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Hyster L005 (H3.50-5.50XM) Service Manual – PDF DOWNLOAD
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Hyster L005 (H3.50-5.50XM) Service Manual – PDF DOWNLOAD
PART NO. 1467898
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Description
Hyster L005 (H3.50-5.50XM) Service Manual – PDF DOWNLOAD
DESCRIPTION:
PART NO. 1467898
Hyster L005 (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 L005 (H3.50-5.50XM) Service Manual – PDF DOWNLOAD
0100SRM0726-1467898(06-2004)-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 0100SRM0778-147186(06-2004)-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 0600SRM1070-1552002(12-2003)-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..................................................110 Engine Data.................................................................112 Engine Removal and Installation.................................................113 Cylinder Head Assembly Repair...................................................113 Engine Breather.............................................................113 Remove..................................................................113 Install.................................................................113 Valve Cover.................................................................114 Remove..................................................................114 Install.................................................................114 Rocker Arm Assembly.........................................................116 Remove..................................................................116 Disassemble.............................................................116 Inspect.................................................................116 Assemble................................................................116 Install.................................................................117 Valve Clearance Adjustments.................................................117 Valve Springs...............................................................118 Cylinder Head Assembly......................................................119 Remove..................................................................119 Inspect.................................................................120 Install.................................................................121 Valves and Valve Springs....................................................122 Remove..................................................................122 Inspect.................................................................123 Install.................................................................123 Valve Guides................................................................124 Inspect.................................................................124 Remove..................................................................124 Install.................................................................124 Valve Seats.................................................................126 Inspect.................................................................126 Repair..................................................................126 New Valve Seats, Install................................................127 Piston and Connecting Rod Assemblies Repair.....................................127 General.....................................................................127 Rod Bearings................................................................128 Remove..................................................................128 Install.................................................................128 Piston and Connecting Rod Assembly..........................................129 Service Note............................................................129 Remove..................................................................129 Disassemble.............................................................130 Inspect.................................................................130 How to Select Correct Replacements......................................131 Assemble................................................................132 Install.................................................................133 Piston Cooling Jets.........................................................134 Remove..................................................................134 Install.................................................................135 Crankshaft Assembly Repair......................................................135 General.....................................................................135 Crankshaft Pulley...........................................................135 Remove..................................................................135 Inspect.................................................................135 Install.................................................................136 Rear Oil Seal...............................................................136 Remove..................................................................136 Install.................................................................136 Crankshaft Flange Wear Sleeve...............................................138 Remove..................................................................138 Install.................................................................138 Main Bearings...............................................................139 Remove..................................................................139 Inspect.................................................................139 Install.................................................................140 Thrust Washers..............................................................141 Crankshaft Axle Movement, Check.........................................141 Remove..................................................................141 Install.................................................................142 Crankshaft..................................................................142 Remove..................................................................142 Inspect.................................................................143 Install.................................................................143 Crankshaft Timing Ring......................................................145 Remove..................................................................145 Install.................................................................145 Flywheel....................................................................145 Remove..................................................................145 Ring Gear, Replace......................................................146 Install.................................................................146 Flywheel Housing............................................................146 Remove..................................................................146 Install.................................................................147 Timing Case and Timing Gears Repair.............................................147 General.....................................................................147 Timing Case Cover...........................................................147 Remove..................................................................147 Install.................................................................148 Front Oil Seal..............................................................149 Remove, With Timing Case Installed......................................149 Install, With Timing Case Installed.....................................149 Remove, With Timing Case Removed........................................150 Install, With Timing Case Removed.......................................150 Crankshaft Pulley Wear Sleeve, Install......................................151 Fuel Pump Gear..............................................................151 Remove..................................................................151 Install.................................................................153 Idler Gear and Hub..........................................................154 Remove..................................................................154 Disassemble.............................................................155 Standard Idler Gear and Hub Assembly................................155 Heavy Duty Idler Gear and Hub Assembly..............................155 Assemble................................................................155 Standard Idler Gear and Hub Assembly................................155 Heavy Duty Idler Gear and Hub Assembly..............................156 Install.................................................................156 Camshaft Gear...............................................................157 Remove..................................................................157 Install.................................................................157 Crankshaft Gear.............................................................158 Remove..................................................................158 Install.................................................................158 Timing Case.................................................................158 Remove..................................................................158 Install.................................................................159 Power Take-Off (PTO) Adaptor................................................160 Remove..................................................................160 Disassemble.............................................................161 Assemble................................................................161 Install.................................................................161 Camshaft and Tappets........................................................161 Remove..................................................................161 Install.................................................................162 Cylinder Block Assembly Repair..................................................162 General.....................................................................162 Cylinder Block..............................................................163 Disassemble.............................................................163 Inspect.................................................................163 Assemble................................................................163 Cylinder Bore...............................................................164 Inspect.................................................................164 Cylinder Liner Condition Check..........................................164 Engine Timing...................................................................164 General.....................................................................164 How to Set Number One Piston to TDC on Compression Stroke...................164 Fuel Injection Pump Timing, Check...........................................166 Fuel Injection Pump Timing, Adjust..........................................167 Lubrication System Repair.......................................................168 General.....................................................................168 Oil Filter, Replace.........................................................168 Oil Filter Head.............................................................169 Remove..................................................................169 Install.................................................................169 Oil Sump....................................................................170 Remove..................................................................170 Install.................................................................170 Oil Pump....................................................................171 Remove..................................................................171 Inspect.................................................................171 Install.................................................................172 Oil Strainer and Suction Pipe...............................................173 Remove..................................................................173 Install.................................................................173 