Complete service repair manual for Hyster G006 (H135-155XL & H6.00-7.00XL Europe) Forklift Trucks, with all the shop information to maintain, diagnose, repair,  and rebuild like professional mechanics.

Hyster G006 (H135-155XL & H6.00-7.00XL 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 G006 (H135-155XL & H6.00-7.00XL Europe) Service Manual.pdf

Total Pages: 1,355 + 2,184 pages
File Format: PDF
Language: English

G006 (H135-155XL)...2
  100322-frame...5
    INTRODUCTION...5
      GENERAL...5
      DESCRIPTION...5
    REPAIRS...6
      COUNTERWEIGHT...6
        Removal...6
        Installation...6
      HOOD...6
        Removal...6
        Installation...7
      OVERHEAD GUARD...7
        Removal...7
        Installation...7
      OPERATOR RESTRAINT SYSTEM...7
      HYDRAULIC TANK...8
        Removal...8
        Inspection...8
        Repairs, Small Leaks...8
        Repairs, Large Leaks...8
        Cleaning...8
        Steam Method of Cleaning...9
        Chemical Solution Method of Cleaning...9
        Other Methods Of Preparation For Repair...9
        Installation...9
      FUEL TANK...9
        Removal...9
        Repairs...10
        Installation...10
      RADIATOR...10
        Removal...10
        Installation...10
      ENGINE...10
        Removal...10
        Installation...10
      SAFETY LABELS...11
      CAB...13
        Cab Replacement...13
        Window Replacement...13
        Windshield Wipers and Heater...13
  1300324...15
    TWO-SPEED POWERSHIFT TRANSMISSION (HYSTER T-40) Description And Operation...15
      GENERAL...15
      MECHANICAL DESCRIPTION...15
        Torque Converter...15
        Transmission Pump...16
        Shaft Assemblies...17
        Input Shaft...17
        Forward Clutch Shaft...17
        Clutch Assemblies...17
      FORWARD LOW AND HIGH CLUTCH ASSEMBLIES...19
      REVERSE LOW AND HIGH CLUTCH ASSEMBLIES...21
        Countershaft...23
        Output Shaft...23
      HYDRAULIC OPERATION...24
        Torque Converter...24
        Seal Rings...25
      CONTROL VALVE...25
        System Pressure Regulator...28
        Clutch Pressure Regulator...28
        Torque Converter Regulator...28
        Inching Spool...28
        Direction Spool, Direction Control Lever...29
        Direction Spool, Monotrol Pedal...29
        Range Spool...30
        Drain Spool...30
        Accumulator...30
        Modulator Spool...30
        Operation (See...30
      LUBRICATION CIRCUIT...31
      MONOTROL PEDAL...31
      OIL FLOW DIAGRAMS...33
        Neutral...33
        Forward-Low...34
        Forward-Low-Inching...35
        Reverse Low...36
  1300325...38
    TWO-SPEED POWERSHIFT TRANSMISSION (HYSTER T-40)...38
      GENERAL...38
      TRANSMISSION...38
        Removal, Transmission And Torque Converter...38
        Transmission, Disassembly...40
        Reverse-Low Clutch, Disassembly...41
        Reverse-High Clutch, Disassembly...43
        Forward-Low Clutch, Disassembly...44
        Forward-High Clutch, Disassembly...45
        Cleaning and Inspection...46
      ASSEMBLY, FORWARD LOW AND HIGH CLUTCHES...46
        Forward Clutches, Assembly...48
        Reverse-Low CLutch, Assembly...52
        Reverse Clutches, Assembly...54
        Transmission, Assembly...59
        Torque Converter, Installation...63
      CONTROL VALVE...64
        Removal...64
        Disassembly...64
        Assembly...65
        Installation...67
        MONOTROL PEDAL...67
        Removal and Disassembly...67
        Assembly and Installation...68
    CHECKS AND ADJUSTMENTS...70
      STALL TEST...70
      LINKAGE ADJUSTMENTS...70
        Linkage For The Inching Pedal, H6.00-7.00XL (H135-155XL)...70
        Linkage For The Inching Pedal, S6.00-7.00XL (S135-155XL)...73
        Linkage For The Range Lever H6.00-7.00XL (H135-155XL)...75
        Linkage For The Direction Control Lever, H6.00-7.00XL (H135-155XL)...75
        Linkage For The Range Lever, S6.00-7.00XL (S135-155XL)...77
        Linkage For The Direction Control Lever S6.00-7.00XL (S135-155XL)...78
      CHECK THE OIL PRESSURE FOR THE TRANSMISSION...78
        System Pressure Check Port...78
        Torque Converter Check Port...78
        Clutch Pressure Check Port...79
        Inching Pressure...79
        Solenoid Check Ports (MONOTROL Control Only)...79
        Lubrication Pressure Check Ports...79
    SPECIFICATIONS...80
      TROUBLESHOOTING...80
  1300344...85
    INTRODUCTION...85
      GENERAL...85
      DESCRIPTION...85
      OPERATION...86
    REPAIRS...86
      REMOVAL...86
      DISASSEMBLY...86
      CLEANING AND INSPECTION...87
      ASSEMBLY...87
      INSTALLATION...89
    CHECKS AND ADJUSTMENTS...89
      ADJUST THE DIRECTION CONTROL LINKAGE...89
  130061...90
    INTRODUCTION...90
      GENERAL...90
      DESCRIPTION...90
        Oil Clutch Assembly, H6.00-7.00XL (H135-155XL)...90
        Manual Transmission...92
    REPAIRS...92
      OIL CLUTCH ASSEMBLY...92
        Removal and Disassembly...92
        Cleaning...92
        Inspection...92
        Assembly and Installation...93
      TRANSMISSION...93
        Removal, H6.00-7.00XL (H135-155XL)...93
        Disassembly...94
        Cleaning...96
        Inspection...96
        Assembly...97
        Installation, H6.00-7.00XL (H135-155XL)...101
    CHECKS AND ADJUSTMENTS...102
      ADJUSTING THE CLUTCH PEDAL LINKAGE, H6.00-7.00XL (H135-155XL)...102
    TROUBLESHOOTING-OIL CLUTCH ASSEMBLY...103
    TROUBLESHOOTING-MANUAL TRANSMISSION...105
  1400046...107
    DIFFERENTIAL...107
      GENERAL...107
      DESCRIPTION...107
    REPAIRS...108
      REMOVAL...108
      DISASSEMBLY...108
      ASSEMBLY...108
      Assemble The Pinion, Bearings And Pinion Carrier...108
      Adjust Preload For Pinion Bearings...108
      Adjust Thickness Of Shim Set For The Pinion Carrier (Depth Of Pinion)...109
      Assemble The Differential And Ring Gear...111
      Assemble Differential Pinion And Side Gear Assembly...112
      Check The Rotating Torque Of Differential Gears...113
      Install The Differential And Ring Gear Assembly...114
      Adjust Preload Of The Differential Bearings...115
      Check Runout Of Ring Gear...115
      Adjust The Gear Clearance...115
      Check Tooth Contact Pattern Of The Gear Set...116
      Installation Into The Axle Housing...116
    SPECIFICATIONS...119
      TABLE 1.  GENERAL SPECIFICATIONS...119
      TABLE 2.  RIVET INSTALLATION PRESSURE...119
      TABLE 3.  PINION PRELOAD PRESSURE...119
      TABLE 4.  PINION ADJUSTMENT...119
      TABLE 5.  TORQUE SPECIFICATIONS...120
      TABLE 6.  TORQUE SPECIFICATIONS FOR METRIC HARDWARE...121
    TROUBLESHOOTING...122
  140049...124
    INTRODUCTION...124
      GENERAL...124
      DESCRIPTION...124
    REPAIRS...124
      DISASSEMBLY...125
      CLEANING...127
      ASSEMBLY...127
    TROUBLESHOOTING...129
  1552002-0600SRM1070-(06-2007)-US-EN...130
    toc...130
      Perkins Diesel Engines...130
      Safety Precautions Maintenance and Repair...131
      General...138
        General Safety Rules...138
      Description...139
        Engine Serial Number Codes...141
        Engine Data...141
      Engine Removal and Installation...142
      Cylinder Head Assembly Repair...143
        Engine Breather...143
          Remove...143
          Install...143
        Valve Cover...144
          Remove...144
          Install...144
        Rocker Arm Assembly...145
          Remove...145
          Disassemble...145
          Inspect...145
          Assemble...146
          Install...146
        Valve Clearance Adjustments...147
        Valve Springs...147
        Cylinder Head Assembly...149
          Remove...149
          Inspect...150
          Install...150
        Valves and Valve Springs...152
          Remove...152
          Inspect...152
          Install...153
        Valve Guides...153
          Inspect...153
          Remove...154
          Install...154
        Valve Seats...155
          Inspect...155
          Repair...155
          New Valve Seats, Install...156
      Piston and Connecting Rod Assemblies Repair...157
        General...157
        Rod Bearings...157
          Remove...157
          Install...158
        Piston and Connecting Rod Assembly...159
          Service Note...159
          Remove...159
          Disassemble...159
          Inspect...159
          How to Select Correct Replacements...161
          Assemble...161
          Install...162
        Piston Cooling Jets...164
          Remove...164
          Install...164
      Crankshaft Assembly Repair...165
        General...165
        Crankshaft Pulley...165
          Remove...165
          Inspect...165
          Install...165
        Rear Oil Seal...166
          Remove...166
          Install...166
        Crankshaft Flange Wear Sleeve...168
          Remove...168
          Install...168
        Main Bearings...169
          Remove...169
          Inspect...169
          Install...169
        Thrust Washers...170
          Crankshaft Axle Movement, Check...170
          Remove...171
          Install...171
        Crankshaft...172
          Remove...172
          Inspect...172
          Install...173
        Crankshaft Timing Ring...174
          Remove...174
          Install...175
        Flywheel...175
          Remove...175
          Ring Gear, Replace...175
          Install...175
        Flywheel Housing...176
          Remove...176
          Install...176
      Timing Case and Timing Gears Repair...177
        General...177
        Timing Case Cover...177
          Remove...177
          Install...177
        Front Oil Seal...178
          Remove, With Timing Case Installed...178
          Install, With Timing Case Installed...179
          Remove, With Timing Case Removed...180
          Install, With Timing Case Removed...180
        Crankshaft Pulley Wear Sleeve, Install...180
        Fuel Pump Gear...181
          Remove...181
          Install...182
        Idler Gear and Hub...183
          Remove...183
          Disassemble...184
            Standard Idler Gear and Hub Assembly...184
            Heavy Duty Idler Gear and Hub Assembly...184
          Assemble...185
            Standard Idler Gear and Hub Assembly...185
            Heavy Duty Idler Gear and Hub Assembly...185
          Install...186
        Camshaft Gear...186
          Remove...186
          Install...187
        Crankshaft Gear...187
          Remove...187
          Install...187
        Timing Case...188
          Remove...188
          Install...189
        Power Take-Off (PTO) Adaptor...190
          Remove...190
          Disassemble...190
          Assemble...191
          Install...191
        Camshaft and Tappets...191
          Remove...191
          Install...191
      Cylinder Block Assembly Repair...192
        General...192
        Cylinder Block...192
          Disassemble...192
          Inspect...193
          Assemble...193
        Cylinder Bore...193
          Inspect...193
          Cylinder Liner Condition Check...193
      Engine Timing...194
        General...194
        How to Set Number One Piston to TDC on Compression Stroke...194
        Fuel Injection Pump Timing, Check...195
        Fuel Injection Pump Timing, Adjust...196
      Lubrication System Repair...198
        General...198
        Oil Filter, Replace...198
        Oil Filter Head...199
          Remove...199
          Install...199
        Oil Sump...199
          Remove...199
          Install...200
        Oil Pump...201
          Remove...201
          Inspect...201
          Install...201
        Oil Strainer and Suction Pipe...202
          Remove...202
          Install...202
        Relief Valve...203
          Remove...203
          Install...203
        Dipstick Tube...203
          Remove and Install...203
      Fuel System Repair...204
        General...204
        Cold Start Advance Unit (KSB)...204
        Typical Fuel System...205
        Fuel Filter...207
          Remove...207
          Install...207
        Fuel Injectors...208
          Remove...208
          Install...209
        Fuel System Air Removal...210
        Bosch EVPE Fuel Injection Pump...210
          General...210
          Remove...211
          Install...212
      Cooling System Repair...212
        General...212
        Thermostat...214
          Remove...214
          Install...214
          Test...214
        Coolant Pump...215
          Remove...215
          Disassemble...215
          Assemble...216
          Install...217
        Fan...218
          Remove and Install...218
        Fan Drive...218
          Remove...218
          Install...218
        Oil Cooler...218
          Remove...218
          Disassemble and Assemble...219
          Install...219
        Coolant Bypass Hose...219
          Removal...219
          Install...219
      Electrical Equipment Repair...220
        Drive Belt...220
          Check...220
          Adjust...220
          Remove...220
          Install...220
        Alternator...221
          Remove...221
          Install...221
          Fault Diagnosis...221
            Normal Operation:...221
            If the Warning Lamp is Not Illuminated When the Ignition Switch ...222
            If the Warning Light Continues to be Illuminated When the Altern...222
        Starter Motor...223
          Remove...223
          Install...223
          Test...223
        Starting Aid...223
          Remove...223
          Install...224
          Check...224
            Power Supply Continuity...224
            Operation...224
        Pressure Sensor...225
          Remove...225
          Install...226
        Temperature Sensor...226
          Remove...226
          Install...227
      Engine Specifications...227
        Cylinder Head Assembly...227
        Piston and Connecting Rods...230
        Crankshaft Assembly...232
          Crankshaft Overhaul...232
        Timing Case and Drive Assembly...234
        Engine Block Assembly...235
        Lubrication System...235
        Fuel System...236
        Cooling System...237
        Flywheel and Housing...238
        Electrical Equipment...238
      Torque Specifications...238
      Special Torque Specifications...239
        Cylinder Head Assembly...239
        Piston and Connecting Rod Assemblies...239
        Crankshaft Assembly...239
        Timing Case and Drive Assembly...239
        Cylinder block...239
        Fuel System...239
        Lubrication System...239
        Cooling System...240
        Flywheel and Housing...240
        Electrical Equipment...240
      Special Tools...241
      Troubleshooting...245
    tables...130
      Table 1. Cylinder Head...227
      Table 2. Valve Guides...228
      Table 3. Inlet Valves...228
      Table 4. Exhaust Valves...229
      Table 5. Valve Springs...230
      Table 6. Tappets...230
      Table 7. Rocker Arm Shaft...230
      Table 8. Rocker Arms and Bushings...230
      Table 9. Pistons...230
      Table 10. Piston Rings...230
      Table 11. Piston Pins...231
      Table 12. Connecting Rods...231
      Table 13. Small End Bushings...231
      Table 14. Connecting Rod Bearings...231
      Table 15. Piston Cooling Jets...232
      Table 16. Crankshaft Overhaul Specifications...232
      Table 17. Maximum Variation (Run-out)...233
      Table 18. Camshaft...234
      Table 19. Camshaft Thrust Washer...234
      Table 20. Camshaft Gear...234
      Table 21. Gear for Fuel Pump...234
      Table 22. Crankshaft Gear...234
      Table 23. Idler Gear and Hub...234
      Table 24. Timing Gear Backlash Values...235
      Table 25. Cylinder Block...235
      Table 26. Oil Pump...235
      Table 27. Idler Gear for Oil Pump...235
      Table 28. Relief Valve...236
      Table 29. Oil Filter...236
      Table 30. Bosch Fuel Injection Pump...236
      Table 31. Fuel Injector Settings...236
      Table 32. Fuel Pump...237
      Table 33. Fuel Filter...237
      Table 34. Coolant Pump...237
      Table 35. Thermostat...237
      Table 36. Fan Drive Housing...237
      Table 37. Limits for Flywheel Run Out and Alignment (Total Indic...238
      Table 38. Alternator...238
      Table 39. Starter Motor...238
      Table 40. Starting Aids...238
      Table 41. List of Possible Causes...246
  1559540-0900SRM1088-(05-2006)-US-EN...250
    toc...250
      Electronic Controlled LPG/Gasoline Fuel System...250
      Safety Precautions Maintenance and Repair...251
      General...256
        Fuel System Warnings and Cautions...256
      Glossary...257
      Description and Operation of LPG Fuel System...261
        Propane Fuel System...261
        LPG Fuel Tank...263
        Service Line...263
        Fuel Filter...263
        Low Pressure Lock-Off (LPL)...264
        Low Pressure Regulator (LPR)...264
        Air Fuel Mixer...264
        Throttle Control Device...265
          Drive By Cable...265
        Three-Way Catalytic (TWC) Muffler...266
        Electronic Control Module (ECM)...266
        Heated Exhaust Gas Oxygen (HEGO) Sensor...269
      Description and Operation of Gasoline Fuel System...269
        Gasoline Fuel System Throttle Body Injection (TBI), 3.0L Engine ...269
        Gasoline Multi-Point Fuel Injection (MPFI) System, 4.3L Only...271
        Gasoline Fuel Storage Tank...271
        Gasoline Fuel Pump...271
        Fuel Filter...271
        Fuel Pressure Regulator, 3.0L Only...273
        Fuel Rail and Pressure Regulator, 4.3L Only...273
        Fuel Injector...273
        Throttle Control Device...273
          Drive By Cable...273
        Three-Way Catalytic Muffler...274
        Electronic Control Module (ECM)...275
        Heated Exhaust Gas Oxygen (HEGO) Sensor...276
      LPG Fuel System Repair...277
        Propane Fuel System Pressure Relief...277
        Propane Fuel System Leak Test...277
        Propane Fuel Filter Replacement...277
          Remove...277
          Install...278
        Low Pressure Lock-Off (LPL) Replacement...278
          Remove...278
          Install...278
        Pressure Trim Valve (PTV) Replacement...280
          Remove...280
          Install...280
        Low Pressure Regulator...280
          Remove...280
          Install...280
        Fuel Trim Valve (FTV) Solenoid Replacement...281
          Remove...281
          Install...281
        Temperature Manifold Absolute Pressure (TMAP)...284
          Remove...284
          Install...284
        Throttle Body Replacement...284
          Remove...284
          Install...285
        Mixer Replacement...285
          Remove...285
          Install...285
        Coolant Hose Replacement...285
          Remove...285
          Install...286
        Vapor Hose Replacement...286
          Remove...286
          Install...286
        Balance Line Hose Replacement...286
          Remove...286
          Install...286
        PTV Hose Replacement...286
          Remove...286
          Install...286
        FTV Hose Replacement...287
          Remove...287
          Install...287
        Throttle Position Sensor (TPS) Replacement...287
        Foot Pedal Position (FPP) Sensor Replacement...289
        Electronic Control Module (ECM) Replacement...292
          Remove...292
          Install...292
        Heated Exhaust Gas Oxygen (HEGO) Sensor Replacement...293
          Remove...293
          Install...293
        Three-Way Catalytic Muffler (TWC) Replacement...293
          Remove...293
          Install...293
        Restricted Exhaust System Diagnosis...293
          Exhaust System Description...293
            Tools Required...293
            Diagnostic Tool...293
          Check at Heated Exhaust Gas Oxygen Sensor (HEGO)...294
      Gasoline Fuel System Repair...294
        Gasoline MPFI and TBI Fuel System Pressure Relief...294
        Gasoline Fuel System Leak Test...295
        Throttle Body Injector (TBI) Assembly Replacement, 3.0L Only...295
          Remove...295
          Install...295
        Throttle Body Assembly Replacement, 3.0L Only...297
          Remove...297
          Install...297
        Throttle Body Assembly Replacement, 4.3L Only...297
          Remove...297
          Install...298
        Fuel Rail Replacement, Gasoline 4.3L Only...300
          Remove...300
          Install...300
        Injector Replacement, Gasoline 4.3L Only...300
          Remove...300
          Install...300
        Injector Replacement, Gasoline 3.0L Only...301
          Remove...301
          Install...301
        Temperature Manifold Absolute Pressure (TMAP) Replacement...301
          Remove...301
          Install...301
        Throttle Position Sensor (TPS) Replacement...301
        Foot Pedal Position (FPP) Sensor Replacement...304
        Electronic Control Module (ECM) Replacement...307
          Remove...307
          Install...307
        Heated Exhaust Gas Oxygen (HEGO) Sensor Replacement...307
          Remove...307
          Install...308
        Three-Way Catalytic Muffler (TWC) Replacement...308
          Remove...308
          Install...308
        Restricted Exhaust System Diagnosis...308
          Exhaust System Description...308
            Tools Required...308
            Diagnostic Tool...308
          Check at Heated Exhaust Gas Oxygen Sensor (HEGO)...308
      LPG System Diagnosis...309
        Fuel System Description...309
        Diagnostic Aids...310
          Tools Required...310
          Duty Cycle Monitoring Tool...310
          Diagnostic Tool...310
          Pressure Gauges...310
          Test Description...310
      Gasoline System Diagnosis...318
        Fuel System Description, 3.0L Only...318
        Fuel System Description, 4.3L Only...318
        Diagnostic Aids...319
          Tools Required...319
          Diagnostic Tool...319
          Test Description...319
      LPG Symptom Diagnosis...326
      Gasoline Symptom Diagnosis...340
      Wire Harness Repair...350
        On Vehicle Service Wiring Harness Repair...350
        Connectors and Terminals...351
          Twisted/Shielded Cable Repair...351
          Twisted Leads Repair...352
          Micro-Pack...353
          Metri-Pack...354
            Remove...354
          Weather-Pack...355
            Weather-Pack Terminal Repair...356
    tables...250
      Table 1. TPS Replacement Procedure...287
      Table 2. FPP Replacement Procedure...290
      Table 3. TPS Replacement Procedure...302
      Table 4. FPP Replacement Procedure...305
      Table 5. LPG Fuel System Diagnosis...310
      Table 6. Fuel Control Diagnosis...314
      Table 7. Gasoline Fuel System Diagnosis, 3.0L Only...320
      Table 8. Gasoline Fuel System Diagnosis, 4.3L Only...323
      Table 9. Preliminary Checks...326
      Table 10. Intermittent ...328
      Table 11. No Start...329
      Table 12. Hard Start...331
      Table 13. Cuts Out or Misses...332
      Table 14. Hesitation, Sag, or Stumble...333
      Table 15. Backfire...334
      Table 16. Lack of Power, Sluggishness, or Sponginess...335
      Table 17. Poor Fuel Economy...336
      Table 18. Rough, Unstable, Incorrect Idle, or Stalling...337
      Table 19. Surges or Chuggles...339
      Table 20. Preliminary Checks...340
      Table 21. Intermittent...341
      Table 22. No Start...342
      Table 23. Hard Start...343
      Table 24. Cuts Out or Misses...344
      Table 25. Hesitation, Sag, or Stumble...345
      Table 26. Backfire...346
      Table 27. Lack of Power, Sluggishness, or Sponginess...347
      Table 28. Poor Fuel Economy...348
      Table 29. Rough, Unstable, Incorrect Idle, or Stalling...349
      Table 30. Surges or Chuggles...350
  1559545-2200SRM1090-(04-2005)-US-EN...360
    toc...360
      Electronic Control Module (ECM) Diagnostic Troubleshooting...360
      Safety Precautions Maintenance and Repair...361
      General...370
      Description of ECM Based Diagnostics...370
        Definition of Terms...370
        Diagnostics Overview of the Spectrum Fuel System...370
        Malfunction Indicator Lamp (MIL)...371
        Spectrum Diagnostic Trouble Codes (DTC)...371
        Using a Laptop Computer to Diagnose the Spectrum System...371
          Installing the Spectrum Diagnostic Software...372
          Connecting a Laptop Computer to the Spectrum System...372
          Diagnostic Communication Error...372
        Diagnostic Trouble Codes...373
          Checking Diagnostic Trouble Codes...373
          Clearing Diagnostic Trouble Codes...373
        DATA Stream...374
          Reading Sensor and Actuator Values...374
          Graphing and Data Logging...375
        Ignition System Test...376
          Disabling Ignition Outputs...376
        Injector Test...377
          Disabling Injectors...377
        Throttle Test...377
          Using a Diagnostic Jumper to Diagnose the ECI System...378
      On-Board Diagnostics System Check/Malfunction Indicator Lamp...379
        Circuit Description...379
      Preliminary and Intermittent Checks...382
      GM 3.0L Wiring Schematics and Connectors...384
      GM 3.0L Diagnostic Trouble Codes...398
        DTC 111 - IAT High Voltage Motorola® TMAP...398
          Circuit Description...398
          Conditions for Setting the DTC...398
        DTC 112 - IAT Low Voltage Motorola® TMAP...401
          Circuit Description...401
          Conditions for Setting the DTC...401
        DTC 113 - IAT Higher Than Expected 1 Motorola® TMAP...403
          Circuit Description...403
          Conditions for Setting the DTC...403
          Diagnostic Aids...404
        DTC 114 - IAT Higher Than Expected 2 Motorola® TMAP...405
          Circuit Description...405
          Conditions for Setting the DTC...405
          Diagnostic Aids...405
        DTC 115 - Oil Pressure Low...406
          Circuit Description...406
          Conditions for Setting the DTC...406
        DTC 121 - ECT Voltage High...409
          Circuit Description...409
          Conditions for Setting the DTC...410
        DTC 122 - ECT Voltage Low...413
          Circuit Description...413
          Conditions for Setting the DTC...413
        DTC 123 - ECT Higher Than Expected 1...415
          Circuit Description...415
          Conditions for Setting the DTC...415
        DTC 124 - ECT Higher Than Expected 2...417
          Circuit Description...417
          Conditions for Setting the DTC...417
        DTC 131 - MAP High Pressure Motorola® TMAP...419
          Circuit Description...419
          Conditions for Setting the DTC...419
          Diagnostic Aids...419
        DTC 132 - MAP Low Voltage Motorola® TMAP...422
          Circuit Description...422
          Conditions for Setting the DTC...422
        DTC 134 - BP High Pressure Motorola® TMAP...426
          Circuit Description...426
          Conditions for Setting the DTC...426
