Complete service repair manual for Hyster G005 (H70-110XL & H3.50-5.00XL Europe) Forklift Trucks, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Hyster G005 (H70-110XL & H3.50-5.00XL Europe) workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

Hyster G005 (H70-110XL & H3.50-5.00XL Europe) Service Manual.pdf

Total Pages: 793 + 663 pages
File Format: PDF
Language: English

G005 (H3.50-5.00XL Europe)...2
  100345...4
    THE FRAME...4
      GENERAL...4
      DESCRIPTION...4
      REPAIRS...4
      COUNTERWEIGHT...4
        Removal...4
      COUNTERWEIGHT...5
        Installation...5
      HOOD...5
        Removal...5
      HOOD...5
        Installation...5
      OVERHEAD GUARD...6
        Removal...6
        Installation...6
      OPERATOR RESTRAINT SYSTEM...6
      RADIATOR...6
        Removal...6
        Installation...7
      EXHAUST SYSTEM...7
        Muffler Replacement...7
      ENGINE...7
        Removal...7
        Installation...10
      FUEL AND HYDRAULIC TANKS...11
        Inspection...11
        Repairs, Small Leaks...11
        Repairs, Large Leaks...11
        Cleaning...11
        Other Methods Of Preparation For Repair...12
      SAFETY LABELS...13
        CAB...13
        Cab Repalacement...13
      Window Repalcement...13
        Windshield Wipers, Heater and Fan...16
        Material Specifications For Cab Windows...16
        Cab Heater Hoses...16
  1200334...17
    INTRODUCTION...17
      General...17
      Description...17
    REPAIRS...19
      Removal and Disassembly...19
      Cleaning and Inspection...20
      Assembly and Installation...21
    CHECKS AND ADJUSTMENTS...23
      Adjusting the Clutch Pedal and Linkage...23
      Adjusting the By-pass Valve for Cold Oil...23
    TROUBLESHOOTING...24
  1300335...26
    INTRODUCTION...26
      General...26
      Description...26
      Operation...26
    REPAIRS...28
      Removal...28
      Disassembly...29
      Cleaning...31
      Inspection...32
      Assembly...32
      Installation...43
    CHECKS AND ADJUSTMENTS...44
      Adjusting The Shift Linkage H3.50-5.00XL (H70-110XL)...44
      Adjusting The Shift Linkage S6.00-7.00XL (S135-155XL)...46
      Adjusting The Clutch Pedal And Linkage...46
    TROUBLESHOOTING...48
    SPECIFICATIONS...50
  1300336...51
    DESCRIPTION...51
      GENERAL...51
    MECHANICAL DESCRIPTION...51
      TORQUE CONVERTER...51
      OIL LAMP...52
      SHAFT AND CLUTCH ASSEMBLIES...52
        Input Shaft...53
        Forward Clutch Shaft...53
        Clutch Assemblies...53
        Output Gear...54
    HYDRAULIC OPERATION...54
      TORQUE CONVERTER...54
      SHAFT ASSEMBLIES...55
      CONTROL VALVE...57
        General...57
        System Regulator...57
        Clutch Pressure Regulator...57
        Torque Converter Regulator...58
        Inching Spool...58
        Direction Spool, Manual Control...58
        Drain Spool...59
        Accumulator...59
        Modulation Spool...60
      LUBRICATION CIRCUIT...61
      MONOTROL PEDAL...61
      OIL FLOW DIAGRAMS...61
        Neutral...61
        Forward...61
        Forward-Inching...61
        Reverse...62
  1300337...67
    REPAIRS ...67
      GENERAL...67
      REMOVAL...67
      TRANSMISSION, DISASSEMBLY...69
        Input Shaft, Disassembly...70
        Forward Shaft, Disassembly...72
        Cleaning and Inspection...73
      TRANSMISSION, ASSEMBLY...74
        Forward Shaft, Assembly...74
        Input Shaft, Assembly...76
        Assembly...78
        Installation...81
      CONTROL VALVE...82
        Removal...82
        Disassembly...83
        Assembly...83
        Installation...85
      THROTTLE PEDAL...85
      MONOTROL PEDAL...85
        Removal and Disassembly...85
        Assembly and Installation...85
    CHECKS AND ADJUSTMENTS...88
      STALL TEST...88
      ADJUST THE LINKAGE FOR THE INCHING PEDAL...89
        Linkage For Models With An Inching Pedal And A Brake Pedal...89
        Linkage For ModelsWith One Inching/Brake Pedal...91
      ADJUST THE LINKAGE FOR THE DIRECTION CONTROL LEVER...92
        Earlier Production...92
        Later Production...93
      CHECK THE OIL PRESSURE FOR THE TRANSMISSION...94
        System Pressure Check Port...95
        Torque Converter Check Port...95
        Clutch Pressure Check Port...96
        Inching Pressure...96
        Solenoid Check Ports (Monotrol Control Only)...96
        Lubrication Pressure Check Ports...96
    TROUBLESHOOTING...97
  1300346...100
    INTRODUCTION...100
      GENERAL...100
      DESCRIPTION...100
    REPAIRS...100
      REMOVAL...100
      DISASSEMBLY...100
      CLEANING...103
      INSPECTION...103
      ASSEMBLY...103
        Pinion Assembly...103
        Differential...104
      INSTALLATION...110
    TROUBLESHOOTING...111
    SPECIFICATIONS...112
  1400361...113
    INTRODUCTION...113
      GENERAL...113
      DESCRIPTION...113
    REPAIRS...114
      REMOVAL...114
        Lift Trucks With A Manual Transmission...114
        Lift Trucks With A Powershift Transmission...115
      DISASSEMBLY...116
      CLEANING...116
      INSPECTION...116
      ASSEMBLY...116
      INSTALLATION...117
        Lift Trucks With A Manual Transmission...117
        Lift Trucks With A Powershift Transmission...118
    TROUBLESHOOTING...119
    SPECIFICATIONS...119
  1600326...120
    INTRODUCTION...120
      GENERAL...120
      DESCRIPTION...120
    REPAIRS...121
      STEERING AXLE, H3.50-5.00XL (H70-110XL) and S/E 3.50-5.50XL (S/E 70-120XL)...121
        Removal...121
        Installation...121
      STEERING AXLE, H6.00-7.00XL (H135-155XL) H8.00-16.00XL (H165-360XL)...122
        Removal...122
        Installation...123
      WHEELS AND HUBS, ALL UNITS...123
        Removal and Disassembly...123
        Cleaning...123
        Assembly and Installation...123
      SPINDLES AND BEARINGS, ALL UNITS...124
        Removal...124
        Cleaning...125
        Assembly and Installation...125
      TIE RODS, ALL UNITS...125
        Removal...125
        Cleaning...125
        Installation...126
      STEERING CYLINDER...127
        Removal and Disassembly...127
        Cleaning and Inspection...127
        Assembly and Installation...127
    TROUBLESHOOTING...128
  160054...129
    INTRODUCTION...129
      GENERAL...129
      DESCRIPTION...129
      OPERATION...129
    REPAIRS...129
      STEERING WHEEL AND COLUMN ASSEMBLY...129
      TYPE "A" STEERING COLUMN ASSEMBLY...131
        Removal And Disassembly...131
        Assembly And Installation...131
      TYPE "A" STEERING COLUMN...132
      TYPE "A" STEERING COLUMN...133
      TYPE "B" STEERING COLUMN...134
        Removal And Disassembly...134
        Assembly And Installation...134
      TYPE "B" STEERING COLUMN...135
        Disassembly of Steering Control Unit...136
        Cleaning of Steering Control Unit...136
        Assembly of Steering Control Unit...138
    CHECKS AND ADJUSTMENTS...141
      REMOVE AIR FROM THE SYSTEM...141
    TROUBLESHOOTING...142
  1800338...143
    INTRODUCTION...143
      GENERAL...143
      DESCRIPTION AND OPERATION...143
      BRAKE BOOSTER AND MASTER CYLINDER...143
      MASTER CYLINDER...143
      SERVICE BRAKE ASSEMBLY...145
      PARKING BRAKE...146
    REPAIRS...146
      BRAKE SHOE ASSEMBLIES...146
        Removal and Disassembly...146
        Cleaning and Inspection...147
        Assembly and Installation...149
      MASTER CYLINDER...152
      S3.50-5.50XL (S70-120XL) and H3.50-5.00XL (H70-110XL...152
        Removal ...152
        Disassembly...152
        Assembly...153
        Installation...153
      MASTER CYLINDER, E3.50-5.50XL (E70-120XL)...153
        Removal and Disassebly...153
        Cleaning and Inspection...154
        Assembly and Installation...154
      BRAKE BOOSTER...154
        Removal...154
        Disassembly...154
        Cleaning and Inspection...155
        Assembly...155
        Installation...156
    CHECKS AND ADJUSTMENTS...156
      REMOVE THE AIR FROM THE BRAKE SYSTEM...156
      ADJUST THE BRAKE PEDAL...156
      ADJUST THE BRAKE SHOES...157
      ADJUST THE PARKING BRAKE...158
      CHECK THE RELIEF VALVE ON THE PARKING BOOSTER...158
    TROUBLESHOOTING...158
  1900333...160
    INTRODUCTION...160
      GENERAL...160
      DESCRIPTION AND OPERATION...160
        Hydraulic Pump...160
        Main Control Valve...161
        Steering Control Unit...163
        Brake Booster...163
    REPAIRS...163
      HYDRAULIC PUMP...163
        Removal...163
        Disassembly...164
        Cleaning and Inspection...164
        Assembly...164
        Installation...165
        Adjust the Flow Divider...165
    SPECIFICATIONS...165
    TROUBLESHOOTING...166
  1900339...168
    INTRODUCTION...168
      GENERAL...168
      DESCRIPTION...168
    REPAIRS...170
      REMOVAL AND DISASSEMBLY...170
      CLEANING...170
      INSPECTION...170
      ASSEMBLY AND INSTALLATION...171
    TROUBLESHOOTING...172
      GENERAL...172
  190097...173
    INTRODUCTION...173
      DESCRIPTION...173
      OPERATION...173
        Flow Control Valve...175
        Relief Valve...175
    REPAIRS...176
      REMOVAL...176
      DISASSEMBLY...176
      CLEANING...178
      INSPECTION...178
      ASSEMBLY...179
      INSTALLATION...180
    CHECKS AND ADUSTMENTS...181
      CHECK THE OUTPUT OF THE PUMP...181
      CHECK FOR AIR IN THE HYDRAULIC SYSTEM...181
    TROUBLESHOOTING...183
  200077...186
    INTRODUCTION...186
      GENERAL...186
      DESCRIPTION...186
      OPERATION...187
        Lift Section...188
        Tilt Section...188
        Relief Valve...190
      SOLENOID VALVE FOR AUXILIARY FUNCTION...191
        Operation...191
    REPAIRS...191
      MAIN CONTROL VALVE...191
        Removal and Disassembly...191
        Cleaning and Inspection...192
        Assembly...192
        Installation...192
      SOLENOID VALVE FOR AUXILIARY FUNCTION...192
        Removal and Disassembly...192
        Assembly and Installation...194
    CHECKS AND ADJUSTMENTS...194
      PRESSURE RELIEF VALVES...194
        Primary Relief Valve...194
        Seconday Relief Valve...195
      CONTROL LEVER ARRANGEMENT...195
    TROUBLESHOOTING...198
    SPECIFICATIONS...200
  2100103...201
    INTRODUCTION...204
      GENERAL...204
      DESCRIPTION...204
    REPAIRS...204
      REMOVAL...204
      DISASSEMBLY...204
      CLEANING...204
      ASSEMBLY...204
        Tilt Cylinders for the XM and XMS Models...204
        Tilt Cylinders with O-Ring or Single Lip Seals...206
        Tilt Cylinders for H700-800A and Early Model H700-920B...206
      INSTALLATION...206
        Tilt Cylinders with Chevron Packing...206
    CHECKS AND ADJUSTMENTS...210
      CHECK THE TILT CYLINDERS FOR LEAKS...210
      ADJUST THE TILT CYLINDER STROKE AND THE MAST TILT ANGLE...210
    TROUBLESHOOTING...213
  2200106...216
    INTRODUCTION...216
      GENERAL...216
      DESCRIPTION AND OPERATION...216
    REPAIRS...218
      REMOVAL...218
      DISSASEMBLY...218
      CLEANING...219
      ASSEMBLY...219
      INSTALLATION...219
    CHECKS AND ADJUSTMENTS...220
      GENERAL...220
    TROUBLESHOOTING...222
  2200143...224
    INTRODUCTION...224
      GENERAL...224
    DESCRIPTION...224
      GENERAL...224
      STEERING COLUMN GAUGES, METERS AND INDICATORS...227
      LED DISPLAY PANEL...227
        Battery Discharge Indicators ...227
        Brush Wear Indicators...228
        Motor Temperature Indicators...229
      "LX" SERIES INSTRUMENT PANEL DISPLAY...230
        Hourmeter Functions...231
        Battery Indicator Function...231
        Status Code Function...231
    CHECKS AND ADJUSTMENTS...231
      GENERAL...231
    REPLACEMENT...232
      GENERAL...232
      METER REPLACEMENT...232
      SENDER REPLACEMENT...233
        Fuel Level Sender...233
        Pressure And Temperature Sender...234
      I.T.W. DISPLAY PANEL...234
        Removal...234
    SPECIFICATIONS...235
    TROUBLESHOOTING...236
  2200144...237
    ELECTRICAL WARNING DEVICES...237
      GENERAL...237
      DESCRIPTION...237
        Operator Controlled Horns...237
        System Warning Lights, Buzzers and Bells...237
        Reverse Warning Horns...238
        Warning Lights...238