Relief Valve................................................................173 Remove..................................................................173 Install.................................................................173 Dipstick Tube...............................................................174 Remove and Install......................................................174 Fuel System Repair..............................................................174 General.....................................................................174 Cold Start Advance Unit (KSB)...............................................175 Typical Fuel System.........................................................176 Fuel Filter.................................................................177 Remove..................................................................177 Install.................................................................177 Fuel Injectors..............................................................178 Remove..................................................................178 Install.................................................................179 Fuel System Air Removal.....................................................180 Bosch EVPE Fuel Injection Pump..............................................180 General.................................................................180 Remove..................................................................181 Install.................................................................182 Cooling System Repair...........................................................182 General.....................................................................182 Thermostat..................................................................184 Remove..................................................................184 Install.................................................................184 Test....................................................................185 Coolant Pump................................................................185 Remove..................................................................185 Disassemble.............................................................186 Assemble................................................................187 Install.................................................................188 Fan.........................................................................188 Remove and Install......................................................188 Fan Drive...................................................................189 Remove..................................................................189 Install.................................................................189 Oil Cooler..................................................................189 Remove..................................................................189 Disassemble and Assemble................................................189 Install.................................................................190 Coolant By-Pass Hose........................................................190 Removal.................................................................190 Install.................................................................190 Electrical Equipment Repair.....................................................190 Drive Belt..................................................................190 Check...................................................................190 Adjust..................................................................191 Remove..................................................................191 Install.................................................................191 Alternator..................................................................191 Remove..................................................................191 Install.................................................................191 Fault Diagnosis.........................................................192 Normal Operation:...................................................192 If the warning lamp is not illuminated when the ignition switch ....192 If the Warning Light Continues to be Illuminated When the Altern....193 Starter Motor...............................................................193 Remove..................................................................193 Install.................................................................194 Test....................................................................194 Starting Aid................................................................194 Remove..................................................................194 Install.................................................................194 Check...................................................................195 Power Supply Continuity.............................................195 Operation...........................................................195 Pressure Sensor.............................................................196 Remove..................................................................196 Install.................................................................197 Temperature Sensor..........................................................197 Remove..................................................................197 Install.................................................................197 Engine Specifications...........................................................198 Cylinder Head Assembly......................................................198 Piston and Connecting Rods..................................................201 Crankshaft Assembly.........................................................202 Crankshaft Overhaul.....................................................202 Timing Case and Drive Assembly..............................................204 Engine Block Assembly.......................................................205 Lubrication System..........................................................206 Fuel System.................................................................206 Cooling System..............................................................207 Flywheel and Housing........................................................208 Electrical Equipment........................................................208 Torque Specifications...........................................................208 Special Torque Specifications...................................................209 Cylinder Head Assembly......................................................209 Piston and Connecting Rod Assemblies........................................209 Crankshaft Assembly.........................................................209 Timing Case and Drive Assembly..............................................209 Cylinder block..............................................................209 Fuel System.................................................................209 Lubrication System..........................................................209 Cooling System..............................................................210 Flywheel and Housing........................................................210 Electrical Equipment........................................................210 Special Tools...................................................................211 Troubleshooting.................................................................214 tables..............................................................................101 Table 1. Cylinder Head..........................................................198 Table 2. Valve Guides...........................................................198 Table 3. Inlet Valves...........................................................199 Table 4. Exhaust Valves.........................................................199 Table 5. Valve Springs..........................................................200 Table 6. Tappets................................................................200 Table 7. Rocker Arm Shaft.......................................................200 Table 8. Rocker Arms and Bushings...............................................201 Table 9. Pistons................................................................201 Table 10. Piston Rings..........................................................201 Table 11. Piston Pins...........................................................201 Table 12. Connecting Rods.......................................................201 Table 13. Small End Bushings....................................................202 Table 14. Connecting Rod Bearings...............................................202 Table 15. Piston Cooling Jets...................................................202 Table 16. Crankshaft Overhaul Specifications....................................203 Table 17. Maximum Variation (Run-out)...........................................204 Table 18. Camshaft..............................................................204 Table 19. Camshaft Thrust Washer................................................204 Table 20. Camshaft Gear.........................................................204 Table 21. Gear for Fuel Pump....................................................204 Table 22. Crankshaft Gear.......................................................204 Table 23. Idler Gear and Hub....................................................205 Table 24. Timing Gear Backlash Values...........................................205 Table 25. Cylinder Block........................................................205 Table 26. Oil Pump..............................................................206 Table 27. Idler Gear for Oil Pump...............................................206 Table 28. Relief Valve..........................................................206 Table 29. Oil Filter............................................................206 Table 30. Bosch Fuel Injection Pump.............................................206 Table 31. Fuel Injector Settings................................................207 Table 32. Fuel Pump.............................................................207 Table 33. Fuel Filter...........................................................207 Table 34. Coolant Pump..........................................................207 Table 35. Thermostat............................................................207 Table 36. Fan Drive Housing.....................................................208 Table 37. Limits for Flywheel Run Out and Alignment (Total Indic................208 Table 38. Alternator............................................................208 Table 39. Starter Motor.........................................................208 Table 40. Starting Aids.........................................................208 Table 41. List of Possible Causes...............................................215 0700SRM740-1466271(02-2004)-EN..........................................................219 toc.................................................................................219 Cooling System..................................................................219 Safety Precautions Maintenance and Repair.......................................220 General.........................................................................223 Description.....................................................................223 Radiator....................................................................223 Radiator Cap................................................................223 Thermostat..................................................................223 Water Pump..................................................................224 Fan and Fan Shroud..........................................................224 Drive Shaft.................................................................224 Cooling System Checks...........................................................224 Exhaust Leaks into Cooling System...........................................224 Radiator Repair.................................................................224 Checks......................................................................224 Clean.......................................................................224 Cooling