        DTC 135 - BP Low Pressure Motorola® TMAP...427
          Circuit Description...427
          Conditions for Setting the DTC...427
        DTC 142 - Crank Sync Noise...431
          Circuit Description...431
          Conditions for setting the DTC...431
        DTC 143 - Never Crank Synced At Start...435
          Circuit Description...435
          Conditions for Setting the DTC...435
        DTC 144 - Camshaft Sensor Loss...438
          Circuit Description...438
          Conditions for Setting the DTC...438
        DTC 145 - Camshaft Sensor Noise...441
          Circuit Description...441
          Conditions for Setting the DTC...441
        DTC 211 - Closed Loop Multiplier High (LPG)...444
          Circuit Description...444
          Conditions for Setting the DTC...444
          Diagnostic Aids...444
        DTC 212 - HO 2 S Open/Inactive...447
          Circuit Description...447
          Conditions for Setting the DTC...447
        DTC 221 - Closed Loop Multiplier High (Gasoline)...449
          Circuit Description...449
          Conditions for Setting the DTC...449
          Diagnostic Aids...450
        DTC 222 - Closed Loop Multiplier Low (Gasoline)...453
          Circuit Description...453
          Conditions for Setting the DTC...453
          Diagnostic Aids...453
        DTC 224 - Closed Loop Multiplier Low (LPG)...455
          Circuit Description...455
          Conditions for Setting the DTC...455
          Diagnostic Aids...455
        DTC 241 - Adaptive Lean Fault (High Limit-Gasoline)...457
          Circuit Description...457
          Conditions for Setting the DTC...457
          Diagnostic Aids...457
        DTC 242 - Adaptive Rich Fault (Low Limit-Gasoline)...460
          Circuit Description...460
          Conditions for Setting the DTC...460
          Diagnostic Aids...460
        DTC 243 - Adaptive Learn High (LPG)...463
          Circuit Description...463
          Conditions for Setting the DTC...463
          Diagnostic Aids...463
        DTC 244 - Adaptive Learn Low (LPG)...466
          Circuit Description...466
          Conditions for Setting the DTC...466
          Diagnostic Aids...466
        DTC 261 - System Voltage High...469
          Circuit Description...469
          Conditions for Setting the DTC...469
        DTC 262 - System Voltage Low...471
          Circuit Description...471
          Conditions for Setting the DTC...471
        DTC 411 - Injector Driver 1 Open...473
          Circuit Description...473
          Conditions for Setting the DTC...473
        DTC 412 - Injector Driver 1 Shorted...476
          Circuit Description...476
          Conditions for Setting the DTC...476
        DTC 511 - COP Failure...479
          Circuit Description...479
          Conditions for Setting the DTC...479
        DTC 512 - Invalid Interrupt...481
          Circuit Description...481
          Conditions for Setting the DTC...481
        DTC 513 - A/D Loss...483
          Circuit Description...483
          Conditions for Setting the DTC...483
        DTC 514 - RTI 1 Loss...485
          Circuit Description...485
          Conditions for Setting the DTC...485
        DTC 515 - Flash Checksum Invalid...487
          Circuit Description...487
          Conditions for Setting the DTC...487
        DTC 516 - Ram Failure...489
          Circuit Description...489
          Conditions for Setting the DTC...489
        DTC 531 - External 5V Ref Lower Than Expected...491
          Circuit Description...491
          Conditions for Setting the DTC...491
        DTC 532 - External 5V Ref Higher Than Expected...493
          Circuit Description...493
          Conditions for Setting the DTC...493
        DTC 555 - RTI 2 Loss...495
          Circuit Description...495
          Conditions for Setting the DTC...495
        DTC 556 - RTI 3 Loss...497
          Circuit Description...497
          Conditions for Setting the DTC...497
        DTC 611 - FPP High Voltage...499
          Circuit Description...499
          Conditions for Setting the DTC...499
        DTC 612 - FPP Low Voltage...503
          Circuit Description...503
          Conditions for Setting the DTC...503
        DTC 631 - TPS1 Signal Voltage High...507
          Circuit Description...507
          Conditions for Setting the DTC...507
        DTC 632 - TPS1 Signal Voltage Low...510
          Circuit Description...510
          Conditions for Setting the DTC...510
        DTC 638 - Throttle Unable To Close...513
          Circuit Description...513
          Conditions for Setting the DTC...513
          Diagnostic Aids...514
        DTC 651 - Maximum Govern Speed Override...516
          Circuit Description...516
          Conditions for Setting the DTC...516
          Diagnostic Aids...516
        DTC 652 - Fuel Rev Limit...519
          Circuit Description...519
          Conditions for Setting the DTC...519
          Diagnostic Aids...519
        DTC 653 - Spark Rev Limit...521
          Circuit Description...521
          Conditions for Setting the DTC...521
          Diagnostic Aids...521
      GM 4.3L Wiring Schematics and Connectors...525
      GM 4.3L Diagnostic Trouble Codes...542
        DTC 111 - IAT High Voltage Bosch® TMAP...542
          Circuit Description...542
          Conditions for Setting the DTC...542
        DTC 111 - IAT High Voltage Motorola® TMAP...545
          Circuit Description...545
          Conditions for Setting the DTC...545
        DTC 112 - IAT Low Voltage Bosch® TMap...547
          Circuit Description...547
          Conditions for Setting the DTC...548
        DTC 112 - IAT Low Voltage Motorola® TMAP...550
          Circuit Description...550
          Conditions for Setting the DTC...550
        DTC 113 - IAT Higher Than Expected 1 Bosch® TMAP...553
          Circuit Description...553
          Conditions for Setting the DTC...553
          Diagnostic Aids...553
        DTC 113 - IAT Higher Than Expected 1 Motorola® TMAP...554
          Circuit Description...554
          Conditions for Setting the DTC...554
          Diagnostic Aids...554
        DTC 114 - IAT Higher Than Expected 2 Bosch® TMAP€...555
          Circuit Description...555
          Conditions for Setting the DTC...555
          Diagnostic Aids...555
        DTC 114 - IAT Higher Than Expected 2 Motorola® TMAP...556
          Circuit Description...556
          Conditions for Setting the DTC...556
          Diagnostic Aids...556
        DTC 115 - Oil Pressure Low...557
          Circuit Description...557
          Conditions for Setting the DTC...557
        DTC 121 - ECT Voltage High...559
          Circuit Description...559
          Conditions for Setting the DTC...560
        DTC 122 - ECT Voltage Low...563
          Circuit Description...563
          Conditions for Setting the DTC...563
        DTC 123 - ECT Higher Than Expected 1...566
          Circuit Description...566
          Conditions for Setting the DTC...566
        DTC 124 - ECT Higher Than Expected 2...568
          Circuit Description...568
          Conditions for Setting the DTC...568
        DTC 131 - MAP High Pressure Bosch® TMAP...569
          Circuit Description...569
          Conditions for Setting the DTC...569
          Diagnostic Aids...569
        DTC 131 - MAP High Pressure Motorola® TMAP...573
          Circuit Description...573
          Conditions for Setting the DTC...573
          Diagnostic Aids...573
        DTC 132 - MAP Low Voltage Bosch® TMAP...576
          Circuit Description...576
          Conditions for Setting the DTC...576
        DTC 132 - MAP Low Voltage Motorola® TMAP...579
          Circuit Description...579
          Conditions for Setting the DTC...579
        DTC 134 - BP High Pressure Bosch® TMAP...584
          Circuit Description...584
          Conditions for Setting the DTC...584
        DTC 134 - BP High Pressure Motorola® TMAP...586
          Circuit Description...586
          Conditions for Setting the DTC...586
        DTC 135 - BP Low Pressure Bosch® TMAP...588
          Circuit Description...588
          Conditions for Setting the DTC...588
        DTC 135 - BP Low Pressure Motorola® TMAP...592
          Circuit Description...592
          Conditions for Setting the DTC...592
        DTC 142 - Crank Sync Noise...595
          Circuit Description...595
          Conditions for setting the DTC...595
        DTC 143 - Never Crank Synced At Start...599
          Circuit Description...599
          Conditions for Setting the DTC...599
        DTC 144 - Camshaft Sensor Loss...602
          Circuit Description...602
          Conditions for Setting the DTC...602
        DTC 145 - Camshaft Sensor Noise...605
          Circuit Description...605
          Conditions for Setting the DTC...605
        DTC 211 - Closed Loop Multiplier High (LPG)...608
          Circuit Description...608
          Conditions for Setting the DTC...608
          Diagnostic Aids...609
        DTC 212 - HO 2 S Open/Inactive...611
          Circuit Description...611
          Conditions for Setting the DTC...611
        DTC 221 - Closed Loop Multiplier High (Gasoline)...614
          Circuit Description...614
          Conditions for Setting the DTC...614
          Diagnostic Aids...614
        DTC 222 - Closed Loop Multiplier Low (Gasoline)...617
          Circuit Description...617
          Conditions for Setting the DTC...617
          Diagnostic Aids...617
        DTC 224 - Closed Loop Multiplier Low (LPG)...619
          Circuit Description...619
          Conditions for Setting the DTC...619
          Diagnostic Aids...620
        DTC 241 - Adaptive Lean Fault (High Limit-Gasoline)...621
          Circuit Description...621
          Conditions for Setting the DTC...621
          Diagnostic Aids...621
        DTC 242 - Adaptive Rich Fault (Low Limit-Gasoline)...624
          Circuit Description...624
          Conditions for Setting the DTC...624
          Diagnostic Aids...624
        DTC 243 - Adaptive Learn High (LPG)...627
          Circuit Description...627
          Conditions for Setting the DTC...627
          Diagnostic Aids...627
        DTC 244 - Adaptive Learn Low (LPG)...630
          Circuit Description...630
          Conditions for Setting the DTC...630
          Diagnostic Aids...630
        DTC 261 - System Voltage High...633
          Circuit Description...633
          Conditions for Setting the DTC...633
        DTC 262 - System Voltage Low...635
          Circuit Description...635
          Conditions for Setting the DTC...635
        DTC 511 - COP Failure...637
          Circuit Description...637
          Conditions for Setting the DTC...637
        DTC 512 - Invalid Interrupt...639
          Circuit Description...639
          Conditions for Setting the DTC...639
        DTC 513 - A/D Loss...641
          Circuit Description...641
          Conditions for Setting the DTC...641
        DTC 514 - RTI 1 Loss...643
          Circuit Description...643
          Conditions for Setting the DTC...643
        DTC 515 - Flash Checksum Invalid...645
          Circuit Description...645
          Conditions for Setting the DTC...645
        DTC 516 - Ram Failure...647
          Circuit Description...647
          Conditions for Setting the DTC...647
        DTC 531 - External 5V Ref Lower Than Expected...649
          Circuit Description...649
          Conditions for Setting the DTC...649
        DTC 532 - External 5V Ref Higher Than Expected...651
          Circuit Description...651
          Conditions for Setting the DTC...651
        DTC 555 - RTI 2 Loss...653
          Circuit Description...653
          Conditions for Setting the DTC...653
        DTC 556 - RTI 3 Loss...655
          Circuit Description...655
          Conditions for Setting the DTC...655
        DTC 611 - FPP High Voltage...657
          Circuit Description...657
          Conditions for Setting the DTC...657
        DTC 612 - FPP Low Voltage...661
          Circuit Description...661
          Conditions for Setting the DTC...661
        DTC 631 - TPS1 Signal Voltage High...665
          Circuit Description...665
          Conditions for Setting the DTC...665
        DTC 632 - TPS1 Signal Voltage Low...668
          Circuit Description...668
          Conditions for Setting the DTC...668
        DTC 638 - Throttle Unable To Close...671
          Circuit Description...671
          Conditions for Setting the DTC...671
          Diagnostic Aids...672
        DTC 651 - Maximum Govern Speed Override...674
          Circuit Description...674
          Conditions for Setting the DTC...674
          Diagnostic Aids...674
        DTC 652 - Fuel Rev Limit...677
          Circuit Description...677
          Conditions for Setting the DTC...677
          Diagnostic Aids...677
        DTC 653 - Spark Rev Limit...679
          Circuit Description...679
          Conditions for Setting the DTC...679
          Diagnostic Aids...679
      Wire Harness Repair...682
        On Vehicle Service Wiring Harness Repair...682
        Connectors and Terminals...683
          Twisted/Shielded Cable Repair...683
          Twisted Leads Repair...684
          Micro-Pack...685
          Metri-Pack...685
            Remove...685
          Weather-Pack...687
            Weather-Pack Terminal Repair...688
    tables...360
      Table 1. OBD System Check...380
      Table 2. Preliminary Checks...382
      Table 3. Intermittent Checks...383
      Table 4. Communication Port C002...384
      Table 5. Coil Connector C003...384
      Table 6. Fuel System Interface C004...384
      Table 7. Oil Pressure Connector C005...385
      Table 8. Distributor Connector C006...385
      Table 9. Magnetic Pickup Connector C007...385
      Table 10. Heated Oxygen Sensor C008...385
      Table 11. Throttle Position Sensor Connector C009...386
      Table 12. Foot Pedal Position Connector C010...386
      Table 13. Governor Motor Connector C011...386
      Table 14. TMAP Connector C012...386
      Table 15. Starter Solenoid C013...387
      Table 16. Engine Coolant Temperature C014...387
      Table 17. Battery Connector C015...387
      Table 18. Alternator Connection C016...387
      Table 19. Battery Connector C017...387
      Table 20. Alternator Connector C018...388
      Table 21. Instrument Panel Connector C019...388
      Table 22. Instrument Panel Connector C020...388
      Table 23. Instrument Panel Connector C021...389
      Table 24. Fuel Trim Valve Connector C022...389
      Table 25. Fuel Lockoff Connector C023...389
      Table 26. Pressure Trim Valve Connector C024...390
      Table 27. Throttle Body Injector Connector C025...390
      Table 28. Relay and Fuse Center...390
      Table 29. DTC 111 - IAT Voltage High (Motorola® TMAP)...399
      Table 30. DTC 112 - IAT Low Voltage (Motorola® TMAP)...402
      Table 31. DTC 115 - Oil Pressure Low...407
      Table 32. Temperature Resistance...409
      Table 33. DTC 121 - ECT VOLTAGE HIGH...410
      Table 34. DTC 122 - ECT Voltage Low...414
      Table 35. DTC 123 - ECT Higher Than Expected 1...416
      Table 36. DTC 124 - ECT Higher Than Expected 2...418
      Table 37. DTC 131 - MAP HIGH PRESSURE (Motorola® TMAP)...420
      Table 38. DTC 132 - MAP Low Voltage (Motorola® TMAP)...423
      Table 39. DTC 134 - BP High Pressure (Motorola® TMAP)...426
      Table 40. DTC 135 - BP Low Pressure (Motorola® TMAP)...428
      Table 41. DTC 142 - Crank Sync Noise...432
      Table 42. DTC 143 - Never Crank Synced At Start...435
      Table 43. DTC 144 - Camshaft Sensor Loss...438
      Table 44. DTC 145 - Camshaft Sensor Noise...441
      Table 45. DTC 211 - Closed Loop Multiplier High (LPG)...445
      Table 46. DTC 212 - HO 2 S Open/Inactive...448
      Table 47. DTC 221 - Closed Loop Multiplier High (Gasoline)...451
      Table 48. DTC 222 - Closed Loop Multiplier Low (Gasoline)...454
      Table 49. DTC 224 - Closed Loop Multiplier Low (LPG)...456
      Table 50. DTC 241 - Adaptive Lean Fault (High Limit-Gasoline)...458
      Table 51. DTC 242 - Adaptive Rich Fault (Low Limit-Gasoline)...461
      Table 52. DTC 243 - Adaptive Learn High (LPG)...464
      Table 53. DTC 244 - Adaptive Learn Low (LPG)...467
      Table 54. DTC 261 - System Voltage High...470
      Table 55. DTC 262 - System Voltage Low...471
      Table 56. DTC 411 - Injector Driver 1 Open...474
      Table 57. DTC 412 - Injector Driver 1 Shorted...477
      Table 58. DTC 511 - COP Failure...480
      Table 59. DTC 512 - Invalid Interrupt...482
      Table 60. DTC 513 - A/D Loss...484
      Table 61. DTC 514 - RTI 1 Loss...486
      Table 62. DTC 515 - Flash Checksum Invalid...488
      Table 63. DTC 516 - Ram Failure...490
      Table 64. DTC 531 - External 5V Ref Lower Than Expected...492
      Table 65. DTC 532 - External 5 V Ref Higher Than Expected...494
      Table 66. DTC 555 - RTI 2 Loss...496
      Table 67. DTC 556 - RTI 3 Loss...498
      Table 68. DTC 611 - FPP High Voltage...500
      Table 69. DTC 612 - FPP Low Voltage...504
      Table 70. DTC 631 - TPS1 Signal Voltage High...508
      Table 71. DTC 632 - TPS1 Signal Voltage Low...511
      Table 72. DTC 638 - Throttle Unable To Close...514
      Table 73. DTC 651 - Maximum Govern Speed Override...517
      Table 74. DTC 652 - Fuel Rev Limit...520
      Table 75. DTC 653 - Spark Rev Limit...522
      Table 76. Communication Port C002...525
      Table 77. Injector Connector C003...525
      Table 78. Injector Connector C004...525
      Table 79. Oil Pressure Connector C005...526
      Table 80. Throttle Position Sensor 1 Connector C006...526
      Table 81. Foot Pedal Position Connector C006A...526
      Table 82. Coil Connector C007...526
      Table 83. Module Connector C008...527
      Table 84. Crank Sensor Connector C009...527
      Table 85. EGO Sensor Connector C010...527
      Table 86. Cam Connector C011...528
      Table 87. Throttle Connector C012...528
      Table 88. Bosch TMAP Connector C013 (Gasoline Fuel System Only)...528
      Table 89. Motorola TMAP Connector C013 (LPG Fuel System Only)...529
      Table 90. Starter Solenoid Connector C014...529
      Table 91. ECT Connector C015...529
      Table 92. Starter Relay C016...529
      Table 93. Power Relay C017...529
      Table 94. Fuel Pump Relay C018...529
      Table 95. Battery Connector C019...530
      Table 96. Alternator Connector C020...530
      Table 97. Alternator Connector C021...530
      Table 98. Instrument Panel Connector C022...530
      Table 99. Instrument Panel Connector C023...531
      Table 100. Instrument Panel Connector C024...531
      Table 101. Fuel Trim Valve Connector C025...531
      Table 102. Fuel Lockoff Connector C026...532
      Table 103. Pressure Trim Valve Connector C027...532
      Table 104. Injector 1 Connector C028...532
      Table 105. Injector 2 Connector C029...533
      Table 106. Injector 3 Connector C030...533
      Table 107. Injector 4 Connector C031...533
      Table 108. Injector 5 Connector C032...534
      Table 109. Injector 6 Connector C033...534
      Table 110. Relay and Fuse Center...534
      Table 111. DTC 111 - IAT Voltage High (Bosch® TMAP)...543
      Table 112. DTC 111 - IAT Voltage High (Motorola® TMAP)...546
      Table 113. DTC 112 - IAT Low Voltage (Bosch® TMAP)...548
      Table 114. DTC 112 - IAT Low Voltage (Motorola® TMAP)...551
      Table 115. DTC 115 - Oil Pressure Low...557
      Table 116. Temperature Resistance...560
      Table 117. DTC 121 - ECT VOLTAGE HIGH...561
      Table 118. DTC 122 - ECT Voltage Low...564
      Table 119. DTC 123 - ECT Higher Than Expected 1...567
      Table 120. DTC 124 - ECT Higher Than Expected 2...569
      Table 121. DTC 131 - MAP High Pressure (Bosch® TMAP)...570
      Table 122. DTC 131 - MAP HIGH PRESSURE (Motorola® TMAP)...574
      Table 123. DTC 132 - MAP Low Voltage (Bosch® TMAP)...577
      Table 124. DTC 132 - MAP Low Voltage (Motorola® TMAP)...580
      Table 125. DTC 134 - BP High Pressure (Bosch® TMAP)...585
      Table 126. DTC 134 - BP High Pressure (Motorola® TMAP)...587
      Table 127. DTC 135 - BP Low Pressure (Bosch® TMAP)...588
      Table 128. DTC 135 - BP Low Pressure (Motorola® TMAP)...592
      Table 129. DTC 142 - Crank Sync Noise...596
      Table 130. DTC 143 - Never Crank Synced At Start...599
      Table 131. DTC 144 - Camshaft Sensor Loss...602
      Table 132. DTC 145 - Camshaft Sensor Noise...605
      Table 133. DTC 211 - Closed Loop Multiplier High (LPG)...609
      Table 134. DTC 212 - HO 2 S Open/Inactive...612
      Table 135. DTC 221 - Closed Loop Multiplier High (Gasoline)...615
      Table 136. DTC 222 - Closed Loop Multiplier Low (Gasoline)...618
      Table 137. DTC 224 - Closed Loop Multiplier Low (LPG)...620
      Table 138. DTC 241 - Adaptive Lean Fault (High Limit-Gasoline)...622
      Table 139. DTC 242 - Adaptive Rich Fault (Low Limit-Gasoline)...625
      Table 140. DTC 243 - Adaptive Learn High (LPG)...628
      Table 141. DTC 244 - Adaptive Learn Low (LPG)...631
      Table 142. DTC 261 - System Voltage High...634
      Table 143. DTC 262 - System Voltage Low...635
      Table 144. DTC 511 - COP Failure...638
      Table 145. DTC 512 - Invalid Interrupt...640
      Table 146. DTC 513 - A/D Loss...642
      Table 147. DTC 514 - RTI 1 Loss...644
      Table 148. DTC 515 - Flash Checksum Invalid...646
      Table 149. DTC 516 - Ram Failure...648
      Table 150. DTC 531 - External 5V Ref Lower Than Expected...650
      Table 151. DTC 532 - External 5 V Ref Higher Than Expected...652
      Table 152. DTC 555 - RTI 2 Loss...654
      Table 153. DTC 556 - RTI 3 Loss...656
      Table 154. DTC 611 - FPP High Voltage...658
      Table 155. DTC 612 - FPP Low Voltage...661
      Table 156. DTC 631 - TPS1 Signal Voltage High...666
      Table 157. DTC 632 - TPS1 Signal Voltage Low...669
      Table 158. DTC 638 - Throttle Unable To Close...672
      Table 159. DTC 651 - Maximum Govern Speed Override...675
      Table 160. DTC 652 - Fuel Rev Limit...678
      Table 161. DTC 653 - Spark Rev Limit...681
  1559550-2200SRM1097-(07-2008)-US-EN...692
    toc...692
      High Voltage Switch (HVS) Ignition...692
      Safety Precautions Maintenance and Repair...693
      Description...696
        Distributor Ignition (DI) System...696
        Crankshaft Position (CKP) Sensor...696
        Camshaft Position (CMP) Sensor...696
        Ignition Coil and Ignition Control Module (ICM)...696
        Secondary Ignition Components...696
      Spark Plugs and Wires...696
        Spark Plug Wire Inspection...696
        Spark Plug Wire Replacement...696
          Remove...696
          Install...697
        Spark Plug Inspection...697
          Usage...697
          Inspection...697
          Visual Inspection...699
        Spark Plug Replacement...699
          Remove...699
          Install...700
      Distributor Repair...700
        Inspect...700
        Overhaul...701
          Disassemble...701
          Assemble...703
        Replace...704
          Remove...704
          Install Procedure 1...706
          Install Procedure 2...706
      Ignition Coil Replacement...708
        Remove...708
        Install...708
      Ignition Control Module Replacement...709
        Remove...709
        Install...709
      Camshaft Position (CMP) Sensor Replacement...710
        Remove...710
        Install...711
      Crankshaft Position (CKP) Sensor Replacement...712
        Remove...712
        Install...712
      Wire Harness Repair...713
        On Vehicle Service Wiring Harness Repair...713
        Connectors and Terminals...713
          Twisted/Shielded Cable Repair...714
          Twisted Leads Repair...715
          Micro-Pack...716
          Metri-Pack...716
            Remove...716
          Weather-Pack...718
            Weather-Pack Terminal Repair...718
      Specifications and Special Tools...720
      System Diagnosis...721
    tables...692
      Table 1. Ignition System Specifications...720
      Table 2. Fastener Tightening Specifications...720
      Table 3. Special Tools...721
      Table 4. Distributor Ignition (DI)...721
  1600326...730
    STEERING AXLE...730
      GENERAL...730
      DESCRIPTION...730
    REPAIRS...731
      STEERING AXLE, H3.50-5.50XL (H70-110XL) and S3.50-5.50XL (S70-120XL), E3.50-5.50XL (E70-120XL, E70-120XL3)...731
        Removal...731
        Installation...731
        STEERING AXLE, H6.00-7.00XL (H135-155XL) H8.00-16.00XL (H165-360L)...732
           Removal...732
          Installation...733
        WHEELS AND HUBS, ALL UNITS...733
        Removal and Disassembly...733
        Cleaning...734
        Assembly and Installation...734
      SPINDLES AND BEARINGS, ALL UNITS...734
        Removal...734
        Cleaning...735
        Assembly and Installation...735
      TIE RODS, ALL UNITS...735
        Removal...735
        Cleaning...736
        Installation...736
      STEERING CYLINDER...737
        Removal and Disassembly...737
        Cleaning and Inspection...737
        Assembly and Installation...737
    TROUBLESHOOTING...738
  160054...739
    INTRODUCTION...739
      GENERAL...739
      DESCRIPTION...739
      OPERATION...739
    REPAIRS...739
      STEERING WHEEL AND COLUMN ASSEMBLY...739
      TYPE "A" STEERING COLUMN ASSEMBLY...741
        Removal And Disassembly...741
        Assembly And Installation...741
      TYPE "A" STEERING COLUMN...742
      TYPE "A" STEERING COLUMN...743
      TYPE "B" STEERING COLUMN...744
        Removal And Disassembly...744
        Assembly And Installation...744
      TYPE "B" STEERING COLUMN...745
        Disassembly of Steering Control Unit...746
        Cleaning of Steering Control Unit...746
        Assembly of Steering Control Unit...748
    CHECKS AND ADJUSTMENTS...751
      REMOVE AIR FROM THE SYSTEM...751
    TROUBLESHOOTING...752
  1800327...753
    INTRODUCTION...753
      GENERAL...753
      DESCRIPTION...753
      OPERATION...753
      BRAKE BOOSTER AND MASTER CYLINDER...753
      SERVICE BRAKE ASSEMBLY...756
      PARKING BRAKE...756
    REPAIRS...757
      BRAKE SHOE ASSEMBLIES...757
        Removal And Disassembly...757
        Cleaning And Inspection...757
        Assembly And Installation...758
      MASTER CYLINDER...760
        Removal...760
        Disassembly...760
        Assembly...761
        Installation...762
      BRAKE BOOSTER...762
        Removal...762
        Disassembly...762
        Cleaning and Inspection...762
        Assembly...762
        Installation...763
    CHECKS AND ADJUSTMENTS...764
      REMOVE AIR FROM THE BRAKE SYSTEM...764
      ADJUST THE BRAKE PEDAL...764
      ADJUST THE BRAKE SHOES...765
      ADJUST THE PARKING BRAKE...765
      ADJUST THE PARKING BRAKE SWITCH...765
