Hyster Forklift S70XL-120XL (D004) S135-155XL (B024, C024) service manual by www.heydownloads.com

ALTERNATOR WITH REGULATOR DELCO, MOTOROLA, AND LEECE-NEVILLE COVERS DELCO, MOTOROLA, AND LEECE-NEVILLE ALTERNATORS USED ON HYSTER LIFT TRUCKS

PART NO. 899784

2200 SRM 2

Alternator with Regulator

Table of Contents

1 1 3 3 3 4 5 5 8 8 8 9 10 11 11 13 14 14 15 16 16 16 16 17 18 18 18

This section is for the following models: Covers Delco, Motorola, and Leece-Neville alternators used on Hyster lift trucks

ÂŠ2003 HYSTER COMPANY

2200 SRM 2

Description

General CAUTION When using an arc welder, always disconnect the ground lead from the lift truck battery to prevent alternator or battery damage. Attach the welding ground clamp as close to the weld area as possible to prevent welding current from damaging the bearings. The diodes and resistors in the electrical system can be damaged if the following cautions are not followed: • Do not disconnect the battery when the engine is running. The voltage surge can damage the diodes and resistors in the electrical system. • Do not disconnect an electric wire before the engine is stopped and the switches are OFF.

• Do not cause a short circuit by connecting the electric wires to the wrong terminals. Make sure a correct identification is made of the wire before it is connected. • Make sure a battery is the correct voltage and polarity before it is connected. • Do not check for current flow by making a spark because the electronic components can be damaged. NOTE: Information on alternators manufactured outside the United States is in the SRM (Service Repair Manual) sections for lift trucks that use those alternators. This section has a description and the repair procedures for the alternator with a voltage regulator as part of the alternator.

Description NOTE: For this SRM section, the alternators are in two groups: Type A and Type B. The two types are very similar, but the Type A alternators have a set of three diodes (diode set) as well as the diode bridge. The Type B alternator has zener diodes as part of the diodes in the diode bridge. This alternator does not have a diode set, but does have an additional fan inside the rear housing. The basic operation of both types is very similar. The alternator generates an alternating current when the engine is running. The alternator is either ON or OFF. The alternator generates maximum current when it is ON and no current when it is OFF. The regulator switches the alternator between ON and OFF to get the average current needed to charge the battery. Alternator output is directly changed by engine speed and rotor field current. The alternating current is changed to a direct current by the diode bridge inside the alternator. The alternator has these parts (see Figure 1 and Figure 2): A stator A rotor A diode bridge A diode set (Type A only) Two end housings or frame halves A solid-state voltage regulator

NOTE: DELCO TYPE A SHOWN. 1. BRUSH ASSEMBLY 2. ROLLER BEARING 3. GREASE RESERVOIR 4. LIP SEAL

5. 6. 7. 8.

DIODE BRIDGE BALL BEARINGS FELT SEAL REGULATOR

Figure 1. Alternator Cross Section

Description

2200 SRM 2

Figure 2. Alternator Schematics

2200 SRM 2

Alternator Repair Legend for Figure 2

NOTE: LEECE-NEVILLE NOT AVAILABLE, SIMILAR TO THOSE SHOWN. A. DELCO TYPE A (SMALL CAPACITY LIFT TRUCKS) B. DELCO TYPE B

C. MOTOROLA TYPE A D. DELCO TYPE A (LARGE CAPACITY LIFT TRUCKS)

1. 2. 3. 4. 5. 6. 7.

8. 9. 10. 11. 12. 13. 14.

BATTERY KEY SWITCH FUSE RESISTOR INDICATOR LIGHT OR AMMETER VOLTAGE REGULATOR ROTOR FIELD

The direct current from the diodes of the diode bridge flows to the output or BAT terminal. A capacitor between the BAT terminal and the electrical ground removes any remaining alternating current from the direct current. The capacitor also protects the diodes from high voltages. The voltage is controlled by the amount of current flowing through the field winding in the alternator and the rpm of the rotor. The voltage regulator, inside the housing, contains a transistor, diodes, resistors, and capacitor. The voltage regulator cannot be repaired. NOTE: On some large capacity lift trucks, the alternator has an external voltage adjustment.

STATOR DIODE BRIDGE DIODE SET FIELD TERMINAL REGULATOR TERMINAL OUTPUT (BAT) TERMINAL VOLTAGE ADJUSTMENT

The voltage regulator controls the alternator to charge the battery. The voltage is set by the manufacturer and is not usually adjustable. Battery voltage decreases as the starting circuit and other circuits take energy from the battery. When the key switch is put in the IGN position, the voltage regulator is energized. A positive current flows to the field terminal (F or 1) on Type A alternators and (L) on Type B alternators. The battery sends a positive current to the regulator terminal (Type A R or 2) and the BAT terminal. The regulator senses a decrease in battery voltage and increases the alternator output to charge the battery.

Alternator Repair ALTERNATOR TYPE A Remove and Disassemble WARNING Always disconnect the battery ground cable before making repairs to prevent possible damage and injury. Install a tag on the battery terminal so that no one connects the cable on the terminal. NOTE: Use Troubleshooting and General Check and Adjustment, Low Output Check (Type A or Type B), High Output Check (Type A or Type B), Brushes Circuit Check, Diodes Check, Diode Bridge Check, Rotor Field Winding Check, Stator Windings Check, and Voltage Regulator Check procedures of this SRM before starting any repair procedures. Make sure that repair or replacement of that part is necessary before removal, disassembly, or replacement of the part.

NOTE: There are some checks of the alternator that are done with the alternator on the engine. See General Check and Adjustment, Low Output Check (Type A or Type B), High Output Check (Type A or Type B), Brushes Circuit Check, Diodes Check, Diode Bridge Check, Rotor Field Winding Check, Stator Windings Check, and Voltage Regulator Check procedures of this SRM before starting any removal or repair procedures. NOTE: Many parts of the Leece-Neville alternator can be replaced without disassembling the alternator. See Figure 5. The alternator must be disassembled to replace only the diode bridge, filter capacitor, rotor, stator, or bearings. 1. Disconnect the battery ground cable. See Figure 3, Figure 4, and Figure 5. Install labels and disconnect the wires at the alternator. Loosen the alternator mount capscrews and remove the drive belt. Remove the capscrews that hold the alternator to the engine.

Alternator Repair

2200 SRM 2

2. On Leece-Neville alternators, remove the brushes, voltage regulator, or diode set. Install labels on all wires for correct connection during installation. 3. Put a mark on each housing and on the stator for correct alignment during assembly. Remove the bolts that hold the housings together. Separate the housings and stator. 4. Put the rotor in a vise that has soft jaws. Do not tighten the vise to cause rotor distortion. Use a socket wrench to remove the pulley nut. Remove the pulley, fan, collar, spacer, shield, or other parts between the fan and housing. Remove the front housing from the rotor. 5. Remove any nuts or screws that fasten parts inside to the rear housing. Then, remove the stator assembly from the rear housing so that the other parts can be removed. Remove the screws for the capacitor, diode bridge, diode set, brushes, and other parts as necessary. If the stator will be removed from the diode bridge, make sure the wires have tags for correct connection during assembly. 6. Mark the stator to show the position of the brushes and connector or diode bridge assembly. Use pliers as a heat sink to keep heat from the

diodes. Use a soldering iron to remove the stator leads from the diode assembly. 7. Remove the bearings from the housings only if they will be replaced.

Clean WARNING Compressed air can move particles so that they cause injury to the user or to other personnel. Make sure that the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes.

CAUTION Never use solvent on the parts of the alternator. NOTE: If necessary, use fine abrasive cloth to polish the slip rings. The abrasive cloth must be number 500 to 600. Remove all dust. Turn the rotor while polishing the slip rings. Use compressed air to remove dirt from the alternator. Clean the brushes and slip rings with a clean, dry cloth.

A. DELCO

B. MOTOROLA

1. GROUND TERMINAL 2. BATTERY TERMINAL (BAT OR +)

3. FIELD TERMINAL 4. REGULATOR TERMINAL

Figure 3. Type A Alternators, Rear Views

2200 SRM 2

Alternator Repair

Assemble

a. Install the brush and holder, voltage regulator, and diodes from the inside of the alternator. Make sure the insulator sleeves are on the screws for the brush holder. Install the capacitor.

1. For Delco (Type A) alternators, install a new bearing(s) in the housing as follows (see Figure 3, Figure 4, and Figure 5): a. Install a new plug and seal in the rear housing. Push the bearing from the outside of the housing until the top of the bearing is even with the outside of the housing. Hold the housing with the collar on the inside of the housing. Keep the lip of the seal away from the bearing. Lubricate the bearing area with non-conductive grease. b. Install a new bearing in the front housing. Fill one quarter of the grease reservoir with non-conductive grease. Move the grease so that it touches the bearing when the retainer plate is installed. c. Add the same type of grease to fill the area between the retainer plate and the bearing. Install the spacer, gasket, and retainer plate on the bearing. Fasten the retainer plate in position with the three screws and lockwashers. 2. For Motorola and Leece-Neville alternators, use a press to install the rear bearing on the rotor. Install the bearing and bearing retainer in the front housing. If used, install the spacer on the bearing.

CAUTION Hold the rotor in a vise that has soft jaws. Do not tighten the vise more than necessary. 3. Install the front housing on the rotor. If used, install the spacer or shield, shaft key, and washer. Install the fan, pulley, lockwasher, and nut. Tighten the nut to 54 to 81 Nâ&#x20AC;˘m (40 to 60 lbf ft).

CAUTION Be sure to install the insulators. Make sure the heat sink does not touch the housing. 4. Install the diode bridge and heat sink in the reverse order of disassembly. Make sure the insulators and washers are in the correct positions. Install the capacitor.

b. Install the stator in the rear housing. Connect the three wires from the stator to the diode bridge and fasten at the studs. Connect the wires from the diodes to the studs on the diode bridge. Install and tighten the three lockwashers and nuts. c. Install the brushes in the brush holders. To hold the brushes in position, put a pin through the hole in the brush holders. Apply a thin layer of oil to the lip of the seal for the bearing. 6. On Motorola alternators, install parts as follows: a. Install the diode bridge on the stator. Use pliers to keep the heat from the soldering iron away from the diodes. b. Install the capacitor, diode set, and terminal on the diode bridge. Align the marks made during removal and install the stator and bridge assembly in the rear housing. 7. Align the marks made during disassembly. Carefully install the stator and the rear housing over the rotor. Do not damage the seal while sliding the housing over the rotor shaft. Install the front housing. 8. Install the four screws to hold the alternator together. On Delco alternators, remove pin to release the brushes. 9. On Motorola alternators, install the brush holder and brushes. Make sure the washer is on the right-hand screw. Install the voltage regulator and tighten the screws. 10. On Leece-Neville alternators, install the brushes, voltage regulator, or diode set in the reverse order of removal.

Install 1. Install the alternator in the bracket on the engine and adjust the tension of the belt.

5. On Delco alternators, install parts as follows:

Alternator Repair

2200 SRM 2

2. Connect all wires and the connector according to the labels made during removal. Also see the schematic diagram for your alternator in Figure 2. Make sure all wires are connected correctly and all fasteners are tight. See Figure 3.

3. Check the indicator light or the ammeter to check the operation of the alternator. The indicator light for Type A alternators will only be ON if the battery is discharged.

Figure 4. Type A Alternators, Exploded Views

2200 SRM 2

Alternator Repair Legend for Figure 4

A. DELCO

B. MOTOROLA

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26.

NUT SCREW DIODE BRIDGE CAPACITOR BEARING SLIP RINGS TERMINAL PULLEY FAN RETAINER SPACER SHIELD GASKET

9. 10. 11. 12. 13. 14. 15. 16.

BOLT FAN ROTOR STATOR NEGATIVE DIODE BRIDGE POSITIVE DIODE BRIDGE FILTER CAPACITOR REAR HOUSING

INSULATOR PLUG AND BEARING BEARING SEAL BOLT HOUSING VOLTAGE REGULATOR LOCKWASHER BRUSH AND HOLDER BRUSH SPRING WASHER ROTOR STATOR DIODES

A. LEECE-NEVILLE 1. 2. 3. 4. 5. 6. 7. 8.

TERMINAL DIODE SET BRUSH AND SPRING BRUSH HOLDER VOLTAGE REGULATOR BEARING RETAINER BEARING FRONT HOUSING

Figure 5. Type A Alternator, Exploded View

Alternator Repair

ALTERNATOR TYPE B Remove and Disassemble WARNING Always disconnect the battery ground cable before making repairs to prevent possible damage and injury. Install a tag on the battery terminal so that no one connects the cable on the terminal.

2200 SRM 2 4. Use a punch to remove the rivets or pins that fasten the cover. Remove the cover for access to the stator leads. Discard the cover. See Figure 7. 5. Cut the stator leads as close to the connectors as possible. Install labels on the leads for correct connection during assembly and remove the stator from the rear housing. 6. Use a punch to remove the three baffle pins and remove the baffle. See Figure 7.

NOTE: Use the Troubleshooting and General Check and Adjustment, Low Output Check (Type A or Type B), High Output Check (Type A or Type B), Brushes Circuit Check, Diodes Check, Diode Bridge Check, Rotor Field Winding Check, Stator Windings Check, and Voltage Regulator Check procedures of this SRM before starting any repair procedures. Make sure that repair or replacement of that part is necessary before removal, disassembly, or replacement of the part.

NOTE: Carefully make a note of the sequence of removal of parts in Step 7 and Step 8 for correct installation. Also make a note of all types of connections (crimp, soldered, or welded) as well as all mechanical fasteners.

8. Open the crimps or use a soldering iron and disconnect the connectors to separate the brush holder, voltage regulator, and diode bridge.

1. Disconnect the battery ground cable. See Figure 6, Figure 7, and Figure 8. Install labels and disconnect the wires at the alternator. Disconnect the wire connector. Loosen the alternator mount capscrews and remove the drive belt. Remove the capscrews that hold the alternator to the engine. 2. Put a mark on each housing and on the stator for correct alignment during assembly. Remove the bolts that hold the housings together. Separate the housings and stator. 3. Put the rotor in a vise that has soft jaws. Do not tighten the vise to cause rotor distortion. Use a socket wrench to remove the pulley nut. Remove the pulley, collar, fan, outside collar, front housing, and inside collar from the rotor. NOTE: The cover must be replaced if the parts will be removed from the stator. If necessary, remove the stator as described in Step 4 and Step 5.

7. Remove the three mount screws and "BAT" terminal nut. See Figure 8. Lift the brush holder, voltage regulator, and diode bridge from the housing.

9. If the bearing will be replaced in the rear housing, remove the bearing and retainer ring.

2200 SRM 2

Alternator Repair

A. DELCO 1. 2. 3. 4. 5. 6. 7.

NUT PULLEY COLLAR OUTSIDE FAN OUTSIDE COLLAR FRONT HOUSING INSIDE COLLAR

8. 9. 10. 11. 12. 13. 14.

STATOR ROTOR AND FAN BAFFLE SCREW DIODE BRIDGE BRUSHES AND HOLDER VOLTAGE REGULATOR

15. 16. 17. 18. 19. 20.

COVER REAR HOUSING BALL BEARING RETAINER RING TERMINAL SET BOLT

Figure 6. Type B Alternator, Exploded View

Assemble 1. If the bearing was removed from the rear housing, install a new retainer ring. See Figure 6.

CAUTION

4. Put a thin coating of silicon grease on the inside of the rear housing under the diode bridge. 5. Install the bridge, regulator, and brush holder assembly in the rear housing and install the screws as removed during disassembly.

The bearing is not completely installed until Step 11 is complete.

6. Install the baffle and use a punch to fasten the pins.

2. Install a new bearing by pushing on the new bearing outer race until the bearing hits the bottom in the rear housing.

7. Align the marks made during disassembly and install the stator in the rear housing. Use pliers on the connectors of the diode bridge to keep heat from the diodes. Use a soldering iron to connect the stator leads to the connectors.

3. Assemble the voltage regulator, diode bridge, and brush holder on a flat surface. Put crimps in the connectors or solder the connectors to fasten and connect the parts as originally assembled. Use a pin to hold the brushes in the brush holder.

Alternator Repair

2200 SRM 2 (0.075 to 0.087 in.) below the surface of the rear housing.

Install 1. Install the alternator in the bracket on the engine and adjust the tension of the belt. 2. Connect all wires and the connector according to the labels made during removal. Also see the schematic diagram for your alternator in Figure 2. Make sure all wires are connected correctly and all fasteners are tight. See Figure 7. 3. Check the indicator light or the ammeter to check the operation of the alternator. The indicator light can also be ON if the alternator output is too high on Type B alternators.