System..............................................................226 Drain...................................................................226 Fill....................................................................226 Water Pump Repair...............................................................226 Checks......................................................................226 Thermostat Repair...............................................................227 Checks......................................................................227 Fan Assembly Repair.............................................................227 Remove......................................................................227 Inspect.....................................................................227 Install.....................................................................227 Fan Belt Repair.................................................................230 Remove......................................................................230 Install.....................................................................230 Drive Shaft Repair..............................................................230 Remove......................................................................230 Install.....................................................................230 Troubleshooting.................................................................230 0900SRM745-1466265(09-2003)-EN..........................................................235 toc.................................................................................235 LPG Fuel System.................................................................235 Safety Precautions Maintenance and Repair.......................................236 General.........................................................................239 Description and Operation.......................................................239 Fuel Tank...................................................................239 Fuel Filter and Fuel Valve Unit.............................................239 LPG Convertor Vaporizer (IMPCO).............................................239 LPG Controller (Dana EPIC/Teleflex-GFI).....................................243 Filter Section..........................................................243 Lock-Off Section........................................................243 Converter Section - Primary Regulation (Stage 1)........................243 Converter Section - Secondary Regulation (Stage 2)......................243 Carburetor..................................................................244 Governor....................................................................247 Two-Way Valves, Open-Loop System............................................247 Closed-Loop Fuel Control....................................................247 O.E. Tune Valve, Closed-Loop Fuel System....................................248 Oxygen Sensor, Closed-Loop Fuel System......................................248 LPG Tank Repair.................................................................248 Remove......................................................................248 Install.....................................................................248 Hydrostatic Relief Valve Repair.................................................249 Remove and Install..........................................................249 Filter Unit Repair..............................................................250 Fuel Filter Element, Replace................................................250 Diaphragm and Fuel Valve, Replace...........................................250 Hoses Replacement...............................................................250 LPG Convertor Vaporizer (IMPCO) Repair..........................................252 Remove......................................................................252 Disassemble.................................................................252 Clean.......................................................................252 Inspect.....................................................................252 Assemble....................................................................254 Install.....................................................................258 LPG Controller (Dana EPIC/Teleflex-GFI) Repairs.................................258 Remove......................................................................258 Disassemble.................................................................258 Converter Section.......................................................258 Filter Section..........................................................260 Lock-Off Section........................................................260 Clean.......................................................................262 Inspect.....................................................................262 LPG Controller Assembly.....................................................262 Filter Section..........................................................262 Lock-Off Section........................................................262 Converter Section.......................................................262 Carburetor Repair...............................................................264 Remove......................................................................264 Disassemble.................................................................264 Clean.......................................................................264 Assemble....................................................................265 Install.....................................................................265 Governor Assembly Repair........................................................266 Governor Motor Repair...........................................................268 Remove......................................................................268 Install.....................................................................268 Filter Unit Check...............................................................268 Vaporizer Check.................................................................269 Pressure Reducer Valve......................................................269 Vapor Valve.................................................................269 Carburetor Adjustment...........................................................269 Idle Mixture................................................................269 Idle Speed..................................................................269 Throttle Linkage Adjustment.....................................................269 LPG Controller Adjustments (Dana EPIC/Teleflex-GFI).............................270 Filter and Lock-Off Sections Leak Check.....................................270 Lock-Off Section Functional Check...........................................271 Controller Pressure Test....................................................271 Adjustment of Secondary Lever...............................................272 Final Adjustment Check......................................................272 Troubleshooting.................................................................273 1300SRM0727-1466259(06-2004)-EN.........................................................283 toc.................................................................................283 Two-Speed Powershift Transmission...............................................283 Safety Precautions Maintenance and Repair.......................................284 General.........................................................................287 Mechanical Description..........................................................287 Torque Converter............................................................288 Transmission Pump...........................................................288 Shaft Assemblies............................................................288 Input (Reverse) Shaft.......................................................288 Counter (Forward) Clutch Shafts.............................................288 Clutch Assemblies...........................................................288 Output Gear and Pinion......................................................289 Electronic Control Unit.....................................................289 Hydraulic Operation.............................................................290 Torque Converter............................................................290 Seal Rings..................................................................291 Control Valve...................................................................291 Clutch Pressure Regulator...................................................291 Inching Spool Assembly......................................................291 Direction Spool.............................................................293 Modulator Circuit...........................................................293 Torque Converter Regulator..................................................293 MONOTROL® Pedal.................................................................294 MONOTROL Pedal Start Circuit................................................294 Direction Control Lever.........................................................295 Oil Flow Diagrams...............................................................295 Neutral.....................................................................295 Modulator Operation.........................................................297 Forward-Low.................................................................300 Forward-Low-Inching.........................................................300 Reverse.....................................................................304 1300SRM0728-1466253(06-2004)-EN.........................................................311 toc.................................................................................311 Two-Speed Powershift Transmission...............................................311 Safety Precautions Maintenance and Repair.......................................312 General.........................................................................315 Transmission Repair.............................................................315 Remove......................................................................315 Install.....................................................................315 Clutch Packs Repair.............................................................318 Remove and Disassemble......................................................318 Clutch Assemblies, Disassemble..........................................321 Inspect.....................................................................323 Assemble and Install........................................................324 Clutch Assemblies, Assemble and Install.................................324 Differential Repair.............................................................332 Remove and Disassemble......................................................332 Inspect.....................................................................333 Original Parts, Assemble and Install........................................333 New Parts, Assemble and Install.............................................333 Adjustments With Original Shim Pack.....................................334 Adjustments Without Original Shim Pack..................................335 Differential and Ring Gear Assembly, Assemble...........................337 Control Valve Repair............................................................342 Remove and Disassemble......................................................342 Inspect.....................................................................344 Assemble and Install........................................................344 MONOTROL® Pedal Repair..........................................................345 Remove and Disassemble......................................................345 Assemble and Install........................................................345 Direction Control Lever.........................................................348 Remove and Disassemble......................................................348 Assemble and Install........................................................348 Stall Test......................................................................349 Inching/Brake Pedal