      REPLACEMENT...239
        General...239
        Replacing Horns or Bells...239
        Replacing Horn Relay or Buzzer...239
        Replacing Warning Lights...239
        Light Assemblies...240
        Replacing Flashing Units...240
  22002...241
    INTRODUCTION...241
      GENERAL...241
      DESCRIPTION...241
    REPAIRS...243
      GENERAL...243
      REMOVAL AND DISASSEMBLY (Type A)...243
      CLEANING...243
      ASSEMBLY (Type A)...244
      REMOVAL AND DISAASSEMBLY (Type B)...246
      CLEANING...248
      ASSEMBLY (Type B)...248
      INSTALLATION (Type A and Type B)...249
    CHECKS AND ADJUSTMENTS...249
      GENERAL...249
      CHECK THE ALTERNATOR FOR LOW OUTPUT (Type A or Type B)...250
      CHECK THE ALTERNATOR FOR HIGH OUTPUT (Type A or Type B)...251
      CHECK THE CIRCUIT FOR THE BRUSHES...253
        Delco Alternators...253
        Motorola Alternators...253
      CHECK THE DIODES...253
      CHECK THE DIODE BRIDGE...253
        Delco and Leece–Neville Alternators...253
        Motorola Alternators...253
      CHECK THE FIELD WINDING FOR THE ROTOR...254
      CHECK THE WINDINGS IN THE STATOR...254
      CHECK THE VOLTAGE REGULATOR...255
    TROUBLESHOOTING...255
  2200463...256
    MICROPROCESSOR SPARK TIMING SYSTEM (MSTS)...256
      GENERAL...256
      DESCRIPTION...256
        What MSTS Does...258
        How MSTS Begins Operation...258
      OPERATION...258
        Pulse Generator...258
        HEI Module...259
        When the Engine Is Being Started...259
        When the Engine Is Running...261
        Manifold Absolute Pressure (MAP)...261
        Coolant Temperature Sensor (CTS)...261
        Electronic Control Module (ECM), Corrections...262
        The Initial Timing Connector...262
        Gasoline and LPG Conversions...263
    TROUBLESHOOTING...265
      GENERAL...265
      TOOLS AND TEST EQUIPMENT...265
      MSTS TROUBLESHOOTING...266
        Test Description...266
      IGNITION SYSTEM TROUBLESHOOTING...268
        Test Description...268
      ELECTRONIC SPARK TIMING (EST) TROUBLESHOOTING...271
        Circuit Description...271
        Test Description...271
      MANIFOLD ABSOLUTE PRESSURE (MAP) TROUBLESHOOTING...274
        Circuit Description...274
        Test Description...274
      COOLANT TEMPERATURE SENSOR (CTS) TROUBLESHOOTING...277
        Circuit Description...277
        Test Description...277
    REPAIRS...279
      DISTRIBUTOR...279
        Removal...279
        Disassembly...280
        Inspection...280
        Assembly...281
        Installation...281
        Igntion Timing...281
      HEI MODULE...282
        Test For A Fault...282
        HEI Module Replacement...282
      SENSING COIL...283
        Test For A Fault...283
        Sensing Coil Replacement...283
      IGNITION COIL...283
        Test For A Fault...283
      ELECTRONIC CONTROL MODULE (ECM)...284
        Removal...284
        Installation...284
      COOLANT TEMPERATURE SENSOR (CTS)...284
        Removal...284
        Installation...285
      MANIFOLD ABSOLUTE PRESSURE (MAP)...285
        Removal...285
        Installation...285
        PRESSURE CONVERSION CHART...286
  2200468...287
    ELECTRONIC ENGINE CONTROL, TROUBLESHOOTING AND REPAIR...287
      GENERAL...287
        Engine Data...287
      LIGHT BULB CHECK...287
      SYSTEM CHECK...289
      TROUBLESHOOTING WITH THE FAULT MONITOR SYSTEM IN THE ECM...289
        How To Clear A Code...290
        Fault In The ECM...290
        Fault In The PROM...291
        CalPak Not Installed...291
        Fuel Control...291
        Idle Air Control (IAC)...291
        Fuel Pump Circuit...291
        Coolant Temperature Sensor (CTS)...292
        Manifold Absolute Pressuer Sensor (MAP)...292
        Throttle Position Sensodr (TPS)...292
        Output Check, Throttle Position Sensor...292
        Electronic Spark Timing...292
        Engine Crank Signal...293
        Distributor Reference Signal...293
    TROUBLESHOOTING CHARTS...294
      CHART A-1-No "Check Engine" Light...294
        Circuit Description, "Check Engine" Light...294
      CHART A-1-No "Check Engine" Light...295
      CHART A-2-No ALDL Data Or No Code 12 From "Check Engine" Light. The "Check Engine" Light Is Continuosly Illuminated...296
        Circuit Description, "Check Engine" Light...296
      CHART A-2-No ALDL Data Or No Code 12 From "Check Engine" Light. The "Check Engine" Light Is Continuously Illuminated...297
      CHART A-3-Starter Cranks The Engine, But Will Not Run...298
        Circuit Description...299
      CHART A-4-Fuel Injector Circuit...300
        Circuit Description...300
      CHART A-5-Fuel Pump Relay Circuit...302
        Circuit Description...302
      CHART A-6-Fuel System Pressure Test...304
        Circuit Description...304
      CHART A-7-MAP Output Check...306
        Circuit Description...306
      CHART A-8-Engine Crank Signal Check...308
        Circuit Description...308
      CHART A-9-Ignition System Troubleshooting...309
      CHART A-9 Ignition System Troubleshooting Chart...310
      CHART A-10-Idle Air Control (IAC) System...312
        Circuit Description...312
    FAULT CODES...314
      CODE 14-Coolant Temperature Sensor Circuit (Indicates High Temperature)...314
        Circuit Description...314
      CODE 15-Coolant Temperature Sensor Circuit (Indicates Low Temperature...316
        Circuit Description...316
      CODE 21-Throttle Position Sensor Circuit (Signal Voltage High) ...318
        Circuit Description...318
      CODE 22-Throttle Position Sensor Circuit (Signal Voltage Low) ...320
        Circuit Description...320
      CODE 31-Engine Governor Circuit...322
        Circuit Description...322
      CODE 33-MAP Sensor Circuit, Signal Voltage High (Low Vacuum...324
        Circuit Description...324
      CODE 34-MAP Sensor Circuit, Signal Voltage Low (High Vacuum)...326
        Circuit Description...326
      CODE 42-Electronic Spark Timing (EST)...328
        Circuit Description...328
      CODE 54-Fuel Pump Circuit (Low Voltage)...330
        Circuit Description...330
      CODE 51-PROM In The ECM Has A Fault ...332
      CODE 52-Fuel CalPak Is Missing...332
      CODE 55-ECM Has A Fault...332
      TROUBLESHOOTING, POOR OPERATION...332
        General...332
        Make A Careful Visual Check...332
        FAULT: Fuel Usage Too High...332
        FAULT: Codes Or Performance That Is Not Regular...333
        FAULT: "Dieseling"...333
        FAULT: "Backfire"...333
        FAULT: Rough Idle or Engine Stalls During Idle...333
        FAULT: Smoke In The Exhaust Gases...334
        FAULT: Engine is Difficult To Start...334
        FAULT: Variation In Engine Power When The Throttle Is Held Steady...335
        FAULT: Decreased Engine Power...335
        FAULT: "Detontion"...335
        FAULT: Engine Momentarily Does Not Increase Power When Throttle Changes...336
        FAULT: One Cylinder In The Engine Does Not Operate Correctly. The Engine Does Not Idle Correctly...336
      REPAIRS, FUEL SYSTEM COMPONENTS ...338
        General...338
        Vacuum Ports...338
        Throttle Body Injection (TBI) Unit...338
        TBI Unit, Removal...338
        TBI Unit, Cleaning and Inspection...339
        TBI Unit, Installation...339
        Cover For Fuel Meter Body, Replacement...339
        Fuel Injectors...340
        Fuel Injectors, Removal...340
        Fuel Injectors, Installation...341
        Pressure Regulator, Removal...341
        Pressure Regulator, Inspection...341
        Pressure Regulator, Installation ...341
        Fuel Meter Body, Removal...342
        Fuel Meter Body, Installation...342
        Throttle Position Sensor (TPS), Removal...342
        Throttle Position Sensor (TPS), Installation...342
        Idle Air Control (IAC) Valve, Removal...343
        Cleaning and Inspection...343
        Idle Air Control (IAC) Valve, Installation...343
        Governor Throttle Drive Assembly, Removal...343
        Governor Throttle Drive Assembly, Inspection...343
        Cleaning and Lubrication...344
        Governor Throttle Drive Assembly, Installation...344
        Governor Drive Motor, Removal...345
        Governor Drive Motor, Cleaning and Lubrication...345
        Governor Drive Motor, Installation...346
        Governor Drive Motor, Inspection...346
        Throttle Body, Removal and Disassembly...346
        Throttle Body, Inspection...346
        Throttle Body, Assembly and Installation...346
        Fuel Pump, Removal and Disassembly...347
        Fuel Pump, Inspection...347
      REPAIRS, ELECTRICAL COMPONENTS...347
        General...347
        Ignition Coil Test...347
        Ignition Module Test...348
        Distributor, Removal...348
        Distributor, Disassembly...349
        Distributor, Assembly...349
        Distributor, Installation...350
        Firing Order...351
        Ignition Timing...351
        Ignition Coil, Removal...352
        Ignition Coil, Installation...352
        Procedures For Spark Plugs, Spark Plug Wires And Boots ...352
        Troubleshooting of Spark Plugs...353
        Coolant Temperature Sensor (CTS), Replacement ...354
        Manifold Absolute Pressure (MAP) Sensor, Replacement...354
        Oil Pressure Switch, Replacement...355
        Coolant Temperature Sender, Replacement...355
        Wire Harness...355
        Connectors And Terminals...355
        Electronic Control Module (ECM)...359
      ECM CONNECTOR A-B IDENTIFICATION...363
      ECM CONNECTOR C-D IDENTIFICATION...364
    SPECIAL TOOLS...365
  2200473...368
    INTRODUCTION...368
      GENERAL...368
    DESCRIPTION AND OPERATION...368
      GENERAL...368
      ECM (ELECTRONIC CONTROL MODULE)...368
        ALDL Connector...370
        How The ECM Begins Operation...370
      ELECTRONIC ENGINE CONTROL...371
        What The ECM Does...371
        Pulse Generator, EST Distributor...372
        EST Module(See FIGURE 9.)...373
        When the Engine Is Being Started...373
        When the Engine Is Running...375
        Electronic Control Module (ECM) With EST Distrubutor, Corrrections...375
        What The ECM Does...375
      FUEL CONTROL...376
        Throttle Body Injection...376
        Fuel Injectors...377
        Fuel Pressure Regulator...377
        Throttle Position Sensor...377
        Idle Air Control...377
        Governor Motor And Throttle Drive Assembly...378
        Vacuum Ports...380
        Fuel Pump...380
      ECM SENSORS AND CONTROLLERS...382
        Manifold Absolute Pressure (MAP)...382
        Coolant Temperature Sensor (CTS)...382
        Initial Timing Connector (EST Distributor)...382
  4000135...384
    SAFETY PROCEDURES WHEN WORKING NEAR THE MAST...384
      SAFETY PROCEDURES WHEN WORKING NEAR THE MAST...384
    LIFT CYLINDERS...387
      GENERAL...387
      DESCRIPTION...387
        Lowering Control Valve...387
        Cylinders (General)...390
        Cylinders (H520-620B,H700-800A)...392
        Cylinders (H360-460B)...393
        Cylinders (Two-Speed)...393
    REPAIRS...394
      REMOVAL OF THE LIFT CYLINDER WITHOUT REMOVING THE MAST...394
        Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast...394
        Standard and Full Free-Lift Masts with the Lift Cylinder to a Crosshead...398
        Masts that have Two Cylinders, A Main Lift Cylinder  and a Free-Lift Cylinder...396
      DISASSEMBLY...396
      ASSEMBLY...398
      INSTALLATION OF THE LIFT CYLINDER IN THE MAST...398
        Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast...398
        Standard and Full-Free-Lift Masts with the Lift Cylinder Fastened to a Crosshead...398
      CHEVRON PACKING...399
    LIFT CYLINDERS FOR VISTA MASTS...402
      DESCRIPTION...402
        Lowering Control Valve...404
      REMOVAL...405
      DISASSEMBLY...405
      ASSEMBLY...405
      INSTALLATION...406
        Main Lift Cylinders...406
        Free-Lift Cylinders...406
    CHECKS AND ADJUSTMENTS...407
      CHECK FOR LEAKS IN LIFT SYSTEM...407
    TROUBLESHOOTING...408
    SPECIFICATIONS...409
  4000340...410
    VISTA® MASTS...410
      GENERAL...410
      DESCRIPTION AND OPERATION...410
      CARRIAGES...410
