... 993 Assemble.................................................................... 993 Install..................................................................... 993 Three-Stage Mast With Full Free-Lift Repair..................................... 995 Remove...................................................................... 995 Disassemble................................................................. 995 Clean and Inspect........................................................... 998 Assemble.................................................................... 998 Install.....................................................................1000 Mast Operation Check............................................................1004 Lift and Tilt System Leak Check.................................................1004 Lift System.................................................................1004 Tilt System.................................................................1005 Tilt Cylinder Stroke and Backward Tilt Angle Adjustment.........................1006 Lift Chain Adjustments..........................................................1007 Mast Adjustments................................................................1010 Carriage Adjustment.............................................................1012 Troubleshooting.................................................................1012 tables.............................................................................. 966 Table 1. Tilt Cylinder Leak Check Specifications, S3.50-5.50XM (................1006 Table 2. Hook type Carriage Chain Adjustment....................................1008 Table 3. Pin-Type Carriage Chain Adjustment.....................................1008 4000SRM741-1466169(10-2003)-EN..........................................................1018 toc.................................................................................1018 Lift Cylinders..................................................................1018 Safety Precautions Maintenance and Repair.......................................1019 Safety Procedures When Working Near Mast........................................1022 General.........................................................................1024 Description.....................................................................1024 Lowering Control Valve (Velocity Fuse)......................................1024 Lift Cylinder Repair............................................................1027 Remove......................................................................1027 Disassemble.................................................................1028 Assemble....................................................................1028 Install.....................................................................1029 Lift System Leak Check..........................................................1029 Troubleshooting.................................................................1030 8000SRM737-1467763(03-2004)-EN..........................................................1034 toc.................................................................................1034 Periodic Maintenance............................................................1034 Safety Precautions Maintenance and Repair.......................................1035 General.........................................................................1040 Serial Number Data..........................................................1040 How to Move Disabled Lift Truck.............................................1040 How to Tow Lift Truck...................................................1040 How to Put Lift Truck on Blocks.............................................1041 How to Raise Drive Tires................................................1041 How to Raise Steering Tires.............................................1041 Maintenance Schedule............................................................1042 Maintenance Procedures Every 8 Hours or Daily...................................1056 How to Make Checks With Engine Stopped......................................1056 Engine Oil..............................................................1057 Hydraulic System Oil....................................................1057 Cooling System..........................................................1058 Heavy Duty Precleaner...................................................1058 Fuel System.............................................................1059 Battery.................................................................1059 Tires and Wheels........................................................1059 Forks...................................................................1060 Adjust..............................................................1061 Hook Fork, Remove...................................................1061 Hook Fork, Install..................................................1061 Forks, Mast, and Lift Chains, Inspect...................................1062 Operator Restraint System...............................................1063 Safety Labels...........................................................1063 How to Make Checks With Engine Running......................................1064 Gauges, Lights, Horn, and Fuses.........................................1064 Engine Oil Pressure.....................................................1064 Cooling System..........................................................1067 Powershift Transmission Oil Level Check.................................1067 Hydrostatic Transmission Oil Level Check................................1068 Control Levers and Pedals...............................................1068 Lift System Operation...................................................1068 Inching/Brake Pedal.....................................................1069 Service Brakes..........................................................1069 Parking Brake...........................................................1069 Steering System.........................................................1069 Maintenance Procedures Every 250 Hours or 6 Weeks...............................1070 Engine Oil and Filter, GM V-6 EPA Compliant Engine (Americas Onl............1070 Air Filter, GM V-6 EPA Compliant Engine.....................................1070 Maintenance Procedures Every 500 Hours or 2 Months..............................1071 Lift Chains Lubrication.....................................................1071 Air Filter..................................................................1071 Hydraulic Pump Drive Shaft..................................................1071 Engine Oil and Filter, Diesel and GM V-6 (European Only)....................1071 Drive Belts.................................................................1072 Fan Drive Belts.........................................................1072 Perkins Diesel Engine.......................................................1072 Alternator Drive Belt...................................................1072 GM 4.3L Engine..............................................................1073 Serpentine Drive Belt...................................................1073 Hydraulic Tank Breather, Clean and Check....................................1074 Hydrostatic Transmission Filter.............................................1074 Filter Cartridge, Replace...............................................1074 Filter Head, Replace....................................................1074 Brake Fluid.................................................................1075 Lift Chains Wear Check......................................................1075 Forks, Wear and Damage Check................................................1076 Mast, Lubrication...........................................................1076 Control Levers and Pedals, Lubrication......................................1077 Steering Axle, Lubrication..................................................1077 Fuel System, Checks and Adjustments.........................................1077 LPG Carburetor..........................................................1077 Fuel Injection (Perkins Engine).........................................1077 GM V-6 Engine...........................................................1077 Cooling System, Clean Debris from Radiator Core.............................1077 Maintenance Procedures Every 1000 Hours or 6 Months.............................1078 PCV Valve, GM V-6...........................................................1078 Crankcase Breather, GM-V6...................................................1078 