NOTE: TYPE B ONLY. 1. REAR HOUSING 2. COVER 3. COVER RIVETS OR PINS

4. BAFFLE PINS 5. BOLTS TO FASTEN HOUSINGS TOGETHER

Figure 7. Outside Rear Housing 8. Install a new cover using rivets or pins to fasten the cover to the rear housing. 9. If necessary, install the bearing in the front housing. Put the rotor in a vise with soft jaws and install the inner collar, front housing, outer collar, fan, collar pulley, and nut on the rotor. Tighten the nut to 54 to 108 Nâ&#x20AC;˘m (40 to 80 lbf ft). 10. Align the front and rear housings using the marks made during disassembly. Push on both the inner and outer races of the rear bearing to push the two housings and stator together. Install the three bolts that fasten the alternator together. 11. Push on both the inner and outer race of the rear bearing so that the outer race is 1.9 to 2.2 mm

NOTE: TYPE B ONLY. 1. REAR HOUSING 2. VOLTAGE REGULATOR 3. BRUSH HOLDER 4. DIODE BRIDGE 5. TERMINALS FOR STATOR LEADS

6. NUT ON "BAT" TERMINAL 7. MOUNT SCREWS 8. SOLDERED OR WELDED CONNECTOR 9. BRUSH PIN

Figure 8. Inside Rear Housing

2200 SRM 2

Low Output Check (Type A or Type B)

General Check and Adjustment There are no adjustments for the alternator or most regulators. One Delco alternator and the Leece-Neville alternator has a voltage adjustment. Always check the general condition of the complete system before doing a complete check on each part. Check the general condition of the following parts: (1) battery, (2) battery cables and connections, and (3) alternator and regulator wires and connectors. Also check the condition and tension of the fan belt for the alternator.

CAUTION NEVER operate the engine if the alternator output BAT terminal is not connected to the battery. Do not short-circuit or connect jumper wires to any of the alternator terminals unless told to by the procedures. Make sure polarity is correct before connecting a battery charger or another battery. Remove the battery cables and clean the terminals and cable connectors. Inspect the insulation on the wires. Make sure all the fasteners and connections are clean and tight. If necessary, use a water and soda solution to clean the top of the battery. Do NOT remove the cell caps or permit the water and soda solution to get in the battery.

WARNING Put the transmission in NEUTRAL. Apply the parking brake.

CAUTION Do not change the polarity of the circuits. Do not connect any wires in the circuits, except as described in these instructions. Never connect the wire from the terminal marked "BAT" to an open circuit. When connecting a charger or another battery, connect the positive terminals to the positive terminal of the battery. Then connect the negative terminal to a clean metal part of the engine. Disconnect the charger or other battery in the reverse order. Problems in the charging circuit are indicated by one or more of the following: â&#x20AC;˘ The starter motor turns slowly. The battery voltage is low because of low alternator output or a bad battery. â&#x20AC;˘ The specific gravity readings are low. Battery is not fully charged or is damaged. â&#x20AC;˘ The battery uses more than 30 ml (1 oz) of water per cell per month. The alternator output is too high. The two problems of the charging circuit are low output and high output. Low output causes a low battery and difficult starting. A high output causes heating of the battery and evaporation of water from the electrolyte. The following two checks will find out if the alternator, regulator, or wiring has a charging fault. The two checks will also find out if the charging system has a correct output. Do the following two checks before removal, disassembly, or replacement of alternator or regulator. NOTE: Information on alternators manufactured outside the United States is in the SRM (service repair manual) sections for lift trucks that use those alternators.

Low Output Check (Type A or Type B) CAUTION Do not connect the wire from the "BAT" terminal to the electrical ground.

2. Connect a voltmeter to the field terminal and the regulator terminal. Follow the procedure in Step 1 and check the readings.

NOTE: Make sure the wire from the voltmeter makes contact with each terminal on the alternator.

3. If there are no readings on the voltmeter during Step 1 and Step 2, check for an open circuit between each terminal and the battery.

1. Connect a voltmeter between the BAT terminal and the electrical ground. Turn the key switch to the ON position and check the reading.

4. If there are readings on the voltmeter during Step 1 and Step 2, disconnect the cable for the electrical ground on the battery.

Low Output Check (Type A or Type B) 5. Make connections to the Type A alternator as shown in Figure 9. Make connections to the Type B alternator as shown in Figure 10. 6. Connect the cable for the electrical ground on the battery.

2200 SRM 2 10. If the ammeter reading is within 10%, the alternator is in good condition. Check the starter or wires for problems. Some alternators on larger lift trucks have a voltage adjustment. See Figure 12. For alternators with the voltage adjustment, do Step a to set the voltage:

7. Connect a carbon pile across the terminals of the battery.

a. The voltage setting can be increased by changing the position of the adjustment plug. LO is the lowest voltage setting. 2 is medium low and 3 is the medium setting. The voltage setting is highest when HI is aligned with the arrow on the alternator. Change the setting as necessary.

8. Run the engine at 2000 to 2500 rpm. Adjust the carbon pile until the maximum charging rate is reached. 9. Read the value of the maximum charging rate shown on the alternator housing or in the section Capacities and Specifications for your lift truck. Read the ammeter. The reading on the ammeter must be within 10% of the maximum value.

NOTE: TYPE B ONLY. NOTE: TYPE A ONLY. 1. 2. 3. 4.

CARBON PILE BATTERY AMMETER STARTER

5. ALTERNATOR 6. BAT TERMINAL 7. FIELD TERMINAL

Figure 9. Alternator Output Check

1. 2. 3. 4.

BATTERY CARBON PILE VOLTMETER RESISTOR (35 OHM 5 WATT TO 500 OHM 1/2 WATT)

5. 6. 7. 8.

AMMETER ALTERNATOR BAT TERMINAL CONNECT TO L TERMINAL

Figure 10. Alternator Output Check

2200 SRM 2

High Output Check (Type A or Type B)

11. On Type A Delco alternators, do the following checks:

CAUTION Do not push the screwdriver into the hole for more than 25 mm (1 in.). a. If the output shown is not within 10%, put a screwdriver into the hole shown in Figure 11. b. Run the engine at 2000 to 2500 rpm. Adjust the carbon pile until the maximum charging rate is reached. c. If the output is within 10%, check the field winding. If the field winding is in good condition, replace the voltage regulator. d. If the output is not within 10%, check the wires to the brushes, diodes, diode bridge, field winding, and stator. e. Remove the screwdriver, ammeter, and variable resistor.

NOTE: DELCO TYPE A SHOWN. 1. HOLE 2. MAKE SURE SCREWDRIVER TOUCHES HOUSING AND METAL TAG. Figure 11. Electrical Ground on Field Winding

High Output Check (Type A or Type B) 1. Connect a voltmeter from the regulator terminal to the electrical ground. Check the reading on the voltmeter. See Figure 9 or Figure 10. 2. If there are no readings, check for an open circuit between the regulator terminal and the battery. 3. If there is a reading, connect a voltmeter between the BAT terminal and the electrical ground. 4. Increase the engine speed until the maximum voltage reading is reached. 5. If the voltage shown is more than 15.5 volts on a 12-volt system or 31 volts on a 24-volt system, disassemble the alternator and do the remainder of the checks. For alternators with the voltage adjustment, do the following:

a. Delco alternator. The voltage setting can be increased or decreased by changing the position of the adjustment plug. See Figure 12. LO is the lowest voltage setting. 2 is medium low and 3 is the medium setting. The voltage setting is highest when HI is aligned with the arrow on the alternator. Do not change the setting when engine is operating. Change the setting as necessary. b. Leece-Neville alternator. Remove the screw in the cover. See Figure 12. Start the engine. Connect a voltmeter across the battery terminals and use a screwdriver to adjust the voltage.

Brushes Circuit Check

2200 SRM 2

1. VOLTAGE ADJUSTMENT CAP SHOWN IN MEDIUM HIGH (3) POSITION.

2. DELCO TYPE A 3. LEECE-NEVILLE

Figure 12. Voltage Adjustment

Brushes Circuit Check DELCO ALTERNATORS 1. Use an ohmmeter that has a 1.5 volt cell. (Use the lowest range scale.) Connect the ohmmeter from the clip for the brushes to the metal housing. Make the test, then connect the ohmmeter leads in the reverse direction and test again. 2. If both readings are zero, either the wire or the clip for the brushes has a short circuit to ground, or the voltage regulator has damage. 3. The cause of the problem can also be a missing washer, a missing sleeve on a screw, or a damaged insulator. See Figure 13. Remove the screw

and inspect the insulator. If the insulator is in good condition, do Step 4, Step 5, and Step 6. 4. Connect the ohmmeter from the wire of the diodes to the housing. 5. If the reading is zero on the ohmmeter, either the wire to the diodes has a short circuit to ground, or the voltage regulator has damage. 6. The cause of the problem can be a missing washer, a missing sleeve on a screw, or a damaged insulator. Remove the screw and inspect the insulator. If the insulator is in good condition, replace the voltage regulator.

2200 SRM 2

Brushes Circuit Check

MOTOROLA ALTERNATORS 1. Use an ohmmeter or a 12-volt test lamp to check the brushes as shown in Figure 13. 2. For correct operation, there must be continuity between A to B and C to D. There must be no continuity from A to D or from C to B. See Figure 13. If there is continuity, the brushes are connected to the wrong terminal.

A. DELCO

B. MOTOROLA

1. 2. 3. 4.

5. DIODES 6. INSULATOR WASHERS 7. OHMMETER

BRUSH HOLDER CAPACITOR DIODE BRIDGE NUTS

Figure 13. Brushes Circuit Check

Diode Bridge Check

2200 SRM 2

Diodes Check Use an ohmmeter with a 1.5 volt cell. Use the lowest range scale. Connect one lead of tester to the common connector, and one lead to one of the three diode connections. Make the test, then reverse the tester

leads and make the same test. If both readings are the same reading, replace the diodes. A good diode will show one high reading, and one low reading. See Figure 14.

A. DELCO TYPE A

B. MOTOROLA

1. OHMMETER 2. COMMON FOR DIODE SET

3. DIODE SET CONNECTIONS Figure 14. Diodes Check

Diode Bridge Check DELCO AND LEECE-NEVILLE ALTERNATORS CAUTION Do not use a 120-volt test lamp to check the diode bridge. Use a 12-volt tester to prevent diode damage. To check the diode bridge, connect the ohmmeter to one heat sink and each of the three diodes in turn.

Check the readings, then connect the leads in the reverse direction. If both readings are the same, replace the diode. Repeat the test for the other heat sink checking in both directions. See Figure 15.

MOTOROLA ALTERNATORS Remove the wires for the diode set from the terminals A, B, and C. Use an ohmmeter, diode tester, or 12-volt test lamp to check between points A, B, and C, and points D and E. Good diodes indicate continuity in only one direction. If any parts are bad, replace the diode bridge assembly. See Figure 14.

2200 SRM 2

Rotor Field Winding Check

A. DELCO TYPE A

B. DELCO TYPE B

C. LEECE-NEVILLE

1. BRUSH HOLDER 2. HEAT SINK

3. VOLTAGE REGULATOR 4. DIODE

5. OHMMETER

Figure 15. Diode Bridge Check

Rotor Field Winding Check Connect an ohmmeter to each slip ring and check for open circuits. If the reading is high (infinity), the winding has an open circuit. To check the resistance of the field, connect the ohmmeter to the two slip rings. The correct reading is 4.0 to 4.5 ohms. If the reading is less than specified, there is a short circuit in the windings. If the reading is more than specified, there is excessive resistance in the windings. NOTE: Make sure the needle in the ohmmeter always returns to zero correctly. The readings will change when the temperature of the winding changes. To check the electrical ground, connect the ohmmeter between either slip ring and the electrical ground as shown in Figure 16. Replace the rotor if the reading is less than infinity. Figure 16. Rotor Coil Checks

Troubleshooting

2200 SRM 2

Stator Windings Check To check the stator windings for electrical ground, connect an ohmmeter as shown in Figure 17. There must be no continuity between any of the stator terminals and the metal housing. To check the stator for open circuits, connect the ohmmeter or test lamp between each pair of wires to the stator as shown in Figure 17. If the test lamp does not illuminate or the meter reading is high, the windings have an open circuit.

Figure 17. Stator Checks

Voltage Regulator Check Use a voltage regulator test device. Do not use an ohmmeter. If the voltage regulator has damage, replace the voltage regulator.

Troubleshooting PROBLEM Battery is charged above normal.

Battery uses more water than normal.

POSSIBLE CAUSE

PROCEDURE OR ACTION

Alternator is not charging correctly.

Repair or install new parts.

Electrical ground in wire to brush or clip.

Repair or install new parts.

High resistance in the circuit.

Repair or install new parts.

Battery is charging more than normal.

Replace voltage regulator.

Alternator has damage in the field windings, diodes, diode bridge, or stator.

Install new parts.

Battery has damage or is too old.

Replace battery.

2200 SRM 2

PROBLEM There is no charge from the alternator.

There is no charge from the alternator. The indicator light or ammeter indicates a discharged condition when the rpm is high and the load is high.

Ammeter or the indicator light indicates a discharged condition at all speeds.

Troubleshooting

POSSIBLE CAUSE

PROCEDURE OR ACTION

The brushes are worn or damaged.

Install new brushes.

Weak springs for brushes. Brushes or brush holders do not move freely.

Install new parts.

Dirt on the slip rings.

Clean or install new parts.

There is an electrical ground in the field winding.

Replace rotor or alternator.

Drive belt is not tight or is broken.

Adjust or replace drive belt.

There is a short circuit in the diodes.

Install new parts.

There is an electrical ground at the end of the windings.

Replace rotor or alternator.

The voltage regulator has damage.

Replace voltage regulator.

NOTES ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________

BRAKE SYSTEM H3.50-5.00XL (H70-110XL) [F005/G005]; S3.50-5.50XL (S70-120XL) [D004]; E3.50-5.50XL (E70-120XL, E70-120XL 3) [C098]; E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) [D098/E098]

PART NO. 897120

1800 SRM 338

Brake System

Table of Contents

TABLE OF CONTENTS General ............................................................................................................................................................... Description and Operation ................................................................................................................................ Brake Booster and Master Cylinder............................................................................................................. Master Cylinder............................................................................................................................................. Service Brake Assembly ................................................................................................................................ Parking Brake................................................................................................................................................ Seat Brake...................................................................................................................................................... Brake Shoe Assemblies Repair ......................................................................................................................... Remove and Disassemble .............................................................................................................................. Clean and Inspect .......................................................................................................................................... Assemble and Install ..................................................................................................................................... Master Cylinder Repair ..................................................................................................................................... Master Cylinder For Lift Truck Models S3.50-5.50XL (S70-120XL) (D004) and H3.50-5.00XL (H70-110XL) (F005/G005) ............................................................................................................................. Remove....................................................................................................................................................... Disassemble ............................................................................................................................................... Assemble .................................................................................................................................................... Install ......................................................................................................................................................... Master Cylinder For Lift Truck Models E3.50-5.50XL (E70-120XL, E70-120XL 3) (C098) and E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/E098) ...................................................................... Remove and Disassemble.......................................................................................................................... Clean and Inspect...................................................................................................................................... Assemble and Install................................................................................................................................. Brake Booster Repair......................................................................................................................................... Remove ........................................................................................................................................................... Disassemble ................................................................................................................................................... Clean and Inspect .......................................................................................................................................... Assemble ........................................................................................................................................................ Install ............................................................................................................................................................. Brake System Air Removal ............................................................................................................................... Brake Pedal Adjustment ................................................................................................................................... Brake Pedal for Lift Truck Models H3.50-5.00XL (H70-110XL) (F005/G005) With Manual Transmission and E3.50-5.50XL (E70-120XL, E70-120XL 3) (C098) and E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/E098) ................................................................................................................. Brake Shoes Adjustment ................................................................................................................................... Parking Brake Adjustment ............................................................................................................................... Parking Brake Adjustment, Lift Truck Models S3.50-5.50XL (S70-120XL) (D004) and H3.50-5.00XL (H70-110XL) (F005/G005) ..................................................................................................... Parking Brake Lever and Switch Adjustment E3.50-5.50XL (E70-120XL, E70-120XL 3) (C098) and E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/E098) ............................................................... Seat Brake Assembly ......................................................................................................................................... Remove ........................................................................................................................................................... Clean and Inspect .......................................................................................................................................... Install ............................................................................................................................................................. Adjustments ................................................................................................................................................... Solenoid Adjustment ................................................................................................................................. Traction cutoff Switch Adjustment........................................................................................................... Cable Adjustment...................................................................................................................................... Brake Booster Relief Valve Check..................................................................................................................... Troubleshooting..................................................................................................................................................

1 1 1 1 1 4 5 6 6 8 8 13 13 13 13 13 13 14 14 15 16 16 16 16 16 17 18 18 18

18 20 20 20 21 22 22 22 22 24 24 24 25 27 27

Table of Contents

Brake System

TABLE OF CONTENTS (Continued) This section is for the following models: H3.50-5.00XL (H70-110XL) [F005/G005]; S3.50-5.50XL (S70-120XL) [D004]; E3.50-5.50XL (E70-120XL, E70-120XL 3) [C098]; E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) [D098/E098]

1800 SRM 338

Description and Operation

General This section has a description and the repair procedures for the parts of the hydraulic brake system. These parts include the brake booster, master cylinder, and brake shoe assemblies.