      TWO-STAGE MAST WITH LIMITED FREE-LIFT...410
      TWO-STAGE MAST WITH FULL FREE-LIFT MAST...411
      THREE-STAGE MAST WITH FULL FREE-LIFT...412
    REPAIRS...414
      SAFETY PROCEDURES WHEN WORKING NEAR THE MAST (1 OF 2)...414
      SAFETY PROCEDURES WHEN WORKING NEAR THE MAST (2 OF 2)...415
      FORKS...415
        Forks, Removal And Installation...415
      CARRIAGE...417
        Removal...417
      SIDE-SHIFT CARRIAGE (EARLIER DESIGNS)...418
        Disassembly, Side Shift Carriage...418
        Assembly, Side Shift Carriage...420
        Installation...421
      SIDE-SHIFT CARRIAGE (1993 AND LATER DESIGN)...421
        Removal...421
        Repairs...422
        Installation...423
      TABLE 1. WEIGHT OF MAST PARTS...423
      TWO-STAGE MAST WITH LIMITED FREE-LIFT...424
        Removal...424
        Disassembly...424
        Cleaning and Inspection...426
        Assembly...426
        Installation...427
      TWO-STAGE MAST WITH FULL FREE-LIFT...427
        Removal...427
        Disassembly...427
        Cleaning and Inspection...428
        Assembly...428
        Installation...428
      THREE-STAGE MAST WITH FULL FREE LIFT...429
        Removal...429
        Disassembly...429
        Cleaning and Inspection...430
        Assembly...430
        Installation...432
    CHECKS AND ADJUSTMENTS...434
      CHECK THE OPERATION OF THE MAST...434
      CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM...434
        Lift System...434
        Tilt System...434
      ADJUST THE TILT CYLINDER STROKE AND THE BACKWARD TILT ANGLE...435
      LIFT CHAIN ADJUSTMENTS...435
      MAST ADJUSTMENTS...436
      CARRIAGE ADJUSTMENT...437
    TROUBLESHOOTING...440
  600412...442
    PERKINS DIESEL ENGINES, SERIES 1000...442
      1.1 GENERAL...442
      GENERAL SAFETY RULES...442
        Viton Seals...442
      1.2 DESCRIPTION...445
        1.3 Engine Serial Number Codes...445
        1.4 Engine Data...445
        1.5 1004–4 ENGINE...446
        1.6 1004–4T ENGINE...446
        1.7 1006–6 ENGINE...446
        1.8 1006–6T ENGINE...446
      1.9 REMOVAL AND INSTALLATION...446
    CYLINDER HEAD ASSEMBLY...447
      1.10 VALVE COVER...447
        1.11 Removal...447
        1.12 Installation...447
      1.13 ROCKER ARM ASSEMBLY...447
        1.14 Removal...447
        1.15 Installation...447
        1.16 Disassembly...448
        1.17 Inspection...448
        1.18 Assembly...448
      1.19 VALVE CLEARANCE ADJUSTMENTS...448
        1.20 Four Cylinder Engines...449
        1.21 Six Cylinder Engines...449
      1.22 VALVE SPRINGS...449
      1.23 CYLINDER HEAD ASSEMBLY...451
        1.24 Removal...451
        1.25 Installation...452
      1.26 VALVES AND VALVE SPRINGS...455
        1.27 Removal...455
        1.28 Inspection...456
        1.29 Installation...456
      1.30 VALVE GUIDES...456
        1.31 Inspection...456
        1.32 Removal...457
        1.33 Installation...457
      1.34 CYLINDER HEAD AND VALVE SEATS...457
        1.35 Inspection...457
        1.36 Repair...458
        1.37 Installation Of New Valve Seats...458
    PISTON AND CONNECTING ROD ASSEMBLIES...459
      1.38 ROD BEARINGS...459
        1.39 Removal...459
        1.40 Installation...460
      1.41 PISTON AND CONNECTING ROD ASSEMBLY...460
        1.42 Service Note...460
        1.43 Removal...460
        1.44 Installation...461
      1.45 PISTON RINGS...462
        1.46 Removal...462
        1.47 Inspection...462
        1.48 Installation...463
      1.49 PISTON AND CONNECTING ROD...464
        1.50 Disassembly...464
        1.51 Inspection...464
        1.52 Installation...464
      1.53 PISTON COOLING JETS...465
        1.54 Removal...465
        1.55 Installation...465
    CRANKSHAFT ASSEMBLY...466
      1.56 GENERAL...466
      1.57 CRANKSHAFT PULLEY...466
        1.58 Removal, Engines AA and AB...466
        1.59 Installation, Engines AA and AB...466
        1.60 Removal, Engines YA and YB...466
        1.61 Installation, Engines YA and YB...466
      1.62 REAR OIL SEAL...467
        1.63 Replacement...467
      1.64 MAIN BEARINGS...468
        1.65 Removal...468
        1.66 Installation...468
      1.67 THRUST WASHERS...469
        1.68 Check The Axial Movement Of The Crankshaft...469
        1.69 Removal...470
        1.70 Installation...470
      1.71 CRANKSHAFT...470
        1.72 Removal...470
        1.73 Inspection...471
        1.74 Installation...471
    TIMING CASE AND TIMING GEARS...473
      1.75 GENERAL...473
      1.76 TIMING CASE COVER...473
        1.77 Removal...473
        1.78 Installation...473
      1.79 FRONT OIL SEAL...474
        1.80 Removal...474
        1.81 Installation...474
      1.82 IDLER GEAR AND HUB...474
        1.83 Removal...474
        1.84 Installation...475
      1.85 GEAR FOR THE FUEL INJECTION PUMP OR THE CAMSHAFT GEAR...476
        1.86 Removal...476
        1.87 Installation...476
      1.88 CRANKSHAFT GEAR...477
        1.89 Removal...477
        1.90 Installation...477
      1.91 TIMING CASE...477
        1.92 Removal...477
        1.93 Installation...477
      1.94 CAMSHAFT AND TAPPETS...478
        1.95 Removal...479
        1.96 Installation...479
    ENGINE BLOCK ASSEMBLY...480
      1.97 DESCRIPTION...480
      1.98 ENGINE BLOCK...480
        1.99 Disassembly...480
        1.100 Inspection...481
        1.101 Assembly...481
      1.102 CYLINDER LINER...481
        1.103 Inspection...481
        1.104 Hone...482
        1.105 Removal...482
        1.106 Installation...483
    TURBOCHARGER, ENGINES AB AND YB...484
      1.107 GENERAL...484
        1.108 Removal...484
        1.109 Installation...485
        1.110 Clean The Impeller And Compressor Housing...485
    LUBRICATION SYSTEM...486
      1.111 GENERAL...486
      1.112 OIL FILTER, REPLACEMENT...486
      1.113 OIL SUMP...487
        1.114 Removal...487
        1.115 Installation...487
      1.116 OIL PUMP...487
        1.117 Removal...487
        1.118 Inspection...488
        1.119 Installation...488
      1.120 RELIEF VALVE...489
        1.121 Removal...489
        1.122 Disassembly...489
        1.123 Inspection...490
        1.124 Installation...490
    FUEL SYSTEM...490
      1.125 DESCRIPTION...490
      1.126 CAV FUEL INJECTION PUMP...491
        1.127 Removal...491
        1.128 Installation...491
      1.129 CAV FUEL INJECTION PUMP, CHECKS AND ADJUSTMENTS...492
        1.130 Timing Gear Marks...492
        1.131 How To Set Number 1 Piston To TDC On The Compression Stroke...493
        1.132 Check The Valve Timing...493
        1.133 Check The Timing Of The Fuel Injection Pump...494
        1.134 Check The Timing Mark Of The Fuel Injection Pump...494
        1.135 Check The Engine Timing Mark...495
      1.136 REMOVE AIR FROM THE FUEL SYSTEM...496
        1.137 Fuel Injection Pump With Vent Tube...496
        1.138 Fuel Injection Pump With Vent Screw...497
      1.139 FUEL FILTER (REPLACEMENT)...498
      1.140 FUEL INJECTORS...498
        1.141 Removal...498
        1.142 Inspection...499
        1.143 Installation...500
      1.144 FUEL PUMP...500
        1.145 Removal...500
        1.146 Disassembly...500
        1.147 Assembly...501
        1.148 Installation...501
        1.149 Test...502
    COOLING SYSTEM...502
      1.150 GENERAL...502
      1.151 THERMOSTAT...502
        1.152 Replacement...502
      1.153 COOLANT PUMP...503
        1.154 Removal...503
        1.155 Disassembly...503
        1.156 Assembly...504
        1.157 Installation...504
      1.158 FAN AND FAN DRIVE...504
        1.159 Removal...504
        1.160 Disassembly...504
        1.161 Assembly...505
        1.162 Installation...505
      1.163 OIL COOLER...505
        1.164 Removal, Engine AB...505
        1.165 Removal, Engines YA and YB...505
        1.166 Disassembly And Assembly...506
        1.167 Installation, Engine AB...506
        1.168 Installation, Engines YA and YB...507
        1.169 By–Pass Valve, Oil Cooler...507
    FLYWHEEL AND FLYWHEEL HOUSING...507
      1.170 GENERAL...507
      1.171 FLYWHEEL...507
        1.172 Removal...507
        1.173 Ring Gear (Replacement)...507
        1.174 Installation...507
      1.175 FLYWHEEL HOUSING...508
        1.176 Removal...508
        1.177 Installation...508
    ELECTRICAL EQUIPMENT...509
      1.178 DRIVE BELTS...509
      1.179 ALTERNATOR...510
      1.180 STARTER MOTOR...510
        1.181 Removal...510
        1.182 Installation...510
      1.183 COLD START AID...510
    AIR COMPRESSOR, ENGINES YA AND YB...510
      1.184 GENERAL...510
        1.185 Air Compressor, Removal, WABCO...510
        1.186 Compressor Drive, Inspection...511
        1.187 Air Compressor, Installation, WABCO...511
        1.188 Compressor Drive, Disassembly, WABCO...511
        1.189 Compressor Drive, Assembly, WABCO...512
        1.190 Air Compressor, Removal, BENDIX...512
        1.191 Air Compressor, Installation, BENDIX...513
        1.192 Compressor Drive, Disassembly, BENDIX...514
        1.193 Compressor Drive, Assembly, BENDIX...514
    ENGINE SPECIFICATIONS...516
      1.194 CYLINDER HEAD ASSEMBLY...516
        1.195 Cylinder Head...516
        1.196 Valve Guides...516
        1.197 Inlet Valves...517
        1.198 Exhaust Valves...517
        1.199 Double Valve Springs To Outer...517
        1.200 Double Valve Springs To Inner...517
        1.201 Single Valve Springs...517
        1.202 Tappets...517
        1.203 Rocker Arm Shaft...517
        1.204 Rocker Arms And Bushings...518
      1.205 PISTON AND CONNECTING RODS...518
        1.206 Pistons, Engines AA And YA...518
        1.207 Pistons, Engines AB And YB...518
        1.208 Piston Rings, Engines AA And YA...518
        1.209 Piston Rings, Engines AB And YB...518
        1.210 Connecting Rods, Engines AB And YB...519
        1.211 Connecting Rods, Engines AB And YB...519
        1.212 Piston Pins, Engines AA And YA...519
        1.213 Piston Pins, Engines AB and YB...519
        1.214 Small End Bushings, Engines AA And YA...519
        1.215 Small End Bushings, Engines AB And YB...519
        1.216 Connecting Rod Bearings, Engines AA And YA...520
        1.217 Connecting Rod Bearings, Engines AB And YB...520
        1.218 Piston Cooling Jets, Engines AB And YB...520
      1.219 CRANKSHAFT ASSEMBLY...520
        1.220 Crankshaft...520
        1.221 Crankshaft Heat Treatment...520
        1.222 Crankshaft Overhaul...520
        1.223 Main Bearings...522
        1.224 Crankshaft Thrust Washers...522
      1.225 TIMING CASE AND DRIVE ASSEMBLY...522
        1.226 Camshaft...522
        1.227 Camshaft Thrust Washer...522
        1.228 Camshaft Gear...523
        1.229 Gear For Fuel Injection Pump...523
        1.230 Crankshaft Gear...523
        1.231 Idler Gear And Hub...523
      1.232 ENGINE BLOCK ASSEMBLY...523
        1.233 Engine Block...523
        1.234 Cylinder Liners...523
      1.235 TURBOCHARGER...524
      1.236 LUBRICATION SYSTEM...524
        1.237 Oil Pump, Engines AA And AB...524
        1.238 Oil Pump, Engines YA And YB...524
        1.239 Relief Valve...524
        1.240 Oil Filter...524
      1.241 FUEL SYSTEM...524
        1.242 Cav Fuel Injection Pump...524
        1.243 FUEL INJECTORS...525
        1.244 Fuel Pump, Engines AA And AB...526
        1.245 Fuel Pump, Engines YA And YB...526
        1.246 Fuel Filter...526
      1.247 COOLING SYSTEM...526
        1.248 Coolant Pump...526
        1.249 Thermostat...527
        1.250 Fan Drive Housing...527
      1.251 FLYWHEEL AND HOUSING...527
        1.252 Limits for flywheel ''run out'' and alignment (total indicator reading)...527
      1.253 ELECTRICAL EQUIPMENT...527
        1.254 Alternator...527
        1.255 Starter Motor...527
        1.256 Cold Start Aid...527
    TORQUE SPECIFICATIONS...528
    SPECIAL TOOLS...529
  600590...533
    GM 4.3 LITRE V-6...533
      INTRODUCTION...533
      DESCRIPTION...533
      ENGINE, REMOVAL AND INSTALLATION...534
      CYLINDER HEAD...534
        Removal And Disassembly...534
        Cleaning And Inspection...534
        Repairs, Valve Guides and Seats...534
        Repairs, Valves...535
        Repairs, Valve Seats...535
        Valve Springs...536