      CHECK THE RELIEF VALVE ON THE BRAKE BOOSTER...765
    TROUBLESHOOTING...766
  1900328...768
    INTRODUCTION...768
      GENERAL...768
      DESCRIPTION AND OPERATION...768
        Hydraulic pumps...768
        Main Control Valve...769
        Steering Control Unit...769
        Brake Valve...769
        Oil Clutch...769
    TROUBLESHOOTING...771
  190097...773
    INTRODUCTION...773
      DESCRIPTION...773
      OPERATION...773
        Flow Control Valve...775
        Relief Valve...775
    REPAIRS...776
      REMOVAL...776
      DISASSEMBLY...776
      CLEANING...778
      INSPECTION...778
      ASSEMBLY...779
      INSTALLATION...780
    CHECKS AND ADUSTMENTS...781
      CHECK THE OUTPUT OF THE PUMP...781
      CHECK FOR AIR IN THE HYDRAULIC SYSTEM...781
    TROUBLESHOOTING...783
  190098...786
    INTRODUCTION...786
      GENERAL...786
      DESCRIPTION...786
      OPERATION...786
        Pump...786
        Relief Valve...787
    REPAIRS...788
      REMOVAL...788
      DISASSEMBLY...788
      ASSEMBLY...789
      INSTALLATION...790
    CHECKS AND ADJUSTMENTS...790
      CHECKING THE RELIEF PRESSURE OF THE RELIEF VALVE...790
        Lift Trucks With Internal Combustion Engines...790
        Electric Lift Trucks...790
        Electric Lift Trucks With Adjustable Relief Valve...791
    SPECIFICATIONS...792
    TROUBLESHOOTING...792
  200090...793
    INTRODUCTION...793
      GENERAL...793
      DESCRIPTION...793
      OPERATION...795
        Lift Spool...795
        Tilt Spool...795
        Relief Valve, Single–Stage...798
        Relief Valve, Two–Stage...799
    REPAIRS...799
      REMOVAL AND DISASSEMBLY...799
      CLEANING AND INSPECTION...800
      ASSEMBLY...800
      INSTALLATION...800
    CHECKS AND ADJUSTMENTS...800
      ADJUST THE SINGLE–STAGE RELIEF VALVE...800
      ADJUST THE TWO–STAGE RELIEF VALVE...801
      ADJUST THE RELIEF VALVE ON THE AUXILIARY CONTROL VALVE, H60–110E ONLY...802
    TROUBLESHOOTING...802
  2100103...804
    INTRODUCTION...804
      GENERAL...804
      DESCRIPTION...804
    REPAIRS...804
      REMOVAL...804
      DISASSEMBLY...804
      CLEANING...804
      ASSEMBLY...804
        Tilt Cylinders with O-Rings or Single Lip Seals...804
        Tilt Cylinders for the XM and XMS Models...805
        Tilt Cylinders for H700 800A and Early Model H700 920B...807
      INSTALLATION...807
        Tilt Cylinders Using Chevron Packing...808
    CHECKS AND ADJUSTMENTS...810
      CHECK THE TILT CYLINDERS FOR LEAKS...810
      ADJUST THE TILT CYLINDER STROKE AND THE MAST TILT ANGLE...810
      TABLE 1. MOVEMENT RATES (MAXIMUM) FOR TILT CYLINDERS...811
      TABLE 2. TORQUE SPECIFICATIONS FOR THE TILT CYLINDERS...812
    TROUBLESHOOTING...814
  2200106...815
    INTRODUCTION...815
      GENERAL...815
      DESCRIPTION AND OPERATION...815
    REPAIRS...817
      REMOVAL...817
      DISSASEMBLY...817
      CLEANING...818
      ASSEMBLY...818
      INSTALLATION...818
    CHECKS AND ADJUSTMENTS...819
      GENERAL...819
    TROUBLESHOOTING...821
  2200107...823
    HIGH ENERGY IGNITION (HEI)...823
      DESCRIPTION...823
    REPAIRS...825
      DISTRIBUTOR...825
        Removal...825
        Disassembly...825
        Assembly...830
      INSTALLATION, IF THE CRANKSHAFT WAS NOT ROTATED WHEN DISTRIBUTOR WAS REMOVED...831
      NSTALLATION, IF THE CRANKSHAFT WAS ROTATED WHEN THE DISTRIBUTOR WAS REMOVED...832
      IGNITION COIL...832
        Removal, Some 4 And 6 Cylinder Models...832
        Installation, Some 4 And 6 Cylinder Models...833
        Removal, V8, Some 4 And 6 Cylinder Models...833
        Installation, V8, Some 4 And 6 Cylinder Models...834
      ELECTRONIC MODULE...835
        Removal...835
        Installation...835
      SENSING COIL...836
        Removal...836
        Installation...836
      SPARK PLUGS...836
        Removal...836
        Installation...837
      CHECKS AND ADJUSTMENTS...837
        Visual Checks...837
        Check The High Voltage Wires...837
        Checking The Ignition Coil...837
        Coil In Distributor Cap Design...837
        Separate Coil Design...838
        Checking The Sensing Coil...838
        Check The Electronic Module...839
        Ignition Timing Adjustment...839
        Ignition System, GM V8-366 (6-litre)...840
        Ignition Timing and Idle Speed Adjustment, GM V6-LPG (4.3-litre)...840
    SPECIFICATIONS...840
    TROUBLESHOOTING...841
  2200143...842
    INTRODUCTION...842
      GENERAL...842
    DESCRIPTION...842
      GENERAL...842
      STEERING COLUMN GAUGES, METERS AND INDICATORS...845
      LED DISPLAY PANEL...845
        Battery Discharge Indicators...845
        Brush Wear Indicators...846
        Motor Temperature Indicators...847
      "LX" SERIES DISPLAY PANEL...848
        Hourmeter Functions...849
        Battery Indicator Function...849
        Status Code Function...849
      "ZX" SERIES DISPLAY PANELS...849
        Display Panel...850
        Basic Display Panels...850
        Performance Display...852
        Brush Wear Indicators...855
    CHECKS AND ADJUSTMENTS...855
      GENERAL...855
    REPLACEMENT...856
      GENERAL...856
      METER REPLACEMENT...856
      SENDER REPLACEMENT...857
        Fuel Level Sender...857
        Pressure And Temperature Sender...857
      I.T.W. DISPLAY PANEL...858
        Removal...858
      DISPLAY PANELS FOR THE EV - 100/200ZX MOTOR CONTROLLERS, COLUMN MOUNT...859
        Removal...859
        Replacing Display Panel Assembly...859
        Indicator LEDs...859
        Battery Indicators...859
        Digital Display (Performance Disply Panel Only)...859
        Status Code Or Performance Level Switches And Indicator LEDs (Performance Display Panel Only)...859
        Replacing Parts Of The Basic Display Panel...860
        Replacing Parts Of The Performance Display Panel...862
      DISPLAY PANELS FOR THE EV-100/200ZX MOTOR CONTROLLERS, DASH MOUNT...862
        Removal And Replacement...862
    SPECIFICATIONS...863
    TROUBLESHOOTING...864
  22002...865
    INTRODUCTION...865
      GENERAL...865
      DESCRIPTION...865
    REPAIRS...867
      GENERAL...867
      REMOVAL AND DISASSEMBLY (Type A)...867
      CLEANING...867
      ASSEMBLY (Type A)...868
      REMOVAL AND DISAASSEMBLY (Type B)...870
      CLEANING...872
      ASSEMBLY (Type B)...872
      INSTALLATION (Type A and Type B)...873
    CHECKS AND ADJUSTMENTS...873
      GENERAL...873
      CHECK THE ALTERNATOR FOR LOW OUTPUT (Type A or Type B)...874
      CHECK THE ALTERNATOR FOR HIGH OUTPUT (Type A or Type B)...875
      CHECK THE CIRCUIT FOR THE BRUSHES...877
        Delco Alternators...877
        Motorola Alternators...877
      CHECK THE DIODES...877
      CHECK THE DIODE BRIDGE...877
        Delco and Leece–Neville Alternators...877
        Motorola Alternators...877
      CHECK THE FIELD WINDING FOR THE ROTOR...878
      CHECK THE WINDINGS IN THE STATOR...878
      CHECK THE VOLTAGE REGULATOR...879
    TROUBLESHOOTING...879
  2200468...880
    ELECTRONIC ENGINE CONTROL, TROUBLESHOOTING AND REPAIR...880
      GENERAL...880
        Engine Data...880
      LIGHT BULB CHECK...880
      SYSTEM CHECK...882
      TROUBLESHOOTING WITH THE FAULT MONITOR SYSTEM IN THE ECM...882
        How To Clear A Code...883
        Fault In The ECM...883
        Fault In The PROM...884
        CalPak Not Installed...884
        Fuel Control...884
        Idle Air Control (IAC)...884
        Fuel Pump Circuit...884
        Coolant Temperature Sensor (CTS)...885
        Manifold Absolute Pressuer Sensor (MAP)...885
        Throttle Position Sensodr (TPS)...885
        Output Check, Throttle Position Sensor...885
        Electronic Spark Timing...885
        Engine Crank Signal...886
        Distributor Reference Signal...886
    TROUBLESHOOTING CHARTS...887
      CHART A-1-No "Check Engine" Light...887
        Circuit Description, "Check Engine" Light...887
      CHART A-1-No "Check Engine" Light...888
      CHART A-2-No ALDL Data Or No Code 12 From "Check Engine" Light. The "Check Engine" Light Is Continuosly Illuminated...889
        Circuit Description, "Check Engine" Light...889
      CHART A-2-No ALDL Data Or No Code 12 From "Check Engine" Light. The "Check Engine" Light Is Continuously Illuminated...890
      CHART A-3-Starter Cranks The Engine, But Will Not Run...891
        Circuit Description...892
      CHART A-4-Fuel Injector Circuit...893
        Circuit Description...893
      CHART A-5-Fuel Pump Relay Circuit...895
        Circuit Description...895
      CHART A-6-Fuel System Pressure Test...897
        Circuit Description...897
      CHART A-7-MAP Output Check...899
        Circuit Description...899
      CHART A-8-Engine Crank Signal Check...901
        Circuit Description...901
      CHART A-9-Ignition System Troubleshooting...902
      CHART A-9 Ignition System Troubleshooting Chart...903
      CHART A-10-Idle Air Control (IAC) System...905
        Circuit Description...905
    FAULT CODES...907
      CODE 14-Coolant Temperature Sensor Circuit (Indicates High Temperature)...907
        Circuit Description...907
      CODE 15-Coolant Temperature Sensor Circuit (Indicates Low Temperature...909
        Circuit Description...909
      CODE 21-Throttle Position Sensor Circuit (Signal Voltage High) ...911
        Circuit Description...911
      CODE 22-Throttle Position Sensor Circuit (Signal Voltage Low) ...913
        Circuit Description...913
      CODE 31-Engine Governor Circuit...915
        Circuit Description...915
      CODE 33-MAP Sensor Circuit, Signal Voltage High (Low Vacuum...917
        Circuit Description...917
      CODE 34-MAP Sensor Circuit, Signal Voltage Low (High Vacuum)...919
        Circuit Description...919
      CODE 42-Electronic Spark Timing (EST)...921
        Circuit Description...921
      CODE 54-Fuel Pump Circuit (Low Voltage)...923
        Circuit Description...923
      CODE 51-PROM In The ECM Has A Fault ...925
      CODE 52-Fuel CalPak Is Missing...925
      CODE 55-ECM Has A Fault...925
      TROUBLESHOOTING, POOR OPERATION...925
        General...925
        Make A Careful Visual Check...925
        FAULT: Fuel Usage Too High...925
        FAULT: Codes Or Performance That Is Not Regular...926
        FAULT: "Dieseling"...926
        FAULT: "Backfire"...926
        FAULT: Rough Idle or Engine Stalls During Idle...926
        FAULT: Smoke In The Exhaust Gases...927
        FAULT: Engine is Difficult To Start...927
        FAULT: Variation In Engine Power When The Throttle Is Held Steady...928
        FAULT: Decreased Engine Power...928
        FAULT: "Detontion"...928
        FAULT: Engine Momentarily Does Not Increase Power When Throttle Changes...929
        FAULT: One Cylinder In The Engine Does Not Operate Correctly. The Engine Does Not Idle Correctly...929
      REPAIRS, FUEL SYSTEM COMPONENTS ...931
        General...931
        Vacuum Ports...931
        Throttle Body Injection (TBI) Unit...931
        TBI Unit, Removal...931
        TBI Unit, Cleaning and Inspection...932
        TBI Unit, Installation...932
        Cover For Fuel Meter Body, Replacement...932
        Fuel Injectors...933
        Fuel Injectors, Removal...933
        Fuel Injectors, Installation...934
        Pressure Regulator, Removal...934
        Pressure Regulator, Inspection...934
        Pressure Regulator, Installation ...934
        Fuel Meter Body, Removal...935
        Fuel Meter Body, Installation...935
        Throttle Position Sensor (TPS), Removal...935
        Throttle Position Sensor (TPS), Installation...935
        Idle Air Control (IAC) Valve, Removal...936
        Cleaning and Inspection...936
        Idle Air Control (IAC) Valve, Installation...936
        Governor Throttle Drive Assembly, Removal...936
        Governor Throttle Drive Assembly, Inspection...936
        Cleaning and Lubrication...937
        Governor Throttle Drive Assembly, Installation...937
        Governor Drive Motor, Removal...938
        Governor Drive Motor, Cleaning and Lubrication...938
        Governor Drive Motor, Installation...939
        Governor Drive Motor, Inspection...939
        Throttle Body, Removal and Disassembly...939
        Throttle Body, Inspection...939
        Throttle Body, Assembly and Installation...939
        Fuel Pump, Removal and Disassembly...940
        Fuel Pump, Inspection...940
      REPAIRS, ELECTRICAL COMPONENTS...940
        General...940
        Ignition Coil Test...940
        Ignition Module Test...941
        Distributor, Removal...941
        Distributor, Disassembly...942
        Distributor, Assembly...942
        Distributor, Installation...943
        Firing Order...944
        Ignition Timing...944
        Ignition Coil, Removal...945
        Ignition Coil, Installation...945
        Procedures For Spark Plugs, Spark Plug Wires And Boots ...945
        Troubleshooting of Spark Plugs...946
        Coolant Temperature Sensor (CTS), Replacement ...947
        Manifold Absolute Pressure (MAP) Sensor, Replacement...947
        Oil Pressure Switch, Replacement...948
        Coolant Temperature Sender, Replacement...948
        Wire Harness...948
        Connectors And Terminals...948
        Electronic Control Module (ECM)...952
      ECM CONNECTOR A-B IDENTIFICATION...956
      ECM CONNECTOR C-D IDENTIFICATION...957
    SPECIAL TOOLS...958
  2200765...961
    INTRODUCTION...961
      GENERAL...961
      DESCRIPTION...961
        What MSTS Does...961
        How MSTS Begins Operation...962
      OPERATION...963
        Distributor...963
        Ignition Coil ...963
        Ignition Module...963
        When the Engine Is Being Started...964
        When the Engine Is Running ...964
        Manifold Absolute Pressure (MAP) Sensor...965
        Engine Coolant Temperature (ECT) Sensor...966
        MSTS Module Corrections...966
    TROUBLESHOOTING...968
      GENERAL...968
      TOOLS AND EQUIPMENT...969
      MSTS...970
      TROUBLESHOOTING PROCEDURE...970
        Where To Start...970
      Visual/Physical Inspection...970
      Knowledge/Tools Required...970
      Damage From Static Discharge (Static Electricity)...971
      TROUBLESHOOTING INFORMATION...971
        Malfunction Indicator Lamp (MIL)...971
        Connecting The CodeMate Tester...971
        Reading Diagnostic Trouble Codes (DTC)...972
        Clearing Diagnostic Trouble Codes (DTC's)...972
        On-Board DIAGNOSTIC (ODB) System Check...973
      NO MALFUNCTION INDICATOR LAMP...975
        Circuit Description...975
        Test Description...975
      NO DTC-12, MALFUNCTION INDICATOR LAMP ON...977
        Circuit Description...977
        Test Description...977
      STARTER ROTATES ENGINE, ENGINE DOES NOT RUN...979
        Test Description...979
      DTC-14 ENGINE COOLANT TEMPERATURE SENSOR (ECT) (LOW TEMPERATURE INDICATED)...982
        Circuit Description...982
        Test Description...982
      DTC-15 ENGINE COOLANT TEMPERATURE SENSOR (ECT) (HIGH TEMPERATURE INDICATED)...984
        Circuit Description...984
        Test Description...984
      DTC-34 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR...986
        Circuit Description...986
        Test Description...986
      DTC-41 ELECTRONIC SPARK TIMING (EST OPEN CIRCUIT)...989
        Circuit Description...989
        Test Description...989
      DTC-42 ELECTRONIC SPARK TIMING (EST GROUNDED CIRCUIT)...991
        Circuit Description...991
        Test Description...991
      DTC 51 MSTS FAILURE...993
        Circuit Description...993
    REPAIRS...993
      DISTRIBUTOR...993
        Removal...993
        Disassembly...994
        Inspection...994
        Assembly...994
        Installation...995
        Ignition Timing...995
      IGNITION MODULE...995
        Test For A Fault...995
        Ignition Module Replacement...996
      SENSING COIL...997
        Test For A Fault...997
        Sensing Coil Replacement...997
      IGNITION COIL...997
        Test For A Fault...997
        Removal...998
        Installation...998
      MSTS MODULE...998
        Removal...998
        Installation...998
      ECT SENSOR REPLACEMENT...998
      MAP SENSOR REPLACEMENT...999
  2200781...1001
    INTRODUCTION...1001
      GENERAL...1001
    DESCRIPTION AND OPERATION...1001
      GENERAL...1001
      ELECTRONIC CONTROL MODULE (ECM)...1001
        Diagnostic Connector...1004
        How The ECM Begins Operation...1004
      ELECTRONIC ENGINE CONTROL...1005
        What The ECM Does...1005
        Distributor...1006
        Ignition Module...1007
        When the Engine Is Being Started...1007
        When the Engine Is Running...1009
        Electronic Control Module (ECM) With Ignition Module Distributor, Corrections...1009
      FUEL CONTROL...1009
        Throttle Body Injection...1010
        Fuel Injectors...1011
        Fuel Pressure Regulator...1011
        Throttle Position Sensor...1011
        Idle Air Control...1011
        GM 4.3L Engine Governor System...1012
        GM 3.0L Engine Governor System...1013
        Vacuum Ports...1014
        Fuel Pump...1014
      ECM SENSORS AND CONTROLLERS...1015
        Manifold Absolute Pressure (MAP)...1015
        Engine Coolant Temperature (ECT) Sensor...1016
  2200782...1017
    INTRODUCTION...1017
      GENERAL...1017
      TROUBLESHOOTING PROCEDURE...1017
      HOW THIS SECTION IS ARRANGED...1017
        Where Do I Start...1017
      VISUAL/PHYSICAL INSPECTION...1017
      KNOWLEDGE/TOOLS REQUIRED...1017
      DAMAGE FROM STATIC DISCHARGE (STATIC ELECTRICITY)...1017
      TROULBLESHOOTING INFORMATION...1018
        Malfunction Indicator Lamp (MIL)...1018
        Reading Diagnostic Trouble Codes (DTC)...1018
        Clearing Diagnostic Trouble Codes (DTC)...1019
      TABLE 1. ECM DIAGNOSTIC CODES AVAILABLE...1022
        Diagnostic Mode...1022
        Field Service Mode...1022
        ECM Learning Ability...1022
      TABLE 2. SCAN TOOL INFORMATION...1023
        On-Board DIAGNOSTIC (OBD) System Check...1024
      TROUBLESHOOTING CHARTS...1026
        GENERAL...1026
        TOOLS AND TEST EQUIPMENT...1027
        CHART A-1 No Malfuntion Indicator Lamp...1028
        CIRCUIT DESCRIPTION...1028
        CHART A-2 - No Scan Data, No DTC12, Malfunction Indicator Lamp On...1030
        CIRCUIT DESCRIPTION...1030
        CHART A-3 - The Starter Rotates The Engine, Engine Will Not Run...1032
        CIRCUIT DESCRIPTION...1032
        CHART A-4 - Fuel Injector Circuit...1034
        CIRCUIT DESCRIPTION...1034
        CHART A-5 - Fuel Pump Relay Circuit...1036
        CIRCUIT DESCRIPTION...1036
        CHART A-6 - Fuel System Troubleshooting (1 of 3)...1038
        CIRCUIT DESCRIPTION...1038
        FUEL PRESSURE CHECK...1042
        CHART A-7 - Ingition System Troubleshooting...1043
        DTC 14 ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT (LOW TEMPERATURE INDICATED)...1046
          CIRCUIT DESCRIPTION...1046
        DTC 15 ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT (HIGH TEMPERATURE INDICATED)...1048
          CIRCUIT DESCRIPTION ...1048
          CODE 15 -  Engine Coolant Temperature Sensor Circuit (High Temperature Indicated)...1049
        DTC 21 THROTTLE POSITION SENSOR CIRCUIT (SIGNAL VOLTAGE HIGH)...1050
          CIRCUIT DESCRIPTION...1050
          CODE 21 - Throttle Position Sensor Circuit (Signal Voltage High)...1051
        DTC 22 THROTTLE POSITION SENSOR CIRCUIT (SIGNAL VOLTAGE LOW)...1052
          CIRCUIT DESCRIPTION...1052
        DTC 31 ENGINE GOVERNOR CIRCUIT...1054
          CIRCUIT DESCRIPTION...1054
        DTC 33 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR CIRCUIT (SIGNAL VOLTAGE HIGH - LOW VACUUM)...1056
          CIRCUIT DESCRIPTION...1056
        DCT 34 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR CIRCUIT (SIGNAL VOLTAGE - HIGH VACUUM)...1058
          CIRCUIT DESCRIPTION...1058
        DTC 41 ELECTRONIC SPARK TIMING (EST) - OPEN EST CIRCUIT ...1060
          CIRCUIT DESCRIPTION...1060
        DTC 42 - ELECTRONIC SPARK TIMING (EST) - GROUNDED EST CIRCUIT, OPEN OR GROUNDED BYPASS CIRCUIT...1062
          CIRCUIT DESCRIPTION...1062
        DTC 51 ECM FAILURE...1064
          CIRCUIT DESCRIPTION...1064
        TROUBLESHOOTING, PERFORMANCE...1065
          GENERAL ...1065
            Make A Careful Visual Check...1065
            FAULT: Codes Or Performance That Is Not Regular...1065
          Fault: Loss Of Diagnostic Trouble Code (DTC) Memory...1065
          FAULT: Engine Quits While Driving...1065
            Additional Checks...1065
          FAULT: Engine Is Difficult To Start...1066
          FAULT: Variation In Engine Power When The Throttle Is Held Steady...1066
          FAULT: Decreased Engine Power...1067
          FAULT: Detonation...1067
          FAULT Engine Momentarily Does Not Increase Power When Throttle Changes...1068
          FAULT: One Or More Cylinders Do Not Operate Correctly.  The Engine Does Not Idle Correctly...1068
          FAULT: Rough Idle Or Engine Stalls During Idle...1069
          FAULT: Fuel Usage Too High...1069
          FAULT: Dieseling...1070
          FAULT: Backfire...1070
        SYSTEM TEST CHARTS...1071
          GENERAL...1071
          ENGINE COOLANT TEMPERATURE (ECT) SENSOR TEST...1071
          THROTTLE POSITION (TP) SENSOR CHECK...1072
          MINIMUN IDLE SPEED...1072
            Adjustment...1072
        CHART B-1 IDLE AIR CONTROL (IAC) SYSTEM CHECK...1073
          CIRCUIT DESCRIPTION...1073
        CHART B-2 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR OUTPUT TEST...1075
          CIRCUIT DESCRIPTION...1075
        CHART B-3 CHECK THE GOVERNOR SYSTEM...1078
          GOVERNOR SYSTEM NOT OPERATING CORRECTLY...1078
            Check The Function Of Governor System...1078
          CHECK THE PVC SYSTEM...1078
        REPAIRS...1080
          FUEL SYSTEM COMPONENTS...1080
            General...1080
            Fuel Pressure Relief Procedure...1080
            Fuel Pump Replacement...1080
            TBI Unit, Removal...1081
            TBI Unit, Cleaning and Inspection...1082
            TBI Unit, Installation...1082
            Fuel Meter Body, Removal...1084
            Fuel Meter Body, Installation...1084
            Fuel Injector, Removal...1084
            Fuel Injector, Installation...1085
            Pressure Regulator, Removal...1085
            Pressure Regulator, Inspection...1085
            Pressure Regulator, Installation...1085
            Throttle Position Sensor (TPS), Removal...1086
            Throttle Position Sensor (TPS), Installation...1086
            Idle Air Control (IAC) Valve, Removal...1086
            Cleaning and Inspection...1086
            Idle Air Control (IAC) Valve, Installation...1086
          GOVERNOR SYSTEM (3.0L ENGINE)...1087
            Governor Module Replacement...1087
            Governor Motor Replacement...1087
            Throttle Cables, Installation and Adjustment...1087
            CHECK THE MONOTROL PEDAL...1088
          GOVERNOR SYSTEM (4.3L ENGINE)...1088
            Governor Throttle Drive Assembly, Removal...1088
            Governor Throttle Drive Assembly, Inspection...1089
            Governor Throttle Drive Assembly, Installation...1089
            Governor Drive Motor, Removal...1090
            Governor Drive Motor, Cleaning and Lubrication...1090
            Governor Drive Motor, Installation...1091
            Governor Drive Motor, Inspection...1091
          IGNITION SYSTEM COMPONENTS...1092
            ECM Replacement...1092
            Function Check...1092
            Distributor, Removal...1092
            Distributor, Disassembly...1092
            Distributor, Inspection...1092
            Distributor, Assembly...1093
            Distributor, Installation...1093
            Firing Order...1094
            Distributor, Ignition Timing...1094
          IGNITION MODULE...1094
            Test For A Fault...1094
            Replacement...1095
            Sensing Coil Test...1096
            Sensing Coil Replacement...1096
            Ignition Coil Test...1096
            Ignition Coil, Removal...1096
            Ignition Coil, Installation...1097
          SENSORS...1097
            Engine Coolant Temperature (ECT) Sensor Replacement...1097
            MAP Sensor Replacement...1097
          PCV SYSTEM...1097
            Replacement...1097
          WIRING...1098
            Connectors And Terminals...1098
            Procedures For Spark Plugs, Spark Plug Wires, And Boots...1101
          WIRING DIAGRAM...1101
        TROUBLESHOOTING OF SPARK PLUGS...1102
          ECM CONNECTOR J1 IDENTIFICATION...1106
          ECM CONNECTOR J2 IDENTIFICATION...1107
        SPECIAL TOOLS...1108
  4000135...1110
    SAFETY PROCEDURES WHEN WORKING NEAR THE MAST...1110
      SAFETY PROCEDURES WHEN WORKING NEAR THE MAST...1110
    LIFT CYLINDERS...1113
      GENERAL...1113
      DESCRIPTION...1113
        Lowering Control Valve...1113
        Cylinders (General)...1116
        Cylinders (H520-620B,H700-800A)...1118
        Cylinders (H360-460B)...1119
        Cylinders (Two-Speed)...1119
    REPAIRS...1120
      REMOVAL OF THE LIFT CYLINDER WITHOUT REMOVING THE MAST...1120
        Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast...1120
        Standard and Full Free-Lift Masts with the Lift Cylinder to a Crosshead...1124
        Masts that have Two Cylinders, A Main Lift Cylinder  and a Free-Lift Cylinder...1122
      DISASSEMBLY...1122
      ASSEMBLY...1124
      INSTALLATION OF THE LIFT CYLINDER IN THE MAST...1124
        Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast...1124
        Standard and Full-Free-Lift Masts with the Lift Cylinder Fastened to a Crosshead...1124
      CHEVRON PACKING...1125
    LIFT CYLINDERS FOR VISTA MASTS...1128
      DESCRIPTION...1128
        Lowering Control Valve...1130
      REMOVAL...1131
      DISASSEMBLY...1131
      ASSEMBLY...1131
      INSTALLATION...1132
        Main Lift Cylinders...1132
        Free-Lift Cylinders...1132
    CHECKS AND ADJUSTMENTS...1133
      CHECK FOR LEAKS IN LIFT SYSTEM...1133
    TROUBLESHOOTING...1134
    SPECIFICATIONS...1135
  4000329...1136
    INTRODUCTION...1136
      GENERAL...1136
    DESCRIPTION AND OPERATION...1136
      GENERAL...1136
      SAFETY PROCEDURE WHEN WORKING NEAR THE MAST...1137
      TWO-STAGE MAST...1138
      THREE-STAGE MAST...1139
    REPAIRS...1140
      CARRIAGE...1140
      REMOVAL...1140
        Disassembly,Side Shift Carriage...1141
        Assembly, Side Shift Carriage...1141
        Installation...1143
      TWO-STAGE MAST...1144
        Removal...1144
        Disassembly...1144
        Cleaning and Inspection...1145
        Assembly...1145
        Installation...1146
      THREE-STAGE MAST...1147
        Removal...1147
        Disassembly...1147