Description and Operation The master cylinder is actuated by a brake booster on S3.50-5.50XL (S70-120XL) (D004) and H3.50-5.00XL (H70-110XL) (F005/G005) lift trucks. The brake booster is a hydraulic valve actuated by the brake pedal. The brake booster uses the oil that flows from the steering control unit to multiply the force of the brake pedal. The system allows braking without hydraulic pressure at the brake booster. Lift trucks of the E3.50-5.50XL (E70-120XL, E70-120XL 3) (C098) and E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/E098) series have a different master cylinder that is not actuated by a brake booster.

BRAKE BOOSTER AND MASTER CYLINDER These parts are for the S3.50-5.50XL (S70-120XL) (D004) and H3.50-5.00XL (H70-110XL) (F005/G005) models. See Figure 1. The operation of the parts is described in Figure 2.

excess fluid from the system can return to the reservoir. The check valve keeps a very small amount of pressure in the brake system. The pressure helps to keep the system effectively sealed.

SERVICE BRAKE ASSEMBLY A service brake assembly is installed at each end of the housing for the drive axle. See Figure 4. Each service brake assembly has a single wheel cylinder at the top of each back plate. The support plate has an anchor for each shoe. When the wheel cylinder is actuated by fluid pressure from the master cylinder, the shoes touch the drum. The primary shoe starts to turn with the drum. This action pushes the secondary shoe tight against the drum and the anchor. This servo action increases the force applied to the brake drums. When the lift truck is traveling in reverse, the primary shoe is pushed against the anchor and the drum by the secondary shoe.

MASTER CYLINDER This master cylinder is for the E3.50-5.50XL (E70-120XL, E70-120XL 3) (C098) and E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/E098) models. See Figure 3. The master cylinder has a housing and a piston assembly. The housing has two ports between the bore for the piston and the reservoir for the fluid. The compensator port in front of the piston is open when the piston is fully retracted. The compensator port lets fluid move to or from the brake system when the temperature changes. Another port keeps fluid in the cavity around the piston. The piston moves in the housing when the operator pushes the brake pedal. A small movement of the piston closes the compensator port. Hydraulic pressure actuates the wheel cylinders as the piston pushes fluid through the check valve. A return spring pushes the piston back to the stop plate when the pedal is released. Fluid can flow through passages in the piston and past the primary cup as the piston returns. Fluid flows across the piston to prevent a vacuum while fluid returns through the check valve. When the piston passes the compensator port,

NOTE: BRAKE BOOSTER AND MASTER CYLINDER FOR LIFT TRUCK MODELS S3.50-5.50XL (S70-120XL) (D004) AND H3.50-5.00XL (H70-110XL) (F005/G005) SHOWN. 1. 2. 3. 4. 5. 6.

BRAKE BOOSTER INLET FROM STEERING CONTROL UNIT OUTLET TO HYDRAULIC TANK MASTER CYLINDER INLET FROM RESERVOIR OUTLET TO WHEEL CYLINDERS

Figure 1. Brake Booster and Master Cylinder

Description and Operation

Figure 2. Brake Booster and Master Cylinder Operation

1800 SRM 338

Description and Operation Legend for Figure 2

NOTE: BRAKE BOOSTER AND MASTER CYLINDER FOR LIFT TRUCK MODELS S3.50-5.50XL (S70-120XL) (D004) AND H3.50-5.00XL (H70-110XL) (F005/G005) SHOWN. A. BRAKES NOT APPLIED Hydraulic oil flows from the steering control unit to the inlet of the brake valve. The hydraulic oil flows freely between the plunger and the piston and returns to the hydraulic tank from the outlet. B. BRAKES APPLIED When the brakes are applied and the engine is not running, the plunger pushes against the piston. The piston and piston rod push against the piston in the master cylinder to actuate the brakes. When the engine is running, there is hydraulic oil flowing through the brake valve. The movement of the plunger makes a restriction in the flow of oil between the plunger and the piston. The hydraulic pressure behind the piston increases and pushes on the piston and piston rod to move the piston in the master cylinder. The oil pressure behind the piston decreases the effort at the brake pedal to apply the brakes. As the piston for the master cylinder moves, brake fluid flows from the outlet to the wheel cylinders. The relief valve gives a 2300 kPa (332 psi) limit to the hydraulic pressure in the brake valve. 1. BRAKE VALVE (BOOSTER) 2. INLET 3. PLUNGER

4. PISTON (BRAKE VALVE) 5. PISTON ROD 6. OUTLET TO HYDRAULIC TANK

7. MASTER CYLINDER 8. PISTON (MASTER CYLINDER) 9. OUTLET TO WHEEL CYLINDERS

10. INLET FROM BRAKE RESERVOIR 11. RELIEF VALVE

NOTE: MASTER CYLINDER FOR LIFT TRUCK MODELS E3.50-5.50XL (E70-120XL, E70-120XL 3) (C098) AND E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/E098) SHOWN. 1. 2. 3. 4. 5.

FILLER PLUG GASKET HOUSING PUSH ROD BOOT

6. 7. 8. 9. 10.

INTAKE PORT COMPENSATOR PORT LOCK WIRE PISTON STOP PLATE PISTON ASSEMBLY

11. PRIMARY CUP 12. RETURN SPRING 13. CHECK VALVE

Figure 3. Master Cylinder

Description and Operation

1800 SRM 338 the shoes apart when the hand lever pulls the cables. On units with a powershift transmission and a MONOTROLÂ® pedal, the hand lever also actuates a switch. The switch de-energizes the circuit for the MONOTROL pedal and the forward and reverse solenoids when the parking brake is applied. The action of the switch puts the transmission in NEUTRAL and makes the Start circuit complete.

1. 2. 3. 4. 5. 6.

WHEEL CYLINDER BACK PLATE RETURN SPRING - GREEN ADJUSTER LINKS ADJUSTER SPRING LEVER ADJUSTER SCREW WHEEL (RIGHT-HAND THREAD) 7. ADJUSTER SCREW NUT 8. FRONT BRAKE SHOE 9. RETURN SPRING - BLACK Figure 4. Service Brakes (Left Side Shown) The automatic adjusting linkage turns the adjuster screw wheel to adjust the clearance between the brake shoes and the brake drum. The secondary shoe and the links move with the drum during a stop when the truck is traveling in reverse. The links permit the adjuster spring lever to rotate the adjuster screw wheel. The adjuster screw wheel can only turn when there is clearance between the lining and the brake drum. The adjuster screw wheel can be turned manually through a slot in the back plate.

PARKING BRAKE The parking brake uses the service brake shoes. See Figure 5 and Figure 6. Additional linkage pushes

1. HAND LEVER 2. SWITCH 3. TERMINALS, NORMALLY CLOSED (NC) CIRCUIT 4. TERMINALS, NORMALLY OPEN (NO) CIRCUIT 5. LINK 6. CABLES TO BRAKE SHOES Figure 5. Parking Brake Arrangement for Lift Truck Models S3.50-5.50XL (S70-120XL) (D004) and H3.50-5.00XL (H70-110XL) (F005/G005)

1800 SRM 338

Description and Operation For adjustment procedures for seat brake used on E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/ E098) lift trucks, go to the section Seat Brake Assembly in this manual. For adjustment procedures for seat brake used on E3.50-5.50XL (E70-120XL, E70120XL 3 (C098) lift trucks, see the section Frame 100 SRM 284.

1. PARKING BRAKE LEVER 2. APPLIED POSITION

3. RELEASED POSITION 4. SWITCH LEVER 5. SWITCH

Figure 6. Parking Brake Arrangement for Lift Truck Models E3.50-5.50XL (E70-120XL, E70-120XL 3) (C098) and E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/E098)

SEAT BRAKE Lift truck models E3.50-5.50XL (E70-120XL, E70120XL 3 (C098) and E3.50-5.50XL, E4.50XLS (E70120Z, E100ZS) (D098/E098) covered in this manual may be equipped with an optional seat brake that is attached to the traction motor and is actuated automatically when the operator leaves seat. See Figure 7. When correctly adjusted, this brake will hold lift truck with a capacity load on a 15% grade [a slope that increases 1.5 m increase in 10 m (1.5 ft increase in 10 ft)]. Make sure service brakes operate correctly before checking operation of seat brake. If brake does not hold lift truck on grade, seat brake must be adjusted by authorized service personnel.

NOTE: TRACTION MOTOR AND SEAT BRAKE FOR LIFT TRUCK MODELS E3.50-5.50XL, E4.50XLS (E70120Z, E100ZS) (D098/E098) SHOWN. 1. GUIDE PIPE CONNECTION 2. ELECTRICAL CONNECTION 3. SEAT BRAKE Figure 7. Traction Motor and Seat Brake Assembly

Brake Shoe Assemblies Repair

1800 SRM 338

Brake Shoe Assemblies Repair REMOVE AND DISASSEMBLE WARNING Brake linings can contain dangerous fibers. Breathing the dust from these brake linings is a cancer or lung disease hazard. Do not create dust! Do not clean brake parts with compressed air or by brushing. Use vacuum equipment approved for brake dust or follow the cleaning procedure in this section. When the brake drums are removed, do not create dust. Do not sand, grind, chisel, hammer, or change linings in any way that will create dust. Any changes to linings must be done in a restricted area with special ventilation. Protective clothing and a respirator must be used. 1. Tilt mast back and put blocks under outer mast weldment. Tilt mast forward to raise tires from floor.

WARNING Completely remove the air from the tires, on lift trucks equipped with pneumatic tires, before removing them from the lift truck. Air pressure in the tires can cause the tire and wheel parts to explode, causing serious injury or death. 2. The wheels, hub, and brake drum can be removed as an assembly. See Figure 4 and Figure 8. Make sure to remove air pressure from tires on lift trucks equipped with pneumatic tires, before you remove wheels from hub. 3. Remove capscrews that hold axle shaft to hub. Remove axle shaft.

4. Remove lock nut, lock plate, and bearing adjustment nut from axle housing. Remove outer bearing cone. Remove wheels, hub, and brake drum as an assembly. Remove inner seals and bearing cone from hub.

WARNING When the brake shoes are removed, do not create dust in the air. See the Clean and Inspect procedures in this section. 5. To loosen brake shoes, turn adjuster screw. Disconnect anchor link and actuator link. Remove adjuster spring lever. 6. Use spring pliers to remove shoe return springs. 7. Remove three spring clips.

CAUTION The adjuster screw assemblies are not the same. Make sure that each assembly has identification for installation on the correct side of the axle. 8. Remove brake shoes from wheel cylinder rods. Remove adjuster screw spring. Remove adjuster screw assembly. 9. Remove parking brake cable from lever. Remove lever from primary shoe. 10. Disconnect and put cap on the line to the wheel cylinder. Remove support flange and backplate. Remove two capscrews that hold wheel cylinder to backplate. Remove cable clamp and pull cable through backplate.

1800 SRM 338

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.

Brake Shoe Assemblies Repair

BACKPLATE SUPPORT FLANGE CAPSCREW AND LOCKWASHER CAPSCREW AND LOCKWASHER WHEEL CYLINDER ASSEMBLY SPRING AND RETAINER ASSEMBLY PISTON CUP PISTON PUSH ROD FITTING BOOT ANCHOR PIN SHOE AND LINING ASSEMBLY SHOE GUIDE SPRING PIN SHOE GUIDE SPRING CLIP

16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30.

RETURN SPRING - BLACK RETURN SPRING - GREEN ADJUSTER SCREW SPRING ADJUSTER SCREW WHEEL ADJUSTER SCREW NUT ADJUSTER SCREW GUIDE AUTOMATIC ADJUSTER SPRING LEVER ACTUATOR LINK ANCHOR END LINK LINK PIVOT SHOE ADJUSTER SLOT PLUG PARKING BRAKE LEVER SPRING CLIP PARKING BRAKE CONNECTING LINK SPECIAL FITTING

Figure 8. Brake Assembly (Right Side Shown)

Brake Shoe Assemblies Repair

CLEAN AND INSPECT 1. Cleaning Procedures:

CAUTION Do not use an oil solvent to clean the wheel cylinder. Use a solvent approved for cleaning of brake parts. Do not permit oil or grease in the brake fluid or on the brake linings. a. Do not release brake lining dust from brake linings into air when brake drum is removed. b. Use a solvent approved for cleaning of brake parts to wet the brake lining dust. Follow instructions and cautions of manufacturer for use of solvent. If a solvent spray is used, do not create dust with spray. c. When dust is wet, clean parts. Put any cloth or towels in a plastic bag or an airtight container while they are still wet. Put a DANGEROUS FIBERS warning label on plastic bag or airtight container. d. Any cleaning cloths that will be washed must be cleaned so fibers are not released into the air.

WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the recommendations of the manufacturer. e. Clean all metal parts except linings and wheel cylinder with solvent. 2. Inspection procedures: NOTE: The procedures in Step a and Step b do not apply to seat brake used on E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/E098) lift truck models. a. Check bore of wheel cylinder for holes or scratches. Replace wheel cylinder if there is any damage. b. Check return springs for damage. Inspect backplate for wear where brake shoes touch backplate.

1800 SRM 338 c. Inspect brake shoes for cracks or damage. If linings or shoes are worn or damaged, replace brake shoes. It is recommended that brake shoes be replaced in complete sets. NOTE: The procedure in Step d does not apply to seat brake used on E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/E098) lift truck models. d. Check adjuster screw wheel for wear. Make sure adjuster screw turns. Check for bent or broken adjuster links. NOTE: Service Brakes only: If brake drums require turning, do not remove more than 1.5 mm (0.060 in.) from the diameter. The maximum inside diameter of the brake drum, including wear, is 319.25 mm (12.57 in.). If the brake drum is larger than this, replace brake drum. e. Inspect brake drums for cracks or damage. Use sandpaper on surface for brake shoes. (1)

For the seat brake used on E3.505.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/E098) lift truck models, inspect brake drums for cracks or damage. Replace drums if there are cracks or damage.

ASSEMBLE AND INSTALL WARNING The brake shoes on both wheels must be replaced if any shoe is damaged. The brake performance on both ends of an axle must be equal or the lift truck can be difficult to steer when the brakes are applied. 1. Install wheel cylinder on backplate. Push parking cable through backplate and fasten clamp. See Figure 4 and Figure 8. 2. Install backplate and support plate. Install tapered dowels, capscrews, and nuts. Use the sequence shown in Figure 9 and tighten nuts to 54 to 81 N•m (40 to 60 lbf ft). Use the same sequence and tighten nuts 108 to 122 N•m (80 to 90 lbf ft). Using a hand torque wrench, verify that nuts are between 95 to 122 N•m (70 to 90 lbf ft).

1800 SRM 338

Brake Shoe Assemblies Repair

CAUTION The shoe return springs are not the same. Always install the black spring on the left-hand brake shoe. 6. Correctly install shoe return springs. Connect cable for parking brake to lever.

WARNING

Figure 9. Support Plate Tightening Sequence 3. Connect brake line to fitting on wheel cylinder. 4. Install link pivot on rear shoe. Install parking brake lever on front shoe. Install anchor pins in support flange so they engage brake shoes. 5. Lubricate shoe pads of backplate with molybdenum grease. Put shoes on backplate and install holddown pins and clips. Engage connecting link with parking brake lever. See Figure 10.

The threads of the adjuster wheel are not the same for each side. If the adjuster assemblies are installed on the wrong side, the brake shoe clearance will increase each time the brakes are applied. The adjuster wheel for the right brake has left-hand threads. The adjuster wheel for the left brake has right-hand threads. 7. Lubricate adjuster screw with Never-SeezeÂŽ. Turn adjuster screw in so brake shoes retract. Install adjuster between shoes. Align adjuster screw wheel with slot in backplate. Install adjuster spring with long hook toward adjuster screw wheel. Install adjuster spring lever and two links. 8. Install brake drum and adjust brake shoes until they touch brake drum. Rotate brake drum so brake shoes are correctly aligned within brake drum. Carefully remove brake drum so brake shoes do not move.

CAUTION If there is too much clearance, the automatic adjusters will not operate. If the clearance is too small, the automatic adjuster cannot turn the adjuster wheel to increase the clearance and the adjuster wheel will not turn until the brake shoes wear. If the adjuster wheel does not move for a long operating period, the adjuster link can wear a spot on the adjuster wheel so that it will not turn correctly.

1. PARKING BRAKE CONNECTING LINK 2. PARKING BRAKE LEVER Figure 10. Parking Brake Linkage (Right Side Shown)

9. The automatic adjuster lever must be set at 1.5 to 3.0 mm (0.06 to 0.12 in.) above the centerline of the adjuster screw wheel. See Figure 11. Use the tool to make sure automatic adjustment lever is in correct position. Bend link away from hub as necessary to adjust automatic adjustment lever. Correct adjustment of lever is necessary for correct operation of automatic adjustment mechanism.