        Studs For The Rocker Arms (Early Models)...537
        Studs For The Rocker Arms (Late Models)...538
        Assembly And Installation...538
      CYLINDER BLOCK, CLEANING AND INSPECTION...540
      PISTON BORE PREPARATION...540
      ENGINE MOUNTS...540
      LUBRICATION SYSTEM...540
        Oil Pump, Removal and Disassembly...540
        Cleaning and Inspection...541
        Oil Pump, Assembly and Installation...541
        Oil Sump, Installation...541
      TIMING COVER, TIMING SPROCKETS, CAMSHAFT AND VALVE LIFTERS...542
        Timing Cover, Removal...542
        Installation...543
        Timing Sprockets, Removal...544
        Timing Sprockets, Installation...544
        Camshaft, Removal...544
        Camshaft, Inspection...544
        Camshaft, Installation...544
        Balance Shaft, Removal...545
        Balance Shaft, Installation...546
        Hydraulic Valve Lifters, Removal...547
        Hydraulic Valve Lifters, Disassembly...547
        Hydraulic Valve Lifters, Cleaning And Inspection...547
        Hydraulic Valve Lifters, Assembly...548
        Hydraulic Valve Lifters, Installation...548
      CRANKSHAFT...549
        Removal...549
        Inspection and Repair...549
        How To Check The Clearance Between The Main Bearings And Their Journals...550
        Installation...551
      PISTON AND CONNECTING ROD ASSEMBLIES...552
        Connecting Rod Bearings, Replacement...552
        Piston And Connecting Rod Assemblies, Removal...553
        Disassembly...553
        Piston, Cleaning And Inspection...553
        Cylinder Bores, Inspection And Repair...554
        Piston Rings...555
        Assembly...555
        Piston And Connecting Rod Assemblies, Installation...556
      FLYWHEEL AND FLYWHEEL HOUSING...556
        Flywheel Repairs...556
        Flywheel, Installation...556
        Flywheel Housing...557
        Engine Adapter...557
      COOLANT PUMP...557
      THERMOSTAT...557
      FAN MOUNT, EARLY MODELS...557
      FAN MOUNT ASSEMBLY, LATE MODELS...558
      DRIVE BELT, INSTALLATION...559
    CHECKS AND ADJUSTMENTS...561
      VALVE CLEARANCE ADJUSTMENT, EARLY MODELS...561
      VALVE CLEARANCE ADJUSTMENT, NEW MODELS...561
      CHECK THE COMPRESSION...561
    ENGINE SPECIFICATIONS...562
      Engine Data...562
      Cylinder head...562
      Hydraulic Valve Lifter...562
      Camshaft...562
      Pistons...562
      Crankshaft...563
      Connecting Rods...563
      Connecting Rods...563
      Balance Shaft...563
      Cooling System...563
      Lubrication System...563
    TORQUE SPECIFICATIONS...564
    TROUBLESHOOTING...565
  600705...568
    PERKINS DIESEL ENGINES, 1004-42 (AR), 1006-60 (YG), 1006-60T (YH) ...568
      GENERAL...568
        General Safety Rules...568
      DESCRIPTION...570
        Engine Serial Number Codes...571
        Engine Data...572
        1004-42 (AR) ENGINE (Low Governed Speed)...572
        1004-42 (AR) ENGINE (High Governed Speed)...572
        1006-60 (YG) ENGINE...572
        1006-60T (YH) ENGINE...572
      REMOVAL AND INSTALLATION...573
        Lifting The Engine...573
    CYLINDER HEAD ASSEMBLY...573
      VALVE COVER...573
        Removal...573
        Installation...574
      ROCKER ARM ASSEMBLY...574
        Removal...574
        Installation...574
        Disassembly...574
        Inspection...575
        Assembly...575
      VALVE CLEARANCE ADJUSTMENTS...575
        Four Cylinder Engines...575
        Six Cylinder Engines...576
      VALVE SPRINGS...576
      CYLINDER HEAD ASSEMBLY...577
        Removal...577
        Installation...580
      VALVE AND VALVE SPRINGS...584
        Removal...584
        Inspection...585
        Installation...585
      VALVE GUIDES...585
        Inspection...585
        Removal...586
        Installation...586
      CYLINDER HEAD AND VALVE SEATS...587
        Inspection...587
        Repair...587
        Installation Of New Valve Seats...588
    PISTON AND CONNECTING ROD ASSEMBLIES...588
      ROD BEARINGS...589
        Removal...589
        Installation...590
      PISTON AND CONNECTING ROD ASSEMBLY...590
        Service Note...590
        Removal...591
        Installation...591
      PISTON RINGS...592
        Removal...592
        Inspection...592
        Installation...593
      PISTON AND CONNECTING RODS...594
        Disassembly...594
        Inspection...595
        How To Select the Correct Replacements...595
        Installation...596
      PISTON COOLING JETS...596
        Removal...596
        Installation...596
    CRANKSHAFT ASSEMBLY...597
      GENERAL...597
      CRANKSHAFT PULLEY...598
        Removal, Engine AR...598
        Removal, Engines YG and YH...598
        Inspection...598
        Installation, Engine AR ...599
        Installation, Engine YG and YH...599
      REAR OIL SEAL...600
        Replacement...600
      MAIN BEARINGS...601
        Removal...601
        Inspection...601
        Installation...602
      THRUST WASHERS...602
        Check The Axial Movement Of The Crankshaft...602
        Removal...603
        Installation...603
      CRANKSHAFT...604
        Removal...604
        Inspection...604
        Installation...604
      FLYWHEEL...606
        Removal...606
        Ring Gear (Replacement)...606
        Installation...606
      FLYWHEEL HOUSING...607
        Removal...607
        Installation...607
    TIMING CASE AND TIMING GEARS...608
      GENERAL...608
      TIMING CASE COVER...608
        Removal...608
        Installation...608
      FRONT OIL SEAL...609
        Removal...609
        Installation...609
      CRANKSHAFT PULLEY WEAR SLEEVE...610
        Installation...610
      IDLER GEAR AND HUB...610
        Removal...610
        Installation...611
      AIR COMPRESSOR, DRIVE, BENDIX...612
        Disassembly...612
        Compressor Drive, Assembly...613
      GEAR FOR THE FUEL INJECTION PUMP...613
        Removal...613
        Installation...614
      CAMSHAFT GEAR...615
        Removal...615
        Installation...615
      CRANKSHAFT GEAR...616
        Removal...616
        Installation...616
      TIMING CASE...616
        Removal...616
        Installation...617
      CAMSHAFT AND TAPPETS...618
        Removal...618
        Installation...618
    CYLINDER BLOCK ASSEMBLY...619
      DESCRIPTION...619
      CYLINDER BLOCK...619
        Disassembly...619
        Inspection...620
        Assembly...620
      CYLINDER BORE (4-CYLINDER ENGINES)...620
      CYLINDER LINER (6-CYLINDER ENGINES)...621
        Inspection...621
        To Check the Condition of a Cylinder Liner...621
        Removal...622
        Installation (Service Liner)...623
        Installation (Partially Finished Liner)...624
    ENGINE TIMING...625
      GENERAL DESCRIPTION...625
        How To Set Number 1 Piston To TDC On The Compression Stroke...626
        How To Set Number 1 Piston To TDC On The Compression Stroke (Alternate Procedure)...627
        Check The Valve Timing...627
        Check The Timing Of The Fuel Injection Pump...628
    TURBOCHARGER, ENGINE YH...629
      GENERAL...629
        Removal...629
        Installation...629
        Clean The Impeller And Compressor Housing...630
    LUBRICATION SYSTEM...631
      GENERAL...631
      OIL FILTER, REPLACEMENT...631
      FILTER HEAD...632
        To Remove and to Install...632
      OIL SUMP...632
        Removal...632
        Installation...633
      OIL PUMP...633
        Removal...633
        Inspection...633
        Installation...634
      RELIEF VALVE...635
        Removal...635
        Disassembly...635
        Inspection...636
        Assembly...636
        Installation...636
      IDLER GEAR SHAFT, REPLACEMENT...636
        Removal...636
        Removal, Alternative ...637
        Installation...638
        Installation, Alternative...638
        Installation, Alternative For 4-Cylinder Engines Only...638
    FUEL SYSTEM...639
      DESCRIPTION...639
      FUEL INJECTION PUMP...639
        Removal...639
        Installation...640
      FUEL INJECTION PUMP, CHECKS AND ADJUSTMENTS...641
      REMOVE AIR FROM THE FUEL CHECK...642
      FUEL FILTER (REPLACEMENT)...643
        Canister Type...643
        Quick Release Canister Type...643
      FUEL INJECTORS...644
        Removal...644
        Inspection...645
        Installation...645
      FUEL PUMP...646
        Removal...646
        Disassembly...646
        Assembly...647
        Installation...647
        Test...648
    COOLING SYSTEM...648
      GENERAL...648
      THERMOSTAT...648
        Thermostats...648
        Remove...648
        Install...648
        Test...648
      COOLANT PUMP...649
        Removal...649
        Disassembly...650
        Assembly...651
        Installation...654
      FAN AND FAN DRIVE...655
        Removal...655
        Installation...655
      OIL COOLER (6-CYLINDER ENGINES)...655
        Removal...655
        Disassembly and Assembly...655
        Installation...656
        By-Pass Valve, Oil Cooler...656
      ELECTRICAL EQUIPMENT...656
        DRIVE BELTS...656
      ALTERNATOR...657
        Removal...657
        Installation...657
      STARTER MOTOR...657
        Removal...657
        Installation...658
      COLD START AID...658
    AIR COMPRESSOR, ENGINES YG AND YH...658
      GENERAL...658
        Air Compressor, Removal...658
        Air Compressor, Installation...659
    ENGINE SPECIFICATIONS...660
      CYLINDER HEAD ASSEMBLY...660
        Cylinder Head...660
        Valve Guides...661
        Inlet Valves...661
        Exhaust Valves...662
        Valve Springs...662
        Tappets...662
        Rocker Arm Shaft...663
        Rocker Arms And Bushings...663
      PISTON AND CONNECTIONG RODS...663
        Pistons (Engine AR)...663
        Pistons (Engine YG and YH)...663
        Piston Rings (Engine AR)...663
        Piston Rings (Engine YG and YH)...664
        Piston Pins...664
        Connecting Rods...664
        Small End Bushings...665
        Connecting Rod Bearings, Engines AR and YG...665
        Connecting Rod Bearings, Engine YH...665
        Piston Cooling Jets...665
      CRANKSHAFT ASSEMBLY...665
        Crankshaft...665
        Main Bearings...666
        Crankshaft Thrust Washers...666
        Crankshaft Heat Treatment...666
        Crankshaft Overhaul...666
      TIMING CASE AND DRIVE ASSEMBLY...668
        Camshaft...668
        Camshaft Thrust Washer...668
        Camshaft Gear...668
        Gear For Fuel Injection Pump...668
        Crankshaft Gear...668
        Idler Gear And Hub...668
      ENGINE BLOCK ASSEMBLY...669
        Cylinder Block (Engine AR)...669
        Cylinder Bore Specifications (Engine AR)...669
        Cylinder Block (Engine YG And YH)...670
        Cylinder Liner (Engine YG And YH)...670
        Cylinder Liner Specifications (Partially Finished)...670
      TURBOCHARGER...671
      LUBRICATION SYSTEM...671
        Oil Pump, Engine AR...671
        Oil Pump, Engine YG And YH...671
        Idler Gear for Oil Pump...671
        Relief Valve...671
        Oil Filter...672
      FUEL SYSTEM...672
        Lucas Fuel Injection Pump...672
        Fuel Injector Codes...673
        Fuel Pump, Engine AR...673
        Fuel Pump, Engine YG And YH...673
        Fuel Filter...674
      COOLING SYSTEM...674
        Coolant Pump...674
        Thermostat...674
        Fan Drive Housing...674
      FLYWHEEL AND HOUSING...674
        Limits for Flywheel "Run Out" and Alignment (Total Indicator Reading)...674
      ELECTRICAL EQUIPMENT...674
        Alternator...674
        Starter Motor...674
        Cold Start Aid...674
    TORQUE SPECIFICATIONS...675
    SPECIAL TORQUE SPECIFICATIONS...677
    SPECIAL TOOLS...678
    TROUBLESHOOTING...682
      List of Possible Causes...683
  700626...685
    COOLING SYSTEM...685
      INTRODUCTION...685
      DESCRIPTION...685
      RADIATOR...685
      RADIATOR CAP...685
      THERMOSTAT...685
      WATER PUMP...686
      FAN AND FAN SHROUD ...686
    REPAIRS...686
      COOLING SYSTEM CHECKS...686
        Exhaust Leaks...686
      RADIATOR...686
        Checks...686
        Cleaning The Radiator...686
        Drain The Cooling System...688
        Fill The Cooling System...688