        Cleaning and Inspection...1148
        Assembly...1148
        Installation...1149
    CHECKS AND ADJUSTMENTS...1149
      CHECK THE OPERATION OF THE MAST...1149
      CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM...1150
        Lift System...1150
        Tilt System...1150
      ADJUST THE TILT CYLINDER STROKE AND THE BACKWARD TILT ANGLE...1150
      LIFT CHAIN ADJUSTMENT...1151
      MAST ADJUSTMENT...1152
      CARRIAGE ADJUSTMENT...1153
    TROUBLESHOOTING...1155
  600104GM...1156
    GM 4.3 LITRE V-6 AND 5.7 LITRE V-8 ENGINES...1156
      DESCRIPTION...1156
      ENGINE, REMOVAL AND INSTALLATION...1156
      CYLINDER HEAD...1156
        Removal And Disassembly...1156
        Cleaning And Inspection...1156
        Repairs, Valve Guides and Seats...1156
        Studs For The Rocker Arms...1157
        Valve Springs...1157
      ASSEMBLY AND INSTALLATION...1158
      CYLINDER BLOCK, CLEANING AND INSPECTION...1159
      PISTON BORE PREPARTION...1159
      ENGINE MOUNTS...1159
      LUBRICATION SYSTEM...1159
        Oil Pump, Removal and Disassembly...1159
        Cleaning and Inspection...1159
        Oil Pump, Assembly and Installation...1159
      TIMING COVER, TIMING SPROCKETS, CAMSHAFT AND CAM FOLLOWERS...1160
        Timing Cover, Removal...1160
        Installation...1160
        Timing Sprockets, Removal...1161
        Timing Sprockets, Installation...1161
        Camshaft, Removal...1161
        Camshaft, Inspection...1161
        Camshaft, Installation...1162
        Hydraulic Valve Lifters, Removal...1162
        Hydraulic Valve Lifters, Disassembly...1162
        Hydraulic Valve Lifters, Cleaning And Inspection...1162
        Hydraulic Valve Lifters, Assembly...1163
      CRANKSHAFT...1163
        Removal...1163
        Inspection and Repair...1164
        How To Check The Clearance Between The Main Bearings And Their Journals...1164
        Installation...1165
      PISTON AND CONNECTING ROD ASSEMBLIES...1166
        Connecting Rod Bearings, Replacement...1166
        Piston And Connecting Rod Assemblies, Removal...1167
        Disassembly...1167
        Piston, Cleaning And Inspection...1168
        Cylinder Bores, Inspection And Repair...1168
        Piston Rings...1169
        Assembly...1169
        Piston And Connecting Rod Assemblies, Installation...1170
      FLYWHEEL AND FLYWEEL HOUSING...1170
        Flywheel Repair For V-6 Engines...1170
        Flywheel For V-6 Engines, Installation...1170
        Flywheel Housing, H3.5-5.00XL (H70-110XL)...1170
        Engine Adapter, H6.00-7.00XL (H135-155XL)...1170
        Ring Gear Replacement (Flywheel) For V-8 Engines...1171
        Flywheel For V-8 Engines, Flywheel Housing...1171
      COOLANT PUMP...1172
      FAN MOUNT...1172
      CHECKS AND ADJUSTEMENTS...1173
        Valve Clearance Adjustment...1173
    ENGINE SPECIFICATIONS...1173
      ENGINE SPECIFICATIONS...1173
        Engine Data...1173
        Cylinder head...1173
        Hydraulic Valve Lifter...1174
        Camshaft...1174
        Pistons...1174
        Crankshaft...1175
        Connecting Rods...1175
        Cooling System...1175
        Lubrication System...1175
      TORQUE SPECIFICATIONS FOR CAPSCREWS AND BOLTS...1176
      TROUBLESHOOTING...1177
  600105-Perkins...1179
    INTRODUCTION...1179
      GENERAL...1179
      DESCRIPTION...1179
      ENGINE SERIAL NUMBER CODES...1180
      REMOVAL AND INSTALLATION...1180
    ENGINE...1180
      CYLINDER HEAD...1180
        Removal...1180
        Installation...1181
        Cylinder Head Repairs...1182
      OIL PUMP...1184
        Removal...1184
        Disassembly...1184
        Inspection...1184
        Assembly...1185
        Installation...1185
      RELIEF VALVE...1186
      TIMING GEAR CASE AND TIMING GEARS...1186
        Removal...1186
        Installation...1187
      PISTONS AND CONNECTING RODS...1188
        Removal...1188
        Disassembly...1188
        Inspection...1189
        Assembly...1190
        Installation...1190
      CRANKSHAFT AND MAIN BEARINGS...1191
        Removal...1191
        Inspection...1191
        Assembly...1192
      CAMSHAFT AND CAM FOLLOWERS...1193
        Removal...1193
        Inspection...1194
        Assembly...1194
      FLYWHEEL AND FLYWHEEL HOUSING...1195
        Removal...1195
        Repairs...1195
        Installation...1195
      STEERING PUMP DRIVE...1195
        Removal...1195
        Installation...1196
      PCV VALVE...1196
    FUEL SYSTEM...1196
      FUEL PUMP...1196
        Removal...1196
        Disassembly...1196
        Assembly...1196
        Installation...1197
      FUEL INJECTION PUMP...1197
        Removal...1197
        Repairs...1197
        Installation...1197
      FUEL INJECTORS...1197
        Removal...1197
        Repairs...1198
        Installation...1198
      COLD START AID...1198
        Description...1198
        Removal...1198
        Installation...1198
    COOLING SYSTEM...1199
      THERMOSTAT...1199
        Removal...1199
        Inspection...1199
        Installation...1199
      WATER PUMP...1199
        Removal...1199
        Disassembly...1199
        Assembly...1199
        Installation...1199
    CHECKS AND ADJUSTMENTS...1199
      CHECKING THE INJECTORS...1199
        Repairs...1200
        Installation...1200
      REMOVING AIR FROM THE FUEL SYSTEM...1200
      CHECKING THE TIMING MARKS...1201
        Method A...1201
        Method B...1202
      CHECKING THE TIMING ANGLE OF THE FUEL INJECTION PUMP WITH THE SPECIAL TOOL...1203
      VALVE CLEARANCE ADJUSTMENT...1204
      ADJUSTING THE THROTTLE LINKAGE...1204
    TROUBLESHOOTING...1206
    SPECIFICATIONS...1207
    TORQUE SPECIFICATIONS...1210
  600590-gm...1211
    GM 4.3 LITRE V-6...1211
      INTRODUCTION...1211
      DESCRIPTION...1211
      ENGINE, REMOVAL AND INSTALLATION ...1212
      CYLINDER HEAD...1212
        Removal And Disassembly...1212
        Cleaning And Inspection...1212
        Repairs, Valve Guides and Seats...1212
        Repairs, Valves ...1213
        Repairs, Valve Seats...1213
        Valve Springs...1214
        Studs For The Rocker Arms (Early Models)...1215
        Studs For The Rocker Arms (Late Models)...1216
        Assembly And Installation...1216
      CYLINDER BLOCK, CLEANING AND INSPECTION...1218
      PISTON BORE PREPARATION...1218
      ENGINE MOUNTS...1218
      LUBRICATION SYSTEM...1218
        Oil Pump, Removal and Disassembly...1218
        Cleaning and Inspection...1219
        Oil Pump, Assembly and Installation...1219
        Oil Sump, Installation...1219
      TIMING COVER, TIMING SPROCKETS, CAMSHAFT AND VALVE LIFTERS...1220
        Timing Cover, Removal...1220
        Installation...1221
        Timing Sprockets, Removal...1222
        Timing Sprockets, Installation...1222
        Camshaft, Removal...1222
        Camshaft, Inspection...1222
        Camshaft, Installation...1222
        Balance Shaft, Removal...1223
        Balance Shaft, Installation...1224
        Hydraulic Valve Lifters, Removal...1225
        Hydraulic Valve Lifters, Disassembly...1225
        Hydraulic Valve Lifters, Cleaning And Inspection...1225
        Hydraulic Valve Lifters, Assembly...1226
        Hydraulic Valve Lifters, Installation...1226
      CRANKSHAFT...1227
        Removal...1227
        Inspection and Repair...1227
        How To Check The Clearance Between The Main Bearings And Their Journals...1228
        Installation...1229
      PISTON AND CONNECTING ROD ASSEMBLIES...1230
        Connecting Rod Bearings, Replacement...1230
        Piston And Connecting Rod Assemblies, Removal...1231
        Disassembly...1231
        Piston, Cleaning And Inspection...1231
        Cylinder Bores, Inspection And Repair...1232
        Piston Rings...1233
        Assembly...1233
        Piston And Connecting Rod Assemblies, Installation...1234
      FLYWHEEL AND FLYWHEEL HOUSING...1234
        Flywheel Repairs...1234
        Flywheel, Installation ...1234
        Flywheel Housing...1235
        Engine Adapter...1235
      COOLANT PUMP...1235
      THERMOSTAT...1235
      FAN MOUNT, EARLY MODELS...1235
      FAN MOUNT ASSEMBLY, LATE MODELS...1236
      DRIVE BELT, INSTALLATION...1237
    CHECKS AND ADJUSTMENTS...1239
      VALVE CLEARANCE ADJUSTMENT, EARLY MODELS...1239
      VALVE CLEARANCE ADJUSTMENT, NEW MODELS...1239
      CHECK THE COMPRESSION...1239
    ENGINE SPECIFICATIONS...1240
      Engine Data...1240
        Engine Data...1240
        Cylinder head...1240
        Hydraulic Valve Lifter...1240
        Camshaft...1240
        Pistons...1240
        Crankshaft...1241
        Connecting Rods...1241
        Connecting Rods...1241
        Balance Shaft...1241
        Cooling System...1241
        Lubrication System...1241
    TORQUE SPECIFICATIONS...1242
    TROUBLESHOOTING...1243
  600705...1246
    PERKINS DIESEL ENGINES, 1004-42 (AR), 1006-60 (YG), 1006-60T (YH)...1246
      GENERAL...1246
        General Safety Rules...1246
      DESCRIPTION...1248
        Engine Serial Number Codes...1249
        Engine Data...1250
        1004-42 (AR) ENGINE (Low Governed Speed)...1250
        1004-42 (AR) ENGINE (High Governed Speed)...1250
        1006-60 (YG) ENGINE...1250
        1006-60 (YH) ENGINE...1250
      REMOVAL AND INSTALLATION...1251
        Lifting The Engine...1251
    CYLINDER HEAD ASSEMBLY...1251
      VALVE COVER...1251
        Removal...1251
        Installation...1252
      ROCKER ARM ASSEMBLY...1252
        Removal...1252
        Installation...1252
        Disassembly...1252
        Inspection...1253
        Assembly...1253
      VALVE CLEARANCE ADJUSTMENTS...1253
        Four Cylinder Engines...1253
        Six Cylinder Engines...1254
      VALVE SPRINGS...1254
      CYLINDER HEAD ASSEMBLY...1255
        Removal...1255
        Installation...1258
      VALVES AND VALVE SPRINGS...1262
        Removal...1262
        Inspection...1263
        Installation...1263
      VALVE GUIDES...1263
        Inspection...1263
        Removal...1264
        Installation...1264
      CYLINDER HEAD AND VALVE SEATS...1265
        Inspection...1265
        Repair...1265
        Installation Of New Valve Seats...1266
    PISTON AND CONNECTING ROD ASSEMBLIES...1266
      ROD BEARINGS...1267
        Removal...1267
        Installation...1268
      PISTON AND CONNECTING ROD ASSEMBLY...1268
        Service Note...1268
        Removal...1269
        Installation...1269
      PISTON RINGS...1270
        Removal...1270
        Inspection...1270
        Installation...1271
      PISTON AND CONNECTING ROD...1272
        Disassembly...1272
        Inspection...1273
        How To Select the Correct Replacements...1273
        Installation...1274
      PISTON COOLING JETS...1274
        Removal...1274
        Installation...1274
    CRANKSHAFT ASSEMBLY...1275
      GENERAL...1275
      CRANKSHAFT PULLEY...1276
        Removal, Engine AR...1276
        Removal, Engine YG and YH...1276
        Inspection...1276
        Installation, Engine AR...1277
        Installation, Engine YG and YH...1277
      REAR OIL SEAL...1278
        Replacement...1278
      MAIN BEARINGS...1279
        Removal...1279
        Inspection...1279
        Installation...1280
      THRUST WASHERS...1280
        Check The Axial Movement Of The Crankshaft...1280
        Removal...1281
        Installation...1281
      CRANKSHAFT...1282
        Removal...1282
        Inspection...1282
        Installation...1282
      FLYWHEEL...1284
        Removal...1284
        Ring Gear (Replacement)...1284
        Installation...1284
      FLYWHEEL HOUSING...1285
        Removal...1285
        Installation...1285
    TIMING CASE AND TIMING GEARS...1286
      GENERAL...1286
      TIMING CASE COVER...1286
        Removal...1286
        Installation...1286
      FRONT OIL SEAL...1287
        Removal...1287
        Installation...1287
      CRANKSHAFT PULLEY WEAR SLEEVE...1288
        Installation...1288
      IDLER GEAR AND HUB...1288
        Removal...1288
        Installation...1289
      AIR COMPRESSOR DRIVE, BENDIX...1290
        Disassembly...1290
        Compressor Drive, Assembly...1291
      GEAR FOR THE FUEL INJECTION PUMP...1291
        Removal...1291
        Installation...1292
      CAMSHAFT GEAR...1293
        Removal...1293
        Installation...1293
      CRANKSHAFT GEAR...1294
        Removal...1294
        Installation...1294
      TIMING CASE...1294
        Removal...1294
        Installation...1295
      CAMSHAFT AND TAPPETS...1296
        Removal...1296
        Installation...1296
    CYLINDER BLOCK ASSEMBLY...1297
      DESCRIPTION...1297
      CYLINDER BLOCK...1297
        Disassembly...1297
        Inspection...1298
        Assembly...1298
      CYLINDER BORE (4-CYLINDER ENGINES)...1298
      CYLINDER BORE (6-CYLINDER ENGINES)...1299
        Inspection...1299
        To Check the Condition of a Cylinder Liner...1299
        Removal...1300
        Installation (Service Liner)...1301
        Installation (Partially Finished Liner)...1302
    ENGINE TIMING...1303
      GENERAL DESCRIPTION...1303
        How To Set Number 1 Piston To TDC On The Compression Stroke...1304
        How To Set Number 1 Piston To TDC On The Compression Stroke (Alternate Procedure)...1305
        Check The Valve Timing...1305
        Check The Timing Of The Fuel Injection Pump...1306
    TURBOCHARGER, ENGINE YH...1307
      GENERAL...1307
        Removal...1307
        Installation...1307
        Clean The Impeller And Compressor Housing...1308
    LUBRICATION SYSTEM...1309
      GENERAL...1309
      OIL FILTER, REPLACEMENT...1309
      FILTER HEAD...1310
        To Remove and to Install...1310
      OIL SUMP...1310
        Removal...1310
        Installation...1311
      OIL PUMP...1311
        Removal...1311
        Inspection...1311
        Installation...1312
      RELIEF VALVE...1313
        Removal...1313
        Disassembly...1313
        Inspection...1314
        Assembly...1314
        Installation...1314
      IDLER GEAR SHAFT, REPLACEMENT...1314
        Removal...1314
        Removal, Alternative...1315
        Installation...1316
        Installation, Alternative...1316
        Installation, Alternative for 4-Cylinder Engines Only...1316
    FUEL SYSTEM...1317
      DESCRIPTION...1317
      FUEL INJECTION PUMP...1317
        Removal...1317
        Installation...1318
        FUEL INJECTION PUMP, CHECKS AND ADJUSTMENTS...1319
        REMOVE AIR FROM THE FUEL SYSTEM...1320
        FUEL FILTER (REPLACEMENT)...1321
          Canister Type...1321
          Quick Release Canister Type...1321
        FUEL INJECTORS...1322
          Removal...1322
          Inspection...1323
          Installation...1323
        FUEL PUMP...1324
          Removal...1324
          Disassembly...1324
          Assembly...1325
          Installation...1325
          Test...1326
      COOLING SYSTEM...1326
        GENERAL...1326
        THERMOSTAT...1326
          Thermostats...1326
          Remove...1326
          Install...1326
          Test...1326
        COOLANT PUMP...1327
          Removal...1327
          Disassembly...1328
          Assembly...1329
          Installation...1332
        FAN AND FAN DRIVE...1333
          Removal...1333
          Installation...1333
        OIL COOLER (6-CYLINDER ENGINES)...1333
          Removal...1333
          Disassembly And Assembly...1333
          Installation...1334
          By-Pass Valve, Oil Cooler...1334
      ELECTRICAL EQUIPMENT...1334
        DRIVE BELTS...1334
        ALTERNATOR...1335
          Removal...1335
          Installation...1335
        STARTER MOTOR...1335
          Removal...1335
          Installation...1336
        COLD START AID...1336
      AIR COMPRESSOR, ENGINES YG AND YH...1336
        GENERAL...1336
          Air Compressor, Removal...1336
          Air Compressor, Installation...1337
      ENGINE SPECIFICATIONS...1338
        CYLINDER HEAD ASSEMBLY...1338
          Cylinder Head...1338
          Valve Guides...1339
          Inlet Valve...1339
          Exhaust Valves...1340
          Valve Springs...1340
          Tappets...1340
          Rocker Arm Shaft...1341
          Rocker Arms And Bushings...1341
        PISTON AND CONNECTING RODS...1341
          Pistons (Engine AR)...1341
          Pistons (Engine YG and YH)...1341
          Piston Rings (Engine AR)...1341
          Piston Rings (Engines YG and YH)...1342
          Piston Pins...1342
          Connecting Rods...1342
          Small End Bushings...1343
          Connecting Rod,Bearings, Engines AR And YG...1343
          Connecting Rod,Bearings, Engines YH...1343
          Piston Cooling Jets...1343
        CRANKSHAFT ASSEMBLY...1343
          Crankshaft...1343
          Main Bearings...1344
          Crankshaft Thrust Washers...1344
          Crankshaft Heat Treatment...1344
          Crankshaft Overhaul...1344
        TIMING CASE AND DRIVE ASSEMBLY...1346
          Camshaft...1346
          Camshaft Thrust Washer...1346
          Camshaft Gear...1346
          Gear For Fuel Injection Pump...1346
          Crankshaft Gear...1346
          Idler Gear And Hub...1346
        ENGINE BLOCK ASSEMBLY...1347
          Cylinder Block (Engine AR)...1347
          Cylinder Bore Specifications (Engine AR)...1347
          Cylinder Block (Engine YG and YH)...1348
          Cylinder LIners (Engine YG and YH)...1348
          Cylinder Liner Specifications (Partially Finished)...1348
        TURBOCHARGER...1349
        LUBRICATION SYSTEM...1349
          Oil Pump, Engine AR...1349
          Oil Pump, Engine YG and YH...1349
          Idler Gear for Oil Pump...1349
          Relief Valve...1349
          Oil Filter...1350
        FUEL SYSTEM...1350
          Lucas Fuel Injection Pump...1350
          Fuel Injector Codes...1351
          Fuel Pump, Engine AR...1351
          Fuel Pump, Engines YG And YH...1351
          Fuel Filter...1352
        COOLING SYSTEM...1352
          Coolant Pump...1352
          Thermostat...1352
          Fan Drive Housing...1352
        FLYWHEEL AND HOUSING...1352
          Limits for Flywheel "Run Out" and Alignment (Total Indicator Reading)...1352
        ELECTRICAL EQUIPMENT...1352
          Alternator...1352
          Starter Motor...1352
          Cold Start Aid...1352
      TORQUE SPECIFICATIONS...1353
      SPECIAL TORQUE SPECIFICATIONS...1355
      SPECIAL TOOLS...1356
      TROUBLESHOOTING...1360
        List of Possible Causes...1361
  700626...1363
    COOLING SYSTEM...1363
      INTRODUCTION...1363
      DESCRIPTION...1363
      RADIATOR...1363
      RADIATOR CAP...1363
      THERMOSTAT...1363
      WATER PUMP...1364
      FAN AND FAN SHROUD...1364
    REPAIRS...1364
      COOLING SYSTEM CHECKS...1364
        Exhaust Leaks...1364
      RADIATOR...1364
        Checks...1364
        Cleaning The Radiator...1364
        Drain The Cooling System...1366
        Fill The Cooling System...1366
      WATER PUMP...1366
        Checks...1366
      THERMOSTAT...1367
        Checks...1367
      FAN AND FAN SHROUD...1367
    TROUBLESHOOTING...1368
  8000331...1369
    LIFT TRUCK WEIGHTS...1369
    CAPACITIES...1369
    TIRE SIZES...1369
    TIRE PRESSURE...1369
    ELECTRICAL SYSTEM...1369
    WHEEL NUT TORQUE...1369
    ENGINE SPECIFICATIONS -GASOLINE/LPG...1370
    HYDRAULIC SYSTEM...1370
    MAST SPEEDS...1370
    TRANSMISSION OIL PRESSURES...1371
    TORQUE SPECIFICATIONS...1371
  8000332...1374
    ELECTRICAL SCHEMATIC (GASOLINE & LPG)...1374
    ELECTRICAL SCHEMATIC (DIESEL, PERKINS 4.2482)...1376
    ELECTRICAL SCHEMATIC (DIESEL, PERKINS 1004.4)...1378
    HYDRAULIC SCHEMATIC...1380
    HYDRAULIC SCHEMATIC, POWERSHIFT TRANSMISSION WITH MANUAL CONTROL...1381
    HYDRAULIC SCHEMATIC, POWERSHIFT TRANSMISSION WITH MONOTROL PEDAL...1382
  8000519...1383
  897104-0100SRM0322-(02-2007)-US-EN...1401
    toc...1401
      Frame...1401
      Safety Precautions Maintenance and Repair...1402
      General...1405
      Description...1405
      Counterweight Repair...1406
        Remove...1406
        Install...1406
      Hood Repair...1407
        Remove...1407
        Install...1407
      Overhead Guard Repair...1407
        Remove...1407
        Install...1407
      Operator Restraint System Repair...1408
        Automatic Locking Retractor (ALR)...1408
        Emergency Locking Retractor (ELR)...1408
      Hydraulic Tank Repair...1410
        Remove...1410
        Inspect...1410
        Small Leaks Repair...1410
        Large Leaks Repair...1410
        Clean...1410
          Steam Method...1411
          Chemical Solution Method...1411
        Other Methods of Preparation for Repair...1411
        Install...1411
      Fuel Tank Repair...1412
        Remove...1412
        Repair...1412
        Install...1412
      Radiator Repair...1412
        Remove...1412
        Install...1412
      Engine Repair...1413
        Remove...1413
        Install...1413
      Throttle Pedal Adjustment...1415
        Perkins 1104C-44(RE) Diesel Engine...1415
      Safety Labels...1416
      Cab Repair...1418
        Cab, Replace...1418
        Window, Replace...1418
        Windshield Wipers and Heater...1418
    tables...1401
      Table 1. Material Specifications for Cab Windows...1420
  897106-1300SRM0324-(10-2003)-US-EN...1423
    toc...1423
      Two-Speed Powershift Transmission...1423
      Safety Precautions Maintenance and Repair...1424
      General...1427
      Mechanical Description...1427
        Torque Converter...1427
        Transmission Pump...1428
        Shaft Assemblies...1428
        Input Shaft...1429
        Forward Clutch Shaft...1429
        Clutch Assemblies...1429
        Countershaft...1436
        Output Shaft...1436
      Hydraulic Operation...1437
        Torque Converter...1437
        Seal Rings...1438
      Control Valve...1438
        System Pressure Regulator...1441
        Clutch Pressure Regulator...1441
        Torque Converter Regulator...1442
        Inching Spool...1442
        Direction Spool, Direction Control Lever...1442
        Direction Spool, MONOTROL Pedal...1443
        Range Spool...1443
        Drain Spool...1444
        Accumulator...1444
        Modulator Spool...1444
        Operation...1444
      Lubrication Circuit...1445
      MONOTROL Pedal...1445
      Oil Flow Diagrams...1447
        Neutral...1447
        Forward-Low...1448
        Forward-Low-Inching...1449
        Reverse-Low...1450
  897107-1300SRM0325-(10-2003)-US-EN...1453
    toc...1453
      Two-Speed Powershift Transmission...1453
      Safety Precautions Maintenance and Repair...1454
      General...1457
      Transmission Repair...1457
        Transmission and Torque Converter, Remove...1457
        Transmission, Disassemble...1459
        Reverse-Low Clutch, Disassemble...1462
        Reverse-High Clutch, Disassemble...1465
        Forward-Low Clutch, Disassemble...1468
        Forward-High Clutch, Disassemble...1471
        Clean and Inspect...1473
      Forward Low and High Clutches Assembly...1474
        Forward Clutches, Assemble...1476
        Reverse-Low Clutch, Assemble...1482
        Reverse Clutches, Assemble...1484
        Transmission, Assemble...1491
        Torque Converter, Install...1498
      Control Valve Repair...1499
        Remove...1499
        Disassemble...1500
        Assemble...1501
        Install...1503
      MONOTROL Pedal...1503
        Remove and Disassemble...1503
        Assemble and Install...1503
      Stall Test...1506
      Linkage Adjustments...1507
        Linkage for Inching Pedal H6.00-7.00XL (H135-155XL, H135-155XL 2...1507
        Linkage for Inching Pedal S6.00-7.00XL (S135-155XL, S135-155XL 2...1510
        Linkage for Range Lever - Early Model H6.00-7.00XL (H135-155XL) ...1513
        Linkage for Direction Control Lever - Early Model H6.00-7.00XL (...1513
        Linkage for Range Lever - Later Model H6.00-7.00XL (H135-155XL, ...1515
        Linkage for Direction Control Lever - Later Model H6.00-7.00XL (...1517
        Linkage for Range Lever S6.00-7.00XL (S135-155XL, S135-155XL 2 )...1519
        Linkage for Direction Control Lever S6.00-7.00XL (S135-155XL, S1...1519
      Oil Pressure Check...1521
        System Pressure Check Port...1521
        Torque Converter Check Port...1521
        Clutch Pressure Check Port...1521
        Inching Pressure...1522
        Solenoid Check Ports (MONOTROL Control Only)...1522
        Lubrication Pressure Check Ports...1522
      Specifications...1523
      Troubleshooting...1523
        Correct System Pressure: 1300 ±124 kPa ( 189 ±18 psi)...1526
        Correct Clutch Pressure: 924 ±69 kPa ( 134 ±10 psi)...1527
        Correct Solenoid Pressure (MONOTROL Only): 965 ±138 kPa ( 140 ±2...1528
        Torque Converter Pressure: 834 ±69 kPa ( 121 ±10 psi)...1528
        Lubrication Pressure: 83 ±21 kPa ( 12 ±3 psi)...1528
    tables...1453
      Table 1. Stall Speed Specifications...1506
  897108-1600SRM0326-(03-2007)-US-EN...1531
    toc...1531
      Steering Axle...1531
      Safety Precautions Maintenance and Repair...1532
      General...1535
      Description...1535
      Steering Axle Assembly Repair...1540
        Steering Axle H3.50-5.00XL (H70-110XL) (G005), S3.50-5.50XL (S70...1540
          Remove...1540
          Install...1540
        Steering Axle H6.00-7.00XL (H135-155XL, H135-155XL 2 ) (F006, G0...1541
          Remove...1541
          Install...1541
      Wheels and Hubs Repair (All Units)...1542
        Remove and Disassemble...1542
        Clean...1542
        Inspect...1542
        Assemble and Install...1542
      Spindles and Bearings Repair (All Units)...1544
        Remove...1544
        Clean...1544
        Assemble and Install...1545
      Tie Rods Repair (All Units)...1546
        Remove...1546
        Clean...1546
        Install...1546
      Steering Cylinder Repair...1549
        Remove and Disassemble...1549
        Clean and Inspect...1549
        Assemble and Install...1549
      Troubleshooting...1550
  897109-1800SRM0327-(09-2003)-US-EN...1555
    toc...1555
      Brake System...1555
      Safety Precautions Maintenance and Repair...1556
      General...1559
      Description...1559
      Operation...1560
        Brake Booster and Master Cylinder...1560
          Brake Booster...1560
          Master Cylinder...1561
        Service Brake Assembly...1562
        Parking Brake...1563
      Brake Shoe Assemblies Repair...1564
        Remove and Disassemble...1564
        Clean and Inspect...1565
          Cleaning Procedures...1565
          Inspect...1565
        Assemble and Install...1566
      Master Cylinder Repair...1567
        Remove...1567
        Disassemble...1567
        Assemble...1569
        Install...1569
      Brake Booster Repair...1569
        Remove...1569