Brake Shoe Assemblies Repair

1800 SRM 338

10. Use the following procedures to install hub and brake drum for lift truck models H3.50-5.00XL (H70-110XL) (F005/G005) (see Figure 12): a. Use new oil seals. Install inner seal, bearing cups, and outer seal in hub. Install inner bearing cone on spindle. Lubricate inner bearing with grease. b. If the brake drum was removed, assemble brake drum, hub, and wheel. Tighten nuts for brake drum to 285 N•m (210 lbf ft) on units with dual wheels. Tighten nuts for wheels to 610 to 680 N•m (450 to 500 lbf ft) on all units.

CAUTION Do not damage the seals when you install the hub assembly. c. Install hub and wheel on spindle. Lubricate outer bearing cone with 80W-90 oil for gears. Install outer bearing cone and adjustment nut. d. Tighten adjustment nut to 203 N•m (150 lbf ft) while you rotate hub. Loosen nut until hub rotates freely. The torque must be less than 27 N•m (20 lbf ft). Tighten nut to 34 N•m (25 lbf ft) or to first alignment position after 34 N•m (25 lbf ft). Install lockwasher to hold nut. Install lock nut. Tighten lock nut to 135 N•m (100 lbf ft). Legend for Figure 11 A. REFERENCE B. BEND 1. 2. 3. 4. 5. 6. 7.

ACTUATOR LINK AUTOMATIC ADJUSTMENT LEVER ADJUSTER SCREW GUIDE ADJUSTER SCREW WHEEL ADJUSTER SCREW WHEEL CENTERLINE BACKPLATE TOOL

Figure 11. Brake Adjustment (Right Side Shown)

1800 SRM 338

Brake Shoe Assemblies Repair

A. FOR H3.50-5.00XL (H70-110XL) (F005/G005) MODELS B. FOR S3.50-5.50XL (S70-120XL) (D004), E3.50-5.50XL (E70-120XL, E70-120XL 3) (C098), AND E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/E098) MODELS 1. 2. 3. 4. 5. 6.

AXLE SHAFT HUB BRAKE DRUM LOCK NUT LOCK PLATE ADJUSTMENT NUT

7. 8. 9. 10. 11. 12.

AXLE SPINDLE BEARING ASSEMBLY OIL SEAL O-RING WHEEL BRACKET

Figure 12. Drive Axle and Brake Assembly

Brake Shoe Assemblies Repair

1800 SRM 338 until hub rotates freely. The torque must be less than 27 N•m (20 lbf ft). Tighten nut to 34 N•m (25 lbf ft) or to first alignment position after 34 N•m (25 lbf ft). Install lockwasher to hold nut. Install lock nut. Tighten lock nut to 135 N•m (100 lbf ft).

CAUTION When the wheels have been installed, check all wheel nuts after 2 to 5 hours of operation. Tighten the nuts to the correct torque. When the nuts stay tight after an 8-hour check, the interval for checking can be extended to 350 hours. e. Apply sealant (Hyster Part Number 264159) to flange of axle shaft. Install axle shaft. Tighten capscrews to 225 N•m (165 lbf ft). 11. Use the following procedures to install hub and brake drum for lift truck models (see Figure 12) S3.50-5.00XL (S70-110XL) (D004), E3.50-5.50XL (E70-120XL, E70-120XL 3) (C098), and E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/E098): a. Use new oil seals. Install inner seal, bearing cups, and outer seal in hub. Install inner bearing cone on spindle. Lubricate inner bearing with grease. b. If brake drum was removed, install brake drum on hub. Install several nuts on studs for wheel. c. Install hub assembly on spindle. Lubricate outer bearing cone with 80W-90 oil for gears. Install outer bearing cone and adjustment nut. d. Tighten adjustment nut to 203 N•m (150 lbf ft) while you rotate hub. Loosen nut

CAUTION Do not damage the seals when you install the hub assembly. e. Install wheels. Tighten nuts for wheels to 610 to 680 N•m (450 to 500 lbf ft). f.

Apply sealant (Hyster Part Number 264159) to flange of axle shaft. Install axle shaft. Tighten capscrews to 225 N•m (165 lbf ft).

CAUTION When the wheels have been installed, check all wheel nuts after 2 to 5 hours of operation. Tighten the nuts to the correct torque. When the nuts stay tight after an 8-hour check, the interval for checking can be extended to 350 hours for lift truck models E3.50-5.50XL (E70-120XL) (C098), S3.50-5.50XL (S70-120XL) (D004), and H3.50-5.00XL (F005/G005) and 500 hours for lift truck models E3.50-5.50XL (E70-120XL 3) (C098), E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/E098) 12. Remove air from brake system and adjust brakes. See Brake System Air Removal and Brake Shoes Adjustment in this section.

1800 SRM 338

Master Cylinder Repair

Master Cylinder Repair MASTER CYLINDER FOR LIFT TRUCK MODELS S3.50-5.50XL (S70-120XL) (D004) AND H3.50-5.00XL (H70-110XL) (F005/G005) NOTE: Replace the brake booster seal (Figure 17) when you repair or replace the master cylinder.

Remove 1. Disconnect brake line at master cylinder. Cover end of brake line. Disconnect wires at brake switch. Disconnect hose from reservoir. Put plug in end of hose. See Figure 13. 2. Remove capscrews that hold master cylinder to brake valve.

Disassemble WARNING The piston has a compressed spring behind it. Remove the piston carefully. 1. Remove retaining ring from end of master cylinder. Carefully remove piston and spring from bore. See Figure 14.

CAUTION DO NOT use an oil solvent to clean the master cylinder, wheel cylinder, or the brake linings. Use a solvent approved for cleaning of brake parts. Do not put oil or grease in the brake fluid or on the linings. 2. Remove seals from piston.

Assemble NOTE: Lubricate parts of master cylinder with clean brake fluid. 1. Install seal support washer on piston. Install seals on piston. Make sure cup washer is installed as shown in Figure 14. Carefully install spring and piston assembly in master cylinder. Do not damage seals. 2. Install retaining ring for piston. 1. 2. 3. 4. 5. 6.

BRAKE BOOSTER INLET FROM STEERING CONTROL UNIT OUTLET TO HYDRAULIC TANK MASTER CYLINDER INLET FROM RESERVOIR OUTLET TO WHEEL CYLINDERS

Figure 13. Brake Booster and Master Cylinder for Lift Truck Models S3.50-5.50XL (S70-120XL) (D004) and H3.50-5.00XL (H70-110XL) (F005/G005)

Install 1. Put master cylinder in position on brake booster and install capscrews for master cylinder. See Figure 13. 2. Connect brake lines and wires. Connect hose to brake fluid reservoir. Fill reservoir and remove air from brake system as described in Brake System Air Removal in this section.

Master Cylinder Repair

1. 2. 3. 4. 5.

1800 SRM 338

6. 7. 8. 9. 10.

HOUSING RETAINING RING SEAL PISTON SPRING

CUP WASHER SEAL SUPPORT WASHER CHECK VALVE SPRING FITTING

Figure 14. Master Cylinder

MASTER CYLINDER FOR LIFT TRUCK MODELS E3.50-5.50XL (E70-120XL, E70-120XL 3) (C098) AND E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/E098) Remove and Disassemble 1. Remove floor plate. Disconnect brake line at master cylinder. Put caps on brake line and port in cylinder. See Figure 15. 2. Remove return spring for pedal. Disconnect rod end at pedal. 3. Remove capscrews that hold master cylinder to frame. Remove master cylinder.

4. Remove boot and push rod as an assembly. Drain fluid in reservoir. 5. Put master cylinder in a vise that has soft jaws. Make sure piston is at upper end of housing. Use a screwdriver to hold piston against return spring. See Figure 16.

WARNING The piston has a compressed spring behind it. Carefully remove the piston so you can control the spring and prevent an injury.

1800 SRM 338

Master Cylinder Repair goggles or a face shield to prevent injury to the eyes.

CAUTION When the piston is removed or installed, make sure the cylinder bore and piston is not scratched or damaged. 6. Remove lock wire and piston stop plate. Carefully remove piston from cylinder. 7. Remove spring and check valve.

Clean and Inspect

WARNING Compressed air can move particles so that they cause injury to the user or to other personnel. Make sure that the path of the compressed air is away from all personnel. Wear protective

2. Inspect bore of master cylinder and machined surfaces of piston. Replace a master cylinder that has a damaged bore or piston.

NOTE: MASTER CYLINDER FOR LIFT TRUCK MODELS E3.50-5.50XL (E70-120XL, E70-120XL 3) (C098) AND E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/E098) SHOWN. 1. 2. 3. 4. 5.

ROD END JAM NUT PUSH ROD BOOT LOCK WIRE

6. 7. 8. 9. 10.

PISTON STOP PLATE PISTON ASSEMBLY PRIMARY CUP RETURN SPRING CHECK VALVE

11. BODY 12. GASKET 13. FILLER PLUG

Figure 15. Master Cylinder

Brake Booster Repair

1800 SRM 338

Assemble and Install 1. Lubricate all parts with clean brake fluid. 2. Use a repair kit (Hyster Part No. 54977A). Install parts in the order shown in Figure 15. Use a screwdriver to hold piston in housing. See Figure 16. Make sure lock ring is correctly installed before you release piston. 3. Insert push rod into piston. Install boot over flange on housing. 4. Install master cylinder on frame. Connect rod end and return spring at brake pedal. 5. Install brake line on master cylinder. See Brake System Air Removal in this section to remove air from brake system and Brake Shoes Adjustment to adjust brake shoes. 6. Install floor plate. 1. PISTON 2. MASTER CYLINDER Figure 16. Piston Removal

Brake Booster Repair REMOVE

WARNING

1. Disconnect brake pedal from brake booster at push rod. See Figure 13.

The retainer has a compressed spring behind it. Carefully remove the retainer so you can control the spring and prevent an injury.

2. Disconnect hydraulic lines at brake booster. Put caps on open lines.

4. Remove retainer from housing.

3. Disconnect brake lines and wires at master cylinder. Disconnect hose from reservoir at master cylinder. Put plug in end of hose. 4. Remove capscrews that hold brake booster to bracket. Remove brake booster and master cylinder as an assembly.

DISASSEMBLE 1. Remove master cylinder from brake booster. See Figure 17. 2. Remove dust cover and push rod. 3. Remove retaining ring and washer for plunger. Remove plunger from retainer.

5. Remove piston, spring, and piston rod from housing. 6. Remove seals and O-rings from the parts of the brake booster. 7. If necessary, remove parts of relief valve from housing.

CLEAN AND INSPECT WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the recommendations of the manufacturer.

1800 SRM 338

Brake Booster Repair

Clean parts of brake booster with solvent. Check surface of machined parts for wear and damage.

ASSEMBLE

1. Assemble parts for relief valve. Make sure all parts are in their original positions. See Figure 17. 2. Install seals for piston rod, plunger, and piston.

NOTE: Use new parts from the repair kit (Hyster Part No. 375653). Lubricate parts with hydraulic oil during assembly. Make sure parts are clean.

CAUTION Do not let brake fluid touch any of the parts of the brake booster. The brake fluid can damage the seals in the brake booster.

3. Install piston rod, piston, and spring in housing. Install retainer and O-ring in housing. Tighten retainer to 210 to 290 Nâ&#x20AC;¢m (155 to 215 lbf ft). 4. Install plunger in retainer. Install washer and retaining ring. 5. Install dust cover and push rod.

NOTE: BRAKE BOOSTER FOR LIFT TRUCK MODELS S3.50-5.50XL (S70-120XL) (D004) AND H3.50-5.00XL (H70-110XL) (F005/G005) SHOWN. 1. 2. 3. 4. 5. 6. 7.

PUSH ROD DUST COVER RETAINING RING WASHER RETAINER PLUNGER SEAL

8. 9. 10. 11. 12. 13. 14.

PISTON PISTON ROD SLEEVE O-RING SCREW RELIEF PISTON SPRING

15. 16. 17. 18. 19. 20.

GUIDE SHIM PLUG SNAP RING SPRING HOUSING

Figure 17. Brake Booster

Brake Pedal Adjustment

1800 SRM 338

INSTALL NOTE: See Figure 18 for lift trucks H3.50-5.00XL (H70-110XL) (F005/G005) with manual transmission. See the section Single-Speed Powershift Transmission, Troubleshooting and Repair 1300 SRM 397 for lift trucks S3.50-5.50XL (S70-120XL) (D004) . 1. Install brake booster on bracket.

2. Connect hydraulic lines to brake booster. Connect brake lines and wires to master cylinder. Connect hose from reservoir to master cylinder. 3. Connect push rod to crank and brake pedal. Install pin for push rod. 4. Remove air from brake system and adjust brake linkage as described in Brake System Air Removal and Brake Shoes Adjustment in this section.

Brake System Air Removal NOTE: The E3.50-5.50XL (E70-120XL, E70-120XL 3) (C098) and E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/E098) models do not have a special fitting at the master cylinder. Loosen nut on tube at master cylinder to remove air that you cannot remove at the wheel cylinders. The air must be removed from the brake fluid. Fill reservoir for master cylinder with brake fluid. Always remove air from master cylinder first, then

wheel cylinders. Put one end of a rubber hose on special fitting at master cylinder or wheel cylinders. Put other end of hose in a container with brake fluid. Loosen special fitting. Push slowly on brake pedal. Close special fitting. Repeat the procedure until no air bubbles are seen in container. Check fluid level in reservoir. Keep reservoir full of brake fluid during these procedures.

Brake Pedal Adjustment BRAKE PEDAL FOR LIFT TRUCK MODELS H3.50-5.00XL (H70-110XL) (F005/G005) WITH MANUAL TRANSMISSION AND E3.50-5.50XL (E70-120XL, E70-120XL 3) (C098) AND E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/E098) NOTE: The brake adjustment procedures for lift truck models H3.50-5.00XL (H70-110XL) (F005/G005), with powershift transmissions are in the section Powershift Transmission, Repairs 1300 SRM 337. For lift truck models S3.50-5.50XL (S70-120XL) (D004) see the section Single-Speed Powershift Transmission, Troubleshooting and Repair 1300 SRM 397 for brake pedal adjustment procedures. 1. Make the adjustments when the key switch is in the OFF position and the engine is not running. Use the stop screw to adjust the height of the brake pedal: • H3.50-5.00XL (H70-110XL) (F005/G005) 111 mm (4.38 in.) (Figure 18) • E3.50-5.50XL (E70-120XL, E70-120XL 3) (C098) and E3.50-5.50XL, E4.50XLS (E70-

120Z, E100ZS) (D098/E098)81 mm (3.19 in.) (Figure 19) Tighten nut on stop screw. 2. Adjust push rod for clearance between end of push rod and plunger (brake booster) or piston (master cylinder). Rotate push rod to make the adjustment. Set clearance as follows: • H3.50-5.00XL (H70-110XL) (F005/G005): Rotate push rod until it just touches plunger in brake booster. Rotate push rod 2.12 turns in the opposite direction to get the correct clearance. The correct clearance lets the pedal move down 9.5 mm (0.37 in.) before the push rod touches the plunger. Tighten jam nut against push rod. • E3.50-5.50XL (E70-120XL, E70-120XL 3) (C098) and E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/E098): Adjust push rod so pedal moves down 1 to 4 mm (0.04 to 0.16 in.) before the push rod touches the piston. Tighten jam nut against push rod.

1800 SRM 338

Brake Pedal Adjustment Legend for Figure 18 1. 2. 3. 4.

BRAKE PEDAL PEDAL PAD FLOOR PLATE STOP SCREW

5. 6. 7. 8.

PUSH ROD PLUNGER BRAKE BOOSTER JAM NUT

Figure 18. Brake Pedal Adjustment H3.50-5.00XL (H70-110XL) (F005/G005)

1. BRAKE PEDAL 2. MASTER CYLINDER 3. PUSH ROD

4. JAM NUT 5. ROD END 6. FLOOR PLATE

7. STOP SCREW 8. RETURN SPRING

Figure 19. Brake Pedal Adjustment E3.50-5.50XL (E70-120XL, E70-120XL 3) (C098) and E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/E098)

Parking Brake Adjustment

1800 SRM 338

Brake Shoes Adjustment The brake shoes are automatically adjusted when the brakes are applied while the truck travels in reverse. Use the procedure that follows to manually adjust the brakes after you make repairs.

screw wheel in opposite direction. Turn adjuster screw wheel 25 teeth (or clicks) for the necessary clearance between brake shoes and drum. Rotate drive wheel to check for clearance.

1. Put lift truck on blocks so drive wheels do not touch ground. See the section Periodic Maintenance for your unit for the correct procedures. Make sure blocks do not prevent access to backplates of brakes.

6. Repeat Step 3, Step 4, and Step 5 at other brake assembly. Install plugs in backplates.

2. Remove plugs in slots in backplates [26, Figure 8]. 3. Use a tool for brake adjustment in slot nearest teeth of adjuster screw wheel [19, Figure 8]. Push up on teeth and turn adjuster screw wheel until brake shoes touch brake drum. 4. Put a small screwdriver through slot in backplate. Move automatic adjustment lever [2, Figure 11] away from adjuster screw wheel.