      WATER PUMP...688
        Checks...688
      THERMOSTAT...689
        Checks...689
      FAN AND FAN SHROUD ...689
    TROUBLESHOOTING...690
  8000231...691
    INTRODUCTION...691
      NOMENCLATURE, THREADS...691
      STRENGTH IDENTIFICATION...692
    TABLE 1. BOLTS AND SCREWS...692
    TABLE 2. STUDS AND NUTS...693
    TABLE 3. TORQUE NUTS...694
    TABLE 4. TORQUE NUTS WITH NYLON INSERT...695
    TABLE 5. TORQUE VALUES FOR INCH FASTENERS...696
    TABLE 6. TORQUE VALUES FOR METRIC FASTENERS...697
  8000341...700
    PERIODIC MAINTENANCE...700
      GENERAL...700
      SERIAL NUMBER DATA...700
      HOW TO MOVE A DISABLED LIFT TRUCK...700
        How To Tow the Lift Truck...700
      HOW TO PUT A LIFT TRUCK ON BLOCKS...701
        How To Raise the Drive Tires...701
        How To Raise the Steering Tires...701
    MAINTENANCE SCHEDULE...703
    MAINTENANCE PROCEDURES...706
    EVERY 8 HOURS OR DAILY...706
      HOW TO MAKE THE CHECKS WITH THE ENGINE STOPPED...706
        Hydraulic System Oil...706
        Engine Oil...708
        Drive Belts...708
        Cooling System...708
        Air Filter...708
        Fuel System...709
        Primary Fuel Filter, Diesel Engine...709
        Battery...709
        Tires and Wheels...709
        Forks...710
        Forks, Adjustment...710
        Forks, Removal And Installation...710
        Inspection of Forks, Mast, And Lift Chains...711
        Operator Restraint System...713
        Safety Labels...714
      HOW TO MAKE THE CHECKS WITH THE ENGINE RUNNING...714
        Gauges, Lights, Horn, and Fuses...714
        Oil Level, Powershift Transmission...714
        Oil Level, Oil Clutch System, H3.50-5.00XL (H70-110XL)...715
        Control Levers and Pedals...715
        Lift System Operation...715
        Inching/Brake Pedal...716
        Service Brakes...716
        Parking Brake...716
        Steering System...716
    EVRY 150 HOURS OR MONTHLY...716
      THRUST SCREW FOR THE DIFFERENTIAL, H6.00-7.00XL (H135-155XL)...716
      LIFT CHAINS, LUBRICATION...716
      DRIVE SHAFTS...717
    EVERY 350 HOURS OR TWO MONTHS...717
      ENGINE OIL AND FILTER...717
      DRIVE BELTS...718
        Perkins Diesel Engine...718
        GM V-6 Engine (Early Models)...718
        GM V-6 Engine (Later Models)...719
      HYDRAULIC TANK BREATHER, CLEAN AND CHECK...720
      BRAKE FLUID...720
      LIFT CHAINS, CHECK FOR WEAR...720
      FORKS, CHECK FOR WEAR AND DAMAGE...721
      MAST, LUBRICATION...721
      CONTROL LEVERS AND PEDALS, LUBRICATION...721
      STEERING AXLE, LUBRICATION...722
      FUEL SYSTEM, CHECKS AND ADJUSTMENTS...722
        Diesel Fuel System...722
        LPG Carburetor (Early Models)...722
        Gasoline Carburetor (Early Models)...723
        Fuel Injection (Late Models)...723
    EVERY 1000 HOURS OR SIX MONTHS...723
      PCV VALVE, GM V-6...723
      MANIFOLD HEAT VALVE, GM V-6 (EARLY MODELS)...723
      CRANKCASE BREATHER, GM-V6...723
      IGNITION SYSTEM (GM V-6)...723
      VALVE CLEARANCE ADJUSTMENT...724
      FUEL FILTER (REPLACEMENT), DIESEL ENGINE...724
      REMOVE AIR FROM THE FUEL SYSTEM: PERKINS 1004-4 DIESEL ENGINE...724
        Fuel Injection Pump With A Vent Tube...724
        Fuel Injection Pump With A Vent Screw...725
      REMOVE AIR FROM THE FUEL SYSTEM: PERKINS 4.2482 DIESEL ENGINE...726
      CHECK THE OIL LEVEL IN THE TRANSMISSION...726
        Manual Transmission, H3.50-5.00XL (H70-110XL)...726
        Speed Reducer For The Powershift Transmission, H3.50-5.00XL (H70-110XL)...727
        Manual Transmission, H6.00-7.00XL (H135-155XL)...727
        Differential And Drive Axle For The Powershift Transmission, H6.00-7.00XL (H135-155XL...727
        Differential, Speed Reducer, And Drive Axle For The Manual Transmission, H6.00-7.00XL (H135-155XL)...727
    EVERY 2000 HOURS OR YEARLY...727
      HYDRAULIC SYSTEM...727
        Replace the Hydraulic Oil and Filter, H3.50-5.00XL (H70-110XL)...727
        Replace the Hydraulic Oil and Filter, H6.00-7.00XL (H135-155XL)...728
      CHANGE THE OIL AND REPLACE THE OIL FILTER, POWERSHIFT TRANSMISSION, ALL UNITS...728
      CHANGE THE OIL, MANUAL TRANSMISSION, H3.50-5.00XL (H70-110XL)...728
      CHANGE THE OIL, MANUAL TRANSMISSION, H6.00-7.00XL (H135-155XL)...728
      CHANGE THE OIL, SPEED REDUCER, POWERSHIFT TRANSMISSION, H3.50-5.00XL (H70-110XL)...729
      CHANGE THE OIL AND FILTER, OIL CLUTCH SYSTEM, H3.50-5.00XL (H70-110XL)...729
      CHANGE THE OIL, DIFFERENTIAL AND DRIVE AXLE FOR THE POWERSHIFT TRANSMISSION, H6.00-7.00XL (H135-155XL)...729
      CHANGE THE OIL, DIFFERENTIAL, SPEED REDUCER, AND DRIVE AXLE FOR MANUAL TRANSMISSION, H6.00-7.00XL (H135-155XL)...729
      COOLING SYSTEM...730
      WHEEL BEARINGS...730
        Steering Wheels, lubrication...730
        Drive Wheels, Lubrication...730
      PCV VALVE, GM V-6...730
      SERVICE BRAKES...730
      LPG FILTER, REPLACEMENT...731
      GASOLINE FUEL FILTER, REPLACEMENT...731
      CHECK THE HOOD LATCH, H3.50-5.00XL (H70-110XL)...731
    GENERAL PROCEDURES...732
      SAFETY PROCEDURES WHEN WORKING NEAR THE MAST...732
      LIFT CHAIN ADJUSTMENTS...734
      FUEL INJECTORS...734
      CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM...735
        Check the Lift Cylinder for Leaks...735
        Check the Tilt Cylinder for Leaks...735
      WELDING REPAIRS...735
      CHANGES TO THE OVERHEAD GUARD...736
      WHEELS AND TIRES...737
        Remove The Wheels From The Lift Truck...737
        Remove The Wheel From The Tire...737
        Install The Wheel In The Tire...739
        Pneumatic Tires, Add Air To The Tires...740
        Install the Wheels...740
      SOLID RUBBER TIRES...741
        Remove The Tire From The Wheel...741
        Install The Tire On The Wheel...742
    REFERENCE TABLE...743
  8000342...744
  8000343...752
    FIGURE 1. ELECTRICAL SCHEMATIC (GASOLINE/LPG, EARLY PRODUCTION)...752
    FIGURE 2. ELECTRICAL SCHEMATIC (GASOLINE/LPG, LATER PRODUCTION)...754
    FIGURE 3. ELECTRICAL SCHEMATIC (DIESEL, PERKINS 4.2482)...756
    FIGURE 4. ELECTRICAL SCHEMATIC (DIESEL, PERKINS 1004-4, EARLY PRODUCTION)...758
    FIGURE 5. ELECTRICAL SCHEMATIC (DIESEL, PERKINS 1004-4, LATER PRODUCTION)...760
    FIGURE 6. HYDRAULIC SCHEMATIC...762
    FIGURE 7. HYDRAULIC SCHEMATIC, POWERSHIFT TRANSMISSION WITH MANUAL CONTROL...763
    FIGURE 8. HYDRAULIC SCHEMATIC, POWERSHIFT TRANSMISSION WITH MONTROL PEDAL...764
    FIGURE 9. WIRING DIAGRAM, BACK-UP ALARM...765
  8000494...766
  900348...780
    INTRODUCTION...780
      GENERAL...780
      DESCRIPTION AND OPERATION...780
        Fuel Tank...781
        Fuel Filter and Fuel Valve Unit...781
        Vaporizer...782
        Carburetor...783
        Governor...784
    REPAIRS...786
      LPG TANK...786
        Removal...786
        Installation...786
      HYDROSTATIC RELIEF VALVE...786
        Removal and Installation...786
      FILTER UNIT...788
        Replacement Of The Fuel Filter Element...788
        Replacement of the Diaphragm and Fuel Valve ...788
      REPLACEMENT OF THE HOSES...788
      VAPORIZER...788
        Removal...788
        Vaporizer Disassembly...790
        Cleaning...790
        Inspection...790
        Vaporizer Assembly...790
        Installation...792
      CARBURETOR...792
        Removal...792
        Disassembly...792
        Cleaning...793
        Assembly...793
        Installation...793
      GOVERNOR...793
    CHECKS AND ADJUSTMENTS...794
      CHECK THE FILTER UNIT...794
      CHECK THE VAPORIZER...794
        Pressure Reducer Valve...794
        Vapor Valve...794
      ADJUST THE CARBURETOR...795
        Idle Mixture...795
        Idle Speed ...795
        Power Mixture...795
      ADJUST THE THROTTLE LINKAGE...795
    TROUBLESHOOTING...796
G005 (H70-110XL)...799
  100345...800
    THE FRAME...800
      GENERAL...800
      DESCRIPTION...800
      REPAIRS...800
      COUNTERWEIGHT...800
        Removal...800
      COUNTERWEIGHT...801
        Installation...801
      HOOD...801
        Removal...801
      HOOD...801
        Installation...801
      OVERHEAD GUARD...802
        Removal...802
        Installation...802
      OPERATOR RESTRAINT SYSTEM...802
      RADIATOR...802
        Removal...802
        Installation...803
      EXHAUST SYSTEM...803
        Muffler Replacement...803
      ENGINE...803
        Removal...803
        Installation...806
      FUEL AND HYDRAULIC TANKS...807
        Inspection...807
        Repairs, Small Leaks...807
        Repairs, Large Leaks...807
        Cleaning...807
        Other Methods Of Preparation For Repair...808
      SAFETY LABELS...809
        CAB...809
        Cab Repalacement...809
      Window Repalcement...809
        Windshield Wipers, Heater and Fan...812
        Material Specifications For Cab Windows...812
        Cab Heater Hoses...812
  1200334...813
    INTRODUCTION...813
      General...813
      Description...813
    REPAIRS...815
      Removal and Disassembly...815
      Cleaning and Inspection...816
      Assembly and Installation...817
    CHECKS AND ADJUSTMENTS...819
      Adjusting the Clutch Pedal and Linkage...819
      Adjusting the By-pass Valve for Cold Oil...819
    TROUBLESHOOTING...820
  1300335...822
    INTRODUCTION...822
      General...822
      Description...822
      Operation...822
    REPAIRS...824
      Removal...824
      Disassembly...825
      Cleaning...827
      Inspection...828
      Assembly...828
      Installation...839
    CHECKS AND ADJUSTMENTS...840
      Adjusting The Shift Linkage H3.50-5.00XL (H70-110XL)...840
      Adjusting The Shift Linkage S6.00-7.00XL (S135-155XL)...842
      Adjusting The Clutch Pedal And Linkage...842
    TROUBLESHOOTING...844
    SPECIFICATIONS...846
  1300336...847
    DESCRIPTION...847
      GENERAL...847
    MECHANICAL DESCRIPTION...847
      TORQUE CONVERTER...847
      OIL LAMP...848
      SHAFT AND CLUTCH ASSEMBLIES...848
        Input Shaft...849
        Forward Clutch Shaft...849
        Clutch Assemblies...849
        Output Gear...850
    HYDRAULIC OPERATION...850
      TORQUE CONVERTER...850
      SHAFT ASSEMBLIES...851
      CONTROL VALVE...853
        General...853
        System Regulator...853
        Clutch Pressure Regulator...853
        Torque Converter Regulator...854
        Inching Spool...854
        Direction Spool, Manual Control...854
        Drain Spool...855
        Accumulator...855
        Modulation Spool...856
      LUBRICATION CIRCUIT...857
      MONOTROL PEDAL...857
      OIL FLOW DIAGRAMS...857
        Neutral...857
        Forward...857
        Forward-Inching...857
        Reverse...858
  1300337...863
    REPAIRS ...863
      GENERAL...863
      REMOVAL...863
      TRANSMISSION, DISASSEMBLY...865
        Input Shaft, Disassembly...866
        Forward Shaft, Disassembly...868
        Cleaning and Inspection...869
      TRANSMISSION, ASSEMBLY...870
        Forward Shaft, Assembly...870
        Input Shaft, Assembly...872
        Assembly...874
        Installation...877
      CONTROL VALVE...878
        Removal...878
        Disassembly...879
        Assembly...879
        Installation...881
      THROTTLE PEDAL...881
      MONOTROL PEDAL...881
        Removal and Disassembly...881
        Assembly and Installation...881
    CHECKS AND ADJUSTMENTS...884
      STALL TEST...884
      ADJUST THE LINKAGE FOR THE INCHING PEDAL...885
        Linkage For Models With An Inching Pedal And A Brake Pedal...885
        Linkage For ModelsWith One Inching/Brake Pedal...887
      ADJUST THE LINKAGE FOR THE DIRECTION CONTROL LEVER...888
        Earlier Production...888
        Later Production...889
      CHECK THE OIL PRESSURE FOR THE TRANSMISSION...890
        System Pressure Check Port...891
        Torque Converter Check Port...891
        Clutch Pressure Check Port...892
        Inching Pressure...892
        Solenoid Check Ports (Monotrol Control Only)...892
        Lubrication Pressure Check Ports...892
    TROUBLESHOOTING...893
  1300346...896
    INTRODUCTION...896
      GENERAL...896
      DESCRIPTION...896
    REPAIRS...896
      REMOVAL...896
      DISASSEMBLY...896
      CLEANING...899