Adjustment..................................................350 MONOTROL® Pedal Neutral Start Switch Adjustment.................................352 MONOTROL® Pedal Neutral Start Switch Test.......................................353 Test 1......................................................................353 Test 2......................................................................353 Electronic Control Unit Check...................................................354 Oil Pressure Check..............................................................355 Transmission Pump Relief Valve, Test Port 1, Check..........................356 Input (Reverse) Clutch Pressure, Test Port 2, Check.........................356 Counter (Forward) Clutch Pressure, Test Ports 3 and 4, Check................356 Torque Converter Regulator, Test Port 5, Check..............................356 Lubrication Circuit Oil Pressure, Test Port 6, Check........................356 Modulator Pressure, Test Port 7, Check......................................356 2-Speed Transmission Will Not Shift.............................................357 Troubleshooting.................................................................358 Troubleshooting - Pressure Tests................................................361 tables..............................................................................311 Table 1. Pinion Variation Numbers Examples......................................334 Table 2. Ring and Pinion Tooth Contact Adjustment...............................340 Table 3. Stall Speeds (New Engines).............................................349 Table 4. Electronic Control Unit Connector......................................354 Table 5. Transmission Pressure Port Check.......................................355 1300SRM800-1480352(03-2004)-EN..........................................................365 toc.................................................................................365 Hydrostatic Transmission........................................................365 Safety Precautions Maintenance and Repair.......................................366 General.........................................................................369 Component Descriptions..........................................................369 Power Unit General Arrangement..............................................369 Hydrostatic Pump Mounting...................................................370 Perkins 1004-42 and 1104C-44(RE) Diesel Engines.........................370 GM 4.3L LPG Engine......................................................370 Hydrostatic Control Components..............................................370 Hydrostatic System Operation....................................................373 Hydrostatic Pump............................................................374 Drive Axle..................................................................374 Transmission Control Module (TCM)...........................................376 Perkins 1004-42 Diesel Engine Trucks....................................376 Perkins 1104C-44(RE) Diesel and GM 4.3L LPG Engine Trucks...............376 Transmission Control Inputs.............................................379 Key Switch..........................................................379 Forward/Reverse Switches, Perkins 1004-42 Diesel Engine Trucks......379 Forward/Reverse Switches, Perkins 1104C-44(RE) Diesel and GM 4.3....379 Parking Brake Switches..............................................379 Engine Speed Sensor.................................................379 Wheel Speed Sensors, Perkins 1104C-44(RE) Diesel and GM 4.3L LPG....382 Brake Pressure Sensor...............................................382 Charge Pressure Sensor..............................................382 Transmission Oil Temperature Sensor.................................382 Throttle Pedal Switch, Perkins 1004-42 Diesel Engine Trucks.........382 Throttle Pedal Switch, Perkins 1104C-44(RE) Diesel and GM 4.3L L....382 Throttle Pedal Position Sensor, Perkins 1004-42 Diesel Engine Tr....382 Throttle Pedal Position Sensor, Perkins 1104C-44(RE) Diesel and ....384 Transmission Control Outputs............................................384 Forward/Reverse Solenoid Enable, Perkins 1004-42 Diesel Engine T....384 Forward/Reverse Solenoid Enable, Perkins 1104C-44(RE) Diesel and....384 Forward/Reverse Solenoids, Perkins 1104C-44(RE) Diesel and GM 4.....384 Engine Start Enable.................................................384 Fuel Cutoff Relay...................................................386 Retard Valve........................................................386 Pilot Solenoid Valve, Perkins 1004-42 Diesel Engine Trucks..........386 Pilot Solenoid Valve Enable, Perkins 1104C-44(RE) Diesel and GM ....386 Transmission Fault Warning Light....................................386 Transmission Overspeed Warning Light................................386 Oil Temperature Warning Light.......................................386 Throttle-Up Inputs......................................................387 Lift Lever Switch, Perkins 1004-42 Diesel Engine Trucks.............387 Lift Lever Position Sensor, Perkins 1004-42 Diesel Engine Trucks....387 Lift Lever Switch, Perkins 1104C-44(RE) and GM 4.3L LPG Engine T....387 Lift Lever Position Sensor, Perkins 1104C-44(RE) and GM 4.3L LPG....387 Tilt/Auxiliary Lever Switches, Perkins 1004-42 Diesel Engine Tru....387 Tilt/Auxiliary Lever Switches, Perkins 1104C-44(RE) Diesel and G....387 Engine Throttle Position Sensor, Perkins 1004-42 Diesel Engine T....387 Throttle-Up Outputs, Perkins 1004-42 Diesel Engine Trucks...............388 Throttle-Up Motor...................................................388 Throttle Servo Motor - Perkins 1104C-44(RE) Diesel and GM 4.3L L........388 Transmission Control Module (TCM) Operation.....................................389 How the TCM Begins Operation................................................389 TCM Operation on a Running Lift Truck.......................................389 Lift Trucks With Perkins 1004-42 Diesel Engine..........................389 Lift Trucks With Perkins 1104C-44(RE) Diesel and GM 4.3L LPG Eng........389 Event and Fault Detection...................................................389 Diagnostic Connector........................................................390 Hydrostatic Transmission Features...............................................390 Travel Control..............................................................390 Lift Trucks With The Perkins 1004-42 Diesel Engine......................390 Lift Trucks With the Perkins 1104C-44(RE) Diesel and GM 4.3L LPG........390 Antistall...................................................................391 Dynamic Braking.............................................................391 Brake Inching...............................................................391 Overspeed Control...........................................................391 Hydraulic Retard............................................................392 Wheel Anti-spin.............................................................392 Temperature Compensation....................................................392 Low Charge Pressure Compensation............................................393 Quick-Roll..................................................................394 Throttle-Up (Option)........................................................394 Perkins 1004-42 Diesel Engine Lift Trucks Only..........................394 Hydraulic Circuit...............................................................394 Loop Circuit................................................................394 Charge Circuit..............................................................397 Pilot Supply Circuit........................................................397 Pilot Control Circuit.......................................................397 Retard Circuit..............................................................398 Cooling Oil Supply Circuit..................................................398 Cooling Circuit.............................................................398 tables..............................................................................365 Table 1. Electronic Transmission Control System - Perkins 1004-4................372 Table 2. Electronic Transmission Control System - Perkins 1104C-................372 1300SRM801-1480353(03-2004)-EN..........................................................401 toc.................................................................................401 Hydrostatic Transmission........................................................401 Safety Precautions Maintenance and Repair.......................................402 General.........................................................................407 TransLink™ User Interface Software..........................................407 Connecting PC to TCM....................................................407 Transmission Fluid..........................................................408 Startup and Calibration.........................................................410 Startup Procedure Following Service or Repairs..............................410 Throttle System Calibration.................................................411 Perkins 1004-42 Diesel Engine...........................................411 Perkins 1104C-44(RE) Diesel Engine and GM 4.3L LPG Engine...............412 Throttle System Calibration Checks..........................................412 Perkins 1104C-44(RE) Diesel Engine and GM 4.3L LPG Engine Lift T........412 Hydrostatic Pump Repair.........................................................413 Remove......................................................................413 Install.....................................................................415 Charge Pump Repair..............................................................417 Remove......................................................................417 Inspect.....................................................................417 Install.....................................................................417 Pump Control Valve Repair.......................................................419 Remove......................................................................419 Inspect.....................................................................419 Install.....................................................................419 Replace Pilot Solenoid......................................................419 Replace Directional Solenoid Pair...........................................419 Clean or Replace Pilot Supply Filter Disk...................................419 Replace Loop Relief Cartridges..............................................420 Replace Filter Cartridge....................................................420 Replace Filter Head.........................................................421 Drive Axle Repair...............................................................421 Remove and Disassemble......................................................421 Inspect.....................................................................424 Assemble and Install........................................................424 Wheel Speed Sensors, Replace................................................425 Lift Trucks With Perkins 1104C-44(RE) Diesel Engine and GM 4.3L ........425 Axle Valve Repair...............................................................425 Remove......................................................................425 Inspect.....................................................................425 Install.....................................................................425 Replace Pressure Reducing Valve.............................................425 Replace Shuttle Valve.......................................................426 Replace Charge Supply Regulator.............................................426 Replace Retard Valve........................................................426 Replace Temperature Sensor..................................................426 Transmission Control Module (TCM) Replacement...................................427 Throttle Pedal/ MONOTROL® Pedal Repair..........................................427 Remove Standard Throttle Pedal..............................................427 Install Standard Throttle Pedal.............................................427 Lift Trucks With Perkins 