Spark Plug Replacement......................................................1078 Remove..................................................................1078 Install.................................................................1078 Valve Clearance, Check and Adjust...........................................1078 Water Separator, Diesel Engine..............................................1079 Fuel Filter, Replace (Diesel Engine)........................................1079 Fuel System Air Removal, Perkins (1004.42 Diesel Engine)....................1079 Differential and Drive Axle.............................................1081 Cooling System, GM V-6 EPA Compliant Engine.................................1081 LPG Fuel Filter GM V-6 EPA Compliant Engine, Replace........................1081 Inspect Engine Electrical System, Connectors, and FCVS Connectio............1082 Maintenance Procedures Every 2000 Hours or Yearly...............................1082 Differential Thrust Screw...................................................1082 Hydraulic System............................................................1083 Hydraulic Oil and Filter, Replace.......................................1083 Powershift Transmission Oil and Filter, Replace.............................1084 Hydrostatic Transmission Oil and Filter, Replace............................1084 Cooling System..............................................................1085 Wheel Bearings..............................................................1085 Steering Wheels, Lubrication............................................1085 Drive Wheels, Lubrication...............................................1085 PCV Valve, GM V-6...........................................................1085 Service Brakes..............................................................1085 Brake Booster Filter, Replace...............................................1086 LPG Filter, Replace (Pre-2004)..............................................1086 Gasoline Fuel Filter, Replace...............................................1086 Operator Restraint System...................................................1086 Oxygen Sensor (Pre 2004)....................................................1087 Oxygen Sensor GM V-6 EPA Compliant Engine...................................1087 Air Filter Element, GM V-6 EPA Compliant Engine.............................1087 Inspect Low Pressure Regulator (LPR) for Oil Buildup and Leaks..............1087 Check Throttle Shaft for Sticking...........................................1088 Inspect Exhaust Manifold and Piping for Leaks...............................1088 Test LPG/GAS Regulator Pressure.............................................1088 Safety Procedures When Working Near Mast........................................1089 Lift Chain Adjustments..........................................................1091 Fuel Injectors Repair...........................................................1092 Lift and Tilt System Leak Check.................................................1093 Lift Cylinders, Leak Check..................................................1093 Tilt Cylinders, Leak Check..................................................1093 Welding Repairs.................................................................1094 Overhead Guard Changes..........................................................1094 Wheel and Tire Replacement......................................................1095 Remove Wheels From Lift Truck...............................................1095 Remove Wheel From Tire......................................................1096 Remove Tire From Two-Piece Wheel........................................1097 Remove Tire From Three- and Four-Piece Wheel............................1099 Install Wheel in Tire.......................................................1100 Install Tire on Three- or Four-Piece Wheel..............................1101 Install Tire in Two-Piece Wheel.........................................1102 Add Air to Tires............................................................1103 Wheels, Install.............................................................1103 Dual Drive Wheels Installation..................................................1103 Solid Rubber Tire Repair........................................................1104 Wheel, Tire Remove..........................................................1104 Wheel, Tire Install.........................................................1106 SIT Tire, Change for H3.50-5.50XM (European Trucks Only)....................1107 Remove SIT Solid Tire From Wheel........................................1108 Install SIT Solid Tire on Wheel.........................................1109 Adhesives and Sealants..........................................................1110 Hydraulic Oil, Lubricant, and Coolant Specifications............................1111 tables..............................................................................1034 Table 1. Maintenance Schedule...................................................1046 Table 2. Hook-Type Carriage Chain Adjustment....................................1091 Table 3. Pin-Type Carriage Chain Adjustment.....................................1092 8000SRM738-1467764(05-2004)-UK-EN.......................................................1114 toc.................................................................................1114 Capacities and Specifications...................................................1114 Safety Precautions Maintenance and Repair.......................................1115 Lift Truck Weights..............................................................1118 Electrical System...............................................................1118 Stall Speeds....................................................................1118 Capacities......................................................................1119 Tire Pressure...................................................................1119 Engine Specifications...........................................................1120 Transmission Oil Pressures......................................................1121 Hydraulic System................................................................1122 Mast Speeds.....................................................................1123 Torque Specifications...........................................................1123 Brake System................................................................1123 Differential................................................................1123 Drive Axle..................................................................1124 Engine, GM V-6 4.3 Liter....................................................1124 Engine, Perkins 1004-42.....................................................1125 Frame.......................................................................1125 Lift Cylinders..............................................................1125 Main Control Valve..........................................................1125 Masts.......................................................................1125 Powershift Transmission.....................................................1126 Steering System.............................................................1126 Tilt Cylinders..............................................................1126 Hydrostatic Components......................................................1126 tables..............................................................................1114 Table 1. Single-Speed...........................................................1121 Table 2. Two-Speed..............................................................1121 Table 3. Hydrostatic Transmission...............................................1122 8000SRM757-1467765(05-2004)-UK-EN.......................................................1130 toc.................................................................................1130 Diagrams........................................................................1130 Safety Precautions Maintenance and Repair.......................................1131
IMAGES PREVIEW OF THE MANUAL:
HYSTER K005 (H3.50-5.50XM) SERVICE MANUAL – PDF DOWNLOAD:
PLEASE NOTE:
- This is the same manual used by the DEALERSHIPS to SERVICE your vehicle.
- The manual can be all yours – Once payment is complete, you will be taken to the download page from where you can download the manual. All in 2-5 minutes time!!
- Need any other service / repair / parts manual, please feel free to contact us at heydownloadss @gmail.com . We may surprise you with a nice offer
S.V