      INSPECTION...899
      ASSEMBLY...899
        Pinion Assembly...899
        Differential...900
      INSTALLATION...906
    TROUBLESHOOTING...907
    SPECIFICATIONS...908
  1400361...909
    INTRODUCTION...909
      GENERAL...909
      DESCRIPTION...909
    REPAIRS...910
      REMOVAL...910
        Lift Trucks With A Manual Transmission...910
        Lift Trucks With A Powershift Transmission...911
      DISASSEMBLY...912
      CLEANING...912
      INSPECTION...912
      ASSEMBLY...912
      INSTALLATION...913
        Lift Trucks With A Manual Transmission...913
        Lift Trucks With A Powershift Transmission...914
    TROUBLESHOOTING...915
    SPECIFICATIONS...915
  1600326...916
    General...918
    Description...918
    Steering Axle Assembly Repair...918
      Steering Axle H3.50-5.00XL (H70-110XL) and S/E3.50-5.50XL (S/E70-120XL)...918
        Remove...918
        Install...919
      Steering Axle H6.00-7.00XL (H135-155XL), H8.00-16.00XL (H165-360XL), and H8.00-16.00XM (H170-360HD)...920
        Remove...920
        Install...921
    Wheels and Hubs Repair (All Units)...922
      Remove and Disassemble...922
      Clean...922
      Assembly and Install...922
    Spindles and Bearings Repair (All Units)...924
      Remove...924
      Clean...924
      Assemble and Install...924
    Tie Rods Repair (All Units)...925
      Remove...925
      Clean...925
      Install...925
    Steering Cylinder Repair...927
      Remove and Disassemble...927
      Clean and Inspect...927
      Assemble and Install...927
    Troubleshooting...928
  160054...931
    INTRODUCTION...931
      GENERAL...931
      DESCRIPTION...931
      OPERATION...931
    REPAIRS...931
      STEERING WHEEL AND COLUMN ASSEMBLY...931
      TYPE "A" STEERING COLUMN ASSEMBLY...933
        Removal And Disassembly...933
        Assembly And Installation...933
      TYPE "A" STEERING COLUMN...934
      TYPE "A" STEERING COLUMN...935
      TYPE "B" STEERING COLUMN...936
        Removal And Disassembly...936
        Assembly And Installation...936
      TYPE "B" STEERING COLUMN...937
        Disassembly of Steering Control Unit...938
        Cleaning of Steering Control Unit...938
        Assembly of Steering Control Unit...940
    CHECKS AND ADJUSTMENTS...943
      REMOVE AIR FROM THE SYSTEM...943
    TROUBLESHOOTING...944
  1800338...945
    ...945
    ...946
    ...947
    ...948
    ...949
    ...950
    ...951
    ...952
    ...953
    ...954
    ...955
    ...956
    ...957
    ...958
    ...959
    ...960
    ...961
    ...962
    ...963
    ...964
    ...965
    ...966
    ...967
    ...968
  1900333...969
    INTRODUCTION...969
      GENERAL...969
      DESCRIPTION AND OPERATION...969
        Hydraulic Pump...969
        Main Control Valve...970
        Steering Control Unit...972
        Brake Booster...972
    REPAIRS...972
      HYDRAULIC PUMP...972
        Removal...972
        Disassembly...973
        Cleaning and Inspection...973
        Assembly...973
        Installation...974
        Adjust the Flow Divider...974
    SPECIFICATIONS...974
    TROUBLESHOOTING...975
  1900339...977
    INTRODUCTION...977
      GENERAL...977
      DESCRIPTION...977
    REPAIRS...979
      REMOVAL AND DISASSEMBLY...979
      CLEANING...979
      INSPECTION...979
      ASSEMBLY AND INSTALLATION...980
    TROUBLESHOOTING...981
      GENERAL...981
  190097...982
    INTRODUCTION...982
      DESCRIPTION...982
      OPERATION...982
        Flow Control Valve...984
        Relief Valve...984
    REPAIRS...985
      REMOVAL...985
      DISASSEMBLY...985
      CLEANING...987
      INSPECTION...987
      ASSEMBLY...988
      INSTALLATION...989
    CHECKS AND ADUSTMENTS...990
      CHECK THE OUTPUT OF THE PUMP...990
      CHECK FOR AIR IN THE HYDRAULIC SYSTEM...990
    TROUBLESHOOTING...992
  2200106...995
    General...997
    Description and Operation...997
    Starter Repair...999
      Remove...999
      Disassemble...999
      Clean...1000
      Assemble...1000
      Install...1001
    General Checks and Adjustments...1001
    Troubleshooting...1004
  2200143...1008
    INTRODUCTION...1008
      GENERAL...1008
    DESCRIPTION...1008
      GENERAL...1008
      STEERING COLUMN GAUGES, METERS AND INDICATORS...1011
      LED DISPLAY PANEL...1011
        Battery Discharge Indicators...1011
        Brush Wear Indicators...1012
        Motor Temperature Indicators...1013
      "LX" SERIES DISPLAY PANEL...1014
        Hourmeter Functions...1015
        Battery Indicator Function...1015
        Status Code Function...1015
      "ZX" SERIES DISPLAY PANELS...1015
        Display Panel...1016
        Basic Display Panels...1016
        Performance Display...1018
        Brush Wear Indicators...1021
    CHECKS AND ADJUSTMENTS...1021
      GENERAL...1021
    REPLACEMENT...1022
      GENERAL...1022
      METER REPLACEMENT...1022
      SENDER REPLACEMENT...1023
        Fuel Level Sender...1023
        Pressure And Temperature Sender...1023
      I.T.W. DISPLAY PANEL...1024
        Removal...1024
      DISPLAY PANELS FOR THE EV - 100/200ZX MOTOR CONTROLLERS, COLUMN MOUNT...1025
        Removal...1025
        Replacing Display Panel Assembly...1025
        Indicator LEDs...1025
        Battery Indicators...1025
        Digital Display (Performance Disply Panel Only)...1025
        Status Code Or Performance Level Switches And Indicator LEDs (Performance Display Panel Only)...1025
        Replacing Parts Of The Basic Display Panel...1026
        Replacing Parts Of The Performance Display Panel...1028
      DISPLAY PANELS FOR THE EV-100/200ZX MOTOR CONTROLLERS, DASH MOUNT...1028
        Removal And Replacement...1028
    SPECIFICATIONS...1029
    TROUBLESHOOTING...1030
  2200144...1031
    ELECTRICAL WARNING DEVICES...1031
      GENERAL...1031
      DESCRIPTION...1031
        Operator Controlled Horns...1031
        System Warning Lights, Buzzers and Bells...1031
        Reverse Warning Horns...1032
        Warning Lights...1032
      REPLACEMENT...1033
        General...1033
        Replacing Horns or Bells...1033
        Replacing Horn Relay or Buzzer...1033
        Replacing Warning Lights...1033
        Light Assemblies...1034
        Replacing Flashing Units...1034
  22002...1035
    General...1037
    Description...1037
    Alternator Repair...1039
      Alternator Type A...1039
        Remove and Disassemble...1039
        Clean...1040
        Assemble...1040
        Install...1041
      Alternator Type B...1044
        Remove and Disassemble...1044
        Clean...1044
        Assemble...1045
        Install...1046
    General Check and Adjustment...1047
    Low Output Check (Type A or Type B)...1047
    High Output Check (Type A or Type B)...1049
    Brushes Circuit Check...1050
      Delco Alternators...1050
      Motorola Alternators...1051
    Diodes Check...1052
    Diodes Bridge Check...1052
      Delco and Leece-Neville Alternators...1052
      Motorola Alternators...1052
    Rotor Field Winding Check...1053
    Stator Windings Check...1054
    Voltage Regulator Check...1054
    Troubleshooting...1055
  2200463...1057
    ...1057
    ...1058
    ...1059
    ...1060
    ...1061
    ...1062
    ...1063
    ...1064
    ...1065
    ...1066
    ...1067
    ...1068
    ...1069
    ...1070
    ...1071
    ...1072
    ...1073
    ...1074
    ...1075
    ...1076
    ...1077
    ...1078
    ...1079
    ...1080
    ...1081
    ...1082
    ...1083
    ...1084
    ...1085
    ...1086
    ...1087
    ...1088
    ...1089
    ...1090
    ...1091
    ...1092
  600412...1093
    PERKINS DIESEL ENGINES, SERIES 1000...1093
      1.1 GENERAL...1093
      GENERAL SAFETY RULES...1093
        Viton Seals...1093
      1.2 DESCRIPTION...1096
        1.3 Engine Serial Number Codes...1096
        1.4 Engine Data...1096
        1.5 1004–4 ENGINE...1097
        1.6 1004–4T ENGINE...1097
        1.7 1006–6 ENGINE...1097
        1.8 1006–6T ENGINE...1097
      1.9 REMOVAL AND INSTALLATION...1097
    CYLINDER HEAD ASSEMBLY...1098
      1.10 VALVE COVER...1098
        1.11 Removal...1098
        1.12 Installation...1098
      1.13 ROCKER ARM ASSEMBLY...1098
        1.14 Removal...1098
        1.15 Installation...1098
        1.16 Disassembly...1099
        1.17 Inspection...1099
        1.18 Assembly...1099
      1.19 VALVE CLEARANCE ADJUSTMENTS...1099
        1.20 Four Cylinder Engines...1100
        1.21 Six Cylinder Engines...1100
      1.22 VALVE SPRINGS...1100
      1.23 CYLINDER HEAD ASSEMBLY...1102
        1.24 Removal...1102
        1.25 Installation...1103
      1.26 VALVES AND VALVE SPRINGS...1106
        1.27 Removal...1106
        1.28 Inspection...1107
        1.29 Installation...1107
      1.30 VALVE GUIDES...1107
        1.31 Inspection...1107
        1.32 Removal...1108
        1.33 Installation...1108
      1.34 CYLINDER HEAD AND VALVE SEATS...1108
        1.35 Inspection...1108
        1.36 Repair...1109
        1.37 Installation Of New Valve Seats...1109
    PISTON AND CONNECTING ROD ASSEMBLIES...1110
      1.38 ROD BEARINGS...1110
        1.39 Removal...1110
        1.40 Installation...1111
      1.41 PISTON AND CONNECTING ROD ASSEMBLY...1111
        1.42 Service Note...1111
        1.43 Removal...1111
        1.44 Installation...1112
      1.45 PISTON RINGS...1113
        1.46 Removal...1113
        1.47 Inspection...1113
        1.48 Installation...1114
      1.49 PISTON AND CONNECTING ROD...1115
        1.50 Disassembly...1115
        1.51 Inspection...1115
        1.52 Installation...1115
      1.53 PISTON COOLING JETS...1116
        1.54 Removal...1116
        1.55 Installation...1116
    CRANKSHAFT ASSEMBLY...1117
      1.56 GENERAL...1117
      1.57 CRANKSHAFT PULLEY...1117
        1.58 Removal, Engines AA and AB...1117
        1.59 Installation, Engines AA and AB...1117
        1.60 Removal, Engines YA and YB...1117
        1.61 Installation, Engines YA and YB...1117
      1.62 REAR OIL SEAL...1118
        1.63 Replacement...1118
      1.64 MAIN BEARINGS...1119
        1.65 Removal...1119
        1.66 Installation...1119
      1.67 THRUST WASHERS...1120
        1.68 Check The Axial Movement Of The Crankshaft...1120
        1.69 Removal...1121
        1.70 Installation...1121
      1.71 CRANKSHAFT...1121
        1.72 Removal...1121
        1.73 Inspection...1122
        1.74 Installation...1122
    TIMING CASE AND TIMING GEARS...1124
      1.75 GENERAL...1124
      1.76 TIMING CASE COVER...1124
        1.77 Removal...1124
        1.78 Installation...1124
      1.79 FRONT OIL SEAL...1125
        1.80 Removal...1125
        1.81 Installation...1125
      1.82 IDLER GEAR AND HUB...1125
        1.83 Removal...1125
        1.84 Installation...1126
      1.85 GEAR FOR THE FUEL INJECTION PUMP OR THE CAMSHAFT GEAR...1127
        1.86 Removal...1127
        1.87 Installation...1127
      1.88 CRANKSHAFT GEAR...1128
        1.89 Removal...1128
        1.90 Installation...1128
      1.91 TIMING CASE...1128
        1.92 Removal...1128
        1.93 Installation...1128
      1.94 CAMSHAFT AND TAPPETS...1129
        1.95 Removal...1130
        1.96 Installation...1130
    ENGINE BLOCK ASSEMBLY...1131
      1.97 DESCRIPTION...1131
      1.98 ENGINE BLOCK...1131
        1.99 Disassembly...1131
        1.100 Inspection...1132
        1.101 Assembly...1132
      1.102 CYLINDER LINER...1132
        1.103 Inspection...1132
        1.104 Hone...1133
        1.105 Removal...1133
        1.106 Installation...1134
    TURBOCHARGER, ENGINES AB AND YB...1135
      1.107 GENERAL...1135
        1.108 Removal...1135
        1.109 Installation...1136
        1.110 Clean The Impeller And Compressor Housing...1136
    LUBRICATION SYSTEM...1137
      1.111 GENERAL...1137
      1.112 OIL FILTER, REPLACEMENT...1137
      1.113 OIL SUMP...1138
        1.114 Removal...1138
        1.115 Installation...1138
      1.116 OIL PUMP...1138
        1.117 Removal...1138
        1.118 Inspection...1139
        1.119 Installation...1139
      1.120 RELIEF VALVE...1140
        1.121 Removal...1140
        1.122 Disassembly...1140
        1.123 Inspection...1141
        1.124 Installation...1141
    FUEL SYSTEM...1141