1004-42 Diesel Engine..........................427 Lift Trucks With Perkins 1104C-44 (RE) Diesel Engine and GM 4.3L........428 Remove and Disassemble MONOTROL Pedal.......................................428 Assemble and Install MONOTROL Pedal.........................................428 Replace Throttle Pedal Position Sensor......................................430 Replace Throttle Pedal Switch...............................................431 Throttle-Up Assembly Replace - Perkins 1004-42 Diesel Engine....................432 Remove......................................................................432 Inspect.....................................................................432 Install.....................................................................432 Replace Throttle Motor......................................................433 Replace Engine Throttle Position Sensor.....................................433 Throttle Servo Motor Replace - Perkins 1104C-44(RE) Diesel and G................433 Remove......................................................................433 Perkins 1104C-44(RE) Diesel Engine......................................433 GM 4.3L LPG Engine......................................................433 Inspect.....................................................................435 Install.....................................................................435 Perkins 1104C-44(RE) Diesel Engine......................................435 GM 4.3L LPG Engine......................................................435 Throttle-Up Switch Assembly Repair..............................................437 Remove......................................................................437 Install.....................................................................437 Replace Lift Lever Position Sensor..........................................437 Replace Throttle-Up Switches................................................437 Hydrostatic Drive Checks and Adjustments........................................438 Swashplate Positioning Cylinder.............................................438 Truck Travel Speed Limit Adjustment.........................................439 Perkins 1004-42 Diesel Engine...........................................439 Perkins 1104C-44(RE) Diesel Engine and GM 4.3L LPG Engine...............439 Charge Pressure.............................................................439 Pilot Supply Pressure.......................................................440 Pilot Pressure..............................................................440 POR Pressure................................................................440 Loop Pressure...............................................................440 Throttle Pedal/ MONOTROL Pedal Checks and Adjustments...........................441 Throttle Cable..............................................................441 Perkins 1004-42 Diesel Engine Trucks....................................441 Pedal Stop..................................................................441 Standard Throttle Pedal.................................................441 Perkins 1004-42 Diesel Engine Trucks................................441 Perkins 1104C-44(RE) Diesel and GM 4.3L LPG Engine Trucks...........441 MONOTROL Pedal..........................................................441 Perkins 1004-42 Diesel Engine Trucks................................441 Perkins 1104C-44(RE) Diesel and GM 4.3L LPG Engine Trucks...........441 MONOTROL Pedal Operation....................................................441 Throttle Pedal Position Sensor..............................................441 Throttle Pedal Switch.......................................................442 MONOTROL Pedal Switch.......................................................443 Throttle-Up Assembly Checks and Adjustments.....................................444 Engine Throttle Position Sensor.............................................444 Throttle-Up Motor...........................................................445 Throttle Servo Motor Checks and Adjustments.....................................445 Throttle Servo Motor Position Sensor........................................445 Throttle Servo Motor........................................................446 Throttle-Up Switch Assembly Checks and Adjustments..............................447 Throttle-Up Switches........................................................447 Lift Lever Position Sensor..................................................447 Sensor Checks...................................................................448 Charge Pressure Sensor......................................................448 Brake Pressure Sensor.......................................................448 Oil Temperature Sensor......................................................449 Engine Speed Sensor.........................................................449 Left Speed Sensor.......................................................450 Right Speed Sensor......................................................451 Event Codes.....................................................................451 Perkins 1004-42 Diesel Engine Trucks........................................451 Event Code Descriptions - Perkins 1004-42 Diesel Engine Trucks..............452 Perkins 1104C-44(RE) Diesel Engine and GM 4.3L LPG Trucks...................458 Event Code Descriptions - Perkins 1104C-44(RE) Diesel and GM 4.3............459 Troubleshooting.................................................................468 Perkins 1004-42 diesel engine trucks only...................................472 Perkins 1004-42 diesel engine trucks only...................................473 Perkins 1104C-44(RE) diesel and GM 4.3L LPG engine trucks...................473 Perkins 1104C-44(RE) diesel and GM 4.3L LPG engine trucks...................473 tables..............................................................................401 Table 1. Charge and Brake Sensor Outputs........................................449 Table 2. Oil Temperature Sensor Outputs.........................................449 Table 3. Engine Speed Sensor Outputs............................................450 Table 4. Wheel Speed Sensor Outputs - Perkins 1104C-44(RE) Diese................450 1400SRM731-1466247(09-2003)-EN..........................................................479 toc.................................................................................479 Drive Axle......................................................................479 Safety Precautions Maintenance and Repair.......................................480 General.........................................................................483 Description.....................................................................483 Drive Axle Repair...............................................................483 Remove and Disassemble......................................................483 Clean and Inspect...........................................................485 Assemble and Install........................................................485 Troubleshooting.................................................................487 1600SRM732-1466241(10-2003)-EN..........................................................491 toc.................................................................................491 Steering Control Unit...........................................................491 Safety Precautions Maintenance and Repair.......................................492 General.........................................................................495 Description.....................................................................495 Operation.......................................................................495 Steering Wheel and Column Assembly Repair.......................................497 Remove and Disassemble......................................................497 Assemble and Install........................................................497 Steering Control Unit.......................................................500 Disassemble.............................................................500 Clean...................................................................502 Assemble................................................................503 System Air Removal..............................................................506 Troubleshooting.................................................................506 1600SRM733-1466235(09-2003)-EN..........................................................511 toc.................................................................................511 Steering Axle...................................................................511 Safety Precautions Maintenance and Repair.......................................512 General.........................................................................515 Description.....................................................................515 Steering Axle Assembly Repair...................................................516 Remove......................................................................516 Install.....................................................................516 Wheels and Hub Repair...........................................................517 Remove and Disassemble......................................................517 Clean.......................................................................517 Inspect.....................................................................517 Assemble and Install........................................................517 Spindles and Bearings Repair....................................................518 Remove......................................................................518 Clean.......................................................................518 Inspect.....................................................................518 Assemble and Install........................................................518 Tie Rods Repair.................................................................519 Remove......................................................................519 Clean.......................................................................519 Inspect.....................................................................519 Install.....................................................................519 Steering Cylinder Repair........................................................519 Remove and Disassemble......................................................519 Clean and Inspect...........................................................520 Assemble and Install........................................................520 Troubleshooting.................................................................521 1800SRM734-1466229(03-2004)-EN..........................................................525 toc.................................................................................525 Brake System....................................................................525 Safety Precautions Maintenance and Repair.......................................526 General.........................................................................529 Description and Operation.......................................................529 Brake Booster and Master Cylinder...........................................529 Service Brake Assembly......................................................529 Parking Brake...............................................................530 Brake Shoe Assemblies Repair....................................................530 Remove and Disassemble......................................................530 Clean.......................................................................533 Inspect.....................................................................533 Assemble and Install........................................................533 Brake Booster and Master Cylinder Repair........................................535 Remove......................................................................535 Disassemble.................................................................535 Clean and Inspect...........................................................535 Assemble....................................................................535 Install.....................................................................537 Brake Booster