        Disassemble...1569
        Clean and Inspect...1571
        Assemble...1571
        Install...1571
      Brake System Air Removal...1571
      Brake Pedal Adjustment...1572
      Brake Shoes Adjustment...1573
      Parking Brake Adjustment...1573
      Parking Brake Switch Adjustment...1573
      Brake Booster Relief Valve Check...1573
      Troubleshooting...1574
  897110-1900SRM0328-(09-2003)-US-EN...1579
    toc...1579
      Hydraulic System...1579
      Safety Precautions Maintenance and Repair...1580
      General...1583
      Description and Operation...1583
        Hydraulic Pumps...1585
        Main Control Valve...1585
        Control Valve Lever...1586
        Steering Control Unit...1586
        Brake Valve...1586
        Oil Clutch, H6.00-7.00XL (H135-155XL) (F006)...1587
      Troubleshooting...1587
        Lift, Lower, and Tilt Circuit...1588
        Steering, Brake, and Oil Clutch System...1589
  897111-4000SRM0329-(10-2003)-US-EN...1593
    toc...1593
      Masts...1593
      Safety Precautions Maintenance and Repair...1594
      General...1597
      Description and Operation...1597
        General...1597
        Safety Procedures When Working Near Mast...1598
        Two-Stage Mast...1598
        Three-Stage Mast...1600
      Carriage Repair...1602
        Remove...1602
        Sideshift Carriage, Disassemble...1602
        Sideshift Carriage, Assemble...1603
        Install...1603
      Two-Stage Mast Repair...1605
        Remove...1605
        Disassemble...1606
        Clean and Inspect...1607
        Assemble...1608
        Install...1608
      Three-Stage Mast Repair...1610
        Remove...1610
        Disassemble...1610
        Clean and Inspect...1610
        Assemble...1610
        Install...1612
      Mast Operation Check...1612
      Lift and Tilt System Leaks Check...1613
        Lift System...1613
        Tilt System...1613
      Tilt Cylinder Stroke and Backward Tilt Angle Adjustment...1614
      Lift Chain Adjustments...1614
      Mast Adjustments...1617
      Carriage Adjustment...1617
      Troubleshooting...1619
    tables...1593
      Table 1. Mast Parts Weight...1606
      Table 2. Hook-Type Carriage Chain Adjustment...1615
      Table 3. Pin-Type Carriage Chain Adjustment...1615
  897113-8000SRM0331-(09-2003)-US-EN...1623
    toc...1623
      Capacities and Specifications...1623
      Safety Precautions Maintenance and Repair...1624
      Lift Truck Weights...1627
      Capacities...1627
      Tire Sizes...1628
      Tire Pressure...1628
      Electrical System...1628
      Wheel Nut Torque...1628
      Engine Specifications...1629
      Hydraulic System...1629
      Mast Speeds...1630
      Transmission Oil Pressures...1630
      Torque Specifications...1631
        Engine - GM 4.3L V-6...1631
        Engine - Perkins 4.2482...1631
        Engine - Perkins 1004.4...1631
        Clutch...1631
        Manual Transmission...1632
        Powershift Transmission...1632
        Speed Reducer...1632
        Drive Axle...1632
        Steering System...1632
        Brake System...1632
        Hydraulic System...1633
        Tilt Cylinder...1633
        Mast...1633
  897123-8000SRM0341-(06-2007)-US-EN...1637
    toc...1637
      Periodic Maintenance...1637
      Safety Precautions Maintenance and Repair...1638
      General...1643
        Serial Number Data...1643
        How to Move Disabled Truck...1643
          How to Tow Lift Truck...1643
        How to Put Lift Truck on Blocks...1644
          How to Raise Drive Tires...1644
          How to Raise Steering Tires...1644
      Maintenance Schedule...1645
      Maintenance Procedures Every 8 Hours or Daily...1658
        How to Make Checks With Engine Stopped...1658
          Hydraulic System Oil...1658
          Engine Oil...1660
          Drive Belts...1660
          Intake Manifold Rubber Cap...1661
          Cooling System...1661
          Air Filter...1661
          Fuel System...1662
          Primary Fuel Filter, Diesel Engine...1662
          Battery...1662
          Tires and Wheels...1662
          Forks...1663
            Adjust...1663
            Remove and Install...1665
          Forks, Mast, and Lift Chains, Inspect...1666
          Operator Restraint System...1667
            Automatic Locking Retractor (ALR)...1667
            Emergency Locking Retractor (ELR)...1667
          Safety Labels...1668
        How to Make Checks With Engine Running...1669
          Gauges, Lights, Horn, and Fuses...1669
          Oil Level, Powershift Transmission...1670
          Oil Level, Oil Clutch System, H3.50-5.00XL (H70-110XL)...1671
          Control Levers and Pedals...1671
          Lift System Operation...1671
          Inching/Brake Pedal...1671
          Service Brakes...1671
          Parking Brake...1672
          Steering System...1672
      Maintenance Procedures Every 250 Hours or 6 Weeks...1672
        Engine Oil and Filter, GM V-6 Engine...1672
        Lift Chains, Lubrication...1672
        Drive Shafts...1672
        Mast Lubrication...1673
        Crankcase Breather, GM V-6...1674
        Air Filter, GM V-6 EPA Compliant Engine ...1674
      Maintenance Procedures Every 350 Hours or 2 Months...1675
        Engine Oil and Filter, Perkins 4.2482 Diesel Engine...1675
        Drive Belts...1675
          Perkins Diesel Engine...1675
          GM V-6 Engine (Early Models)...1675
          GM V-6 Engine (Late Models)...1676
        Brake Fluid...1678
        Lift Chains Wear Check...1678
        Forks Wear and Damage Check...1678
        Steering Axle Lubrication...1678
        Fuel System, Checks and Adjustments...1679
          Diesel Fuel System...1679
          LPG Carburetor (Early Models)...1679
          Gasoline Carburetor (Early Models)...1680
          Fuel Injection (Late Models)...1680
        Crankcase Breather, Perkins 4.2482 Diesel Engine...1680
        Hydraulic Tank Breather...1680
        Cooling System, Clean Debris from Radiator Core...1680
      Maintenance Procedures Every 500 Hours or 3 Months...1681
        Engine Oil and Filter, Perkins Diesel Engine...1681
        Crankcase Breather, Perkins Diesel Engine...1681
        PCV Valve, GM V-6...1681
      Maintenance Procedures Every 1000 Hours or 6 Months...1681
        Manifold Heat Valve, GM V-6 (Early Models)...1681
        Ignition System, GM V-6...1681
        Valve Clearance Adjustment...1681
        Fuel Filter, Replace (Diesel Engine)...1682
        Fuel System Air Removal (Perkins 1004-4 Diesel Engine)...1682
          Fuel Injection Pump With Vent Tube...1682
          Fuel Injection Pump With Vent Screw...1683
        Fuel System Air Removal (Perkins 4.2482 Diesel Engine)...1685
        Oil Level Check in Transmission...1685
          Manual Transmission, H3.50-5.00XL (H70-110XL)...1685
          Speed Reducer for Powershift Transmission, H3.50-5.00XL (H70-110...1685
          Manual Transmission, H6.00-7.00XL (H135-155XL)...1685
          Differential and Drive Axle for Powershift Transmission, H6.00-7...1685
          Differential, Speed Reducer, and Drive Axle for Manual Transmiss...1686
        Control Levers and Pedals, Lubricate...1686
        Crankcase Breather, Replace...1686
        Cooling System, GM V-6 EPA Compliant Engine...1686
        Spark Plug Replacement...1686
          Remove...1686
          Install...1687
        LPG Fuel Filter GM V-6 EPA Compliant Engine, Replace...1687
        Inspect Engine Electrical System, Connectors, and FCVS Connectio...1688
      Maintenance Procedures Every 2000 Hours or Yearly...1688
        Hydraulic System...1688
          Hydraulic Oil and Filter, H3.50-5.00XL (H70-110XL), Replace...1688
          Hydraulic Oil and Filter, H6.00-7.00XL (H135-155XL, H135-155XL 2...1689
        Oil Change and Oil Filter Replacement, Powershift Transmission, ...1689
        Oil Change, Manual Transmission, H3.50-5.00XL (H70-110XL)...1689
        Oil Change, Manual Transmission, H6.00-7.00XL (H135-155XL)...1689
        Oil Change, Speed Reducer, Powershift Transmission, H3.50-5.00XL...1689
        Oil and Filter Change, Oil Clutch System, H3.50-5.00XL (H70-110X...1690
        Oil Change, Differential and Drive Axle, Powershift Transmission...1690
        Oil Change, Differential, Speed Reducer, and Drive Axle, Manual ...1690
        Cooling System...1690
        PCV Valve, GM V-6...1690
        Service Brakes...1691
        LPG Filter, Replace...1691
        Gasoline Fuel Filter, Replace...1692
        Hood Latch Check, H3.50-5.00XL (H70-110XL)...1692
        Air Filter Element, GM V-6 EPA Compliant Engine...1692
        Oxygen Sensor GM V-6 EPA Compliant Engine...1692
        Inspect Low Pressure Regulator (LPR) for Oil Buildup and Leaks...1693
        Check Throttle Shaft for Sticking...1694
        Inspect Exhaust Manifold and Piping for Leaks...1694
        Test LPG/GAS Regulator Pressure...1694
      Safety Procedures When Working Near Mast...1694
      Lift Chain Adjustments...1696
      Fuel Injectors Repair...1698
      Lift and Tilt System Leak Check...1699
        Lift Cylinders, Leak Check...1699
        Tilt Cylinders, Leak Check...1699
      Welding Repairs...1700
      Overhead Guard Changes...1700
      Wheel and Tire Replacement...1701
        Remove Wheels From Lift Truck...1701
        Remove Wheels From Tire...1701
          Remove Tire From Two-Piece Wheel...1703
          Remove Tire From Three- and Four-Piece Wheels...1705
        Install Wheel in Tire...1706
          Install Three- or Four-Piece Wheel in Tire...1707
          Install Two-Piece Wheel in Tire...1708
        Add Air to Pneumatic Tires...1709
        Wheels, Install...1709
      Solid Rubber Tires Repair...1710
        Wheel, Tire Remove...1710
        Wheel, Tire Install...1712
        SIT Tire, Change for H3.50-5.00XL (G005), and H6.00-7.00XL (F006...1714
          Remove SIT Solid Tire From Wheel...1714
          Install SIT Solid Tire on Wheel...1715
      Adhesives and Sealants...1716
      Hydraulic Oil, Lubricant, and Coolant Specifications...1717
    tables...1637
      Table 1. Maintenance Schedule...1647
      Table 2. Hook-Type Carriage Chain Adjustment...1697
      Table 3. Pin-Type Carriage Chain Adjustment...1697
  897501-8000SRM0519-(06-2007)-US-EN...1721
    toc...1721
      Diagrams...1721
      Safety Precautions Maintenance and Repair...1722
  897800-0600SRM0590-(08-2005)-US-EN...1809
    toc...1809
      GM Engines...1809
      Safety Precautions Maintenance and Repair...1810
      General...1813
      Description...1813
      Engine Removal and Installation...1814
      Cylinder Head Repair...1814
        Remove and Disassemble...1814
        Clean and Inspect...1814
        Valve Guides and Seats, Repairs...1815
        Valves, Repair...1815
        Valve Seats, Repair...1816
        Valve Springs...1816
        Rocker Arm Studs (Early Models)...1818
        Rocker Arm Studs (Late Models)...1818
        Assemble and Install...1819
      Cylinder Block Cleaning and Inspection...1822
      Piston Bore Preparation...1822
      Engine Mounts Installation...1823
      Lubrication System Repair...1823
        Oil Pump, Remove and Disassemble...1823
        Clean and Inspect...1823
        Oil Pump, Assemble and Install...1824
        Oil Sump, Install...1824
      Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters...1825
        Timing Cover...1825
          Remove...1825
          Install...1827
        Timing Sprockets...1827
          Remove...1827
          Install...1827
        Camshaft...1828
          Remove...1828
          Inspect...1828
          Install...1828
        Balance Shaft...1829
          Remove...1829
          Install...1830
        Hydraulic Valve Lifters...1830
          Remove...1830
          Disassemble...1831
          Clean and Inspect...1831
          Assemble...1831
          Install...1832
      Crankshaft Repair...1833
        Remove...1833
        Inspect and Repair...1833
        How to Check Clearance Between Main Bearings and Their Journals...1834
        Install...1835
      Piston and Connecting Rod Assemblies Repair...1836
        Connecting Rod Bearings, Replace...1836
        Piston and Connecting Rod Assemblies, Remove...1837
        Disassemble...1837
        Piston, Clean and Inspect...1838
        Cylinder Bores, Inspect and Repair...1838
        Piston Rings...1839
        Assemble...1840
        Piston and Connecting Rod Assemblies, Install...1840
      Flywheel and Flywheel Housing Repair...1841
        Flywheel, Repair...1841
        Flywheel, Install...1841
          H3.50-5.00XL (H70-110XL), S3.50-5.50XL (S70-120XL), S6.00-7.00XL...1841
          H6.00-7.00XL (H135-155XL)...1841
        Flywheel Housing H3.50-5.00XL (H70-110XL), H3.50-5.50XM (H70-120...1841
        Engine Adapter H6.00-7.00XL (H135-155XL)...1841
      Coolant Pump Repair...1842
      Thermostat Replacement...1842
      Fan Mount Repair (Early Models)...1842
      Fan Mount Assembly Repair (Late Models)...1842
      Drive Belt Installation...1844
      Valve Clearance Adjustment (Early Models)...1845
      Valve Clearance Adjustment (New Models)...1846
      Compression Check...1846
      Engine Specifications...1847
        Engine Data...1847
        Cylinder Head...1847
        Hydraulic Valve Lifter...1848
        Camshaft...1848
        Pistons...1848
        Crankshaft...1849
        Connecting Rods...1849
        Balance Shaft...1850
        Cooling System...1850
        Lubrication System...1850
      Torque Specifications...1850
      Troubleshooting...1851
    tables...1809
      Table 1. Piston Rings Arrangement on Piston...1840
  897934-0700SRM0626-(11-2001)-US-EN...1857
    toc...1857
      Cooling System...1857
      Safety Precautions Maintenance and Repair...1858
      General...1861
      Description...1862
        Radiator...1862
        Radiator Cap...1862
        Thermostat...1862
        Water Pump...1863
        Fan and Fan Shroud...1863
      Cooling System Checks...1863
        Radiator...1863
        Thermostat...1863
        Water Pump...1864
        Exhaust Leaks...1864
        Fan and Fan Shroud...1864
      Radiator Cleaning...1864
        Drain...1864
        Clean...1864
        Fill...1865
      Troubleshooting...1866
  899783-2000SRM0090-(10-2003)-US-EN...1869
    toc...1869
      Main Control Valve...1869
      Safety Precautions Maintenance and Repair...1870
      General...1873
      Description...1873
      Operation...1876
        Lift Spool...1876
        Tilt Spool...1877
          Tilt Backward...1877
          Tilt Forward...1878
        Single-Stage Relief Valve...1880
        Two-Stage Relief Valve...1881
      Main Control Valve Repair...1882
        Remove and Disassemble...1882
        Clean and Inspect...1882
        Assemble...1882
        Install...1883
      Single-Stage Relief Valve Adjustment...1883
      Two-Stage Relief Valve...1884
      Auxiliary Control Valve Relief Valve Adjustment (H60-110E Only)...1884
      Troubleshooting...1885
    tables...1869
      Table 1. Relief Pressures (Oil temperature at 55 to 66 C ( 131 t...1883
  899784-2200SRM0002-(12-2004)-US-EN...1889
    toc...1889
      Alternator with Regulator...1889
      Safety Precautions Maintenance and Repair...1890
      General...1893
      Description...1893
      Alternator Repair...1895
        Alternator Type A...1895
          Remove and Disassemble...1895
          Clean...1896
          Assemble...1897
          Install...1897
        Alternator Type B...1900
          Remove and Disassemble...1900
          Clean...1900
          Assemble...1901
          Install...1902
      General Check and Adjustment...1903
      Low Output Check (Type A or Type B)...1903
      High Output Check (Type A or Type B)...1905
      Brushes Circuit Check...1906
        Delco Alternators...1906
        Motorola Alternators...1907
      Diodes Check...1908
      Diode Bridge Check...1908
        Delco and Leece-Neville Alternators...1908
        Motorola Alternators...1908
      Rotor Field Winding Check...1909
      Stator Windings Check...1910
      Voltage Regulator Check...1910
      Troubleshooting...1910
  900347...1915
    WEBER CARBURETOR WITH GOVERNOR...1915
      GENERAL...1915
      DESCRIPTION...1915
        Carburetor...1915
        Governor...1915
      OPERATION...1916
        Carburetor, Float System...1916
        Carburetor, Idle System...1916
        Carburetor, Main Metering System...1916
        Carburetor, Power System...1917
        Carburetor, Accelerator Pump System...1917
        Carburetor, Choke System...1918
      GOVERNOR...1919
    REPAIRS...1920
      CARBURETOR...1920
        Removal...1920
        Disassembly...1920
        Cleaning...1920
        Assembly...1920
        Installation...1921
      GOVERNOR...1921
    CHECKS AND ADJUSTMENTS...1922
      GENERAL...1922
      CHOKE SYSTEM...1922
      ELECTRIC CHOKE...1922
      IDLE MIXTURE ADJUSTMENT...1923
      IDLE SPEED ADJUSTMENT...1923
      THROTTLE LINKAGE ADJUSTMENT...1924
      TROUBLESHOOTING...1925
  900348...1926
    INTRODUCTION...1926
      GENERAL...1926
      DESCRIPTION AND OPERATION...1926
        Fuel Tank...1927
        Fuel Filter and Fuel Valve Unit...1927
        Vaporizer...1928
        Carburetor...1929
        Governor...1930
    REPAIRS...1932
      LPG TANK...1932
        Removal...1932
        Installation...1932
      HYDROSTATIC RELIEF VALVE...1932
        Removal and Installation...1932
      FILTER UNIT...1934
        Replacement Of The Fuel Filter Element...1934
        Replacement of the Diaphragm and Fuel Valve ...1934
      REPLACEMENT OF THE HOSES...1934
      VAPORIZER...1934
        Removal...1934
        Vaporizer Disassembly...1936
        Cleaning...1936
        Inspection...1936
        Vaporizer Assembly...1936
        Installation...1938
      CARBURETOR...1938
        Removal...1938
        Disassembly...1938
        Cleaning...1939
        Assembly...1939
        Installation...1939
      GOVERNOR...1939
    CHECKS AND ADJUSTMENTS...1940
      CHECK THE FILTER UNIT...1940
      CHECK THE VAPORIZER...1940
        Pressure Reducer Valve...1940
        Vapor Valve...1940
      ADJUST THE CARBURETOR...1941
        Idle Mixture...1941
        Idle Speed ...1941
        Power Mixture...1941
      ADJUST THE THROTTLE LINKAGE...1941
    TROUBLESHOOTING...1942
  910072-1400SRM0046-(07-2007)-US-EN...1945
    toc...1945
      Differential...1945
      Safety Precautions Maintenance and Repair...1946
      General...1949
      Description...1949
      Differential Repair...1950
        Remove...1950
          Differential Carrier From Axle Housing, Remove...1950
          Differential and Ring Gear From Differential Carrier, Remove...1952
          Drive Pinion and Pinion Carrier From Differential Carrier, Remov...1954
        Disassemble...1955
          Differential and Ring Gear Assembly, Disassemble...1955
          Drive Pinion and Pinion Carrier, Disassemble...1957
        Clean and Inspect...1960
        Assemble...1961
          Pinion, Bearings, and Pinion Carrier, Assemble...1961
          Pinion Bearings, Adjust Preload...1961
            Press Method...1961
            Yoke or Flange Method...1962
          Triple-Lip Seal, Install...1963
          Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion)...1964
          Differential and Ring Gear, Assemble...1966
          Differential Gears Rotating Torque, Check...1968
          Differential and Ring Gear Assembly, Install...1969
          Differential Bearings, Preload Adjust...1971
          Ring Gear, Runout Check...1972
          Ring Gear Backlash, Adjust...1972
          Gear Set, Tooth Contact Pattern Check...1974
          Thrust Screw, Install and Adjust...1977
        Install...1977
          Differential Assembly Into Axle Housing, Install...1977
      Specifications...1979
      Troubleshooting...1984
    tables...1945
      Table 1. Ring Gear Backlash Adjustment Specifications...1974
      Table 2. Ring and Pinion Tooth Contact Adjustment...1975
      Table 3. General Specifications...1979
      Table 4. Rivet Installation Pressure...1979
      Table 5. Pinion Adjustment...1980
      Table 6. Pinion Preload Pressure...1980
      Table 7. Torque Specifications...1981
      Table 8. Torque Specifications for Metric Hardware...1982
      Table 9. Torque Specifications for Metric (Fine) Hardware...1983
  910073-1400SRM0049-(09-2003)-US-EN...1987
    toc...1987
      Drive Axle...1987
      Safety Precautions Maintenance and Repair...1988
      General...1991
      Description...1991
      Drive Axle Repair...1992
        Disassemble (Type 1 Shown)...1992
        Clean...1995
        Inspect...1995
        Assemble (Type 1 Shown)...1996
      Torque Specifications...1999
      Troubleshooting...2000
  910076-1600SRM0054-(10-2003)-US-EN...2003
    toc...2003
      Steering Control Unit...2003
      Safety Precautions Maintenance and Repair...2004
      General...2007
      Description...2007
      Operation...2007
      Steering Wheel and Column Assembly Repair...2009
      Steering Column Assembly Repair...2009
        Type A Steering Column Assembly...2009
          Remove and Disassemble...2009
          Assemble and Install...2011
        Type B Steering Column Assembly...2013
          Remove and Disassemble...2013
          Assemble and Install...2013
          Steering Control Unit...2016
            Disassemble...2016
            Clean...2019
            Assemble...2020
      System Air Removal...2025
      Troubleshooting...2025
  910091-1900SRM0097-(07-2006)-US-EN...2029
    toc...2029
      Hydraulic Gear Pumps...2029
      Safety Precautions Maintenance and Repair...2030
      Description...2033
      Operation...2034
        Flow Control Valve...2034
        Relief Valve...2035
      Hydraulic Gear Pump Repair...2035
        Remove...2035
        Disassemble...2036
        Clean...2036
        Inspect...2037
        Assemble...2040
        Install...2042
      Pump Output Check...2042
        Method No. 1...2042
        Method No. 2...2043
      Hydraulic System Air Check...2044
      Troubleshooting...2045
  910102-2100SRM0103-(03-2007)-US-EN...2051
    toc...2051
      Tilt Cylinders...2051
      Safety Precautions Maintenance and Repair...2052
      General...2055
      Description...2055
      Tilt Cylinder Repair...2055
        Remove...2055
        Disassemble...2055
        Clean...2055
        Assemble...2055
          Tilt Cylinders With O-Ring or Single-Lip Seals...2055
          Tilt Cylinders for XM and XMS Models...2057
          Tilt Cylinders for XL, XLS, and XL 3 Models...2058
          Tilt Cylinders for H700-800A and Early Model H700-920B...2060
        Install...2061
          Tilt Cylinders Using Chevron Packing...2061
            Install...2062
      Tilt Cylinder Leak Check...2064
      Tilt Cylinder Stroke and Mast Tilt Angle Adjustment...2066
      Torque Specifications...2066
        Piston Rod Nut...2066
        Retainer...2067
      Troubleshooting...2069
    tables...2051
      Table 1. Movement Rates (Maximum) for Tilt Cylinders...2065
  910107-2200SRM0106-(12-2004)-US-EN...2073
    toc...2073
      Starter...2073
      Safety Precautions Maintenance and Repair...2074
      General...2077
      Description and Operation...2077
      Starter Repair...2079
        Remove...2079
        Disassemble...2079
        Clean...2080
        Assemble...2080
        Install...2081
      General Checks and Adjustments...2081
      Troubleshooting...2084
  910110-2200SRM0143-(02-2007)-US-EN...2089
    toc...2089
      Instrument Panel Indicators and Senders...2089
      Safety Precautions Maintenance and Repair...2090
      General...2093
      Description...2094
        Steering Column Gauges, Meters, and Indicators...2094
        LED Display Panel...2094
          Battery Discharge Indicators...2094
          Brush Wear Indicators...2100
          Motor Temperature Indicators...2100
        LX Series Display Panel...2102
          Hourmeter Functions...2103
          Battery Indicator Function...2103
          Status Code Function...2103
        ZX Series Display Panels...2105
          Display Panel...2105
          Basic Display Panels...2105
          Performance Display...2107
          Brush Wear Indicators...2111
      Adjustments - General...2111
      Replacement - General Information...2111
      Meter Replacement...2112
      Sender Replacement...2113
        Fuel Level Sender...2113
        Pressure and Temperature Sender...2113
        Seat Sensor, Operator Presence System (OPS)...2114
          Remove...2114
          Install...2114
        Operator Presence System Module Replacement...2114
          Remove...2115
          Install...2116
      ITW Display Panel Replacement...2117
        Remove...2117
      Column Mount Display Panel (EV-100/200ZX Motor Controllers) Repl...2117
        Remove...2117
        Display Panel Assembly, Replace...2117
        Indicator LEDs...2118
        Battery Indicators...2118
        Digital Display (Performance Display Panel Only)...2118
        Status Code or Performance Level Switches and Indicator LEDs (Pe...2119
        Basic Display Panel, Replace Parts...2119
        Performance Display Panel, Replace Parts...2121
      Dash Mount Display Panel (EV100/200ZX Motor Controllers) Replace...2121
        Remove and Replace...2121
      Specifications...2122
        Meter Specifications...2122
        Sender Specifications...2122
      Troubleshooting...2123
        Meter...2123
      Troubleshooting for Operator Presence System...2124
    tables...2089
      Table 1. Troubleshooting Procedure for Operator Presence Module...2124
  910119-4000SRM0135-(10-2003)-US-EN...2129
    toc...2129
      Lift Cylinders...2129
      Safety Precautions Maintenance and Repair...2130
      Safety Procedures When Working Near Mast...2133
      General...2137
      Description...2137
        Lowering Control Valve...2137
        Cylinders (General)...2140
        Cylinders (H520-620B, H700-800A)...2140
          Retainer, Install...2140
        Cylinders (H360-460B)...2142
        Cylinders (Two-Speed)...2144
      Lift Cylinder Repair...2146
        Lift Cylinder Removal Without Removing Mast...2146
          Standard Masts With Main Lift Cylinder Fastened to Crossmember o...2146
          Standard and Full Free-Lift Masts With Lift Cylinder Fastened to...2146
          Masts That Have Two Cylinders, Main Lift Cylinder and Free-Lift ...2146
        Disassemble...2148
        Assemble...2148
        Lift Cylinder Installation in Mast...2150
          Standard Masts With Main Lift Cylinder Fastened to Crossmember o...2150