7. Remove lift truck from blocks. Drive lift truck in FORWARD and REVERSE. Use brakes to stop ten times in each direction. NOTE: If the automatic brake adjusters adjust the brake shoes too much or too little, refer to Assembly and Installation in this section for the brake shoes. If the brake shoes are too tight (too much adjustment), adjust position of automatic adjustment lever to 1.5 mm (0.06 in.) above centerline of adjuster screw wheel. If brake shoes are too loose (not enough adjustment), adjust position of automatic adjustment lever to 3.0 mm (0.12 in.) above centerline of adjuster screw wheel.

5. Turn adjuster screw wheel with tool for brake adjustment. Push down on teeth to turn adjuster

Parking Brake Adjustment PARKING BRAKE ADJUSTMENT, LIFT TRUCK MODELS S3.50-5.50XL (S70-120XL) (D004) AND H3.50-5.00XL (H70-110XL) (F005/G005) Turn knob on parking brake lever to adjust parking brake. The brake must hold the lift truck with a capacity load on a 15% grade [a slope that increases 1.5 m in 10 m (1.5 ft increase in 10 ft)]. Lift trucks with a powershift transmission and a MONOTROL pedal have a switch on the inside of

the cowl. See Figure 20. A link on the parking brake lever operates the switch. The switch closes the circuit for starting the engine and opens the circuit for the MONOTROL control system. Make sure that the link moves up far enough to actuate the switch when the parking brake is applied. The normally closed (NC) circuit (Figure 20) of the switch must be open when the parking brake is applied. The normally open (NO) circuit (Figure 20) must be closed so you can start the engine. Bend link as necessary or replace link if link does not correctly actuate switch.

1800 SRM 338

Parking Brake Adjustment Turn knob on parking brake lever to adjust parking brake. See Figure 21. The brake must hold the lift truck with a capacity load on a 15% grade [a slope that increases 1.5 m in 10 m (1.5 ft increase in 10 ft)]. The parking brake switch is actuated by the parking brake lever. When the lever is released (OFF), the switch is closed, energizing the traction circuit. When the parking brake is applied, the switch is open and the traction circuit will not operate. Check the adjustment of the parking brake switch when the lever is released. In this position, the switch lever must be 1 to 3 mm (0.04 to 0.12 in.) past the applied position.

1. HAND LEVER 2. SWITCH 3. TERMINALS, NORMALLY CLOSED (NC) CIRCUIT 4. TERMINALS, NORMALLY OPEN (NO) CIRCUIT 5. LINK 6. CABLES TO BRAKE SHOES Figure 20. Parking Brake Arrangement, Lift Truck Models S3.50-5.50XL (S70-120XL) (D004) and H3.50-5.00XL (H70-110XL) (F005/G005)

PARKING BRAKE LEVER AND SWITCH ADJUSTMENT E3.50-5.50XL (E70-120XL, E70-120XL 3) (C098) AND E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/E098) NOTE: See the section Frame 100 SRM 284 for lift truck models E3.50-5.50XL (E70-120XL, E70-120XL 3) (C098) and Frame 100 SRM 1200 for lift truck models E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/E098) for the adjustment procedure for the seat brake.

1. 2. 3. 4. 5.

PARKING BRAKE LEVER APPLIED POSITION RELEASED POSITION SWITCH LEVER SWITCH Figure 21. Parking Brake E3.50-5.50XL (E70-120XL, E70-120XL 3) [C098] and E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) [D098/E098]

Seat Brake Assembly

1800 SRM 338

Seat Brake Assembly REMOVE NOTE: The procedures in this section apply only to lift truck models E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (D098/E098) NOTE: Remove the battery from the lift truck before removing the seat brake. See the Operating Manual or the section Periodic Maintenance 8000 SRM 1201 for the procedures. 1. Loosen brake drum capscrew. Pull manual release lever up to release the compression spring. Remove capscrew, washer, and lockwasher from brake drum. Remove brake drum from brake assembly. Remove spacer from motor shaft. 2. Put manual release lever down. Disconnect guide pipe and brake cable. Disconnect electrical connections. See Figure 7 and Figure 22. 3. Loosen the compression spring. Remove pin securing clevis and stud to brake assembly and traction motor. Remove brake assembly from traction motor. 4. Remove two capscrews from seat brake mounting bracket. Remove seat brake mounting bracket from traction motor.

5. Remove two rod end pins from seat brake mounting bracket to disconnect the solenoid.

CLEAN AND INSPECT Follow the Clean and Inspect procedures in the Brake Shoe Assemblies Repair section in this SRM.

INSTALL 1. Install and connect the solenoid to seat brake mounting bracket using two rod end pins. 2. Install seat brake to mounting bracket and traction motor with two capscrews. 3. Install pins to secure clevis and stud to brake assembly and traction motor. Tighten nuts on compression spring. 4. Connect the electrical connections, brake cable, and guide pipe. 5. Install spacer on motor shaft. Install lockwasher, washer, and capscrew into brake drum and install brake drum onto brake assembly. Tighten brake drum capscrew.

Legend for Figure 22 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

CAPSCREW BRACKET MOUNTING BRACKET FOR TRACTION MOTOR NUT WASHER DISC SPRING MANUAL RELEASE LEVER PIN ROD END PIN WIRE STOP BRAKE CABLE CONTROLLER LOCKWASHER GUIDE PIPE

15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27.

CABLE LINK COMPRESSION SPRING CUP STUD SPACER BRAKE ASSEMBLY BRAKE DRUM COTTER PIN MOUNTING PLATE CLEVIS SWITCH SOLENOID GUIDE PIPE FITTING

1800 SRM 338

Seat Brake Assembly

Figure 22. Seat Brake Assembly

Seat Brake Assembly

ADJUSTMENTS Solenoid Adjustment NOTE: The solenoid is energized when the brake is released and de-energized when the brake is applied. 1. With the brake fully assembled and the solenoid de-energized, adjust the adjusting nut so the compression spring plus cup is 70 mm (2.75 in.) in length. Tighten Locknut. See Figure 24. NOTE: The stroke is the amount the plunger protrudes from the solenoid body when it is de-energized. 2. Loosen locknut. Screw the plunger in or out of the clevis to adjust plunger stroke to 4 mm (0.016 in.). Tighten locknut. See Figure 24. 3. Raise the handle to energize the solenoid which will release the seat brake and check for drag by rotating the brake drum by hand. 4. If the brake drags while the solenoid is de-energize tighten locknut to increase the plunger stroke by 1/2 a turn and repeat Step 3 and Step 4 until the brake does not drag. 5. Tighten the clevis lock nut. NOTE: The solenoid is correctly adjusted when the brake fully releases with the minimum possible solenoid stroke.

1800 SRM 338 NOTE: After the solenoid is adjusted, verify there is a minimum 7.0 mm (.028 in.) clearance between the jam nut on the thumb wheel and the inside of the solenoid housing when the solenoid is de-energized (brake applied). See Figure 23.

Traction cutoff Switch Adjustment 1. Mount switch to bracket leaving both screws loose enough to rotate the switch. 2. Mount the bracket and switch to the brake assembly and apply loctite part number 251099 to the screws and install washers and nuts as shown in Figure 23. 3. Using the Powered Solenoid, adjust the switch by rotating it so that a full solenoid compression the switch is actuated, switch should "click", allowing for a 0.5 mm (0.019 in.) feeler gauge to be placed between the metal leaf and the switch housing. Once the correct position is determined the mounting screws should be tightened to 0.45 to 0.56 Nâ&#x20AC;˘m (4 to 5 lbf in). 4. Once switch is correctly adjusted the manual release handle will need to be readjusted to ensure that the minimum 0.5 mm (0.019 in.) clearance is maintained between the leaf and the switch housing.

1800 SRM 338

1. 2. 3. 4. 5.

Seat Brake Assembly

6. 7. 8. 9. 10.

TRACTION SWITCH CAPSCREWS SOLENOID JAM NUT THUMB WHEEL

BRACKET LEAF SCREW WASHER NUT

Figure 23. Traction Cutoff Switch Adjustment

Cable Adjustment

2. Move the handle to the DOWN position.

NOTE: The Solenoid and Traction Cutoff Switch adjustment must be completed before adjusting the release cable.

3. Pull the handle back into the UP position, and check for drag by rotating the brake drum by hand.

NOTE: When handle is in the UP position, brake is released. When handle is in the DOWN position, brake is applied. NOTE: The solenoid must NOT be energized when performing this procedure.

4. If the brake drags while the handle is in the UP position, lower the handle, loosen the wire stop, pull cable through, and retighten the wire stop. Repeat Step 3 and Step 4 until the brake no longer drags. Lower the handle to the DOWN position.

NOTE: When the handle is in the UP position, the air gap between the leaf and the switch housing must be 0.5 mm (0.019 in.) minimum.

5. Adjust handle by tightening nut to 0.85 Nâ&#x20AC;˘m (7.5 lbf in) so that the washers clamp onto the handle but allows handle to pivot easily.

1. With brake fully assembled, and the handle in the UP position. Pull the cable tight through the wire stop. Insert excess cable into the handle. See Figure 24.

Seat Brake Assembly

1800 SRM 338

Figure 24. Seat Brake Adjustment

1800 SRM 338

Troubleshooting Legend for Figure 24

1. 2. 3. 4. 5. 6. 7. 8. 9.

BRACKET LOCKNUT ADJUSTING NUT CUP COMPRESSION SPRING CLEVIS SOLENOID HANDLE SCREW

10. 11. 12. 13. 14. 15. 16. 17. 18.

WASHER LOCKWASHER CAPSCREW BRAKE DRUM TRACTION MOTOR CABLE-BRAKE NUT WASHER WIRE STOP

Brake Booster Relief Valve Check The relief valve is adjusted at the factory and is not normally adjustable. Shims can be added or removed

between the spring and the valve stem. The correct relief pressure is 2300 kPa (332 psi).

Troubleshooting PROBLEM The brakes do not stop the lift truck correctly.

POSSIBLE CAUSE

PROCEDURE OR ACTION

Air is in the brake system.

Remove air from brake system.

The mount for the master cylinder is loose.

Tighten master cylinder.

The brake shoes are worn or damaged.

Install new brake shoes.

The linings are too hard.

Install new brake shoes.

A brake drum is cracked.

Install new brake drum.

A backplate is damaged.

Install new backplate.

A wheel cylinder is leaking or does not operate correctly.

Repair or install a new wheel cylinder.

The brake linings do not fit the brake drums.

Install new brake shoes.

The master cylinder is damaged.

Repair or install a new master cylinder.

Water or oil is on the brake linings.

Clean linings or install new brake shoes.

Troubleshooting

PROBLEM One brake does not release.

The brakes make too much noise.

The brakes do not operate equally.

Both brakes do not release.

1800 SRM 338

POSSIBLE CAUSE

PROCEDURE OR ACTION

A brake shoe is damaged.

Install new brake shoes.

A return spring is wrong.

Install new spring.

The brake lines have a restriction.

Install new brake lines.

A parking brake cable is damaged or needs adjustment.

Adjust or install new brake cable(s).

The wheel cylinder is damaged.

Repair or install new wheel cylinder.

The backplate is worn or damaged.

Install new backplate.

Oil, water, or brake fluid is on the linings.

Clean linings or install new brake shoes.

The brake linings or brake shoes are worn or damaged.

Install new brake shoes.

The brake drum is damaged.

Install new brake drum.

Oil or brake fluid is on the linings.

Clean linings or install new brake shoes.

The lining are worn or hard.

Install new brake shoes.

A wheel cylinder is leaking.

Repair or install new wheel cylinder.

The brake shoes are not correctly installed.

Install brake shoes.

The backplate or brake shoes are damaged.

Install new parts.

The brake drum is not round.

Repair or install new brake drum.

The shoes are adjusted too tightly.

Adjust brake shoes correctly.

The parking brake is not released.

Adjust parking brake.

The parking brake cables need adjustment.

Adjust parking brake.

There is not enough clearance for the push rod.

Adjust brake linkage.

The master cylinder is damaged.

Repair or install new master cylinder.

Brake shoes are adjusted too tightly.

Adjust brake shoes.

1800 SRM 338

PROBLEM The parking brake will not hold the lift truck.

The parking brake will not release.

Troubleshooting

POSSIBLE CAUSE

PROCEDURE OR ACTION

Oil, water, or brake fluid is on the linings.

Clean linings or install new brake shoes.

The parking brake cables need adjustment.

Adjust parking brake.

The parking brake cable is damaged.

Install new cable(s).

The parking brake lever is adjusted too tightly.

Adjust parking brake.

The parking brake cables are damaged.

Install new cable(s).

&22/,1* 6<67(0 INTERNAL COMBUSTION ENGINE POWERED UNITS

PART NO. 897934

700 SRM 626

Cooling System

Table of Contents

1 2 2 2 2 3 3 3 3 3 4 4 4 4 4 4 5 6

This section is for the following models: Internal Combustion Engine Powered Units

700 SRM 626

General

General This section has the description and the checks for some parts of the cooling system. Prodecures for cleaning the radiator and troubleshooting are also included in this section.

The cooling system has the following parts: radiator, auxiliary coolant reservoir, water pump, thermostat, fan, and fan shroud. See Figure 1.

1. 2. 3. 4.

5. 6. 7. 8.

AUXILIARY COOLANT RESERVOIR RADIATOR CAP RADIATOR RADIATOR DRAIN VALVE

TOP RADIATOR HOSE FAN SHROUD BOTTOM RADIATOR HOSE PORTS FOR TRANSMISSION OIL COOLER

Figure 1. Typical Radiator Arrangement

Description

700 SRM 626

Description The purpose of the cooling system is to control the operating temperature of the engine (and in some units, the transmission, brakes, and hydraulic system). A centrifugal water pump circulates coolant through passages in the engine block and the radiator. A thermostat is installed in the water outlet fitting on the engine. As the coolant flows through the radiator, the fan moves air through the radiator to help cool the system. The coolant is a mixture of water and antifreeze. The antifreeze prevents the coolant from freezing in cold weather, and thereby preventing damage to the engine and radiator. The antifreeze also prevents rust and lubricates the water pump.

RADIATOR The radiator is the heat exchanger for the cooling system. The fan causes air to flow through the radiator and reduces the temperature of the coolant. The auxiliary coolant reservoir is connected to the radiator by a hose. As the engine gets hot, the coolant expands. During expansion, coolant moves from the radiator to the reservoir. When the engine stops, the coolant becomes cool and contracts. The coolant in the reservoir flows back into the radiator. In this way, the radiator is kept filled with coolant during normal operation.

by another spring. The vacuum valve opens to relieve the vacuum created when the coolant temperature decreases. In certain conditions this vacuum can cause the radiator or top hose to collapse.

THERMOSTAT The thermostat is a device that controls coolant flow by opening and closing to regulate coolant temperature. The thermostat uses a wax pellet to control its operation. The wax pellet expands when it is heated and contracts when it is cold. When heated, the wax pellet pushes on the piston, causing the valve in the thermostat to open. As the wax pellet cools, it contracts and lets a spring close the valve. When the engine is first started and the coolant is cold, the thermostat remains closed. During this time the coolant circulates through the engine, letting it warm quickly. As the engine becomes warm the thermostat opens, letting coolant circulate through the radiator. The opening and closing of the thermostat helps keep the coolant within the operating limits of the system. The same thermostat is used for summer and winter seasons. Do not operate the engine without a thermostat. The engine will take longer to get warm and may run improperly. See Figure 2.

On units with a powershift transmission, an oil cooler is built into the radiator. Oil from the transmission flows through coils in the radiator tank to help control the oil temperature.

RADIATOR CAP The radiator cap is a pressure-vent type that lets the pressure in the cooling system increase to 103 kPa (15 psi). The pressure in the system prevents vapor from forming in the coolant flowing to the water pump. This action maintains the efficiency of the water pump and the performance of the cooling system. The increase in pressure also raises the boiling point of the coolant mixture to approximately 125 C (257 F) at sea level. The radiator cap has a pressure valve and a vacuum valve. The pressure valve is held against its seat by a spring. The pressure valve opens when the pressure in the cooling system exceeds 103 kPa (15 psi). The vacuum valve is held against its seat

1. 2. 3. 4.

PISTON VALVE SEAT SPRING DIAPHRAGM

5. 6. 7. 8.

WAX PELLET FRAME FLANGE VENT HOLE

Figure 2. Typical Thermostat

700 SRM 626

Cooling System Checks

WATER PUMP

FAN AND FAN SHROUD

The centrifugal-type water pump is installed at the front of the engine block. The inlet for the pump is connected to the bottom of the radiator by a hose. From the pump, coolant passes through the passages in the engine block to the top of the radiator. The thermostat controls the flow of coolant through the engine and radiator.