      1.125 DESCRIPTION...1141
      1.126 CAV FUEL INJECTION PUMP...1142
        1.127 Removal...1142
        1.128 Installation...1142
      1.129 CAV FUEL INJECTION PUMP, CHECKS AND ADJUSTMENTS...1143
        1.130 Timing Gear Marks...1143
        1.131 How To Set Number 1 Piston To TDC On The Compression Stroke...1144
        1.132 Check The Valve Timing...1144
        1.133 Check The Timing Of The Fuel Injection Pump...1145
        1.134 Check The Timing Mark Of The Fuel Injection Pump...1145
        1.135 Check The Engine Timing Mark...1146
      1.136 REMOVE AIR FROM THE FUEL SYSTEM...1147
        1.137 Fuel Injection Pump With Vent Tube...1147
        1.138 Fuel Injection Pump With Vent Screw...1148
      1.139 FUEL FILTER (REPLACEMENT)...1149
      1.140 FUEL INJECTORS...1149
        1.141 Removal...1149
        1.142 Inspection...1150
        1.143 Installation...1151
      1.144 FUEL PUMP...1151
        1.145 Removal...1151
        1.146 Disassembly...1151
        1.147 Assembly...1152
        1.148 Installation...1152
        1.149 Test...1153
    COOLING SYSTEM...1153
      1.150 GENERAL...1153
      1.151 THERMOSTAT...1153
        1.152 Replacement...1153
      1.153 COOLANT PUMP...1154
        1.154 Removal...1154
        1.155 Disassembly...1154
        1.156 Assembly...1155
        1.157 Installation...1155
      1.158 FAN AND FAN DRIVE...1155
        1.159 Removal...1155
        1.160 Disassembly...1155
        1.161 Assembly...1156
        1.162 Installation...1156
      1.163 OIL COOLER...1156
        1.164 Removal, Engine AB...1156
        1.165 Removal, Engines YA and YB...1156
        1.166 Disassembly And Assembly...1157
        1.167 Installation, Engine AB...1157
        1.168 Installation, Engines YA and YB...1158
        1.169 By–Pass Valve, Oil Cooler...1158
    FLYWHEEL AND FLYWHEEL HOUSING...1158
      1.170 GENERAL...1158
      1.171 FLYWHEEL...1158
        1.172 Removal...1158
        1.173 Ring Gear (Replacement)...1158
        1.174 Installation...1158
      1.175 FLYWHEEL HOUSING...1159
        1.176 Removal...1159
        1.177 Installation...1159
    ELECTRICAL EQUIPMENT...1160
      1.178 DRIVE BELTS...1160
      1.179 ALTERNATOR...1161
      1.180 STARTER MOTOR...1161
        1.181 Removal...1161
        1.182 Installation...1161
      1.183 COLD START AID...1161
    AIR COMPRESSOR, ENGINES YA AND YB...1161
      1.184 GENERAL...1161
        1.185 Air Compressor, Removal, WABCO...1161
        1.186 Compressor Drive, Inspection...1162
        1.187 Air Compressor, Installation, WABCO...1162
        1.188 Compressor Drive, Disassembly, WABCO...1162
        1.189 Compressor Drive, Assembly, WABCO...1163
        1.190 Air Compressor, Removal, BENDIX...1163
        1.191 Air Compressor, Installation, BENDIX...1164
        1.192 Compressor Drive, Disassembly, BENDIX...1165
        1.193 Compressor Drive, Assembly, BENDIX...1165
    ENGINE SPECIFICATIONS...1167
      1.194 CYLINDER HEAD ASSEMBLY...1167
        1.195 Cylinder Head...1167
        1.196 Valve Guides...1167
        1.197 Inlet Valves...1168
        1.198 Exhaust Valves...1168
        1.199 Double Valve Springs To Outer...1168
        1.200 Double Valve Springs To Inner...1168
        1.201 Single Valve Springs...1168
        1.202 Tappets...1168
        1.203 Rocker Arm Shaft...1168
        1.204 Rocker Arms And Bushings...1169
      1.205 PISTON AND CONNECTING RODS...1169
        1.206 Pistons, Engines AA And YA...1169
        1.207 Pistons, Engines AB And YB...1169
        1.208 Piston Rings, Engines AA And YA...1169
        1.209 Piston Rings, Engines AB And YB...1169
        1.210 Connecting Rods, Engines AB And YB...1170
        1.211 Connecting Rods, Engines AB And YB...1170
        1.212 Piston Pins, Engines AA And YA...1170
        1.213 Piston Pins, Engines AB and YB...1170
        1.214 Small End Bushings, Engines AA And YA...1170
        1.215 Small End Bushings, Engines AB And YB...1170
        1.216 Connecting Rod Bearings, Engines AA And YA...1171
        1.217 Connecting Rod Bearings, Engines AB And YB...1171
        1.218 Piston Cooling Jets, Engines AB And YB...1171
      1.219 CRANKSHAFT ASSEMBLY...1171
        1.220 Crankshaft...1171
        1.221 Crankshaft Heat Treatment...1171
        1.222 Crankshaft Overhaul...1171
        1.223 Main Bearings...1173
        1.224 Crankshaft Thrust Washers...1173
      1.225 TIMING CASE AND DRIVE ASSEMBLY...1173
        1.226 Camshaft...1173
        1.227 Camshaft Thrust Washer...1173
        1.228 Camshaft Gear...1174
        1.229 Gear For Fuel Injection Pump...1174
        1.230 Crankshaft Gear...1174
        1.231 Idler Gear And Hub...1174
      1.232 ENGINE BLOCK ASSEMBLY...1174
        1.233 Engine Block...1174
        1.234 Cylinder Liners...1174
      1.235 TURBOCHARGER...1175
      1.236 LUBRICATION SYSTEM...1175
        1.237 Oil Pump, Engines AA And AB...1175
        1.238 Oil Pump, Engines YA And YB...1175
        1.239 Relief Valve...1175
        1.240 Oil Filter...1175
      1.241 FUEL SYSTEM...1175
        1.242 Cav Fuel Injection Pump...1175
        1.243 FUEL INJECTORS...1176
        1.244 Fuel Pump, Engines AA And AB...1177
        1.245 Fuel Pump, Engines YA And YB...1177
        1.246 Fuel Filter...1177
      1.247 COOLING SYSTEM...1177
        1.248 Coolant Pump...1177
        1.249 Thermostat...1178
        1.250 Fan Drive Housing...1178
      1.251 FLYWHEEL AND HOUSING...1178
        1.252 Limits for flywheel ''run out'' and alignment (total indicator reading)...1178
      1.253 ELECTRICAL EQUIPMENT...1178
        1.254 Alternator...1178
        1.255 Starter Motor...1178
        1.256 Cold Start Aid...1178
    TORQUE SPECIFICATIONS...1179
    SPECIAL TOOLS...1180
  600590...1184
    GM 4.3 LITRE V-6...1184
      INTRODUCTION...1184
      DESCRIPTION...1184
      ENGINE, REMOVAL AND INSTALLATION ...1185
      CYLINDER HEAD...1185
        Removal And Disassembly...1185
        Cleaning And Inspection...1185
        Repairs, Valve Guides and Seats...1185
        Repairs, Valves ...1186
        Repairs, Valve Seats...1186
        Valve Springs...1187
        Studs For The Rocker Arms (Early Models)...1188
        Studs For The Rocker Arms (Late Models)...1189
        Assembly And Installation...1189
      CYLINDER BLOCK, CLEANING AND INSPECTION...1191
      PISTON BORE PREPARATION...1191
      ENGINE MOUNTS...1191
      LUBRICATION SYSTEM...1191
        Oil Pump, Removal and Disassembly...1191
        Cleaning and Inspection...1192
        Oil Pump, Assembly and Installation...1192
        Oil Sump, Installation...1192
      TIMING COVER, TIMING SPROCKETS, CAMSHAFT AND VALVE LIFTERS...1193
        Timing Cover, Removal...1193
        Installation...1194
        Timing Sprockets, Removal...1195
        Timing Sprockets, Installation...1195
        Camshaft, Removal...1195
        Camshaft, Inspection...1195
        Camshaft, Installation...1195
        Balance Shaft, Removal...1196
        Balance Shaft, Installation...1197
        Hydraulic Valve Lifters, Removal...1198
        Hydraulic Valve Lifters, Disassembly...1198
        Hydraulic Valve Lifters, Cleaning And Inspection...1198
        Hydraulic Valve Lifters, Assembly...1199
        Hydraulic Valve Lifters, Installation...1199
      CRANKSHAFT...1200
        Removal...1200
        Inspection and Repair...1200
        How To Check The Clearance Between The Main Bearings And Their Journals...1201
        Installation...1202
      PISTON AND CONNECTING ROD ASSEMBLIES...1203
        Connecting Rod Bearings, Replacement...1203
        Piston And Connecting Rod Assemblies, Removal...1204
        Disassembly...1204
        Piston, Cleaning And Inspection...1204
        Cylinder Bores, Inspection And Repair...1205
        Piston Rings...1206
        Assembly...1206
        Piston And Connecting Rod Assemblies, Installation...1207
      FLYWHEEL AND FLYWHEEL HOUSING...1207
        Flywheel Repairs...1207
        Flywheel, Installation ...1207
        Flywheel Housing...1208
        Engine Adapter...1208
      COOLANT PUMP...1208
      THERMOSTAT...1208
      FAN MOUNT, EARLY MODELS...1208
      FAN MOUNT ASSEMBLY, LATE MODELS...1209
      DRIVE BELT, INSTALLATION...1210
    CHECKS AND ADJUSTMENTS...1212
      VALVE CLEARANCE ADJUSTMENT, EARLY MODELS...1212
      VALVE CLEARANCE ADJUSTMENT, NEW MODELS...1212
      CHECK THE COMPRESSION...1212
    ENGINE SPECIFICATIONS...1213
      Engine Data...1213
        Engine Data...1213
        Cylinder head...1213
        Hydraulic Valve Lifter...1213
        Camshaft...1213
        Pistons...1213
        Crankshaft...1214
        Connecting Rods...1214
        Connecting Rods...1214
        Balance Shaft...1214
        Cooling System...1214
        Lubrication System...1214
    TORQUE SPECIFICATIONS...1215
    TROUBLESHOOTING...1216
  600705...1219
    General...1221
      General Safety Rules...1221
    Description...1222
      Engine Serial Number Codes...1225
      Engine Data...1225
    Engine Removal and Installation...1227
      Lift Engine...1227
    Cylinder Head Assembly Repair...1227
      Valve Cover...1227
        Remove...1227
        Install...1228
      Rocker Arm Assembly...1228
        Remove...1228
        Install...1228
        Disassemble...1228
        Inspect...1228
        Assemble...1229
      Valve Clearance Adjustments...1229
        Four-Cylinder Engines...1230
        Six-Cylinder Engines...1230
      Valve Springs...1230
      Cylinder Head Assembly...1232
        Remove...1232
        Install...1234
      Valves and Valve Springs...1238
        Remove...1238
        Inspect...1238
        Install...1239
      Valve Guides...1239
        Inspect...1239
        Remove...1240
        Install...1240
      Cylinder Head and Valve Seats...1240
        Inspect...1240
        Repair...1240
        New Valve Seat, Install...1240
    Piston and Connecting Rod Assemblies Repair...1242
      Rod Bearings...1242
        Remove...1243
        Install...1243
      Piston and Connecting Rod Assembly...1244
        Service Note...1244
        Remove...1244
        Install...1245
      Piston Rings...1246
        Remove...1246
        Inspect...1246
        Install...1246
      Piston and Connecting Rod...1247
        Disassemble...1247
        Inspect...1248
        How to Select Correct Replacements...1248
        Install...1249
      Piston Cooling Jets...1249
        Remove...1249
        Install...1250
    Crankshaft Assembly Repair...1250
      General...1250
      Crankshaft Pulley...1251
        Engine AR, Remove...1251
        Engine YG and YH, Remove...1251
        Inspect...1252
        Engine AR, Install...1252
        Engines YG and YH, Install...1252
      Rear Oil Seal...1253
        Replace...1253
      Main Bearings...1254
        Remove...1254
        Inspect...1255
        Install...1255
      Thrust Washers...1255
        Crankshaft Axial Movement, Check...1255
        Remove...1256
        Install...1256
      Crankshaft...1257
        Remove...1257
        Inspect...1257
        Install...1257
      Flywheel...1259
        Remove...1259
        Ring Gear, Replace...1259
        Install...1259
      Flywheel Housing...1260
        Remove...1260
        Install...1260
    Timing Case and Timing Gears Repair...1261
      General...1261
      Timing Case Cover...1261
        Remove...1261
        Install...1262
      Front Oil Seal...1262
        Remove...1262
        Install...1262
      Crankshaft Pulley Wear Sleeve...1263
        Install...1263
      Idler Gear and Hub...1263
        Remove...1263
        Install...1264
      Air Compressor Drive, Bendix...1265
        Disassemble...1265
        Assemble...1266
      Fuel Injection Pump Gear...1266
        Remove...1267
        Install...1267
      Camshaft Gear...1268
        Remove...1268
        Install...1268
      Crankshaft Gear...1269
        Remove...1269
        Install...1269
      Timing Case...1269
        Remove...1269
        Install...1270
      Camshaft and Tappets...1271
        Remove...1271
        Install...1271
    Cylinder Block Assembly Repair...1272