          Standard and Full Free-Lift Masts With Lift Cylinder Fastened to...2150
        Chevron-Style Packing...2150
          Chevron-Style Packing Installation on Piston...2151
          Chevron-Style Packing Installation in Packing Gland...2153
      Lift Cylinders for VISTA® Masts...2154
        Description...2154
          Lowering Control Valve...2154
        Remove...2156
        Disassemble...2157
        Assemble...2158
        Install...2159
          Main Lift Cylinders...2159
          Free-Lift Cylinder...2159
      Lift System Leak Check...2160
      Specifications...2161
      Troubleshooting...2162
    tables...2129
      Table 1. Lift Trucks with Two-Speed Lift Cylinders...2145
      Table 2. Cylinder Retainer Torque Specifications and Weight Guid...2161
  910442-8000SRM0231-(12-2004)-US-EN...2165
    toc...2165
      Metric and Inch (SAE) Fasteners...2165
      Safety Precautions Maintenance and Repair...2166
      General...2169
        Threaded Fasteners...2169
        Nomenclature, Threads...2169
        Strength Identification...2170
        Cotter (Split) Pins...2170
        Fastener Torque Tables...2175
        Conversion Table...2177
    tables...2165
      Table 1. Bolts and Screws...2171
      Table 2. Studs and Nuts...2172
      Table 3. Torque Nuts...2173
      Table 4. Torque Nuts With Nylon Insert...2174
      Table 5. Torque Values for Metric Fasteners*...2175
      Table 6. Torque Values for Inch Fasteners*...2176
      Table 7. Conversion Table for Metric and English Units...2177
      Table 8. Cotter Pin Dimensional Data...2178
      Table 9. Cotter Pin Dimensional Data...2179
      Table 10. Cotter Pin Dimensional Data...2180
      Table 11. Cotter Pin Dimensional Data...2182
G006 (H6.00-7.00XL Europe)...2187
  1552002-0600SRM1070-(06-2007)-UK-EN...2188
    toc...2188
      Perkins Diesel Engines...2188
      Safety Precautions Maintenance and Repair...2189
      General...2196
        General Safety Rules...2196
      Description...2197
        Engine Serial Number Codes...2199
        Engine Data...2199
      Engine Removal and Installation...2200
      Cylinder Head Assembly Repair...2201
        Engine Breather...2201
          Remove...2201
          Install...2201
        Valve Cover...2202
          Remove...2202
          Install...2202
        Rocker Arm Assembly...2203
          Remove...2203
          Disassemble...2203
          Inspect...2203
          Assemble...2204
          Install...2204
        Valve Clearance Adjustments...2205
        Valve Springs...2205
        Cylinder Head Assembly...2207
          Remove...2207
          Inspect...2208
          Install...2208
        Valves and Valve Springs...2210
          Remove...2210
          Inspect...2210
          Install...2211
        Valve Guides...2211
          Inspect...2211
          Remove...2212
          Install...2212
        Valve Seats...2213
          Inspect...2213
          Repair...2213
          New Valve Seats, Install...2214
      Piston and Connecting Rod Assemblies Repair...2215
        General...2215
        Rod Bearings...2215
          Remove...2215
          Install...2216
        Piston and Connecting Rod Assembly...2217
          Service Note...2217
          Remove...2217
          Disassemble...2217
          Inspect...2217
          How to Select Correct Replacements...2219
          Assemble...2219
          Install...2220
        Piston Cooling Jets...2222
          Remove...2222
          Install...2222
      Crankshaft Assembly Repair...2223
        General...2223
        Crankshaft Pulley...2223
          Remove...2223
          Inspect...2223
          Install...2223
        Rear Oil Seal...2224
          Remove...2224
          Install...2224
        Crankshaft Flange Wear Sleeve...2226
          Remove...2226
          Install...2226
        Main Bearings...2227
          Remove...2227
          Inspect...2227
          Install...2227
        Thrust Washers...2228
          Crankshaft Axle Movement, Check...2228
          Remove...2229
          Install...2229
        Crankshaft...2230
          Remove...2230
          Inspect...2230
          Install...2231
        Crankshaft Timing Ring...2232
          Remove...2232
          Install...2233
        Flywheel...2233
          Remove...2233
          Ring Gear, Replace...2233
          Install...2233
        Flywheel Housing...2234
          Remove...2234
          Install...2234
      Timing Case and Timing Gears Repair...2235
        General...2235
        Timing Case Cover...2235
          Remove...2235
          Install...2235
        Front Oil Seal...2236
          Remove, With Timing Case Installed...2236
          Install, With Timing Case Installed...2237
          Remove, With Timing Case Removed...2238
          Install, With Timing Case Removed...2238
        Crankshaft Pulley Wear Sleeve, Install...2238
        Fuel Pump Gear...2239
          Remove...2239
          Install...2240
        Idler Gear and Hub...2241
          Remove...2241
          Disassemble...2242
            Standard Idler Gear and Hub Assembly...2242
            Heavy Duty Idler Gear and Hub Assembly...2242
          Assemble...2243
            Standard Idler Gear and Hub Assembly...2243
            Heavy Duty Idler Gear and Hub Assembly...2243
          Install...2244
        Camshaft Gear...2244
          Remove...2244
          Install...2245
        Crankshaft Gear...2245
          Remove...2245
          Install...2245
        Timing Case...2246
          Remove...2246
          Install...2247
        Power Take-Off (PTO) Adaptor...2248
          Remove...2248
          Disassemble...2248
          Assemble...2249
          Install...2249
        Camshaft and Tappets...2249
          Remove...2249
          Install...2249
      Cylinder Block Assembly Repair...2250
        General...2250
        Cylinder Block...2250
          Disassemble...2250
          Inspect...2251
          Assemble...2251
        Cylinder Bore...2251
          Inspect...2251
          Cylinder Liner Condition Check...2251
      Engine Timing...2252
        General...2252
        How to Set Number One Piston to TDC on Compression Stroke...2252
        Fuel Injection Pump Timing, Check...2253
        Fuel Injection Pump Timing, Adjust...2254
      Lubrication System Repair...2256
        General...2256
        Oil Filter, Replace...2256
        Oil Filter Head...2257
          Remove...2257
          Install...2257
        Oil Sump...2257
          Remove...2257
          Install...2258
        Oil Pump...2259
          Remove...2259
          Inspect...2259
          Install...2259
        Oil Strainer and Suction Pipe...2260
          Remove...2260
          Install...2260
        Relief Valve...2261
          Remove...2261
          Install...2261
        Dipstick Tube...2261
          Remove and Install...2261
      Fuel System Repair...2262
        General...2262
        Cold Start Advance Unit (KSB)...2262
        Typical Fuel System...2263
        Fuel Filter...2265
          Remove...2265
          Install...2265
        Fuel Injectors...2266
          Remove...2266
          Install...2267
        Fuel System Air Removal...2268
        Bosch EVPE Fuel Injection Pump...2268
          General...2268
          Remove...2269
          Install...2270
      Cooling System Repair...2270
        General...2270
        Thermostat...2272
          Remove...2272
          Install...2272
          Test...2272
        Coolant Pump...2273
          Remove...2273
          Disassemble...2273
          Assemble...2274
          Install...2275
        Fan...2276
          Remove and Install...2276
        Fan Drive...2276
          Remove...2276
          Install...2276
        Oil Cooler...2276
          Remove...2276
          Disassemble and Assemble...2277
          Install...2277
        Coolant Bypass Hose...2277
          Removal...2277
          Install...2277
      Electrical Equipment Repair...2278
        Drive Belt...2278
          Check...2278
          Adjust...2278
          Remove...2278
          Install...2278
        Alternator...2279
          Remove...2279
          Install...2279
          Fault Diagnosis...2279
            Normal Operation:...2279
            If the Warning Lamp is Not Illuminated When the Ignition Switch ...2280
            If the Warning Light Continues to be Illuminated When the Altern...2280
        Starter Motor...2281
          Remove...2281
          Install...2281
          Test...2281
        Starting Aid...2281
          Remove...2281
          Install...2282
          Check...2282
            Power Supply Continuity...2282
            Operation...2282
        Pressure Sensor...2283
          Remove...2283
          Install...2284
        Temperature Sensor...2284
          Remove...2284
          Install...2285
      Engine Specifications...2285
        Cylinder Head Assembly...2285
        Piston and Connecting Rods...2288
        Crankshaft Assembly...2290
          Crankshaft Overhaul...2290
        Timing Case and Drive Assembly...2292
        Engine Block Assembly...2293
        Lubrication System...2293
        Fuel System...2294
        Cooling System...2295
        Flywheel and Housing...2296
        Electrical Equipment...2296
      Torque Specifications...2296
      Special Torque Specifications...2297
        Cylinder Head Assembly...2297
        Piston and Connecting Rod Assemblies...2297
        Crankshaft Assembly...2297
        Timing Case and Drive Assembly...2297
        Cylinder block...2297
        Fuel System...2297
        Lubrication System...2297
        Cooling System...2298
        Flywheel and Housing...2298
        Electrical Equipment...2298
      Special Tools...2299
      Troubleshooting...2303
    tables...2188
      Table 1. Cylinder Head...2285
      Table 2. Valve Guides...2286
      Table 3. Inlet Valves...2286
      Table 4. Exhaust Valves...2287
      Table 5. Valve Springs...2288
      Table 6. Tappets...2288
      Table 7. Rocker Arm Shaft...2288
      Table 8. Rocker Arms and Bushings...2288
      Table 9. Pistons...2288
      Table 10. Piston Rings...2288
      Table 11. Piston Pins...2289
      Table 12. Connecting Rods...2289
      Table 13. Small End Bushings...2289
      Table 14. Connecting Rod Bearings...2289
      Table 15. Piston Cooling Jets...2290
      Table 16. Crankshaft Overhaul Specifications...2290
      Table 17. Maximum Variation (Run-out)...2291
      Table 18. Camshaft...2292
      Table 19. Camshaft Thrust Washer...2292
      Table 20. Camshaft Gear...2292
      Table 21. Gear for Fuel Pump...2292
      Table 22. Crankshaft Gear...2292
      Table 23. Idler Gear and Hub...2292
      Table 24. Timing Gear Backlash Values...2293
      Table 25. Cylinder Block...2293
      Table 26. Oil Pump...2293
      Table 27. Idler Gear for Oil Pump...2293
      Table 28. Relief Valve...2294
      Table 29. Oil Filter...2294
      Table 30. Bosch Fuel Injection Pump...2294
      Table 31. Fuel Injector Settings...2294
      Table 32. Fuel Pump...2295
      Table 33. Fuel Filter...2295
      Table 34. Coolant Pump...2295
      Table 35. Thermostat...2295
      Table 36. Fan Drive Housing...2295
      Table 37. Limits for Flywheel Run Out and Alignment (Total Indic...2296
      Table 38. Alternator...2296
      Table 39. Starter Motor...2296
      Table 40. Starting Aids...2296
      Table 41. List of Possible Causes...2304
  1559540-0900SRM1088-(05-2006)-UK-EN...2308
    toc...2308
      Electronic Controlled LPG/Gasoline Fuel System...2308
      Safety Precautions Maintenance and Repair...2309
      General...2314
        Fuel System Warnings and Cautions...2314
      Glossary...2315
      Description and Operation of LPG Fuel System...2319
        Propane Fuel System...2319
        LPG Fuel Tank...2321
        Service Line...2321
        Fuel Filter...2321
        Low Pressure Lock-Off (LPL)...2322
        Low Pressure Regulator (LPR)...2322
        Air Fuel Mixer...2322
        Throttle Control Device...2323
          Drive By Cable...2323
        Three-Way Catalytic (TWC) Muffler...2324
        Electronic Control Module (ECM)...2324
        Heated Exhaust Gas Oxygen (HEGO) Sensor...2327
      Description and Operation of Gasoline Fuel System...2327
        Gasoline Fuel System Throttle Body Injection (TBI), 3.0L Engine ...2327
        Gasoline Multi-Point Fuel Injection (MPFI) System, 4.3L Only...2329
        Gasoline Fuel Storage Tank...2329
        Gasoline Fuel Pump...2329
        Fuel Filter...2329
        Fuel Pressure Regulator, 3.0L Only...2331
        Fuel Rail and Pressure Regulator, 4.3L Only...2331
        Fuel Injector...2331
        Throttle Control Device...2331
          Drive By Cable...2331
        Three-Way Catalytic Muffler...2332
        Electronic Control Module (ECM)...2333
        Heated Exhaust Gas Oxygen (HEGO) Sensor...2334
      LPG Fuel System Repair...2335
        Propane Fuel System Pressure Relief...2335
        Propane Fuel System Leak Test...2335
        Propane Fuel Filter Replacement...2335
          Remove...2335
          Install...2336
        Low Pressure Lock-Off (LPL) Replacement...2336
          Remove...2336
          Install...2336
        Pressure Trim Valve (PTV) Replacement...2338
          Remove...2338
          Install...2338
        Low Pressure Regulator...2338
          Remove...2338
          Install...2338
        Fuel Trim Valve (FTV) Solenoid Replacement...2339
          Remove...2339
          Install...2339
        Temperature Manifold Absolute Pressure (TMAP)...2342
          Remove...2342
          Install...2342
        Throttle Body Replacement...2342
          Remove...2342
          Install...2343
        Mixer Replacement...2343
          Remove...2343
          Install...2343
        Coolant Hose Replacement...2343
          Remove...2343
          Install...2344
        Vapor Hose Replacement...2344
          Remove...2344
          Install...2344
        Balance Line Hose Replacement...2344
          Remove...2344
          Install...2344
        PTV Hose Replacement...2344
          Remove...2344
          Install...2344
        FTV Hose Replacement...2345
          Remove...2345
          Install...2345
        Throttle Position Sensor (TPS) Replacement...2345
        Foot Pedal Position (FPP) Sensor Replacement...2347
        Electronic Control Module (ECM) Replacement...2350
          Remove...2350
          Install...2350
        Heated Exhaust Gas Oxygen (HEGO) Sensor Replacement...2351
          Remove...2351
          Install...2351
        Three-Way Catalytic Muffler (TWC) Replacement...2351
          Remove...2351
          Install...2351
        Restricted Exhaust System Diagnosis...2351
          Exhaust System Description...2351
            Tools Required...2351
            Diagnostic Tool...2351
          Check at Heated Exhaust Gas Oxygen Sensor (HEGO)...2352
      Gasoline Fuel System Repair...2352
        Gasoline MPFI and TBI Fuel System Pressure Relief...2352
        Gasoline Fuel System Leak Test...2353
        Throttle Body Injector (TBI) Assembly Replacement, 3.0L Only...2353
          Remove...2353
          Install...2353
        Throttle Body Assembly Replacement, 3.0L Only...2355
          Remove...2355
          Install...2355
        Throttle Body Assembly Replacement, 4.3L Only...2355
          Remove...2355
          Install...2356
        Fuel Rail Replacement, Gasoline 4.3L Only...2358
          Remove...2358
          Install...2358
        Injector Replacement, Gasoline 4.3L Only...2358
          Remove...2358
          Install...2358
        Injector Replacement, Gasoline 3.0L Only...2359
          Remove...2359
          Install...2359
        Temperature Manifold Absolute Pressure (TMAP) Replacement...2359
          Remove...2359
          Install...2359
        Throttle Position Sensor (TPS) Replacement...2359
        Foot Pedal Position (FPP) Sensor Replacement...2362
        Electronic Control Module (ECM) Replacement...2365
          Remove...2365
          Install...2365
        Heated Exhaust Gas Oxygen (HEGO) Sensor Replacement...2365
          Remove...2365
          Install...2366
        Three-Way Catalytic Muffler (TWC) Replacement...2366
          Remove...2366
          Install...2366
        Restricted Exhaust System Diagnosis...2366
          Exhaust System Description...2366
            Tools Required...2366
            Diagnostic Tool...2366
          Check at Heated Exhaust Gas Oxygen Sensor (HEGO)...2366
      LPG System Diagnosis...2367
        Fuel System Description...2367
        Diagnostic Aids...2368
          Tools Required...2368
          Duty Cycle Monitoring Tool...2368
          Diagnostic Tool...2368
          Pressure Gauges...2368
          Test Description...2368
      Gasoline System Diagnosis...2376
        Fuel System Description, 3.0L Only...2376
        Fuel System Description, 4.3L Only...2376
        Diagnostic Aids...2377
          Tools Required...2377
          Diagnostic Tool...2377
          Test Description...2377
      LPG Symptom Diagnosis...2384
      Gasoline Symptom Diagnosis...2398
      Wire Harness Repair...2408
        On Vehicle Service Wiring Harness Repair...2408
        Connectors and Terminals...2409
          Twisted/Shielded Cable Repair...2409
          Twisted Leads Repair...2410
          Micro-Pack...2411
          Metri-Pack...2412
            Remove...2412
          Weather-Pack...2413
            Weather-Pack Terminal Repair...2414
    tables...2308
      Table 1. TPS Replacement Procedure...2345
      Table 2. FPP Replacement Procedure...2348
      Table 3. TPS Replacement Procedure...2360
      Table 4. FPP Replacement Procedure...2363
      Table 5. LPG Fuel System Diagnosis...2368
      Table 6. Fuel Control Diagnosis...2372
      Table 7. Gasoline Fuel System Diagnosis, 3.0L Only...2378
      Table 8. Gasoline Fuel System Diagnosis, 4.3L Only...2381
      Table 9. Preliminary Checks...2384
      Table 10. Intermittent ...2386
      Table 11. No Start...2387
      Table 12. Hard Start...2389
      Table 13. Cuts Out or Misses...2390
      Table 14. Hesitation, Sag, or Stumble...2391
      Table 15. Backfire...2392
      Table 16. Lack of Power, Sluggishness, or Sponginess...2393
      Table 17. Poor Fuel Economy...2394
      Table 18. Rough, Unstable, Incorrect Idle, or Stalling...2395
      Table 19. Surges or Chuggles...2397
      Table 20. Preliminary Checks...2398
      Table 21. Intermittent...2399
      Table 22. No Start...2400
      Table 23. Hard Start...2401
      Table 24. Cuts Out or Misses...2402
      Table 25. Hesitation, Sag, or Stumble...2403
      Table 26. Backfire...2404
      Table 27. Lack of Power, Sluggishness, or Sponginess...2405
      Table 28. Poor Fuel Economy...2406
      Table 29. Rough, Unstable, Incorrect Idle, or Stalling...2407
      Table 30. Surges or Chuggles...2408
  1559545-2200SRM1090-(04-2005)-UK-EN...2418
    toc...2418
      Electronic Control Module (ECM) Diagnostic Troubleshooting...2418
      Safety Precautions Maintenance and Repair...2419
      General...2428
      Description of ECM Based Diagnostics...2428
        Definition of Terms...2428
        Diagnostics Overview of the Spectrum Fuel System...2428
        Malfunction Indicator Lamp (MIL)...2429
        Spectrum Diagnostic Trouble Codes (DTC)...2429
        Using a Laptop Computer to Diagnose the Spectrum System...2429
          Installing the Spectrum Diagnostic Software...2430
          Connecting a Laptop Computer to the Spectrum System...2430
          Diagnostic Communication Error...2430
        Diagnostic Trouble Codes...2431
          Checking Diagnostic Trouble Codes...2431
          Clearing Diagnostic Trouble Codes...2431
        DATA Stream...2432
          Reading Sensor and Actuator Values...2432
          Graphing and Data Logging...2433
        Ignition System Test...2434
          Disabling Ignition Outputs...2434
        Injector Test...2435
          Disabling Injectors...2435
        Throttle Test...2435
          Using a Diagnostic Jumper to Diagnose the ECI System...2436
      On-Board Diagnostics System Check/Malfunction Indicator Lamp...2437
        Circuit Description...2437
      Preliminary and Intermittent Checks...2440
      GM 3.0L Wiring Schematics and Connectors...2442
      GM 3.0L Diagnostic Trouble Codes...2456
        DTC 111 - IAT High Voltage Motorola® TMAP...2456
          Circuit Description...2456
          Conditions for Setting the DTC...2456
        DTC 112 - IAT Low Voltage Motorola® TMAP...2459
          Circuit Description...2459
          Conditions for Setting the DTC...2459
        DTC 113 - IAT Higher Than Expected 1 Motorola® TMAP...2461
          Circuit Description...2461
          Conditions for Setting the DTC...2461
          Diagnostic Aids...2462
        DTC 114 - IAT Higher Than Expected 2 Motorola® TMAP...2463
          Circuit Description...2463
          Conditions for Setting the DTC...2463
          Diagnostic Aids...2463
        DTC 115 - Oil Pressure Low...2464
          Circuit Description...2464
          Conditions for Setting the DTC...2464
        DTC 121 - ECT Voltage High...2467
          Circuit Description...2467
          Conditions for Setting the DTC...2468
        DTC 122 - ECT Voltage Low...2471
          Circuit Description...2471
          Conditions for Setting the DTC...2471
        DTC 123 - ECT Higher Than Expected 1...2473
          Circuit Description...2473
          Conditions for Setting the DTC...2473
        DTC 124 - ECT Higher Than Expected 2...2475
          Circuit Description...2475
          Conditions for Setting the DTC...2475
        DTC 131 - MAP High Pressure Motorola® TMAP...2477
          Circuit Description...2477
          Conditions for Setting the DTC...2477
          Diagnostic Aids...2477
        DTC 132 - MAP Low Voltage Motorola® TMAP...2480
          Circuit Description...2480
          Conditions for Setting the DTC...2480
        DTC 134 - BP High Pressure Motorola® TMAP...2484
          Circuit Description...2484
          Conditions for Setting the DTC...2484
        DTC 135 - BP Low Pressure Motorola® TMAP...2485
          Circuit Description...2485
          Conditions for Setting the DTC...2485
        DTC 142 - Crank Sync Noise...2489
          Circuit Description...2489
          Conditions for setting the DTC...2489
        DTC 143 - Never Crank Synced At Start...2493
          Circuit Description...2493
          Conditions for Setting the DTC...2493
        DTC 144 - Camshaft Sensor Loss...2496
          Circuit Description...2496
          Conditions for Setting the DTC...2496
        DTC 145 - Camshaft Sensor Noise...2499
          Circuit Description...2499
          Conditions for Setting the DTC...2499
        DTC 211 - Closed Loop Multiplier High (LPG)...2502
          Circuit Description...2502
          Conditions for Setting the DTC...2502
          Diagnostic Aids...2502
        DTC 212 - HO 2 S Open/Inactive...2505
          Circuit Description...2505
          Conditions for Setting the DTC...2505
        DTC 221 - Closed Loop Multiplier High (Gasoline)...2507
          Circuit Description...2507
          Conditions for Setting the DTC...2507
          Diagnostic Aids...2508
        DTC 222 - Closed Loop Multiplier Low (Gasoline)...2511
          Circuit Description...2511
          Conditions for Setting the DTC...2511
          Diagnostic Aids...2511
        DTC 224 - Closed Loop Multiplier Low (LPG)...2513
          Circuit Description...2513
          Conditions for Setting the DTC...2513
          Diagnostic Aids...2513
        DTC 241 - Adaptive Lean Fault (High Limit-Gasoline)...2515
          Circuit Description...2515
          Conditions for Setting the DTC...2515
          Diagnostic Aids...2515
        DTC 242 - Adaptive Rich Fault (Low Limit-Gasoline)...2518
          Circuit Description...2518
          Conditions for Setting the DTC...2518
          Diagnostic Aids...2518
        DTC 243 - Adaptive Learn High (LPG)...2521
          Circuit Description...2521
          Conditions for Setting the DTC...2521
          Diagnostic Aids...2521
        DTC 244 - Adaptive Learn Low (LPG)...2524
          Circuit Description...2524
          Conditions for Setting the DTC...2524
          Diagnostic Aids...2524
        DTC 261 - System Voltage High...2527
          Circuit Description...2527
          Conditions for Setting the DTC...2527
        DTC 262 - System Voltage Low...2529
          Circuit Description...2529
          Conditions for Setting the DTC...2529
        DTC 411 - Injector Driver 1 Open...2531
          Circuit Description...2531
          Conditions for Setting the DTC...2531
        DTC 412 - Injector Driver 1 Shorted...2534
          Circuit Description...2534
          Conditions for Setting the DTC...2534
        DTC 511 - COP Failure...2537
          Circuit Description...2537
          Conditions for Setting the DTC...2537
        DTC 512 - Invalid Interrupt...2539
          Circuit Description...2539
          Conditions for Setting the DTC...2539
        DTC 513 - A/D Loss...2541
          Circuit Description...2541
          Conditions for Setting the DTC...2541
        DTC 514 - RTI 1 Loss...2543
          Circuit Description...2543
          Conditions for Setting the DTC...2543
        DTC 515 - Flash Checksum Invalid...2545
          Circuit Description...2545
          Conditions for Setting the DTC...2545
        DTC 516 - Ram Failure...2547
          Circuit Description...2547
          Conditions for Setting the DTC...2547
        DTC 531 - External 5V Ref Lower Than Expected...2549
          Circuit Description...2549
          Conditions for Setting the DTC...2549
        DTC 532 - External 5V Ref Higher Than Expected...2551
          Circuit Description...2551
          Conditions for Setting the DTC...2551
        DTC 555 - RTI 2 Loss...2553
          Circuit Description...2553
          Conditions for Setting the DTC...2553
        DTC 556 - RTI 3 Loss...2555
          Circuit Description...2555
          Conditions for Setting the DTC...2555
        DTC 611 - FPP High Voltage...2557
          Circuit Description...2557
          Conditions for Setting the DTC...2557
        DTC 612 - FPP Low Voltage...2561
          Circuit Description...2561
          Conditions for Setting the DTC...2561
        DTC 631 - TPS1 Signal Voltage High...2565
          Circuit Description...2565
          Conditions for Setting the DTC...2565
        DTC 632 - TPS1 Signal Voltage Low...2568
          Circuit Description...2568