The fan is used to provide airflow through the radiator at all engine speeds. The fan is a pusher-type or puller-type and can be installed on the water pump or on a separate hub. The fan is driven by a drive belt from the engine crankshaft. The fan shroud ensures the air flow from the fan goes through the core of the radiator.

Cooling System Checks RADIATOR

2. Mix solution of water with 33% antifreeze. Heat solution to 14 C (57 F) above temperature on thermostat.

WARNING During engine operation, be careful not to touch the fan, pulleys, or drive belts. Contact with these parts can cause serious injury.

3. Hold thermostat with wire and put it in solution. Stir solution. If operating correctly, thermostat will open.

NOTE: The Repair procedures for the radiator are in the Frame section of the Service Manual.

4. Remove thermostat and put in same solution at â&#x2C6;&#x2019;12 C (10 F) below temperature on thermostat. Valve must close completely.

To check for water flow restrictions in the radiator, run the engine until it is warm. Shut the engine OFF and feel the radiator. The temperature must be even across the radiator. (The radiator will be hotter near the top radiator hose.) Cold spots on the radiator indicate restrictions. If the radiator has leaks, have it repaired by trained personnel.

THERMOSTAT WARNING During engine operation, be careful not to touch the fan, pulleys, or drive belts. Contact with these parts can cause serious injury.

CAUTION DO NOT operate the engine without a thermostat. The engine and cooling system can be damaged. NOTE: Repair procedures for the thermostat are in the Engine section of the Service Manual. 1. Remove thermostat from cooling system. Figure 3.

See

1. 2. 3. 4.

FAN SPACER HUB/PULLEY WATER PUMP

5. THERMOSTAT 6. THERMOSTAT HOUSING

Figure 3. Cooling System Components Typical Arrangement

Radiator Cleaning

700 SRM 626

WATER PUMP

FAN AND FAN SHROUD

WARNING

During engine operation, be careful not to touch the fan, pulleys, or drive belts. Contact with these parts can cause serious injury. NOTE: Repair procedures for the water pump are in the Engine section of the Service Manual. Run the engine until it is warm. Check the operation of the water pump by holding the top radiator hose. If the pump is operating, there will be pressure surges in the hose. See Figure 3.

During engine operation, be careful not to touch the fan, pulleys, or drive belts. Contact with these parts can cause serious injury.

WARNING DO NOT try to repair a damaged fan. If a fan has a bent blade or is cracked, install a new fan. A damaged fan can break during use and cause damage or serious injury. NOTE: Repair procedures for the fan and shroud are in the Frame section of the Service Manual.

EXHAUST LEAKS WARNING During engine operation, be careful not to touch the fan, pulleys, or drive belts. Contact with these parts can cause serious injury. To check for exhaust leaks into the cooling system, use a kit for this purpose. Follow the manufacturerâ&#x20AC;&#x2122;s instructions when doing the test.

1. When installing fan, make sure correct spacers are installed and mounting capscrews are tight. See Figure 1 and Figure 3. 2. When installing fan shroud, make sure correct seals are on shroud. Before tightening capscrews, make sure clearance around circumference of fan is even with shroud. Also make sure 1/3 to 1/2 of cross-section of fan blade extends into fan shroud. 3. Make sure WARNING labels are installed on shroud.

Radiator Cleaning DRAIN WARNING DO NOT remove the radiator cap from the radiator when the engine is hot. When the radiator cap is removed, the pressure is released from the system. If the system is hot, the steam and boiling coolant can cause burns.

CAUTION Disposal of lubricants and fluids must meet local environmental regulations. 1. Let coolant cool to room temperature. Put drain pan under radiator. Remove radiator cap. See Figure 1.

2. Open drain valve or remove bottom radiator hose. Remove drain plug from engine block to drain engine.

CLEAN CAUTION Disposal of lubricants and fluids must meet local environmental regulations. 1. Drain cooling system. Fill cooling system with clean water. 2. Install radiator cap. Run engine until top radiator hose is hot. Stop engine and let engine cool.

700 SRM 626 3. Drain water from radiator. If water is dirty, fill system with water and repeat procedure until water is clean.

CAUTION Follow the manufacturer’s instructions when using a chemical radiator cleaner. 4. If water does not clean system, use chemical radiator cleaner.

CAUTION Follow the manufacturer’s instructions when using special equipment to reverse clean the radiator. NOTE: On lift truck models S3.50-5.50XM (S70-120XM) (E004), the cooling system may be equipped with an optional radiator screen.

Radiator Cleaning NOTE: Units with a Mazda engine must use a boronfree type of antifreeze. 2. Fill cooling system with mixture of 50% water and 50% ethylene glycol antifreeze. Install radiator cap. The 50/50 mixture will protect the cooling system to −37 C (−35 F). 3. Use same coolant mixture to fill auxiliary coolant reservoir to FULL mark. See Figure 4. 4. Start and run engine until thermostat opens. (Top radiator hose will be warm.) 5. Check coolant level at auxiliary coolant reservoir. Add coolant as necessary to keep level between FULL and ADD marks.

5. If radiator or cooling system is very dirty or has restriction, use reverse cleaning method. This method uses air pressure to force water through radiator in opposite direction of normal flow.

WARNING Compressed air can move particles so they cause injury to the user or to other personnel. Make sure the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes. 6. Check radiator fins. Clean exterior of radiator with compressed air or water as needed.

FILL 1. Install drain plug in engine block. Close drain valve or install bottom radiator hose as needed.

1. 2. 3. 4. 5.

ADD MARK FULL MARK AUXILIARY COOLANT RESERVOIR FILL CAP RADIATOR CAP

WARNING Do not use an alcohol or methanol-base antifreeze. They are flammable and can cause personal injury or damage to the lift truck.

Figure 4. Auxiliary Coolant Reservoir

Troubleshooting

700 SRM 626

Troubleshooting PROBLEM Coolant leaks.

The engine is too hot during operation.

Exhaust leaks into coolant.

POSSIBLE CAUSE

PROCEDURE OR ACTION

There is a leak in the radiator.

Repair radiator.

There is a leak in a radiator hose or coolant hose.

Install new hoses.

There is a leak from a plug or sensor in the engine block.

Check sensors and plugs, and repair leaks.

Water pump leaks.

Install new water pump.

Thermostat housing leaks.

Install new thermostat housing. Check for correct installation of thermostat.

Cylinder head gasket is damaged.

Install new head gasket.

Cylinder head is cracked.

Install new cylinder head.

Engine block is cracked.

Install new cylinder block.

There is not enough coolant in the cooling system.

Check coolant level in radiator and coolant recovery bottle. Add coolant to correct level.

The radiator is dirty.

Drain and clean radiator. Clean radiator fins with low pressure air or water in reverse direction of normal air flow. Be careful not to bend fins. Refill with clean coolant.

The drive belt for water pump is not adjusted correctly, worn, or broken.

Check water pump drive belt. Adjust or install new belt as required.

The thermostat is wrong heat range or does not operate correctly.

Check heat range. Install new thermostat.

The cooling system has restrictions.

Drain and back-flush engine and radiator. Refill with clean coolant.

The water pump is worn or damaged.

Install new water pump.

The exhaust system has restrictions.

Check exhaust system. Remove restrictions.

Ignition timing is not correct.

Check and adjust timing.

Head gasket(s) leaks.

Install new gasket(s).

Cylinder head is damaged.

Install new cylinder head.

INTRODUCTION GENERAL

can rotate in the mounts. The outer ends of the axle housings are the spindles for the wheel bearings. The wheel bearings are tapered roller bearings with the cups pressed into the hubs. The nut on the end of the axle housing adjusts and holds the wheel bearings. The axle shafts are fastened to the hubs by capscrews and two dowel pins. The back plate and brake assembly are fastened to the axle mounts. The axle housing also has the bearing journals for the upright.

This section has the description and repair procedures for the drive axle, wheel bearings and the mounts for the axle housing. The differential and ring and pinion gears are described in the sections for the SINGLEâ&#x20AC;&#x201C;SPEED POWERSHIFT TRANSMISSION, 900 SRM 347 and 900 SRM 348.

DESCRIPTION (See FIGURE 1.) The outer wheel bearing is lubricated by gear oil from the differential housing. The inner wheel bearing is lubricated by wheel bearing grease.

The drive axle assembly is fastened to the frame of the lift truck by separate mounts. The drive axle assembly

1. 2. 3. 4. 5.

AXLE HOUSING AXLE MOUNT BRAKE ASSEMBLY BRAKE DRUM SEAL

15 6 10

8 3

11 12 13

1 12179

3 5

4 6 7

6. 7. 8. 9. 10. 11. 12. 13. 14. 15.

BEARING CONE BEARING CUP HUB ADJUSTMENT NUT LOCK WASHER LOCK NUT AXLE SHAFT TIRE AND WHEEL MOUNTING PIN DOWEL PIN

FIGURE 1. DRIVE AXLE ASSEMBLY

REPAIRS REMOVAL 1. Remove the upright assembly as described in the section for the VISTA MASTS, 4000 SRM 340.

REMOVAL

2. Raise the front of the lift truck and put blocks under the frame. Drain the oil from the differential housing. 3. Remove the drive wheels. 4. Remove the capscrews that hold the axle shafts to the hubs. There are two holes with threads in the flange of the axle shaft. Put capscrews (M16x2) in these holes to push the axle shaft from the hub. Or, hit the end of the axle shaft with a soft hammer. Remove the axle shaft.

WARNING Brake linings contain dangerous fibers. Breathing the dust from these brake linings is a cancer and lung disease hazard. Do not create dust! Do not clean brake parts with compressed air or by brushing. Use vacuum equipment approved for brake dust or follow the cleaning procedure in this section. When the brake drums are removed, do not create dust. Do not sand, grind, chisel, hammer or change linings in any way that will create dust. Any changes to linings must be done in a restricted area with special ventilation. Protective clothing and a respirator must be used. 5. Remove the nut, lock washer and flat washer. Remove the hub and brake drum and the bearings. If the brake drum cannot be easily removed, loosen the brake shoes by turning the adjuster wheel. 6. Disconnect the brake lines at the wheel cylinders. Remove the brake shoe assemblies from the back plates. Remove the back plates from the axle housings. 7. Put a block for support under the transmission. Remove the capscrews that hold the axle housing to the transmission housing. 8. Use a lifting device to hold the weight of the axle housing. Use a puller (see FIGURE 2.) to remove the mounting pins from the frame and the axle mount. Remove the bolts that hold the axle mounts to the frame. Remove the mounts from the axle housings. 2

INSTALLATION 1. FRAME 2. AXLE MOUNT 3. MOUNTING PIN

4. BOLT 5. SPACER

FIGURE 2. AXLE MOUNT NOTE: If a mounting pin cannot be removed, soak it in penetrating oil or use a hacksaw blade to saw a slot in the pin. Use a puller as shown in FIGURE 2. to remove the pin.

CLEANING 1. Do not release brake lining dust from the brake linings into the air when the brake drum is removed. 2. Use a solvent approved for cleaning of brake parts to wet the brake lining dust. Follow the instructions and cautions of the manufacturer for the use of the solvent.to wet the asbestos dust on the parts of the brake. If a solvent spray is used, do not create brake lining dust with the spray.

CAUTION Do not use an oil solvent to clean the wheel cylinder. Use a solvent approved for cleaning of brake parts. Do not permit oil or grease in the brake fluid or on the brake linings. 3. When the brake lining is wet, clean the parts. Put any cloth or towels in a plastic bag or an airtight container while they are still wet. Put a “DANGEROUS FIBERS” warning label on the plastic bag or airtight container.

WARNING Cleaning solvents can be flammable and toxic, and can cause skin irritation. When using cleaning solvents, always follow the safety instructions for the solvent manufacturer. 4. Any cleaning cloths that will be washed must be cleaned so that fibers are not released into the air. 5. Clean all parts of the drive axle with solvent. Dry with compressed air.

with the frame and install the axle housing onto the transmission housing. Install the capscrews and washers. Tighten the capscrews to 65 Nm (50 lbf ft). 3. Install the capscrews for the axle mounts, but do not tighten them. Lubricate the mounting pins with an anti– sieze compound. Use the bolt and spacer shown in Figure 2 to install the mounting pins in the axle mounts and the frame. Make sure the mounting pins are installed as shown in Figure 2. After the mounting pins are installed tighten the capscrews for the axle mounts to 320 Nm (235 lbf ft). 4. Assemble the brake assembly to the mount for the axle housing as described in the section for THE BRAKE SYSTEM, 1800 SRM 338.

6 7 9

7 2

11 5

10 8

1 8

INSPECTION 4

Inspect the bearings and seals for defects. The axle housings must rotate freely in the mounts. The splines for the axle shafts must not be damaged.

ASSEMBLY (See FIGURE 1., FIGURE 2. AND FIGURE 3.) 1. Use a lifting device to hold the axle housing. Apply sealant Hyster Part No. 264159 on the flange of the axle housing. 2. Lubricate the surface for the axle mounts on the axle housing with an anti–sieze compound. Slide the axle mounts onto the axle housing. Align the axle mounts

12190

1. 2. 3. 4. 5.

AXLE HOUSING AXLE MOUNT BRAKE SYSTEM HUB AXLE SHAFT

6. 7. 8. 9. 10. 11.

WHEEL SEAL BEARING ASSEMBLY ADJUSTMENT NUT LOCK WASHER LOCK NUT

FIGURE 3. DRIVE AXLE 5. Install the seal in the center of the hub. Lubricate the inner bearing with grease. Install the inner seal in the hub. Install the brake drum on the hub. Install the hub and brake drum on the axle. Use care not to damage the

seals when installing the hub. Lubricate the outer bearing cone with grease and install the outer bearing cone. 6. Install the adjustment nut. Tighten the nut to 205 Nm (150 lbf ft) while rotating the hub. Loosen the nut until the hub rotates freely. The torque must be less than 25 Nm (20 lbf ft). Tighten the nut to 35 Nm (25 lbf ft) or to the first alignment position after 35 Nm (25 lbf ft). Install the lock washer to hold the nut. Install the lock nut and tighten it to 135 Nm (100 lbf ft). 7. Apply sealant Hyster Part No. 264159 to the flange of the axle shaft. Install the axle shaft. Tighten the capscrews to 225 Nm (165 lbf ft). 8. Install the wheels. Tighten the wheel nuts to 610–680 Nm (450–500 lbf ft).

CAUTION When the wheels have been installed, check all wheel nuts after 2–5 hours of operation. Tighten the nuts in a cross pattern to the correct torque value. When the nuts stay tight after an eight hour check, the interval for checking the torque can be extended to 350 hours. 9. Install the upright as described in the section for the UPRIGHT. Fill the differential housing with 80W–90EP or 85W–140 gear lubricant through the fill hole. Remove the air from the brake system as described in the section for THE BRAKE SYSTEM, 1800 SRM 338.

TROUBLESHOOTING PROBLEM

CAUSE

The lift truck will not move.

An axle shaft is broken.

The drive axle assembly has leaks.

The drain plug or fill plug is loose. The seals are damaged.

The drive axle makes noise.

The bearings are damaged. The brake assembly is installed wrong. The oil level is too low. The capscrews for the axle shaft(s) or axle housing are loose or missing. The brake drum is damaged.

INTRODUCTION GENERAL

There is a counterweight for each capacity of lift truck. The counterweights are similar, but are different weights. The muffler is fastened to the frame inside of the counterweight.

This section has the description of the frame and some connected parts. See FIGURE 1. Procedures for the removal and installation of the counterweight, hood, overhead guard, and engine (including the transmission and radiator) are described in REPAIRS. Checks for the operator restraint system and procedures for the repair of tanks and replacement of safety labels are included.

An overhead guard is fastened to the cowl at the front of the lift truck and to a frame plate at the rear of the lift truck. The hood is connected to the frame plate with hinges. A gas controlled spring gives assistance when raising the hood and holds the hood in the open position. The floor plates can be removed for access to the transmission and other components.

DESCRIPTION The frame is one weldment and includes the hydraulic tank and the fuel tank for gasoline or diesel fuel.

REPAIRS blocks under the counterweight so that the lift truck can not fall backward.

WARNING The lift truck must be put on blocks for some types of maintenance and repair. The removal of the following assemblies will cause large changes in the center of gravity: mast, drive axle, engine and transmission, and the counterweight. When the lift truck is put on blocks, put additional blocks in the following positions to maintain stability:

b. Before removing the counterweight, put blocks under the mast assembly so that the lift truck can not fall forward. The surface must be solid, even, and level when the lift truck is put on blocks. Make sure that any blocks used to support the lift truck are solid, one piece units.

a. Before removing the mast and drive axle, put

1 1. OVERHEAD GUARD 2. HOOD 3. COUNTERWEIGHT 4. FRAME 5. FLOOR PLATE 6. DRIVE AXLE 7. STEERING AXLE 8. MAST 9.CARRIAGE

2 3

FIGURE 1. FRAME AND CONNECTED PARTS 1

COUNTERWEIGHT The counterweight is held in position on the frame by two hooks that are part of the frame. See FIGURE 2.