Filter, Replace...............................................538 Parking Brake Repair............................................................538 Remove and Disassemble......................................................538 Assemble and Install........................................................538 Brake System Air Removal........................................................538 Brake Pedal Adjustment..........................................................539 Parking Brake Adjustment........................................................539 Parking Brake Not Applied Switch Test...........................................540 Parking Brake Switch Test ( MONOTROL® Pedal Only)...............................540 Brake Shoes Adjustment..........................................................541 Troubleshooting.................................................................541 1900SRM743-1466217(10-2003)-EN..........................................................547 toc.................................................................................547 Hydraulic System................................................................547 Safety Precautions Maintenance and Repair.......................................548 General.........................................................................551 Description.....................................................................551 Operation.......................................................................553 Hydraulic Pump H3.50-5.50XM (H70-120XM).....................................553 Hydraulic Pump S3.50-5.50XM (S70-120XM).....................................553 Main Control Valve..........................................................554 Steering Control Unit.......................................................554 Specifications..................................................................555 Hydraulic System Capacity...................................................555 Hydraulic Tank Capacity.....................................................555 Relief Pressures @ 2200 rpm, 50 to 80 C ( 120 to 180 F).....................555 Hydraulic Pump Flow to Valve................................................555 Steering Priority Flow......................................................555 Troubleshooting.................................................................556 Lift, Lower and Tilt Circuit................................................556 Steering Circuit............................................................557 1900SRM753-1466223(09-2003)-EN..........................................................561 toc.................................................................................561 Hydraulic Gear Pump.............................................................561 Safety Precautions Maintenance and Repair.......................................562 General.........................................................................565 Description.....................................................................565 Operation.......................................................................565 Hydraulic Gear Pump Repair......................................................566 Remove......................................................................566 Disassemble.................................................................566 Clean.......................................................................566 Inspect.....................................................................568 Assemble....................................................................568 Install.....................................................................569 Pump Output Check...............................................................570 Method No. 1................................................................570 Method No. 2................................................................571 Hydraulic System Air Check......................................................572 Troubleshooting.................................................................572 2000SRM754-1466211(12-2003)-EN..........................................................577 toc.................................................................................577 Main Control Valve..............................................................577 Safety Precautions Maintenance and Repair.......................................578 General.........................................................................581 Description.....................................................................581 Operation.......................................................................581 Lift Section................................................................581 Tilt and Auxiliary Sections.................................................585 Reattaching the Clevis End of the Tilt Spool............................586 Relief Valve................................................................586 Main Control Valve Repair.......................................................586 Remove and Disassemble......................................................586 Clean and Inspect...........................................................588 Assemble....................................................................590 Install.....................................................................590 Pressure Relief Valve Check and Adjustment......................................591 Main Relief Valve (Lift)....................................................591 Steering Relief Valve.......................................................591 Secondary Relief Valve (Tilt and Auxiliary).................................594 Specifications..................................................................595 Troubleshooting.................................................................595 2100SRM735-1466205(09-2003)-EN..........................................................601 toc.................................................................................601 Tilt Cylinders..................................................................601 Safety Precautions Maintenance and Repair.......................................602 General.........................................................................605 Description.....................................................................605 Tilt Cylinder Repair............................................................605 Remove......................................................................605 Disassemble.................................................................606 Clean.......................................................................607 Inspect.....................................................................607 Assemble....................................................................607 Install.....................................................................607 Tilt Cylinder Leak Check........................................................608 Tilt Cylinder Stroke and Mast Tilt Angle Adjustment.............................608 Troubleshooting.................................................................608 2200SRM002-899784(10-2003)-EN...........................................................613 toc.................................................................................613 Alternator with Regulator.......................................................613 Safety Precautions Maintenance and Repair.......................................614 General.........................................................................617 Description.....................................................................617 Alternator Repair...............................................................619 Alternator Type A...........................................................619 Remove and Disassemble..................................................619 Clean...................................................................620 Assemble................................................................621 Install.................................................................621 Alternator Type B...........................................................624 Remove and Disassemble..................................................624 Clean...................................................................624 Assemble................................................................625 Install.................................................................626 General Check and Adjustment....................................................627 Low Output Check (Type A or Type B).............................................627 High Output Check (Type A or Type B)............................................629 Brushes Circuit Check...........................................................630 Delco Alternators...........................................................630 Motorola Alternators........................................................631 Diodes Check....................................................................632 Diode Bridge Check..............................................................632 Delco and Leece-Neville Alternators.........................................632 Motorola Alternators........................................................632 Rotor Field Winding Check.......................................................633 Stator Windings Check...........................................................634 Voltage Regulator Check.........................................................634 Troubleshooting.................................................................634 2200SRM744-1466175(09-2003)-EN..........................................................639 toc.................................................................................639 Carbureted Engine Management System (CEMS)......................................639 Safety Precautions Maintenance and Repair.......................................640 Description.....................................................................643 Ignition Control System.........................................................644 Setting Timing Reference....................................................644 Idle Speed Control System...................................................644 Curb Idle Setting Procedure.................................................645 Governor Control System.........................................................645 Closed-Loop Fuel System.........................................................646 Closed-Loop Fuel Control....................................................646 Entering Closed-Loop Control................................................646 Normal Closed-Loop Operation................................................646 Closed-Loop Diagnostics.....................................................646 O.E. Tune Valve Action at Engine Shutdown...................................646 Diagnostic System...............................................................647 Closed-Loop Diagnostic Troubleshooting......................................648 Diagnostic Troubleshooting..................................................648 tables..............................................................................639 Table 1. Diagnostic Codes.......................................................647 Table 2. Diagnostic Troubleshooting.............................................648 2200SRM755-1466193(11-2001)-EN..........................................................657 toc.................................................................................657 Starter.........................................................................657 Safety Precautions Maintenance and Repair.......................................658 General.........................................................................661 Description.....................................................................661 Yoke Assembly...............................................................662 Armature Assembly...........................................................662 Clutch Assembly.............................................................662 Magnetic Switch Assembly....................................................662 Operation.......................................................................662 Starter Repair..................................................................663 