          Conditions for Setting the DTC...2568
        DTC 638 - Throttle Unable To Close...2571
          Circuit Description...2571
          Conditions for Setting the DTC...2571
          Diagnostic Aids...2572
        DTC 651 - Maximum Govern Speed Override...2574
          Circuit Description...2574
          Conditions for Setting the DTC...2574
          Diagnostic Aids...2574
        DTC 652 - Fuel Rev Limit...2577
          Circuit Description...2577
          Conditions for Setting the DTC...2577
          Diagnostic Aids...2577
        DTC 653 - Spark Rev Limit...2579
          Circuit Description...2579
          Conditions for Setting the DTC...2579
          Diagnostic Aids...2579
      GM 4.3L Wiring Schematics and Connectors...2583
      GM 4.3L Diagnostic Trouble Codes...2600
        DTC 111 - IAT High Voltage Bosch® TMAP...2600
          Circuit Description...2600
          Conditions for Setting the DTC...2600
        DTC 111 - IAT High Voltage Motorola® TMAP...2603
          Circuit Description...2603
          Conditions for Setting the DTC...2603
        DTC 112 - IAT Low Voltage Bosch® TMap...2605
          Circuit Description...2605
          Conditions for Setting the DTC...2606
        DTC 112 - IAT Low Voltage Motorola® TMAP...2608
          Circuit Description...2608
          Conditions for Setting the DTC...2608
        DTC 113 - IAT Higher Than Expected 1 Bosch® TMAP...2611
          Circuit Description...2611
          Conditions for Setting the DTC...2611
          Diagnostic Aids...2611
        DTC 113 - IAT Higher Than Expected 1 Motorola® TMAP...2612
          Circuit Description...2612
          Conditions for Setting the DTC...2612
          Diagnostic Aids...2612
        DTC 114 - IAT Higher Than Expected 2 Bosch® TMAP€...2613
          Circuit Description...2613
          Conditions for Setting the DTC...2613
          Diagnostic Aids...2613
        DTC 114 - IAT Higher Than Expected 2 Motorola® TMAP...2614
          Circuit Description...2614
          Conditions for Setting the DTC...2614
          Diagnostic Aids...2614
        DTC 115 - Oil Pressure Low...2615
          Circuit Description...2615
          Conditions for Setting the DTC...2615
        DTC 121 - ECT Voltage High...2617
          Circuit Description...2617
          Conditions for Setting the DTC...2618
        DTC 122 - ECT Voltage Low...2621
          Circuit Description...2621
          Conditions for Setting the DTC...2621
        DTC 123 - ECT Higher Than Expected 1...2624
          Circuit Description...2624
          Conditions for Setting the DTC...2624
        DTC 124 - ECT Higher Than Expected 2...2626
          Circuit Description...2626
          Conditions for Setting the DTC...2626
        DTC 131 - MAP High Pressure Bosch® TMAP...2627
          Circuit Description...2627
          Conditions for Setting the DTC...2627
          Diagnostic Aids...2627
        DTC 131 - MAP High Pressure Motorola® TMAP...2631
          Circuit Description...2631
          Conditions for Setting the DTC...2631
          Diagnostic Aids...2631
        DTC 132 - MAP Low Voltage Bosch® TMAP...2634
          Circuit Description...2634
          Conditions for Setting the DTC...2634
        DTC 132 - MAP Low Voltage Motorola® TMAP...2637
          Circuit Description...2637
          Conditions for Setting the DTC...2637
        DTC 134 - BP High Pressure Bosch® TMAP...2642
          Circuit Description...2642
          Conditions for Setting the DTC...2642
        DTC 134 - BP High Pressure Motorola® TMAP...2644
          Circuit Description...2644
          Conditions for Setting the DTC...2644
        DTC 135 - BP Low Pressure Bosch® TMAP...2646
          Circuit Description...2646
          Conditions for Setting the DTC...2646
        DTC 135 - BP Low Pressure Motorola® TMAP...2650
          Circuit Description...2650
          Conditions for Setting the DTC...2650
        DTC 142 - Crank Sync Noise...2653
          Circuit Description...2653
          Conditions for setting the DTC...2653
        DTC 143 - Never Crank Synced At Start...2657
          Circuit Description...2657
          Conditions for Setting the DTC...2657
        DTC 144 - Camshaft Sensor Loss...2660
          Circuit Description...2660
          Conditions for Setting the DTC...2660
        DTC 145 - Camshaft Sensor Noise...2663
          Circuit Description...2663
          Conditions for Setting the DTC...2663
        DTC 211 - Closed Loop Multiplier High (LPG)...2666
          Circuit Description...2666
          Conditions for Setting the DTC...2666
          Diagnostic Aids...2667
        DTC 212 - HO 2 S Open/Inactive...2669
          Circuit Description...2669
          Conditions for Setting the DTC...2669
        DTC 221 - Closed Loop Multiplier High (Gasoline)...2672
          Circuit Description...2672
          Conditions for Setting the DTC...2672
          Diagnostic Aids...2672
        DTC 222 - Closed Loop Multiplier Low (Gasoline)...2675
          Circuit Description...2675
          Conditions for Setting the DTC...2675
          Diagnostic Aids...2675
        DTC 224 - Closed Loop Multiplier Low (LPG)...2677
          Circuit Description...2677
          Conditions for Setting the DTC...2677
          Diagnostic Aids...2678
        DTC 241 - Adaptive Lean Fault (High Limit-Gasoline)...2679
          Circuit Description...2679
          Conditions for Setting the DTC...2679
          Diagnostic Aids...2679
        DTC 242 - Adaptive Rich Fault (Low Limit-Gasoline)...2682
          Circuit Description...2682
          Conditions for Setting the DTC...2682
          Diagnostic Aids...2682
        DTC 243 - Adaptive Learn High (LPG)...2685
          Circuit Description...2685
          Conditions for Setting the DTC...2685
          Diagnostic Aids...2685
        DTC 244 - Adaptive Learn Low (LPG)...2688
          Circuit Description...2688
          Conditions for Setting the DTC...2688
          Diagnostic Aids...2688
        DTC 261 - System Voltage High...2691
          Circuit Description...2691
          Conditions for Setting the DTC...2691
        DTC 262 - System Voltage Low...2693
          Circuit Description...2693
          Conditions for Setting the DTC...2693
        DTC 511 - COP Failure...2695
          Circuit Description...2695
          Conditions for Setting the DTC...2695
        DTC 512 - Invalid Interrupt...2697
          Circuit Description...2697
          Conditions for Setting the DTC...2697
        DTC 513 - A/D Loss...2699
          Circuit Description...2699
          Conditions for Setting the DTC...2699
        DTC 514 - RTI 1 Loss...2701
          Circuit Description...2701
          Conditions for Setting the DTC...2701
        DTC 515 - Flash Checksum Invalid...2703
          Circuit Description...2703
          Conditions for Setting the DTC...2703
        DTC 516 - Ram Failure...2705
          Circuit Description...2705
          Conditions for Setting the DTC...2705
        DTC 531 - External 5V Ref Lower Than Expected...2707
          Circuit Description...2707
          Conditions for Setting the DTC...2707
        DTC 532 - External 5V Ref Higher Than Expected...2709
          Circuit Description...2709
          Conditions for Setting the DTC...2709
        DTC 555 - RTI 2 Loss...2711
          Circuit Description...2711
          Conditions for Setting the DTC...2711
        DTC 556 - RTI 3 Loss...2713
          Circuit Description...2713
          Conditions for Setting the DTC...2713
        DTC 611 - FPP High Voltage...2715
          Circuit Description...2715
          Conditions for Setting the DTC...2715
        DTC 612 - FPP Low Voltage...2719
          Circuit Description...2719
          Conditions for Setting the DTC...2719
        DTC 631 - TPS1 Signal Voltage High...2723
          Circuit Description...2723
          Conditions for Setting the DTC...2723
        DTC 632 - TPS1 Signal Voltage Low...2726
          Circuit Description...2726
          Conditions for Setting the DTC...2726
        DTC 638 - Throttle Unable To Close...2729
          Circuit Description...2729
          Conditions for Setting the DTC...2729
          Diagnostic Aids...2730
        DTC 651 - Maximum Govern Speed Override...2732
          Circuit Description...2732
          Conditions for Setting the DTC...2732
          Diagnostic Aids...2732
        DTC 652 - Fuel Rev Limit...2735
          Circuit Description...2735
          Conditions for Setting the DTC...2735
          Diagnostic Aids...2735
        DTC 653 - Spark Rev Limit...2737
          Circuit Description...2737
          Conditions for Setting the DTC...2737
          Diagnostic Aids...2737
      Wire Harness Repair...2740
        On Vehicle Service Wiring Harness Repair...2740
        Connectors and Terminals...2741
          Twisted/Shielded Cable Repair...2741
          Twisted Leads Repair...2742
          Micro-Pack...2743
          Metri-Pack...2743
            Remove...2743
          Weather-Pack...2745
            Weather-Pack Terminal Repair...2746
    tables...2418
      Table 1. OBD System Check...2438
      Table 2. Preliminary Checks...2440
      Table 3. Intermittent Checks...2441
      Table 4. Communication Port C002...2442
      Table 5. Coil Connector C003...2442
      Table 6. Fuel System Interface C004...2442
      Table 7. Oil Pressure Connector C005...2443
      Table 8. Distributor Connector C006...2443
      Table 9. Magnetic Pickup Connector C007...2443
      Table 10. Heated Oxygen Sensor C008...2443
      Table 11. Throttle Position Sensor Connector C009...2444
      Table 12. Foot Pedal Position Connector C010...2444
      Table 13. Governor Motor Connector C011...2444
      Table 14. TMAP Connector C012...2444
      Table 15. Starter Solenoid C013...2445
      Table 16. Engine Coolant Temperature C014...2445
      Table 17. Battery Connector C015...2445
      Table 18. Alternator Connection C016...2445
      Table 19. Battery Connector C017...2445
      Table 20. Alternator Connector C018...2446
      Table 21. Instrument Panel Connector C019...2446
      Table 22. Instrument Panel Connector C020...2446
      Table 23. Instrument Panel Connector C021...2447
      Table 24. Fuel Trim Valve Connector C022...2447
      Table 25. Fuel Lockoff Connector C023...2447
      Table 26. Pressure Trim Valve Connector C024...2448
      Table 27. Throttle Body Injector Connector C025...2448
      Table 28. Relay and Fuse Center...2448
      Table 29. DTC 111 - IAT Voltage High (Motorola® TMAP)...2457
      Table 30. DTC 112 - IAT Low Voltage (Motorola® TMAP)...2460
      Table 31. DTC 115 - Oil Pressure Low...2465
      Table 32. Temperature Resistance...2467
      Table 33. DTC 121 - ECT VOLTAGE HIGH...2468
      Table 34. DTC 122 - ECT Voltage Low...2472
      Table 35. DTC 123 - ECT Higher Than Expected 1...2474
      Table 36. DTC 124 - ECT Higher Than Expected 2...2476
      Table 37. DTC 131 - MAP HIGH PRESSURE (Motorola® TMAP)...2478
      Table 38. DTC 132 - MAP Low Voltage (Motorola® TMAP)...2481
      Table 39. DTC 134 - BP High Pressure (Motorola® TMAP)...2484
      Table 40. DTC 135 - BP Low Pressure (Motorola® TMAP)...2486
      Table 41. DTC 142 - Crank Sync Noise...2490
      Table 42. DTC 143 - Never Crank Synced At Start...2493
      Table 43. DTC 144 - Camshaft Sensor Loss...2496
      Table 44. DTC 145 - Camshaft Sensor Noise...2499
      Table 45. DTC 211 - Closed Loop Multiplier High (LPG)...2503
      Table 46. DTC 212 - HO 2 S Open/Inactive...2506
      Table 47. DTC 221 - Closed Loop Multiplier High (Gasoline)...2509
      Table 48. DTC 222 - Closed Loop Multiplier Low (Gasoline)...2512
      Table 49. DTC 224 - Closed Loop Multiplier Low (LPG)...2514
      Table 50. DTC 241 - Adaptive Lean Fault (High Limit-Gasoline)...2516
      Table 51. DTC 242 - Adaptive Rich Fault (Low Limit-Gasoline)...2519
      Table 52. DTC 243 - Adaptive Learn High (LPG)...2522
      Table 53. DTC 244 - Adaptive Learn Low (LPG)...2525
      Table 54. DTC 261 - System Voltage High...2528
      Table 55. DTC 262 - System Voltage Low...2529
      Table 56. DTC 411 - Injector Driver 1 Open...2532
      Table 57. DTC 412 - Injector Driver 1 Shorted...2535
      Table 58. DTC 511 - COP Failure...2538
      Table 59. DTC 512 - Invalid Interrupt...2540
      Table 60. DTC 513 - A/D Loss...2542
      Table 61. DTC 514 - RTI 1 Loss...2544
      Table 62. DTC 515 - Flash Checksum Invalid...2546
      Table 63. DTC 516 - Ram Failure...2548
      Table 64. DTC 531 - External 5V Ref Lower Than Expected...2550
      Table 65. DTC 532 - External 5 V Ref Higher Than Expected...2552
      Table 66. DTC 555 - RTI 2 Loss...2554
      Table 67. DTC 556 - RTI 3 Loss...2556
      Table 68. DTC 611 - FPP High Voltage...2558
      Table 69. DTC 612 - FPP Low Voltage...2562
      Table 70. DTC 631 - TPS1 Signal Voltage High...2566
      Table 71. DTC 632 - TPS1 Signal Voltage Low...2569
      Table 72. DTC 638 - Throttle Unable To Close...2572
      Table 73. DTC 651 - Maximum Govern Speed Override...2575
      Table 74. DTC 652 - Fuel Rev Limit...2578
      Table 75. DTC 653 - Spark Rev Limit...2580
      Table 76. Communication Port C002...2583
      Table 77. Injector Connector C003...2583
      Table 78. Injector Connector C004...2583
      Table 79. Oil Pressure Connector C005...2584
      Table 80. Throttle Position Sensor 1 Connector C006...2584
      Table 81. Foot Pedal Position Connector C006A...2584
      Table 82. Coil Connector C007...2584
      Table 83. Module Connector C008...2585
      Table 84. Crank Sensor Connector C009...2585
      Table 85. EGO Sensor Connector C010...2585
      Table 86. Cam Connector C011...2586
      Table 87. Throttle Connector C012...2586
      Table 88. Bosch TMAP Connector C013 (Gasoline Fuel System Only)...2586
      Table 89. Motorola TMAP Connector C013 (LPG Fuel System Only)...2587
      Table 90. Starter Solenoid Connector C014...2587
      Table 91. ECT Connector C015...2587
      Table 92. Starter Relay C016...2587
      Table 93. Power Relay C017...2587
      Table 94. Fuel Pump Relay C018...2587
      Table 95. Battery Connector C019...2588
      Table 96. Alternator Connector C020...2588
      Table 97. Alternator Connector C021...2588
      Table 98. Instrument Panel Connector C022...2588
      Table 99. Instrument Panel Connector C023...2589
      Table 100. Instrument Panel Connector C024...2589
      Table 101. Fuel Trim Valve Connector C025...2589
      Table 102. Fuel Lockoff Connector C026...2590
      Table 103. Pressure Trim Valve Connector C027...2590
      Table 104. Injector 1 Connector C028...2590
      Table 105. Injector 2 Connector C029...2591
      Table 106. Injector 3 Connector C030...2591
      Table 107. Injector 4 Connector C031...2591
      Table 108. Injector 5 Connector C032...2592
      Table 109. Injector 6 Connector C033...2592
      Table 110. Relay and Fuse Center...2592
      Table 111. DTC 111 - IAT Voltage High (Bosch® TMAP)...2601
      Table 112. DTC 111 - IAT Voltage High (Motorola® TMAP)...2604
      Table 113. DTC 112 - IAT Low Voltage (Bosch® TMAP)...2606
      Table 114. DTC 112 - IAT Low Voltage (Motorola® TMAP)...2609
      Table 115. DTC 115 - Oil Pressure Low...2615
      Table 116. Temperature Resistance...2618
      Table 117. DTC 121 - ECT VOLTAGE HIGH...2619
      Table 118. DTC 122 - ECT Voltage Low...2622
      Table 119. DTC 123 - ECT Higher Than Expected 1...2625
      Table 120. DTC 124 - ECT Higher Than Expected 2...2627
      Table 121. DTC 131 - MAP High Pressure (Bosch® TMAP)...2628
      Table 122. DTC 131 - MAP HIGH PRESSURE (Motorola® TMAP)...2632
      Table 123. DTC 132 - MAP Low Voltage (Bosch® TMAP)...2635
      Table 124. DTC 132 - MAP Low Voltage (Motorola® TMAP)...2638
      Table 125. DTC 134 - BP High Pressure (Bosch® TMAP)...2643
      Table 126. DTC 134 - BP High Pressure (Motorola® TMAP)...2645
      Table 127. DTC 135 - BP Low Pressure (Bosch® TMAP)...2646
      Table 128. DTC 135 - BP Low Pressure (Motorola® TMAP)...2650
      Table 129. DTC 142 - Crank Sync Noise...2654
      Table 130. DTC 143 - Never Crank Synced At Start...2657
      Table 131. DTC 144 - Camshaft Sensor Loss...2660
      Table 132. DTC 145 - Camshaft Sensor Noise...2663
      Table 133. DTC 211 - Closed Loop Multiplier High (LPG)...2667
      Table 134. DTC 212 - HO 2 S Open/Inactive...2670
      Table 135. DTC 221 - Closed Loop Multiplier High (Gasoline)...2673
      Table 136. DTC 222 - Closed Loop Multiplier Low (Gasoline)...2676
      Table 137. DTC 224 - Closed Loop Multiplier Low (LPG)...2678
      Table 138. DTC 241 - Adaptive Lean Fault (High Limit-Gasoline)...2680
      Table 139. DTC 242 - Adaptive Rich Fault (Low Limit-Gasoline)...2683
      Table 140. DTC 243 - Adaptive Learn High (LPG)...2686
      Table 141. DTC 244 - Adaptive Learn Low (LPG)...2689
      Table 142. DTC 261 - System Voltage High...2692
      Table 143. DTC 262 - System Voltage Low...2693
      Table 144. DTC 511 - COP Failure...2696
      Table 145. DTC 512 - Invalid Interrupt...2698
      Table 146. DTC 513 - A/D Loss...2700
      Table 147. DTC 514 - RTI 1 Loss...2702
      Table 148. DTC 515 - Flash Checksum Invalid...2704
      Table 149. DTC 516 - Ram Failure...2706
      Table 150. DTC 531 - External 5V Ref Lower Than Expected...2708
      Table 151. DTC 532 - External 5 V Ref Higher Than Expected...2710
      Table 152. DTC 555 - RTI 2 Loss...2712
      Table 153. DTC 556 - RTI 3 Loss...2714
      Table 154. DTC 611 - FPP High Voltage...2716
      Table 155. DTC 612 - FPP Low Voltage...2719
      Table 156. DTC 631 - TPS1 Signal Voltage High...2724
      Table 157. DTC 632 - TPS1 Signal Voltage Low...2727
      Table 158. DTC 638 - Throttle Unable To Close...2730
      Table 159. DTC 651 - Maximum Govern Speed Override...2733
      Table 160. DTC 652 - Fuel Rev Limit...2736
      Table 161. DTC 653 - Spark Rev Limit...2739
  1559550-2200SRM1097-(07-2008)-UK-EN...2750
    toc...2750
      High Voltage Switch (HVS) Ignition...2750
      Safety Precautions Maintenance and Repair...2751
      Description...2754
        Distributor Ignition (DI) System...2754
        Crankshaft Position (CKP) Sensor...2754
        Camshaft Position (CMP) Sensor...2754
        Ignition Coil and Ignition Control Module (ICM)...2754
        Secondary Ignition Components...2754
      Spark Plugs and Wires...2754
        Spark Plug Wire Inspection...2754
        Spark Plug Wire Replacement...2754
          Remove...2754
          Install...2755
        Spark Plug Inspection...2755
          Usage...2755
          Inspection...2755
          Visual Inspection...2757
        Spark Plug Replacement...2757
          Remove...2757
          Install...2758
      Distributor Repair...2758
        Inspect...2758
        Overhaul...2759
          Disassemble...2759
          Assemble...2761
        Replace...2762
          Remove...2762
          Install Procedure 1...2764
          Install Procedure 2...2764
      Ignition Coil Replacement...2766
        Remove...2766
        Install...2766
      Ignition Control Module Replacement...2767
        Remove...2767
        Install...2767
      Camshaft Position (CMP) Sensor Replacement...2768
        Remove...2768
        Install...2769
      Crankshaft Position (CKP) Sensor Replacement...2770
        Remove...2770
        Install...2770
      Wire Harness Repair...2771
        On Vehicle Service Wiring Harness Repair...2771
        Connectors and Terminals...2771
          Twisted/Shielded Cable Repair...2772
          Twisted Leads Repair...2773
          Micro-Pack...2774
          Metri-Pack...2774
            Remove...2774
          Weather-Pack...2776
            Weather-Pack Terminal Repair...2776
      Specifications and Special Tools...2778
      System Diagnosis...2779
    tables...2750
      Table 1. Ignition System Specifications...2778
      Table 2. Fastener Tightening Specifications...2778
      Table 3. Special Tools...2779
      Table 4. Distributor Ignition (DI)...2779
  897104-0100SRM0322-(02-2007)-UK-EN...2788
    toc...2788
      Frame...2788
      Safety Precautions Maintenance and Repair...2789
      General...2792
      Description...2792
      Counterweight Repair...2793
        Remove...2793
        Install...2793
      Hood Repair...2794
        Remove...2794
        Install...2794
      Overhead Guard Repair...2794
        Remove...2794
        Install...2794
      Operator Restraint System Repair...2795
        Automatic Locking Retractor (ALR)...2795
        Emergency Locking Retractor (ELR)...2795
      Hydraulic Tank Repair...2797
        Remove...2797
        Inspect...2797
        Small Leaks Repair...2797
        Large Leaks Repair...2797
        Clean...2797
          Steam Method...2798
          Chemical Solution Method...2798
        Other Methods of Preparation for Repair...2798
        Install...2798
      Fuel Tank Repair...2799
        Remove...2799
        Repair...2799
        Install...2799
      Radiator Repair...2799
        Remove...2799
        Install...2799
      Engine Repair...2800
        Remove...2800
        Install...2800
      Throttle Pedal Adjustment...2802
        Perkins 1104C-44(RE) Diesel Engine...2802
      Safety Labels...2803
      Cab Repair...2805
        Cab, Replace...2805
        Window, Replace...2805
        Windshield Wipers and Heater...2805
    tables...2788
      Table 1. Material Specifications for Cab Windows...2807
  897106-1300SRM0324-(10-2003)-UK-EN...2810
    toc...2810
      Two-Speed Powershift Transmission...2810
      Safety Precautions Maintenance and Repair...2811
      General...2814
      Mechanical Description...2814
        Torque Converter...2814
        Transmission Pump...2815
        Shaft Assemblies...2815
        Input Shaft...2816
        Forward Clutch Shaft...2816
        Clutch Assemblies...2816
        Countershaft...2823
        Output Shaft...2823
      Hydraulic Operation...2824
        Torque Converter...2824
        Seal Rings...2825
      Control Valve...2825
        System Pressure Regulator...2828
        Clutch Pressure Regulator...2828
        Torque Converter Regulator...2829
        Inching Spool...2829
        Direction Spool, Direction Control Lever...2829
        Direction Spool, MONOTROL Pedal...2830
        Range Spool...2830
        Drain Spool...2831
        Accumulator...2831
        Modulator Spool...2831
        Operation...2831
      Lubrication Circuit...2832
      MONOTROL Pedal...2832
      Oil Flow Diagrams...2834
        Neutral...2834
        Forward-Low...2835
        Forward-Low-Inching...2836
        Reverse-Low...2837
  897107-1300SRM0325-(10-2003)-UK-EN...2840
    toc...2840
      Two-Speed Powershift Transmission...2840
      Safety Precautions Maintenance and Repair...2841
      General...2844
      Transmission Repair...2844
        Transmission and Torque Converter, Remove...2844
        Transmission, Disassemble...2846
        Reverse-Low Clutch, Disassemble...2849
        Reverse-High Clutch, Disassemble...2852
        Forward-Low Clutch, Disassemble...2855
        Forward-High Clutch, Disassemble...2858
        Clean and Inspect...2860
      Forward Low and High Clutches Assembly...2861
        Forward Clutches, Assemble...2863
        Reverse-Low Clutch, Assemble...2869
        Reverse Clutches, Assemble...2871
        Transmission, Assemble...2878
        Torque Converter, Install...2885
      Control Valve Repair...2886
        Remove...2886
        Disassemble...2887
        Assemble...2888
        Install...2890
      MONOTROL Pedal...2890
        Remove and Disassemble...2890
        Assemble and Install...2890
      Stall Test...2893
      Linkage Adjustments...2894
        Linkage for Inching Pedal H6.00-7.00XL (H135-155XL, H135-155XL 2...2894
        Linkage for Inching Pedal S6.00-7.00XL (S135-155XL, S135-155XL 2...2897
        Linkage for Range Lever - Early Model H6.00-7.00XL (H135-155XL) ...2900
        Linkage for Direction Control Lever - Early Model H6.00-7.00XL (...2900
        Linkage for Range Lever - Later Model H6.00-7.00XL (H135-155XL, ...2902
        Linkage for Direction Control Lever - Later Model H6.00-7.00XL (...2904
        Linkage for Range Lever S6.00-7.00XL (S135-155XL, S135-155XL 2 )...2906
        Linkage for Direction Control Lever S6.00-7.00XL (S135-155XL, S1...2906
      Oil Pressure Check...2908
        System Pressure Check Port...2908
        Torque Converter Check Port...2908
        Clutch Pressure Check Port...2908
        Inching Pressure...2909
        Solenoid Check Ports (MONOTROL Control Only)...2909
        Lubrication Pressure Check Ports...2909
      Specifications...2910
      Troubleshooting...2910
        Correct System Pressure: 1300 ±124 kPa ( 189 ±18 psi)...2913
        Correct Clutch Pressure: 924 ±69 kPa ( 134 ±10 psi)...2914
        Correct Solenoid Pressure (MONOTROL Only): 965 ±138 kPa ( 140 ±2...2915
        Torque Converter Pressure: 834 ±69 kPa ( 121 ±10 psi)...2915
        Lubrication Pressure: 83 ±21 kPa ( 12 ±3 psi)...2915
    tables...2840
      Table 1. Stall Speed Specifications...2893
  897108-1600SRM0326-(03-2007)-UK-EN...2918
    toc...2918
      Steering Axle...2918
      Safety Precautions Maintenance and Repair...2919
      General...2922
      Description...2922
      Steering Axle Assembly Repair...2927
        Steering Axle H3.50-5.00XL (H70-110XL) (G005), S3.50-5.50XL (S70...2927
          Remove...2927
          Install...2927
        Steering Axle H6.00-7.00XL (H135-155XL, H135-155XL 2 ) (F006, G0...2928
          Remove...2928
          Install...2928
      Wheels and Hubs Repair (All Units)...2929
        Remove and Disassemble...2929
        Clean...2929
        Inspect...2929
        Assemble and Install...2929
      Spindles and Bearings Repair (All Units)...2931
        Remove...2931
        Clean...2931
        Assemble and Install...2932
      Tie Rods Repair (All Units)...2933
        Remove...2933
        Clean...2933
        Install...2933
      Steering Cylinder Repair...2936
        Remove and Disassemble...2936
        Clean and Inspect...2936
        Assemble and Install...2936
      Troubleshooting...2937
  897109-1800SRM0327-(09-2003)-UK-EN...2942
    toc...2942
      Brake System...2942
      Safety Precautions Maintenance and Repair...2943
      General...2946
      Description...2946
      Operation...2947
        Brake Booster and Master Cylinder...2947
          Brake Booster...2947
          Master Cylinder...2948
        Service Brake Assembly...2949
        Parking Brake...2950