One large capscrew holds the counterweight to the lower part of the frame.

WARNING Do not operate the lift truck if the capscrew for the counterweight is not installed. When the capscrew is removed, the counterweight can fall from the lift truck.

12228

Close the fuel valve on the LPG tank before any part of the engine fuel system is disconnected. Run the engine until the fuel in the system is used and the engine stops. If the engine will not run, close the fuel valve on the LPG tank. Loosen the fitting on the supply hose from the LPG tank where it enters the filter unit. Permit the pressure in the fuel system to decrease slowly. Fuel leaving the fitting removes heat. Use a cloth to protect your hands from the cold fitting. 2. Use the following procedure to remove the LPG tank: a. Removable LPG tanks can be removed and replaced indoors only if the lift truck is at least 8 metres (25 feet) from any open flame or ignition source. b. Move the lift truck to the area where tanks are changed.

1. FRAME HOOKS (COUNTERWEIGHT MOUNTS) 2. COUNTERWEIGHT 3. SHIM 4. CAPSCREW 5. LIFTING EYE

FIGURE 2. COUNTERWEIGHT MOUNT

Removal 1. If the lift truck has an LPG fuel system, remove the LPG tank and bracket so that the counterweight can be removed. Additional information on the LPG fuel system can be found in the section, THE LPG FUEL SYSTEM, 900 SRM 15.

WARNING LPG can cause an explosion. Do not cause sparks or permit flammable material near the LPG system. LPG fuel systems can be disconnected indoors only if the lift truck is at least 8 metres (25 feet) from any open flame, motor vehicles, electrical equipment, or ignition source. 2

c. Turn the tank fuel valve clockwise until the valve is completely closed. d. Run the engine until it stops, then turn the key switch to the OFF position. e. Disconnect the quick disconnect fitting. f. Release the LPG tank latch and remove the tank from the bracket.

WARNING The counterweight castings have the following approximate weights: S3.50XL 1910 to 1980 kg (S70XL) (4214 to 4368 lb) S4.00XL 2242 to 2312 kg (S80XL) (4946 to 5100 lb) S4.00XL BCS 2120 to 2210 kg (S80XL BCS) (4677 to 4831 lb) S4.50XL 2450 TO 2520 kg (S100XL) (5405 to 5559 lb) S5.50XLS 3125 to 3225 kg (S120XLS) (6894 to 7114 lb) S5.50XL 3035 to 3125 kg (S120XL) (6695 to 6893 lb)

3. Install a lifting eye in the lifting hole of the counterweight. Connect a crane to the lifting eye and raise the crane until it holds part of the weight of the counterweight. Remove the capscrew that holds the counterweight to the frame. Use the crane to lift the counterweight from the lift truck. Installation

nect the gas controlled spring to the hood. Adjust the position of the hood with the latch on the front cover. Tighten the capscrews for the hood hinges.

WARNING The hood, hood latch and hood striker must be correctly adjusted for the correct operation of the operator restraint system.

1. When the counterweight is installed, make sure the hooks on the frame fully engage the counterweight so that it is aligned with the parts of the frame. Tighten the M24 x 3 capscrew to 555 N.m (410 lbf ft).

2. See FIGURE 5. Use the following procedure to adjust the hood latch:

2. If the lift truck has an LPG fuel system, install the bracket for the LPG tank. Use the following procedure to install the LPG tank:

b. Install the latch striker in the highest slot position on the floor plate. Check that the latch striker is in the center of the jaws of the hood latch.

a. Before the LPG tank is installed on the lift truck, make sure the tank has fuel in it. Check the operation of the fuel gauge. Look at the fuel gauge and move the tank. If the gauge needle does not move, a new tank must be installed.

c. Close the hood to the fully closed position. The hood latch has two positions. The hood is fully closed after two clicks of the latch.

b. Put the tank in the tank bracket. Make sure that the tank is aligned with the alignment pin. c. Close the latch. d. Connect the quick disconnect fitting to the fuel valve on the tank. Use your hand to tighten the fitting. Do not open the fuel valve until the quick disconnect fitting is completely tightened. Turn the fuel valve counterclockwise to open the fuel valve. e. Inspect the fuel system for leaks when the fuel valve is open. Frost on the surface of the tank, valves or fittings or a strong odor indicates leakage.

HOOD (See FIGURE 1.) Removal 1. Raise the hood. Hold the hood so that it does not fall and disconnect the gas controlled spring at the hood. 2. Remove the capscrews that hold the hood hinges to the frame of the lift truck. Remove the hood. Installation 1. Install the hood in position on the lift truck. Install the capscrews that hold the hood hinges to the frame. Con-

a. Install the floor plate and tighten the capscrews.

d. Loosen the capscrews for the latch striker just enough to let the striker move. Push the hood down until the hood just touches the rubber bumpers on the frame. Make sure the latch striker is still in the center of the hood latch. Tighten the capscrews for the striker. e. Check the operation of the hood latch. Have an operator sit in the seat. Make sure that the hood is fully closed (two clicks). Also check that the hood touches the rubber bumpers. If additional adjustment is necessary, repeat Step d.

MUFFLER (See FIGURE 3.) The muffler is inside the counterweight and between the counterweight and the radiator. A short exhaust pipe sends the exhaust gases out of the lift truck through the grille in the counterweight. The lift truck can have an overhead exhaust system. The exhaust pipe is fastened to the right rear leg of the overhead guard. 2. Install the fan and fan shroud in position on the radiator. Install the four capscrews that hold the fan shroud and the radiator to the frame. Install the capscrews that fasten the fan to the hub. Connect the upper coolant hose at the radiator. 3

4 OVERHEAD EXHAUST

4 3 1

1. 2. 3. 4.

MUFFLER MOUNT EXHAUST PIPE (FROM ENGINE EXHAUST PIPE (OUTLET)

3 1

FIGURE 3. EXHAUST PIPES AND MUFFLER

RADIATOR AND COOLANT SYSTEM Removal

tor. Also disconnect these lines at the transmission housing. Put caps on the open lines and ports. Remove the two capscrews that still hold the radiator. Remove the radiator.

1. Drain the coolant from the radiator and the engine. Installation 2. Remove the capscrews that hold the fan shroud to the radiator. Remove the four capscrews that fasten the fan to the hub and remove both the fan and the fan shroud. 3. Disconnect the coolant hoses at the radiator. Disconnect the lines to the oil cooler in the bottom of the radia4

1. Install the radiator with the two capscrews that do not fasten the fan shroud. Connect the lines for transmission oil to the oil cooler in the radiator. Also connect these lines at the ports in the transmission housing. Connect the lower coolant hose to the radiator.

OVERHEAD GUARD

WARNING Do not operate the lift truck without the overhead guard correctly fastened to the lift truck. Changes that are made by welding, or by drilling holes that are too big in the wrong location, can reduce the strength of the overhead guard. See the instructions for â&#x20AC;&#x153;Changes to the Overhead Guardâ&#x20AC;? in the PERIODIC MAINTENANCE section included with this lift truck.

and retracts smoothly. The seat belt must be in good condition. A seat belt that is damaged or worn will not give protection when it is needed. If the seat belt can not be pulled from the retractor assembly, remove the screw that keeps the cover on the retractor. Push the bar to release the spool. Straighten the belt so that it will pull and retract smoothly from the retractor assembly. See FIGURE 4.

Removal and Installation Connect a crane or lifting device to remove or install the overhead guard. If the lift truck has an overhead exhaust, disconnect and remove the exhaust pipe assembly. Four bolts and two capscrews hold the overhead guard to the frame. The overhead guard is fastened to the cowl and the rear frame plate. The two capscrews for the front legs of the overhead guard are under the cowl. Disconnect any electric wires from under the cowl that go through the legs of the overhead guard. When the overhead guard is lifted from the frame, make sure any electric wires are moved through the holes in the frame so that they are not damaged.

OPERATOR RESTRAINT SYSTEM (See FIGURE 4. and FIGURE 5.) The seat belt, hip restraint brackets, seat and mount, hood, latches and floor plates are all part of the operator restraint system. Each item must be checked to make sure it is fastened correctly, functions correctly and is in good condition. The end of the seat belt must fasten correctly in the latch. Make sure the seat belt pulls from the retractor assembly

2 3 1. OPEN COVER 2. SEAT BELT RETRACTOR

11806

3. SEAT BELT 4. BAR

FIGURE 4. RELEASE A JAMMED SEAT BELT See FIGURE 5. Make sure the seat rails and latch striker are not loose. The seat rails must lock tightly in position, but move freely when unlocked. The seat rails must be correctly fastened to the mount surface. If the mount surface is the hood, the hood must be fastened to the floor plate with the latch. The floor plate must be fastened to the lift truck frame. Try to lift the hood to make sure it is fastened correctly and will not move. Adjust the hood, hood latch and latch striker when any of the parts of the operator restraint system are installed or replaced. See HOOD for the adjustment procedures.

4 2

9 1

1 8

11858

1. 2. 3. 4. 5. 6. 7. 8. 9

LATCH STRIKER HOOD LATCH LATCH LEVER SEAT SEAT BELT LATCH HIP RESTRAINT SEAT RAIL FLOOR PLATE HOOD

FIGURE 5. CHECK THE HOOD AND SEAT LATCHES

ENGINE REMOVAL AND INSTALLATION NOTE: The engine can be removed with or without the transmission. To remove only the engine, do step 1 through step 6. To remove the engine and the transmission, do steps 1 through 5 and step 7. Removal 1. Put the lift truck on blocks. See the OPERATING MANUAL or the section PERIODIC MAINTENANCE, 8000 SRM 393 for the correct procedures to put the lift truck on blocks. Remove the overhead guard and the hood and hood crossâ&#x20AC;&#x201C;bar. Remove the floor plates. Remove the cover between the hood and the counterweight. 2. Disconnect the cables at the battery. Remove the battery and the battery tray. 3. Remove the radiator, fan and fan shroud. Disconnect the exhaust pipe at the exhaust manifolds. Remove the air filter housing from the frame. 4. Disconnect the fuel lines at the engine. Disconnect the throttle linkage at the engine. Disconnect the wires and wiring harnesses at the engine. 5. Disconnect the hydraulic line between the hydraulic filter and the tank. Put plugs in the open holes and move 6

the filter toward the cowl. Disconnect the oil lines at the hydraulic pump. Drain the hydraulic tank and put plugs on the open ports. 6. Do the following procedures to remove only the engine and not the transmission: a. Remove the rightâ&#x20AC;&#x201C;hand bracket for the brake pedal shaft. See FIGURE 6. b. Remove the plug in the torque converter housing. Remove the capscrews that hold the drive plate for the torque converter to the flywheel. c. Connect a lifting device to the engine. Make sure the lifting device has a capacity of at least 450 kg (1000 lb). Put blocks under the transmission to hold it in position. d. Remove the bolts that hold the engine mounts to the frame of the lift truck. Use the lifting device to hold the weight of the engine. e. Remove the capscrews that hold the transmission to the flywheel housing. Put capscrews in the holes with threads in the housing to push the transmission from the flywheel housing. f. Raise the engine from the frame. Be careful of the hydraulic pump and the brake booster. Make sure that all wires and hoses are disconnected.

11858

1. 2. 3. 4. 5. 6. 7. 8. 9 10. 11.

BRAKE SWITCH PEDAL SHAFT PEDAL PAD BRACKET, RIGHT BRACKET, LEFT FLANGE (2) COLLAR BRAKE BOOSTER LINK (2) SPRING PIN

12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.

SPRING (2) SPRING LINK SPACER WASHER CRANK BRACKET SPACER (2) PIN (3) PIN COTTER PIN (4)

23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39.

BALL JOINT BALL JOINT, LEFT NUT (3) WASHER (5) LOCKWASHER (3) NUT CAPSCREW CAPSCREW (8) CAPSCREW CAPSCREW (3) NUT (5) NUT LOCKWASHER (11) NUT WASHER CAPSCREW (2) LOCKWASHER (2)

FIGURE 6. BRAKE PEDAL ASSEMBLY

7. Do the following procedures to remove the engine and transmission as a unit:

a. Remove the accelerator or Monotrol pedal assembly. See FIGURE 6. Remove the brake pedal 7

shaft. Disconnect the lines at the brake booster and remove the brake booster and the bracket. b. Disconnect the inching linkage at the transmission. On lift trucks with manual control, disconnect the direction control linkage at the transmission. Disconnect the supply line at the main control valve and put a plug on the line. c. Drain the oil from the axle housing. Remove the capscrews that hold the axle shafts to the hubs. Remove the axle shafts. d. Connect a crane and slings to the engine and the transmission. Make sure the crane has a capacity of at least 1000 kg (2000 lb). Make sure the crane is holding the weight of the engine and the transmission. Remove the bolts that hold the engine mounts to the frame of the lift truck. e. Remove the clamp for the parking brake cable at the bottom of the transmission. Remove the capscrews that hold the drive axle housing to the transmission housing. There are two holes with threads in the drive axle housing. Use capscrews in these holes to separate the housings. f. Carefully lift the engine and transmission from the frame. Put the engine in a position so that it has stability and will not fall over. g. Remove the transmission from the engine as described in the section POWERSHIFT TRANSMISSION, REPAIRS, 1600 SRM 397. Installation 1. See FIGURE 7. Install the engine mounts on the engine: a. GM Vâ&#x20AC;&#x201C;6: Tighten the capscrews that hold the engine mount to the engine to 30 N.m (25 lbf ft). Tighten the capscrews that hold the engine mount to the flywheel housing to 165 N.m (120 lbf ft). Tighten the bolts that hold the engine mounts to the mount plate to 65 N.m (50 lbf ft). b. Perkins: Apply a sealant to the threads of the capscrews and tighten the capscrews that hold the engine mounts to the engine to 65 N.m (50 lbf ft). 2. Do the following procedures to install the engine: a. Connect a lifting device to the engine. Make sure the lifting device has a capacity of 450 kg (1000 8

lb). Apply a sealant (Hyster Part No. 264159) to the flange of the flywheel housing. Make sure the torque converter is installed correctly and engaged with the oil pump.

CAUTION Make sure the tabs on the torque converter hub are aligned with the notches in the oil pump. If the parts are not engaged correctly, the oil pump or torque converter will be damaged. b. Install the engine in the lift truck. Carefully align the engine with the transmission making sure the pilot on the torque converter engages with the flywheel. Also check that the bearing for the drive gear for the hydraulic pump is aligned with the torque converter housing. c. Install the capscrews that hold the torque converter housing to the flywheel housing. Tighten the capscrews to 40 N.m (30 lbf ft). d. Install the capscrews that hold the drive plate for the torque converter to the flywheel. Tighten the capscrews to 45 N.m (30 lbf ft). Install the plug in the torque converter housing. e. Install the bolts for the engine mounts. (See FIGURE 7.) Tighten the bolts to 120 N.m (90 lbf ft). f. Install the radiator, fan and fan shroud. Connect the radiator hoses and oil lines at the radiator. Make sure that all hoses are kept away from the lower fan pulley. g. Connect the wiring harness and wires at the engine and transmission. Connect the throttle linkage and fuel lines at the engine. Install and connect the pipes for the exhaust system. h. Connect the hydraulic lines for the hydraulic pump, hydraulic filter and powershift transmission. i. Install the battery tray and batteries. Install the air filter assembly. j. Check all of the fluid levels and fill as necessary. Install the floor plates and covers. Install the hood. Install the overhead guard. Connect the cables at the battery.

1. ENGINE MOUNT 2. ENGINE BLOCK 3. CAPSCREW FOR ENGINE AT FLYWHEEL HOUSING 4. MOUNT PLATE 5. BOLT 6. WASHER 7. RUBBER MOUNT 8. LIFT TRUCK FRAME

GM Vâ&#x20AC;&#x201C;6

PERKINS 1000â&#x20AC;&#x201C;4

FIGURE 7. ENGINE MOUNTS 3. Do the following procedures to install the engine and the transmission: a. Install the transmission on the engine as described in the section POWERSHIFT TRANSMISSION, REPAIRS, 1600 SRM 397. b. Connect a crane to the engine and transmission. Clean the flanges on the transmission housing and the axle housing. Apply a sealant (Hyster Part No. 264159) to the flange of the transmission housing. c. Install the engine and transmission in the lift truck. Carefully align the transmission with the axle housing. Install the capscrews that hold the axle housing to the transmission. Tighten the capscrews to 65 N.m (50 lbf ft). Install the bolts for the engine mounts (see FIGURE 7.). Tighten the bolts to 120 N.m (90 lbf ft).

d. Install the radiator, fan and fan shroud. Connect the radiator hoses and oil lines at the radiator. Make sure that all hoses are kept away from the lower fan pulley. NOTE: See the section POWERSHIFT TRANSMISSION, REPAIRS, 1600 SRM 397 for procedures on connecting and adjusting the linkages for the transmission, Monotrol or accelerator pedal, and the brake pedal. e. See FIGURE 6. Install the brake booster. Connect the oil lines to the brake booster. Connect the brake lines to the master cylinder. Connect the wires to the brake switch on the master cylinder. Connect the oil lines to the main control valve and the transmission control valve. f. Install the inching linkage and the direction control linkage at the transmission. Install the inching/brake pedal shaft. Install the accelerator or Monotrol pedal. 9

g. Connect the wiring harness and wires at the engine and transmission. Connect the throttle linkage and fuel lines at the engine. Install and connect the pipes for the exhaust system. h. Connect the hydraulic lines for the hydraulic pump, hydraulic filter. i. Install the battery tray and batteries. Install the air filter assembly. j. Check all of the fluid levels and fill as necessary. Remove the air from the brake system. Install the floor plates and covers. Install the hood. Install the overhead guard. Connect the cables at the battery.