Remove......................................................................663 Disassemble.................................................................664 Clean.......................................................................667 Assemble....................................................................668 Install.....................................................................671 General Checks and Adjustments..................................................671 Armature Tests..................................................................672 Armature Short Circuit Test.................................................672 Armature Winding Ground Test................................................672 Commutator Run-Out Test.....................................................672 Yoke Test.......................................................................673 Brush and Brush Holder Check....................................................673 Brush Holder Insulation Test................................................673 Clutch Test.................................................................673 Magnetic Switch Test............................................................674 Pull-In Test................................................................674 Hold-In Test................................................................674 Return Test.................................................................674 Performance Tests...............................................................675 No-Load Test................................................................675 Troubleshooting.................................................................675 2200SRM756-1468474(11-2003)-EN..........................................................681 toc.................................................................................681 Instrument Panel Indicators and Senders.........................................681 Safety Precautions Maintenance and Repair.......................................682 General.........................................................................685 Description.....................................................................685 Instruments and Senders.....................................................685 Password Function...........................................................692 Supervisor Password Function............................................692 Entering Operator Passwords.........................................692 Deleting Operator Passwords.........................................693 Retrieve the Most Recent Operator Password Used to Enable the Tr....693 Display All Operator Passwords Programmed Into the System...........693 Enable and Disable Operator Passwords Function......................693 Allow Supervisor Password to Enable the Truck to Start..............693 Operator Passwords Function.............................................693 Component Replacement - General Information.....................................694 Sender Replacement..............................................................694 Fuel Level Sender...........................................................694 Pressure and Temperature Sender.............................................695 Display Panel Replacement.......................................................696 Specifications..................................................................698 Troubleshooting.................................................................699 tables..............................................................................681 Table 1. Instrument Panel Description...........................................686 Table 2. Sender Description.....................................................691 Table 3. Meter and Sender Specifications........................................698 4000SRM736-1466163(10-2003)-EN..........................................................703 toc.................................................................................703 Masts...........................................................................703 Safety Precautions Maintenance and Repair.......................................704 General.........................................................................707 Description and Operation.......................................................707 Carriages...................................................................707 Two-Stage Mast With Limited Free-Lift.......................................707 Two-Stage Mast With Full Free-Lift..........................................708 Three-Stage Mast With Full Free-Lift........................................709 Safety Procedures When Working Near Mast........................................711 Fork Replacement................................................................713 Remove......................................................................714 Install.....................................................................714 Carriage Repair.................................................................715 Remove......................................................................715 Sideshift Carriage Repair.......................................................716 Remove......................................................................716 Disassemble.................................................................716 Assemble....................................................................716 Install.....................................................................717 Two-Stage Mast With Limited Free-Lift Repair....................................718 Remove - H3.50-5.50XM (H70-120XM) Model Lift Trucks.........................718 Remove - S3.50-5.50XM (S70-120XM) and E3.50-5.50XL 3 (E70-120XL ............718 Disassemble.................................................................718 Clean and Inspect...........................................................722 Assemble....................................................................723 Install - H3.50-5.50XM (H70-120XM) Lift Truck Models........................724 Install - S3.50-5.50XM (S70-120XM) and E3.50-5.50XL 3 (E70-120XL............726 Two-Stage Mast With Full Free-Lift Repair.......................................728 Remove......................................................................728 Disassemble.................................................................728 Clean and Inspect...........................................................730 Assemble....................................................................730 Install.....................................................................730 Three-Stage Mast With Full Free-Lift Repair.....................................732 Remove......................................................................732 Disassemble.................................................................732 Clean and Inspect...........................................................735 Assemble....................................................................735 Install.....................................................................737 Mast Operation Check............................................................741 Lift and Tilt System Leak Check.................................................741 Lift System.................................................................741 Tilt System.................................................................742 Tilt Cylinder Stroke and Backward Tilt Angle Adjustment.........................743 Lift Chain Adjustments..........................................................744 Mast Adjustments................................................................747 Carriage Adjustment.............................................................749 Troubleshooting.................................................................749 tables..............................................................................703 Table 1. Tilt Cylinder Leak Check Specifications, S3.50-5.50XM (................743 Table 2. Hook type Carriage Chain Adjustment....................................745 Table 3. Pin-Type Carriage Chain Adjustment.....................................745 4000SRM741-1466169(10-2003)-EN..........................................................755 toc.................................................................................755 Lift Cylinders..................................................................755 Safety Precautions Maintenance and Repair.......................................756 Safety Procedures When Working Near Mast........................................759 General.........................................................................761 Description.....................................................................761 Lowering Control Valve (Velocity Fuse)......................................761 Lift Cylinder Repair............................................................764 Remove......................................................................764 Disassemble.................................................................765 Assemble....................................................................765 Install.....................................................................766 Lift System Leak Check..........................................................766 Troubleshooting.................................................................767 8000SRM231-910442(03-2004)-EN...........................................................771 toc.................................................................................771 Metric and Inch (SAE) Fasteners.................................................771 Safety Precautions Maintenance and Repair.......................................772 General.........................................................................775 Threaded Fasteners..........................................................775 Nomenclature, Threads.......................................................775 Strength Identification.....................................................776 Cotter (Split) Pins.........................................................776 Fastener Torque Tables......................................................781 Conversion Table............................................................783 tables..............................................................................771 Table 1. Bolts and Screws.......................................................777 Table 2. Studs and Nuts.........................................................778 Table 3. Torque Nuts............................................................779 Table 4. Torque Nuts With Nylon Insert..........................................780 Table 5. Torque Values for Metric Fasteners*....................................781 Table 6. Torque Values for Inch Fasteners*......................................782 Table 7. Conversion Table for Metric and English Units..........................783 Table 8. Cotter Pin Dimensional Data............................................784 Table 9. Cotter Pin Dimensional Data............................................785 Table 10. Cotter Pin Dimensional Data...........................................786 Table 11. Cotter Pin Dimensional Data...........................................788 8000SRM737-1467763(03-2004)-EN..........................................................791 toc.................................................................................791 Periodic Maintenance............................................................791 Safety Precautions Maintenance and Repair.......................................792 General.........................................................................797 Serial Number Data..........................................................797 How to Move Disabled Lift Truck.............................................797 How to Tow Lift Truck...................................................797 How to Put Lift Truck on Blocks.............................................798 How to Raise Drive Tires................................................798 How to Raise Steering Tires.............................................798 Maintenance Schedule............................................................799 Maintenance Procedures Every 8 Hours or Daily...................................813 How to Make Checks With Engine Stopped......................................813 Engine Oil..............................................................814 