      Description...1272
      Cylinder Block...1272
        Disassemble...1272
        Inspect...1273
        Assemble...1273
      Cylinder Bore (Four-Cylinder Engines)...1274
      Cylinder Liner (Six-Cylinder Engines)...1274
        Inspect...1274
        Cylinder Liner Condition, Check...1274
        Remove...1275
        Service Liner, Install...1276
        Partially Finished Liner, Install...1277
    Engine Timing...1278
      Description...1278
        How to Set Number One Piston to TDC on Compression Stroke...1279
        How to Set Number One Piston to TDC on Compression Stroke (Alternate Procedure)...1280
        Valve Timing, Check...1280
        Fuel Injection Pump Timing, Check...1281
    Turbocharger - Engine YH Repair...1282
      General...1282
        Remove...1282
        Install...1282
        Impeller and Compressor Housing, Clean...1283
    Lubrication System Repair...1284
      General...1284
      Oil Filter, Replace...1284
        Filter Head...1285
          Remove and Install...1285
        Oil Sump...1285
          Remove...1285
          Install...1286
        Oil Pump...1286
          Remove...1286
          Inspect...1286
          Install...1287
        Relief Valve...1287
          Remove...1287
          Disassemble...1288
          Inspect...1288
          Assemble...1288
          Install...1288
        Idler Gear Shaft, Replace...1289
          Remove...1289
          Remove (Alternative)...1289
          Install...1290
          Install (Alternative)...1290
          Install (Alternative for Four-Cylinder Engines Only)...1291
    Fuel System Repair...1291
      Description...1291
      Fuel Injection Pump...1292
        Remove...1292
        Install...1293
        Check and Adjust...1294
      Fuel System, Remove Air...1294
      Fuel Filter, Replace...1295
        Canister Type...1296
        Quick Release Canister Type...1296
      Fuel Injectors...1297
        Remove...1297
        Inspect...1298
        Install...1298
      Fuel Pump...1299
        Remove...1299
        Disassemble...1299
        Assemble...1299
        Install...1300
        Test...1300
    Cooling System Repair...1301
      General...1301
      Thermostat...1301
        Remove...1301
        Install...1301
        Test...1302
      Coolant Pump...1302
        Remove...1302
        Disassemble...1302
        Assemble...1304
        Install...1306
      Fan and Fan Drive...1307
        Remove...1307
        Install...1307
      Oil Cooler (Six-Cylinder Engines)...1308
        Remove...1308
        Disassemble and Assemble...1308
        Install...1308
        Oil Cooler By-Pass Valve...1308
    Electrical Equipment Repair...1309
      Drive Belts...1309
      Alternator...1310
        Remove...1310
        Install...1310
      Starter Motor...1310
        Remove...1310
        Install...1310
      Cold Start Aid...1310
    Air Compressor - Engines YG and YH...1310
      General...1310
      Repair...1311
        Remove...1311
        Install...1311
    Engine Specifications...1313
      Cylinder Head Assembly...1313
      Piston and Connecting Rods...1317
      Crankshaft Assembly...1319
        Crankshaft Overhaul...1321
      Timing Case and Drive Assembly...1323
      Engine Block Assembly...1324
      Turbocharger...1327
      Lubrication System...1327
      Fuel System...1328
      Cooling System...1330
      Flywheel and Housing...1330
      Electrical Equipment...1330
    Torque Specifications...1331
      Cylinder Head Assembly...1331
      Piston and Connecting Rod Assemblies...1331
      Crankshaft Assembly...1331
      Timing Case and Drive Assembly...1331
      Turbocharger...1331
      Lubrication System...1331
      Fuel System...1332
      Cooling System...1332
      Flywheel ...1332
      Auxiliary Equipment...1332
    Special Torque Specifications...1333
      Flywheel and Housing...1333
      Turbocharger...1333
      Electrical Equipment...1333
      Auxiliary Equipment...1333
    Special Tools...1333
    Troubleshooting...1338
  700626...1342
    General...1344
    Description...1345
      Radiator...1345
      Radiator Cap...1345
      Thermostat...1345
      Water Pump...1346
      Fan and Fan Shroud...1346
    Cooling System Checks...1346
      Radiator...1346
      Thermostat...1346
      Water Pump...1347
      Exhaust Leaks...1347
      Fan and Fan Shroud...1347
    Radiator Cleaning...1347
      Drain...1347
      Clean...1347
      Fill...1348
    Troubleshooting...1349
  8000231...1351
    General...1353
      Nomenclature, Threads...1353
      Strength Identification...1354
      Fastener Torque Tables...1358
      Conversion Table...1360
  8000341...1362
    PERIODIC MAINTENANCE...1362
      GENERAL...1362
      SERIAL NUMBER DATA...1362
      HOW TO MOVE A DISABLED LIFT TRUCK   ...1362
        How To Tow the Lift Truck...1362
      HOW TO PUT A LIFT TRUCK ON BLOCKS...1363
        How To Raise the Drive Tires...1363
        How To Raise the Steering Tires...1363
    MAINTENANCE SCHEDULE...1365
    MAINTENANCE PROCEDURES EVERY 8 HOURS OR DAILY...1368
      HOW TO MAKE CHECKS WITH THE ENGINE STOPPED...1368
        Hydraulic System Oil...1368
        Engine Oil...1370
        Drive Belts...1370
        Cooling System...1370
        Air Filter...1370
        Fuel System...1371
        Primary Fuel Filter, Diesel Engine...1371
        Battery...1371
        Tires and Wheels...1371
        Forks...1372
        Forks, Adjustment...1372
        Forks, Removal And Installation...1372
        Inspection Of Forks, Mast, and Lift Chains...1373
        Operator Restraint System...1375
        Safety Labels...1376
      HOW TO MAKE THE CHECKS WITH THE ENGINE RUNNING...1376
        Gauges, Lights, Horns, and Fuses...1376
        Oil Level, Powershift Transmission...1376
        Oil Level, Oil Clutch System, H3.50-5.00Xl (H70-110XL)...1377
        Control Levers and Pedals...1377
        Lift System Operation...1377
        Inching/Brake Pedal...1378
        Service Brakes...1378
        Parking Brake...1378
        Steering System...1378
    EVERY 150 HOURS OR MONTHLY...1378
      THRUST SCREW FOR THE DIFFERENTIAL, H6.00-7.00XL (H135-155XL)...1378
      LIFT CHAINS, LUBRICATION...1378
      DRIVE SHAFTS...1379
    EVERY 350 HOURS OR TWO MONTHS...1379
      ENGINE OIL AND FILTER...1379
      DRIVE BELTS...1380
        Perkins Diesel Engine...1380
        GM V-6 Engine (Early Models)...1380
        GM V-6 Engine (Late Models)...1381
      HYDRAULIC TANK BREATHER, CLEAN AND CHECK...1382
      BRAKE FLUID...1382
      LIFT CHAINS, CHECK FOR WEAR...1382
      FORKS, CHECK FOR WEAR AND DAMAGE...1383
      MAST, LUBRICATION...1383
      CONTROL LEVERS AND PEDALS, LUBRICATION...1383
      STEERING AXLE, LUBRICATION...1384
      FUEL SYSTEM, CHECKS AND ADJUSTMENT...1384
        Diesel Fuel System...1384
        LPG Carburetor (Early Models)...1384
        Gasoline Carburetor (Early Models)...1385
        Fuel Injection (Late Models)...1385
    EVERY 1000 HOURS OR SIX MONTHS...1385
      PCV VALVE, GM V-6...1385
      MANIFOLD HEAT VALVE, GM V-6 (EARLY MODELS)...1385
      CRANKCASE BREATHER, GM-V6...1385
      IGNITION SYSTEM (GM V-6)...1385
      VALVE CLEARANCE ADJUSTMENT...1386
      FUEL FILTER (REPLACEMENT), DIESEL ENGINE...1386
      REMOVE AIR FROM THE FUEL SYSTEM: PERKINS 1004-4 DIESEL ENGINE...1386
        Fuel Injection Pump With A Vent Tube...1386
        Fuel Injection Pump With A Vent Screw...1387
      REMOVE THE AIR FROM THE FUEL SYSTEM: PERKINS 4.2482 DIESEL ENGINE...1388
      CHECK THE OIL LEVEL IN THE TRANSMISSION...1388
        Manual Transmission, H3.50-5.00XL (H70-110Xl)...1388
        Speed Reducer For The Powershift Transmission, H3.50-5.00XL (H70-110XL)...1389
        Manual Transmission, H6.00-7.00XL (H135-155XL)...1389
        Differential And Drive Axle For The Powershift Transmission, H6.00-7.00Xl (H135-155XL)...1389
        Differential, Speed Reducer, And Drive Axle For The Manual Transmission, H6.00-7.00Xl (H135-155XL) ...1389
    EVERY 2000 HOURS OR YEARLY...1389
      HYDRAULIC SYSTEM...1389
        Replace the Hydraulic Oil and Filter, H3.50-5.00XL (H70-110XL) ...1389
        Replace the Hydraulic Oil and Filter, H6.00-7.00XL (H135-155XL) ...1390
      CHANGE THE OIL AND REPLACE THE OIL FILTER, POWERSHIFT TRANSMISSION, ALL UNITS ...1390
      CHANGE THE OIL, MANUAL TRANSMISSION, H3.50-5.00XL (H70-110XL)...1390
      CHANGE THE OIL, MANUAL TRANSMISSION, H6.00-7.00XL (H135-155XL)...1390
      CHANGE THE OIL, SPEED REDUCER, POWERSHIFT TRANSMISSION, H3.50-5.00XL (H70-110XL)...1391
      CHANGE THE OIL AND FILTER, OIL CLUTCH SYSTEM, H3.50-5.00XL (H70-110XL)...1391
      CHANGE THE OIL, DIFFERENTIAL AND DRIVE AXLE FOR THE POWERSHIFT TRANSMISSION, H6.00-7.00XL (H135-155XL)...1391
      CHANGE THE OIL, DIFFERENTIAL, SPEED REDUCER, AND DRIVE AXLE FOR MANUAL TRANSMISSION, H6.00-7.00XL (H135-155XL)...1391
      COOLING SYSTEM...1392
      WHEEL BEARINGS...1392
        Steering Wheel, lubrication...1392
        Drive Wheels, Lubrication...1392
      PCV VALVE, GM V-6...1392
      SERVICE BRAKES...1392
      LPG FILTER, REPLACEMENT...1393
      GASOLINE FUEL FILTER, REPLACEMENT...1393
      CHECK THE HOOD LATCH, H3.50-5.00XL (H70-110XL)...1393
    GENERAL PROCEDURES...1394
      SAFETY PROCEDURES WHEN WORKING NEAR THE MAST...1394
      LIFT CHAIN ADJUSTMENTS...1396
      FUEL INJECTORS...1396
      CHECKS FOR LEAKS IN THE LIFT AND TILT SYSTEM ...1397
        Check the Lift Cylinders for Leaks...1397
        Check the Tilt Cylinders for Leaks...1397
      WELDING REPAIRS...1397
      CHANGES TO THE OVERHEAD GUARD...1398
      WHEELS AND TIRES...1399
        Remove The Wheels From The Lift Truck...1399
        Remove The Wheel From The Tire...1399
        Install The Wheel In The Tire...1401
        Pneumatic Tires, Add Air To The Tires...1402
        Install the Wheels ...1402
      SOLID RUBBER TIRES...1403
        Remove The Tire From The Wheel...1403
        Install The Tire On The Wheel...1404
    REFERENCE TABLE...1405
  8000342...1407
  8000343...1415
    FIGURE 1. ELECTRICAL SCHEMATIC (GASOLINE/LPG, EARLY PRODUCTION)...1415
    FIGURE 2. ELECTRICAL SCHEMATIC (GASOLINE/LPG, LATER PRODUCTION)...1417
    FIGURE 3. ELECTRICAL SCHEMATIC (DIESEL, PERKINS 4.2482)...1419
    FIGURE 4. ELECTRICAL SCHEMATIC (DIESEL, PERKINS 1004-4, EARLY PRODUCTION)...1421
    FIGURE 5. ELECTRICAL SCHEMATIC (DIESEL, PERKINS 1004-4, LATER PRODUCTION)...1423
    FIGURE 6. HYDRAULIC SCHEMATIC...1425
    FIGURE 7. HYDRAULIC SCHEMATIC, POWERSHIFT TRANSMISSION WITH MANUAL CONTROL...1426
    FIGURE 8. HYDRAULIC SCHEMATIC, POWERSHIFT TRANSMISSION WITH MONTROL PEDAL...1427
    FIGURE 9. WIRING DIAGRAM, BACK-UP ALARM...1428
  8000494...1429
  900348...1443
    INTRODUCTION...1443
      GENERAL...1443
      DESCRIPTION AND OPERATION...1443
        Fuel Tank...1444
        Fuel Filter and Fuel Valve Unit...1444
        Vaporizer...1445
        Carburetor...1446
        Governor...1447
    REPAIRS...1449
      LPG TANK...1449
        Removal...1449
        Installation...1449
      HYDROSTATIC RELIEF VALVE...1449
        Removal and Installation...1449
      FILTER UNIT...1451
        Replacement Of The Fuel Filter Element...1451
        Replacement of the Diaphragm and Fuel Valve ...1451
      REPLACEMENT OF THE HOSES...1451
      VAPORIZER...1451
        Removal...1451
        Vaporizer Disassembly...1453
        Cleaning...1453
        Inspection...1453
        Vaporizer Assembly...1453
        Installation...1455
      CARBURETOR...1455
        Removal...1455
        Disassembly...1455
        Cleaning...1456
        Assembly...1456
        Installation...1456
      GOVERNOR...1456
    CHECKS AND ADJUSTMENTS...1457
      CHECK THE FILTER UNIT...1457
      CHECK THE VAPORIZER...1457
        Pressure Reducer Valve...1457
        Vapor Valve...1457
      ADJUST THE CARBURETOR...1458
        Idle Mixture...1458
        Idle Speed ...1458
        Power Mixture...1458
      ADJUST THE THROTTLE LINKAGE...1458
    TROUBLESHOOTING...1459

Hyster Forklift Trucks G005 (H70-110XL & H3.50-5.00XL Europe) Repair Service Manual