      Brake Shoe Assemblies Repair...2951
        Remove and Disassemble...2951
        Clean and Inspect...2952
          Cleaning Procedures...2952
          Inspect...2952
        Assemble and Install...2953
      Master Cylinder Repair...2954
        Remove...2954
        Disassemble...2954
        Assemble...2956
        Install...2956
      Brake Booster Repair...2956
        Remove...2956
        Disassemble...2956
        Clean and Inspect...2958
        Assemble...2958
        Install...2958
      Brake System Air Removal...2958
      Brake Pedal Adjustment...2959
      Brake Shoes Adjustment...2960
      Parking Brake Adjustment...2960
      Parking Brake Switch Adjustment...2960
      Brake Booster Relief Valve Check...2960
      Troubleshooting...2961
  897110-1900SRM0328-(09-2003)-UK-EN...2966
    toc...2966
      Hydraulic System...2966
      Safety Precautions Maintenance and Repair...2967
      General...2970
      Description and Operation...2970
        Hydraulic Pumps...2972
        Main Control Valve...2972
        Control Valve Lever...2973
        Steering Control Unit...2973
        Brake Valve...2973
        Oil Clutch, H6.00-7.00XL (H135-155XL) (F006)...2974
      Troubleshooting...2974
        Lift, Lower, and Tilt Circuit...2975
        Steering, Brake, and Oil Clutch System...2976
  897111-4000SRM0329-(10-2003)-UK-EN...2980
    toc...2980
      Masts...2980
      Safety Precautions Maintenance and Repair...2981
      General...2984
      Description and Operation...2984
        General...2984
        Safety Procedures When Working Near Mast...2985
        Two-Stage Mast...2985
        Three-Stage Mast...2987
      Carriage Repair...2989
        Remove...2989
        Sideshift Carriage, Disassemble...2989
        Sideshift Carriage, Assemble...2990
        Install...2990
      Two-Stage Mast Repair...2992
        Remove...2992
        Disassemble...2993
        Clean and Inspect...2994
        Assemble...2995
        Install...2995
      Three-Stage Mast Repair...2997
        Remove...2997
        Disassemble...2997
        Clean and Inspect...2997
        Assemble...2997
        Install...2999
      Mast Operation Check...2999
      Lift and Tilt System Leaks Check...3000
        Lift System...3000
        Tilt System...3000
      Tilt Cylinder Stroke and Backward Tilt Angle Adjustment...3001
      Lift Chain Adjustments...3001
      Mast Adjustments...3004
      Carriage Adjustment...3004
      Troubleshooting...3006
    tables...2980
      Table 1. Mast Parts Weight...2993
      Table 2. Hook-Type Carriage Chain Adjustment...3002
      Table 3. Pin-Type Carriage Chain Adjustment...3002
  897113-8000SRM0331-(09-2003)-UK-EN...3010
    toc...3010
      Capacities and Specifications...3010
      Safety Precautions Maintenance and Repair...3011
      Lift Truck Weights...3014
      Capacities...3014
      Tire Sizes...3015
      Tire Pressure...3015
      Electrical System...3015
      Wheel Nut Torque...3015
      Engine Specifications...3016
      Hydraulic System...3016
      Mast Speeds...3017
      Transmission Oil Pressures...3017
      Torque Specifications...3018
        Engine - GM 4.3L V-6...3018
        Engine - Perkins 4.2482...3018
        Engine - Perkins 1004.4...3018
        Clutch...3018
        Manual Transmission...3019
        Powershift Transmission...3019
        Speed Reducer...3019
        Drive Axle...3019
        Steering System...3019
        Brake System...3019
        Hydraulic System...3020
        Tilt Cylinder...3020
        Mast...3020
  897123-8000SRM0341-(06-2007)-UK-EN...3024
    toc...3024
      Periodic Maintenance...3024
      Safety Precautions Maintenance and Repair...3025
      General...3030
        Serial Number Data...3030
        How to Move Disabled Truck...3030
          How to Tow Lift Truck...3030
        How to Put Lift Truck on Blocks...3031
          How to Raise Drive Tires...3031
          How to Raise Steering Tires...3031
      Maintenance Schedule...3032
      Maintenance Procedures Every 8 Hours or Daily...3045
        How to Make Checks With Engine Stopped...3045
          Hydraulic System Oil...3045
          Engine Oil...3047
          Drive Belts...3047
          Intake Manifold Rubber Cap...3048
          Cooling System...3048
          Air Filter...3048
          Fuel System...3049
          Primary Fuel Filter, Diesel Engine...3049
          Battery...3049
          Tires and Wheels...3049
          Forks...3050
            Adjust...3050
            Remove and Install...3052
          Forks, Mast, and Lift Chains, Inspect...3053
          Operator Restraint System...3054
            Automatic Locking Retractor (ALR)...3054
            Emergency Locking Retractor (ELR)...3054
          Safety Labels...3055
        How to Make Checks With Engine Running...3056
          Gauges, Lights, Horn, and Fuses...3056
          Oil Level, Powershift Transmission...3057
          Oil Level, Oil Clutch System, H3.50-5.00XL (H70-110XL)...3058
          Control Levers and Pedals...3058
          Lift System Operation...3058
          Inching/Brake Pedal...3058
          Service Brakes...3058
          Parking Brake...3059
          Steering System...3059
      Maintenance Procedures Every 250 Hours or 6 Weeks...3059
        Engine Oil and Filter, GM V-6 Engine...3059
        Lift Chains, Lubrication...3059
        Drive Shafts...3059
        Mast Lubrication...3060
        Crankcase Breather, GM V-6...3061
        Air Filter, GM V-6 EPA Compliant Engine ...3061
      Maintenance Procedures Every 350 Hours or 2 Months...3062
        Engine Oil and Filter, Perkins 4.2482 Diesel Engine...3062
        Drive Belts...3062
          Perkins Diesel Engine...3062
          GM V-6 Engine (Early Models)...3062
          GM V-6 Engine (Late Models)...3063
        Brake Fluid...3065
        Lift Chains Wear Check...3065
        Forks Wear and Damage Check...3065
        Steering Axle Lubrication...3065
        Fuel System, Checks and Adjustments...3066
          Diesel Fuel System...3066
          LPG Carburetor (Early Models)...3066
          Gasoline Carburetor (Early Models)...3067
          Fuel Injection (Late Models)...3067
        Crankcase Breather, Perkins 4.2482 Diesel Engine...3067
        Hydraulic Tank Breather...3067
        Cooling System, Clean Debris from Radiator Core...3067
      Maintenance Procedures Every 500 Hours or 3 Months...3068
        Engine Oil and Filter, Perkins Diesel Engine...3068
        Crankcase Breather, Perkins Diesel Engine...3068
        PCV Valve, GM V-6...3068
      Maintenance Procedures Every 1000 Hours or 6 Months...3068
        Manifold Heat Valve, GM V-6 (Early Models)...3068
        Ignition System, GM V-6...3068
        Valve Clearance Adjustment...3068
        Fuel Filter, Replace (Diesel Engine)...3069
        Fuel System Air Removal (Perkins 1004-4 Diesel Engine)...3069
          Fuel Injection Pump With Vent Tube...3069
          Fuel Injection Pump With Vent Screw...3070
        Fuel System Air Removal (Perkins 4.2482 Diesel Engine)...3072
        Oil Level Check in Transmission...3072
          Manual Transmission, H3.50-5.00XL (H70-110XL)...3072
          Speed Reducer for Powershift Transmission, H3.50-5.00XL (H70-110...3072
          Manual Transmission, H6.00-7.00XL (H135-155XL)...3072
          Differential and Drive Axle for Powershift Transmission, H6.00-7...3072
          Differential, Speed Reducer, and Drive Axle for Manual Transmiss...3073
        Control Levers and Pedals, Lubricate...3073
        Crankcase Breather, Replace...3073
        Cooling System, GM V-6 EPA Compliant Engine...3073
        Spark Plug Replacement...3073
          Remove...3073
          Install...3074
        LPG Fuel Filter GM V-6 EPA Compliant Engine, Replace...3074
        Inspect Engine Electrical System, Connectors, and FCVS Connectio...3075
      Maintenance Procedures Every 2000 Hours or Yearly...3075
        Hydraulic System...3075
          Hydraulic Oil and Filter, H3.50-5.00XL (H70-110XL), Replace...3075
          Hydraulic Oil and Filter, H6.00-7.00XL (H135-155XL, H135-155XL 2...3076
        Oil Change and Oil Filter Replacement, Powershift Transmission, ...3076
        Oil Change, Manual Transmission, H3.50-5.00XL (H70-110XL)...3076
        Oil Change, Manual Transmission, H6.00-7.00XL (H135-155XL)...3076
        Oil Change, Speed Reducer, Powershift Transmission, H3.50-5.00XL...3076
        Oil and Filter Change, Oil Clutch System, H3.50-5.00XL (H70-110X...3077
        Oil Change, Differential and Drive Axle, Powershift Transmission...3077
        Oil Change, Differential, Speed Reducer, and Drive Axle, Manual ...3077
        Cooling System...3077
        PCV Valve, GM V-6...3077
        Service Brakes...3078
        LPG Filter, Replace...3078
        Gasoline Fuel Filter, Replace...3079
        Hood Latch Check, H3.50-5.00XL (H70-110XL)...3079
        Air Filter Element, GM V-6 EPA Compliant Engine...3079
        Oxygen Sensor GM V-6 EPA Compliant Engine...3079
        Inspect Low Pressure Regulator (LPR) for Oil Buildup and Leaks...3080
        Check Throttle Shaft for Sticking...3081
        Inspect Exhaust Manifold and Piping for Leaks...3081
        Test LPG/GAS Regulator Pressure...3081
      Safety Procedures When Working Near Mast...3081
      Lift Chain Adjustments...3083
      Fuel Injectors Repair...3085
      Lift and Tilt System Leak Check...3086
        Lift Cylinders, Leak Check...3086
        Tilt Cylinders, Leak Check...3086
      Welding Repairs...3087
      Overhead Guard Changes...3087
      Wheel and Tire Replacement...3088
        Remove Wheels From Lift Truck...3088
        Remove Wheels From Tire...3088
          Remove Tire From Two-Piece Wheel...3090
          Remove Tire From Three- and Four-Piece Wheels...3092
        Install Wheel in Tire...3093
          Install Three- or Four-Piece Wheel in Tire...3094
          Install Two-Piece Wheel in Tire...3095
        Add Air to Pneumatic Tires...3096
        Wheels, Install...3096
      Solid Rubber Tires Repair...3097
        Wheel, Tire Remove...3097
        Wheel, Tire Install...3099
        SIT Tire, Change for H3.50-5.00XL (G005), and H6.00-7.00XL (F006...3101
          Remove SIT Solid Tire From Wheel...3101
          Install SIT Solid Tire on Wheel...3102
      Adhesives and Sealants...3103
      Hydraulic Oil, Lubricant, and Coolant Specifications...3104
    tables...3024
      Table 1. Maintenance Schedule...3034
      Table 2. Hook-Type Carriage Chain Adjustment...3084
      Table 3. Pin-Type Carriage Chain Adjustment...3084
  897501-8000SRM0519-(06-2007)-UK-EN...3108
    toc...3108
      Diagrams...3108
      Safety Precautions Maintenance and Repair...3109
  897800-0600SRM0590-(08-2005)-UK-EN...3196
    toc...3196
      GM Engines...3196
      Safety Precautions Maintenance and Repair...3197
      General...3200
      Description...3200
      Engine Removal and Installation...3201
      Cylinder Head Repair...3201
        Remove and Disassemble...3201
        Clean and Inspect...3201
        Valve Guides and Seats, Repairs...3202
        Valves, Repair...3202
        Valve Seats, Repair...3203
        Valve Springs...3203
        Rocker Arm Studs (Early Models)...3205
        Rocker Arm Studs (Late Models)...3205
        Assemble and Install...3206
      Cylinder Block Cleaning and Inspection...3209
      Piston Bore Preparation...3209
      Engine Mounts Installation...3210
      Lubrication System Repair...3210
        Oil Pump, Remove and Disassemble...3210
        Clean and Inspect...3210
        Oil Pump, Assemble and Install...3211
        Oil Sump, Install...3211
      Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters...3212
        Timing Cover...3212
          Remove...3212
          Install...3214
        Timing Sprockets...3214
          Remove...3214
          Install...3214
        Camshaft...3215
          Remove...3215
          Inspect...3215
          Install...3215
        Balance Shaft...3216
          Remove...3216
          Install...3217
        Hydraulic Valve Lifters...3217
          Remove...3217
          Disassemble...3218
          Clean and Inspect...3218
          Assemble...3218
          Install...3219
      Crankshaft Repair...3220
        Remove...3220
        Inspect and Repair...3220
        How to Check Clearance Between Main Bearings and Their Journals...3221
        Install...3222
      Piston and Connecting Rod Assemblies Repair...3223
        Connecting Rod Bearings, Replace...3223
        Piston and Connecting Rod Assemblies, Remove...3224
        Disassemble...3224
        Piston, Clean and Inspect...3225
        Cylinder Bores, Inspect and Repair...3225
        Piston Rings...3226
        Assemble...3227
        Piston and Connecting Rod Assemblies, Install...3227
      Flywheel and Flywheel Housing Repair...3228
        Flywheel, Repair...3228
        Flywheel, Install...3228
          H3.50-5.00XL (H70-110XL), S3.50-5.50XL (S70-120XL), S6.00-7.00XL...3228
          H6.00-7.00XL (H135-155XL)...3228
        Flywheel Housing H3.50-5.00XL (H70-110XL), H3.50-5.50XM (H70-120...3228
        Engine Adapter H6.00-7.00XL (H135-155XL)...3228
      Coolant Pump Repair...3229
      Thermostat Replacement...3229
      Fan Mount Repair (Early Models)...3229
      Fan Mount Assembly Repair (Late Models)...3229
      Drive Belt Installation...3231
      Valve Clearance Adjustment (Early Models)...3232
      Valve Clearance Adjustment (New Models)...3233
      Compression Check...3233
      Engine Specifications...3234
        Engine Data...3234
        Cylinder Head...3234
        Hydraulic Valve Lifter...3235
        Camshaft...3235
        Pistons...3235
        Crankshaft...3236
        Connecting Rods...3236
        Balance Shaft...3237
        Cooling System...3237
        Lubrication System...3237
      Torque Specifications...3237
      Troubleshooting...3238
    tables...3196
      Table 1. Piston Rings Arrangement on Piston...3227
  897934-0700SRM0626-(11-2001)-UK-EN...3244
    toc...3244
      Cooling System...3244
      Safety Precautions Maintenance and Repair...3245
      General...3248
      Description...3249
        Radiator...3249
        Radiator Cap...3249
        Thermostat...3249
        Water Pump...3250
        Fan and Fan Shroud...3250
      Cooling System Checks...3250
        Radiator...3250
        Thermostat...3250
        Water Pump...3251
        Exhaust Leaks...3251
        Fan and Fan Shroud...3251
      Radiator Cleaning...3251
        Drain...3251
        Clean...3251
        Fill...3252
      Troubleshooting...3253
  899783-2000SRM0090-(10-2003)-UK-EN...3256
    toc...3256
      Main Control Valve...3256
      Safety Precautions Maintenance and Repair...3257
      General...3260
      Description...3260
      Operation...3263
        Lift Spool...3263
        Tilt Spool...3264
          Tilt Backward...3264
          Tilt Forward...3265
        Single-Stage Relief Valve...3267
        Two-Stage Relief Valve...3268
      Main Control Valve Repair...3269
        Remove and Disassemble...3269
        Clean and Inspect...3269
        Assemble...3269
        Install...3270
      Single-Stage Relief Valve Adjustment...3270
      Two-Stage Relief Valve...3271
      Auxiliary Control Valve Relief Valve Adjustment (H60-110E Only)...3271
      Troubleshooting...3272
    tables...3256
      Table 1. Relief Pressures (Oil temperature at 55 to 66 C ( 131 t...3270
  899784-2200SRM0002-(10-2003)-UK-EN...3276
    toc...3276
      Alternator with Regulator...3276
      Safety Precautions Maintenance and Repair...3277
      General...3280
      Description...3280
      Alternator Repair...3282
        Alternator Type A...3282
          Remove and Disassemble...3282
          Clean...3283
          Assemble...3284
          Install...3284
        Alternator Type B...3287
          Remove and Disassemble...3287
          Clean...3287
          Assemble...3288
          Install...3289
      General Check and Adjustment...3290
      Low Output Check (Type A or Type B)...3290
      High Output Check (Type A or Type B)...3292
      Brushes Circuit Check...3293
        Delco Alternators...3293
        Motorola Alternators...3294
      Diodes Check...3295
      Diode Bridge Check...3295
        Delco and Leece-Neville Alternators...3295
        Motorola Alternators...3295
      Rotor Field Winding Check...3296
      Stator Windings Check...3297
      Voltage Regulator Check...3297
      Troubleshooting...3297
  910072-1400SRM0046-(07-2007)-UK-EN...3302
    toc...3302
      Differential...3302
      Safety Precautions Maintenance and Repair...3303
      General...3306
      Description...3306
      Differential Repair...3307
        Remove...3307
          Differential Carrier From Axle Housing, Remove...3307
          Differential and Ring Gear From Differential Carrier, Remove...3309
          Drive Pinion and Pinion Carrier From Differential Carrier, Remov...3311
        Disassemble...3312
          Differential and Ring Gear Assembly, Disassemble...3312
          Drive Pinion and Pinion Carrier, Disassemble...3314
        Clean and Inspect...3317
        Assemble...3318
          Pinion, Bearings, and Pinion Carrier, Assemble...3318
          Pinion Bearings, Adjust Preload...3318
            Press Method...3318
            Yoke or Flange Method...3319
          Triple-Lip Seal, Install...3320
          Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion)...3321
          Differential and Ring Gear, Assemble...3323
          Differential Gears Rotating Torque, Check...3325
          Differential and Ring Gear Assembly, Install...3326
          Differential Bearings, Preload Adjust...3328
          Ring Gear, Runout Check...3329
          Ring Gear Backlash, Adjust...3329
          Gear Set, Tooth Contact Pattern Check...3331
          Thrust Screw, Install and Adjust...3334
        Install...3334
          Differential Assembly Into Axle Housing, Install...3334
      Specifications...3336
      Troubleshooting...3341
    tables...3302
      Table 1. Ring Gear Backlash Adjustment Specifications...3331
      Table 2. Ring and Pinion Tooth Contact Adjustment...3332
      Table 3. General Specifications...3336
      Table 4. Rivet Installation Pressure...3336
      Table 5. Pinion Adjustment...3337
      Table 6. Pinion Preload Pressure...3337
      Table 7. Torque Specifications...3338
      Table 8. Torque Specifications for Metric Hardware...3339
      Table 9. Torque Specifications for Metric (Fine) Hardware...3340
  910073-1400SRM0049-(09-2003)-UK-EN...3344
    toc...3344
      Drive Axle...3344
      Safety Precautions Maintenance and Repair...3345
      General...3348
      Description...3348
      Drive Axle Repair...3349
        Disassemble (Type 1 Shown)...3349
        Clean...3352
        Inspect...3352
        Assemble (Type 1 Shown)...3353
      Torque Specifications...3356
      Troubleshooting...3357
  910076-1600SRM0054-(10-2003)-UK-EN...3360
    toc...3360
      Steering Control Unit...3360
      Safety Precautions Maintenance and Repair...3361
      General...3364
      Description...3364
      Operation...3364
      Steering Wheel and Column Assembly Repair...3366
      Steering Column Assembly Repair...3366
        Type A Steering Column Assembly...3366
          Remove and Disassemble...3366
          Assemble and Install...3368
        Type B Steering Column Assembly...3370
          Remove and Disassemble...3370
          Assemble and Install...3370
          Steering Control Unit...3373
            Disassemble...3373
            Clean...3376
            Assemble...3377
      System Air Removal...3382
      Troubleshooting...3382
  910091-1900SRM0097-(07-2006)-UK-EN...3386
    toc...3386
      Hydraulic Gear Pumps...3386
      Safety Precautions Maintenance and Repair...3387
      Description...3390
      Operation...3391
        Flow Control Valve...3391
        Relief Valve...3392
      Hydraulic Gear Pump Repair...3392
        Remove...3392
        Disassemble...3393
        Clean...3393
        Inspect...3394
        Assemble...3397
        Install...3399
      Pump Output Check...3399
        Method No. 1...3399
        Method No. 2...3400
      Hydraulic System Air Check...3401
      Troubleshooting...3402
  910102-2100SRM0103-(03-2007)-UK-EN...3408
    toc...3408
      Tilt Cylinders...3408
      Safety Precautions Maintenance and Repair...3409
      General...3412
      Description...3412
      Tilt Cylinder Repair...3412
        Remove...3412
        Disassemble...3412
        Clean...3412
        Assemble...3412
          Tilt Cylinders With O-Ring or Single-Lip Seals...3412
          Tilt Cylinders for XM and XMS Models...3414
          Tilt Cylinders for XL, XLS, and XL 3 Models...3415
          Tilt Cylinders for H700-800A and Early Model H700-920B...3417
        Install...3418
          Tilt Cylinders Using Chevron Packing...3418
            Install...3419
      Tilt Cylinder Leak Check...3421
      Tilt Cylinder Stroke and Mast Tilt Angle Adjustment...3423
      Torque Specifications...3423
        Piston Rod Nut...3423
        Retainer...3424
      Troubleshooting...3426
    tables...3408
      Table 1. Movement Rates (Maximum) for Tilt Cylinders...3422
  910107-2200SRM0106-(02-2001)-UK-EN...3430
    toc...3430
      Starter...3430
      Safety Precautions Maintenance and Repair...3431
      General...3434
      Description and Operation...3434
      Starter Repair...3436
        Remove...3436
        Disassemble...3436
        Clean...3437
        Assemble...3437
        Install...3438
      General Checks and Adjustments...3438
      Troubleshooting...3441
  910110-2200SRM0143-(02-2007)-UK-EN...3446
    toc...3446
      Instrument Panel Indicators and Senders...3446
      Safety Precautions Maintenance and Repair...3447
      General...3450
      Description...3451
        Steering Column Gauges, Meters, and Indicators...3451
        LED Display Panel...3451
          Battery Discharge Indicators...3451
          Brush Wear Indicators...3457
          Motor Temperature Indicators...3457
        LX Series Display Panel...3459
          Hourmeter Functions...3460
          Battery Indicator Function...3460
          Status Code Function...3460
        ZX Series Display Panels...3462
          Display Panel...3462
          Basic Display Panels...3462
          Performance Display...3464
          Brush Wear Indicators...3468
      Adjustments - General...3468
      Replacement - General Information...3468
      Meter Replacement...3469
      Sender Replacement...3470
        Fuel Level Sender...3470
        Pressure and Temperature Sender...3470
        Seat Sensor, Operator Presence System (OPS)...3471
          Remove...3471
          Install...3471
        Operator Presence System Module Replacement...3471
          Remove...3472
          Install...3473
      ITW Display Panel Replacement...3474
        Remove...3474
      Column Mount Display Panel (EV-100/200ZX Motor Controllers) Repl...3474
        Remove...3474
        Display Panel Assembly, Replace...3474
        Indicator LEDs...3475
        Battery Indicators...3475
        Digital Display (Performance Display Panel Only)...3475
        Status Code or Performance Level Switches and Indicator LEDs (Pe...3476
        Basic Display Panel, Replace Parts...3476
        Performance Display Panel, Replace Parts...3478
      Dash Mount Display Panel (EV100/200ZX Motor Controllers) Replace...3478
        Remove and Replace...3478
      Specifications...3479
        Meter Specifications...3479
        Sender Specifications...3479
      Troubleshooting...3480
        Meter...3480
      Troubleshooting for Operator Presence System...3481
    tables...3446
      Table 1. Troubleshooting Procedure for Operator Presence Module...3481
  910119-4000SRM0135-(10-2003)-UK-EN...3486
    toc...3486
      Lift Cylinders...3486
      Safety Precautions Maintenance and Repair...3487
      Safety Procedures When Working Near Mast...3490
      General...3494
      Description...3494
        Lowering Control Valve...3494
        Cylinders (General)...3497
        Cylinders (H520-620B, H700-800A)...3497
          Retainer, Install...3497
        Cylinders (H360-460B)...3499
        Cylinders (Two-Speed)...3501
      Lift Cylinder Repair...3503
        Lift Cylinder Removal Without Removing Mast...3503
          Standard Masts With Main Lift Cylinder Fastened to Crossmember o...3503
          Standard and Full Free-Lift Masts With Lift Cylinder Fastened to...3503
          Masts That Have Two Cylinders, Main Lift Cylinder and Free-Lift ...3503
        Disassemble...3505
        Assemble...3505
        Lift Cylinder Installation in Mast...3507
          Standard Masts With Main Lift Cylinder Fastened to Crossmember o...3507
          Standard and Full Free-Lift Masts With Lift Cylinder Fastened to...3507
        Chevron-Style Packing...3507
          Chevron-Style Packing Installation on Piston...3508
          Chevron-Style Packing Installation in Packing Gland...3510
      Lift Cylinders for VISTA® Masts...3511
        Description...3511
          Lowering Control Valve...3511
        Remove...3513
        Disassemble...3514
        Assemble...3515
        Install...3516
          Main Lift Cylinders...3516
          Free-Lift Cylinder...3516
      Lift System Leak Check...3517
      Specifications...3518
      Troubleshooting...3519
    tables...3486
      Table 1. Lift Trucks with Two-Speed Lift Cylinders...3502
      Table 2. Cylinder Retainer Torque Specifications and Weight Guid...3518
  910442-8000SRM0231-(12-2004)-UK-EN...3522
    toc...3522
      Metric and Inch (SAE) Fasteners...3522
      Safety Precautions Maintenance and Repair...3523
      General...3526
        Threaded Fasteners...3526
        Nomenclature, Threads...3526
        Strength Identification...3527
        Cotter (Split) Pins...3527
        Fastener Torque Tables...3532
        Conversion Table...3534
    tables...3522
      Table 1. Bolts and Screws...3528
      Table 2. Studs and Nuts...3529
      Table 3. Torque Nuts...3530
      Table 4. Torque Nuts With Nylon Insert...3531
      Table 5. Torque Values for Metric Fasteners*...3532
      Table 6. Torque Values for Inch Fasteners*...3533
      Table 7. Conversion Table for Metric and English Units...3534
      Table 8. Cotter Pin Dimensional Data...3535
      Table 9. Cotter Pin Dimensional Data...3536
      Table 10. Cotter Pin Dimensional Data...3537
      Table 11. Cotter Pin Dimensional Data...3539

Hyster Forklift Trucks G006 (H135-155XL & H6.00-7.00XL Europe) Repair Service Manual