Hydraulic System Oil....................................................814 Cooling System..........................................................815 Heavy Duty Precleaner...................................................815 Fuel System.............................................................816 Battery.................................................................816 Tires and Wheels........................................................816 Forks...................................................................817 Adjust..............................................................818 Hook Fork, Remove...................................................818 Hook Fork, Install..................................................818 Forks, Mast, and Lift Chains, Inspect...................................819 Operator Restraint System...............................................820 Safety Labels...........................................................820 How to Make Checks With Engine Running......................................821 Gauges, Lights, Horn, and Fuses.........................................821 Engine Oil Pressure.....................................................821 Cooling System..........................................................824 Powershift Transmission Oil Level Check.................................824 Hydrostatic Transmission Oil Level Check................................825 Control Levers and Pedals...............................................825 Lift System Operation...................................................825 Inching/Brake Pedal.....................................................826 Service Brakes..........................................................826 Parking Brake...........................................................826 Steering System.........................................................826 Maintenance Procedures Every 250 Hours or 6 Weeks...............................827 Engine Oil and Filter, GM V-6 EPA Compliant Engine (Americas Onl............827 Air Filter, GM V-6 EPA Compliant Engine.....................................827 Maintenance Procedures Every 500 Hours or 2 Months..............................828 Lift Chains Lubrication.....................................................828 Air Filter..................................................................828 Hydraulic Pump Drive Shaft..................................................828 Engine Oil and Filter, Diesel and GM V-6 (European Only)....................828 Drive Belts.................................................................829 Fan Drive Belts.........................................................829 Perkins Diesel Engine.......................................................829 Alternator Drive Belt...................................................829 GM 4.3L Engine..............................................................830 Serpentine Drive Belt...................................................830 Hydraulic Tank Breather, Clean and Check....................................831 Hydrostatic Transmission Filter.............................................831 Filter Cartridge, Replace...............................................831 Filter Head, Replace....................................................831 Brake Fluid.................................................................832 Lift Chains Wear Check......................................................832 Forks, Wear and Damage Check................................................833 Mast, Lubrication...........................................................833 Control Levers and Pedals, Lubrication......................................834 Steering Axle, Lubrication..................................................834 Fuel System, Checks and Adjustments.........................................834 LPG Carburetor..........................................................834 Fuel Injection (Perkins Engine).........................................834 GM V-6 Engine...........................................................834 Cooling System, Clean Debris from Radiator Core.............................834 Maintenance Procedures Every 1000 Hours or 6 Months.............................835 PCV Valve, GM V-6...........................................................835 Crankcase Breather, GM-V6...................................................835 Spark Plug Replacement......................................................835 Remove..................................................................835 Install.................................................................835 Valve Clearance, Check and Adjust...........................................835 Water Separator, Diesel Engine..............................................836 Fuel Filter, Replace (Diesel Engine)........................................836 Fuel System Air Removal, Perkins (1004.42 Diesel Engine)....................836 Differential and Drive Axle.............................................838 Cooling System, GM V-6 EPA Compliant Engine.................................838 LPG Fuel Filter GM V-6 EPA Compliant Engine, Replace........................838 Inspect Engine Electrical System, Connectors, and FCVS Connectio............839 Maintenance Procedures Every 2000 Hours or Yearly...............................839 Differential Thrust Screw...................................................839 Hydraulic System............................................................840 Hydraulic Oil and Filter, Replace.......................................840 Powershift Transmission Oil and Filter, Replace.............................841 Hydrostatic Transmission Oil and Filter, Replace............................841 Cooling System..............................................................842 Wheel Bearings..............................................................842 Steering Wheels, Lubrication............................................842 Drive Wheels, Lubrication...............................................842 PCV Valve, GM V-6...........................................................842 Service Brakes..............................................................842 Brake Booster Filter, Replace...............................................843 LPG Filter, Replace (Pre-2004)..............................................843 Gasoline Fuel Filter, Replace...............................................843 Operator Restraint System...................................................843 Oxygen Sensor (Pre 2004)....................................................844 Oxygen Sensor GM V-6 EPA Compliant Engine...................................844 Air Filter Element, GM V-6 EPA Compliant Engine.............................844 Inspect Low Pressure Regulator (LPR) for Oil Buildup and Leaks..............844 Check Throttle Shaft for Sticking...........................................845 Inspect Exhaust Manifold and Piping for Leaks...............................845 Test LPG/GAS Regulator Pressure.............................................845 Safety Procedures When Working Near Mast........................................846 Lift Chain Adjustments..........................................................848 Fuel Injectors Repair...........................................................849 Lift and Tilt System Leak Check.................................................850 Lift Cylinders, Leak Check..................................................850 Tilt Cylinders, Leak Check..................................................850 Welding Repairs.................................................................851 Overhead Guard Changes..........................................................851 Wheel and Tire Replacement......................................................852 Remove Wheels From Lift Truck...............................................852 Remove Wheel From Tire......................................................853 Remove Tire From Two-Piece Wheel........................................854 Remove Tire From Three- and Four-Piece Wheel............................856 Install Wheel in Tire.......................................................857 Install Tire on Three- or Four-Piece Wheel..............................858 Install Tire in Two-Piece Wheel.........................................859 Add Air to Tires............................................................860 Wheels, Install.............................................................860 Dual Drive Wheels Installation..................................................860 Solid Rubber Tire Repair........................................................861 Wheel, Tire Remove..........................................................861 Wheel, Tire Install.........................................................863 SIT Tire, Change for H3.50-5.50XM (European Trucks Only)....................864 Remove SIT Solid Tire From Wheel........................................865 Install SIT Solid Tire on Wheel.........................................866 Adhesives and Sealants..........................................................867 Hydraulic Oil, Lubricant, and Coolant Specifications............................868 tables..............................................................................791 Table 1. Maintenance Schedule...................................................803 Table 2. Hook-Type Carriage Chain Adjustment....................................848 Table 3. Pin-Type Carriage Chain Adjustment.....................................849 8000SRM738-1467764(05-2004)-EN..........................................................871 toc.................................................................................871 Capacities and Specifications...................................................871 Safety Precautions Maintenance and Repair.......................................872 Lift Truck Weights..............................................................875 Electrical System...............................................................875 Stall Speeds....................................................................875 Capacities......................................................................876 Tire Pressure...................................................................876 Engine Specifications...........................................................877 Transmission Oil Pressures......................................................878 Hydraulic System................................................................879 Mast Speeds.....................................................................880 Torque Specifications...........................................................880 Brake System................................................................880 Differential................................................................880 Drive Axle..................................................................881 Engine, GM V-6 4.3 Liter....................................................881 Engine, Perkins 1004-42.....................................................882 Frame.......................................................................882 Lift Cylinders..............................................................882 Main Control Valve..........................................................882 Masts.......................................................................882 Powershift Transmission.....................................................883 Steering System.............................................................883 Tilt Cylinders..............................................................883 Hydrostatic Components......................................................883 tables..............................................................................871 Table 1. Single-Speed...........................................................878 Table 2. Two-Speed..............................................................878 Table 3. Hydrostatic Transmission...............................................879 8000SRM757-1467765(05-2004)-EN..........................................................887 toc.................................................................................887 Diagrams........................................................................887 Safety Precautions Maintenance and Repair.......................................888
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