Repairs, Small Leaks Use the following procedure to repair small leaks: a. Use steam to clean the area around the leak. Remove all paint and dirt around the leak.

WARNING Do not use tools that can make sparks, heat or static electricity. The vapors in the tank can cause an explosion. b. Apply Loctite 290 to the leak. Follow the instructions of the manufacturer.

FUEL AND HYDRAULIC TANKS

Repairs, Large Leaks

Inspection

1. Use one of the procedures described under Cleaning to clean and prepare the tank for repairs.

Make a visual inspection of all sides of the tank. Inspect the welds for cracks and leakage. Check for wet areas, accumulation of dirt, and loose or missing paint caused by leakage. Areas of the tank that are not easily seen can be checked with an inspection mirror and a light that is approved for locations with flammable vapors.

2. Use acceptable welding practices to repair the tank. See the American National Standard Safety In Welding And Cutting ANSI Z 49.1 – 1973. Cleaning

WARNING Special procedures must be followed when large leaks or other repairs need welding or cutting. All work must be done by authorized personnel. If the tank is cleaned inside of a building, make sure there is enough ventilation. See the following manuals for additional information: • Safe Practices For Welding And Cutting Con-

tainers That Have Held Combustibles” by the American Welding Society, A6.0–65. • Safety In Welding And Cutting”, American

National Standard, ANSI Z 49.1 – 1973. When cleaning the tank, do not use solutions that make dangerous gases at normal temperatures or when heated. Wear eye and face protection. Protect the body from burns. When cleaning with steam, use a hose with a minimum diameter of 19 mm (0.75 inch). Control the pressure of the steam by a valve installed at the nozzle of the hose. If a metal nozzle is used, it must be made of a material that does not make sparks. Make an electrical connection be10

tween the nozzle and the tank. Connect a ground wire to the tank to prevent static electricity. Steam Method Of Cleaning Use the following procedure to clean the tank with steam: a. Remove all the parts from the tank. Install the drain plug. b. Fill the tank 1/4 full with a solution of water and sodium bicarbonate or sodium carbonate. Mix 0.5 kg (1 lb) per 4 litres (1 gal) of water. c. Mix the solution in the tank using air pressure. Make sure all the surfaces on the inside of the tank are flushed with the solution. Drain the tank. d. Put steam into the tank until the tank does not have odors and the metal is hot. Steam vapors must come from all the openings. e. Flush the inside of the tank with boiling water. Make sure all the loose material is removed from the inside of the tank. f. Make an inspection of the inside of the tank. If it is not clean, repeat steps 4 and 5 and make anoth-

er inspection. When making inspections, use a light that is approved for locations with flammable vapors. g. Put plugs in all the openings in the tank. Wait 15 minutes, then remove the inlet and outlet plugs. Test a sample of the vapor with a special indicator for gas vapors. If the amount of flammable vapors is above the lower flammable limit, repeat the cleaning procedures.

able, another method using water can be used as follows: a. Fill the tank with water to just below the point where the work will be done. Make sure the space above the level of the water has a vent. b. Use acceptable welding practices to repair the tank. See the American National Standard “Safety in Welding and Cutting,” ANSI Z 49.1 – 1973.

SAFETY LABELS (See FIGURE 8.) Chemical Solution Method of Cleaning If the tank cannot be cleaned with steam, use the following procedure: a. Mix a solution of water and trisodium phosphate or a cleaning compound with an alkali base. Follow the instructions given by the manufacturer. b. Fill the tank with the cleaning solution. Use compressed air to mix the solution in the tank. c. Drain the tank. Flush the inside of the tank with hot (boiling) water. Make sure all the cleaning compound is removed.

WARNING Safety labels are installed on the lift truck to give information about operation and possible hazards. It is important that all safety labels are installed on the lift truck and can be read. DO NOT add to or modify the lift truck. Any change to the lift truck, the tires or its equipment can change the lifting capacity. The lift truck must be rated as equipped and the nameplate must show the new capacity rating. Contact your dealer for Hyster lift trucks for a replacement nameplate. If necessary, install new and correct labels as follows:

d. Make an inspection of the inside of the tank. If the tank is not clean, repeat steps 1 through 3. Make another inspection of the tank. When making inspections, use a light that is approved for locations with flammable vapors. e. Check the tank for flammable vapors using special indicator for gas vapors. If the amount of flammable vapors is not below the lower flammable limit, repeat the cleaning procedures.

WARNING Cleaning solvents can be flammable and toxic, and can cause skin irritation. When using cleaning solvents, always follow the recommendations of the manufacturer. a. Make sure the surface is dry and has no oil or grease. Do not use solvent on new paint. Clean the surface of old paint with a cleaning solvent.

Other Methods Of Preparation For Repair

b. Remove the paper from the back of the label. Do not touch the adhesive surface.

If nitrogen gas or carbon dioxide gas is available, prepare the tank for welding using these gases. See the manual Safe Practices For Welding and Cutting Containers That Have Held Combustibles by the American Welding Society, A6.0–65. If these gases are not avail-

c. Carefully hold the label in the correct position above the surface. The label cannot be moved after it touches the surface. Put the label on the surface. Make sure that all air is removed from under the label and the corners and edges are tight.

7 15

21 9 8 16 17

16 1

14 17 13 22 12

24 23 1 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

20 MAST SAFETY (2) INSPECTION PLATE, UL PARKING BRAKE WARNING NOTICE TO USER NAMEPLATE (INFORMATION MUST BE COMPLETE) LIFT AND TILT CONTROLS AUXILIARY FUNCTIONS WARNING FOR SAFETY IMPACT TEST PLATE, OVERHEAD GUARD OPERATOR RESTRAINT (FOR EQUIPPED UNITS) OR TIPOVER WARNING FOR OTHER UNITS PATENT LABEL (INSIDE, LEFT) FIRE SAFETY, UL (2) (U.S. ONLY) TREAD

14. MODEL LABEL (2) 15. CASE, OPERATING MANUAL 16. NAMEPLATE, LPG TANK (U.S. AND CANADA) 17. FLAMMABLE, LP GAS 18. LABEL, LPG TANK INDENTIFIER (U.S. AND CANADA) 19. INSTALL COVER AND FAN WARNING 20. FAN WARNING 21. “NO RIDERS” LABEL 22. XL2 LABEL 23. LIFTING EYE SYMBOL 24. 5–PLUNGER OPTION

FIGURE 8. LABEL POSITIONS 12

GM ENGINES 4.3 LITER V-6 H3.50-5.00XL (H70-110XL) [G005]; S3.50-5.50XL (S70-120XL) [D004]; H6.00-7.00XL (H135-155XL) [F006, G006]; S6.00-7.00XL (S135-155XL) [B024, C024]; H3.50-5.50XM (H70-120XM) [K005, L005]; S3.50-5.50XM (S70-120XM) [E004, F004]

PART NO. 897800

600 SRM 590

GM Engines

Table of Contents

TABLE OF CONTENTS General ............................................................................................................................................................... Description ......................................................................................................................................................... Engine Removal and Installation ..................................................................................................................... Cylinder Head Repair ........................................................................................................................................ Remove and Disassemble .............................................................................................................................. Clean and Inspect .......................................................................................................................................... Valve Guides and Seats, Repairs .................................................................................................................. Valves, Repair ................................................................................................................................................ Valve Seats, Repair........................................................................................................................................ Valve Springs ................................................................................................................................................. Rocker Arm Studs (Early Models) ................................................................................................................ Rocker Arm Studs (Late Models) .................................................................................................................. Assemble and Install ..................................................................................................................................... Cylinder Block Cleaning and Inspection .......................................................................................................... Piston Bore Preparation .................................................................................................................................... Engine Mounts Installation .............................................................................................................................. Lubrication System Repair................................................................................................................................ Oil Pump, Remove and Disassemble ............................................................................................................ Clean and Inspect .......................................................................................................................................... Oil Pump, Assemble and Install ................................................................................................................... Oil Sump, Install ........................................................................................................................................... Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters ...................................................................... Timing Cover.................................................................................................................................................. Remove....................................................................................................................................................... Install ......................................................................................................................................................... Timing Sprockets ........................................................................................................................................... Remove....................................................................................................................................................... Install ......................................................................................................................................................... Camshaft ........................................................................................................................................................ Remove....................................................................................................................................................... Inspect........................................................................................................................................................ Install ......................................................................................................................................................... Balance Shaft................................................................................................................................................. Remove....................................................................................................................................................... Install ......................................................................................................................................................... Hydraulic Valve Lifters ................................................................................................................................. Remove....................................................................................................................................................... Disassemble ............................................................................................................................................... Clean and Inspect...................................................................................................................................... Assemble .................................................................................................................................................... Install ......................................................................................................................................................... Crankshaft Repair ............................................................................................................................................. Remove ........................................................................................................................................................... Inspect and Repair......................................................................................................................................... How to Check Clearance Between Main Bearings and Their Journals ..................................................... Install ............................................................................................................................................................. Piston and Connecting Rod Assemblies Repair ............................................................................................... Connecting Rod Bearings, Replace ............................................................................................................... Piston and Connecting Rod Assemblies, Remove ........................................................................................ Disassemble ................................................................................................................................................... Piston, Clean and Inspect .............................................................................................................................

ÂŠ2005 HYSTER COMPANY

1 1 2 2 2 2 3 3 4 4 6 6 7 10 10 11 11 11 11 12 12 13 13 13 15 15 15 15 16 16 16 16 17 17 18 18 18 19 19 19 20 21 21 21 22 23 24 24 25 25 26

Table of Contents

GM Engines

TABLE OF CONTENTS (Continued) Cylinder Bores, Inspect and Repair.............................................................................................................. Piston Rings ................................................................................................................................................... Assemble ........................................................................................................................................................ Piston and Connecting Rod Assemblies, Install .......................................................................................... Flywheel and Flywheel Housing Repair........................................................................................................... Flywheel, Repair............................................................................................................................................ Flywheel, Install ............................................................................................................................................ H3.50-5.00XL (H70-110XL), S3.50-5.50XL (S70-120XL), S6.00-7.00XL (S135-155XL) ........................ H6.00-7.00XL (H135-155XL) .................................................................................................................... Flywheel Housing H3.50-5.00XL (H70-110XL), H3.50-5.50XM (H70-120XM), S3.50-5.50XL (S70-120XL), S6.00-7.00XL (S135-155XL) ................................................................................................... Engine Adapter H6.00-7.00XL (H135-155XL) ............................................................................................. Coolant Pump Repair......................................................................................................................................... Thermostat Replacement .................................................................................................................................. Fan Mount Repair (Early Models) .................................................................................................................... Fan Mount Assembly Repair (Late Models) ..................................................................................................... Drive Belt Installation....................................................................................................................................... Valve Clearance Adjustment (Early Models).................................................................................................... Valve Clearance Adjustment (New Models) ..................................................................................................... Compression Check............................................................................................................................................ Engine Specifications......................................................................................................................................... Engine Data ................................................................................................................................................... Cylinder Head ................................................................................................................................................ Hydraulic Valve Lifter ................................................................................................................................... Camshaft ........................................................................................................................................................ Pistons ............................................................................................................................................................ Crankshaft ..................................................................................................................................................... Connecting Rods ............................................................................................................................................ Balance Shaft................................................................................................................................................. Cooling System .............................................................................................................................................. Lubrication System ....................................................................................................................................... Torque Specifications ......................................................................................................................................... Troubleshooting.................................................................................................................................................. This section is for the following models: H3.50-5.00XL (H70-110XL) [G005]; S3.50-5.50XL (S70-120XL) [D004]; H6.00-7.00XL (H135-155XL) [F006, G006]; S6.00-7.00XL (S135-155XL) [B024, C024]; H3.50-5.50XM (H70-120XM) [K005, L005]; S3.50-5.50XM (S70-120XM) [E004, F004]

26 27 28 28 29 29 29 29 29 29 29 30 30 30 30 32 33 34 34 35 35 35 36 36 36 37 37 38 38 38 38 39

600 SRM 590

Description

General NOTE: This SRM applies to different model years of the GM 4.3 liter, V-6 engine. While there can be physical differences in the parts, many of the procedures will apply to all of the models. If the different parts require separate procedures, all the procedures will be given.

CAUTION Changes to the engines have occurred at each model year. Do not install parts from one model year engine into another model year engine. Installation of the wrong parts will cause poor performance, wear, and failure of the engine.

CAUTION Disconnect the battery cables before doing any disassembly and repair of the engine or parts of the electrical system.

The diodes and resistors in the electrical system can be damaged if the following cautions are not followed: • Do not disconnect the battery when the engine is running. The voltage surge can damage the diodes and resistors. • Do not disconnect an electric wire before the engine is stopped and the switches are OFF. • Do not cause a short circuit by connection of the electric wires to the wrong terminals. Make sure a correct identification of the wire is made before it is connected. • Make sure a battery is the correct voltage and polarity before it is connected. • Do not check for current flow by making a spark because the electronic components can be damaged. This SRM has the description and the repair instructions for the GM 4.3 liter, V-6 engine. Checks and Adjustments, Troubleshooting procedures, and Specifications are also included.

Description The cylinder block is made of cast iron. The arrangement of the cylinders is in a V shape, with three cylinders on each bank. From the front, cylinders on the right bank are numbered 1, 3, and 5 and cylinders on the left bank are numbered 2, 4, and 6. The cylinder heads are cast iron and have one intake valve and one exhaust valve for each cylinder. A spark plug is located between the valves in the side of the cylinder head. The valve guides and seats are integral to the cylinder head. The crankshaft is supported by four main bearings. The number four bearing at the rear of the engine is the end thrust bearing. The bearings are retained by bearing caps that are matched with the block for proper alignment and clearances. The camshaft is steel and is supported by four bearings pressed into the engine block. The camshaft is driven by a chain from the crankshaft. A spiral gear machined into the camshaft near the rear journal drives a shaft assembly which operates the oil pump drive shaft assembly. The pistons are made of cast aluminum and have two compression rings and one oil control ring assembly.

The piston is a low-friction, lightweight design with a flat top and barrel-shaped skirt. The piston pins are offset to reduce piston slap. They have a floating fit in the piston and are retained by a press fit in the connecting rod. The connecting rods are forged steel and are machined with the rod cap installed for proper clearances and alignment. The balance shaft is cast iron and mounted in the crankcase above and in-line with the camshaft. The balance shaft is driven by a gear from the camshaft. The valve mechanism is actuated by push rods and rocker arms from the camshaft. The rocker arm pivots on a ball to open the valve. Later model engines have hydraulic valve lifters that keep all parts of the valve train in constant contact. Each lifter acts as an automatic adjuster and maintains zero lash in the valve train, eliminating the need for periodic valve adjustment. When the engine has a gasoline fuel system, it has electronic fuel injection with an electronic engine control system. When the engine has a LPG fuel system, it uses an LPG carburetor with the Microprocessor Spark Timing System (MSTS).

Cylinder Head Repair

600 SRM 590

Engine Removal and Installation The Removal and Installation procedures for the engine are in the Frame section for each model of lift truck. See the Transmission sections to separate the transmission from the engine.

Cylinder Head Repair REMOVE AND DISASSEMBLE WARNING Disconnect the battery cables before making repairs to the engine. 1. Drain cooling system. 2. Disconnect and remove coolant hose from housing for thermostat. 3. Remove air cleaner, distributor, throttle body, intake manifold, and exhaust manifolds. Remove drive belt(s) and remove brackets for drive belt tensioner and alternator. 4. Remove spark plugs. 5. Remove rocker arm cover. See Figure 1. NOTE: For year 2002 or later model engines, go to Step 10. 6. Remove nuts and balls for rocker arms. Remove rocker arms and push rods. Keep parts for each rocker arm assembly together. Mark assemblies so they can be installed in their original positions.

1. 2. 3. 4.

ROCKER COVER NUT BALL ROCKER ARM

5. CYLINDER HEAD 6. HEAD GASKET 7. GASKET

Figure 1. Cylinder Head 7. Remove rocker arm studs. 8. Remove capscrews that hold cylinder head to block. Remove capscrews in the reverse order of the tightening sequence shown in Figure 12. Remove cylinder head and gasket. 9. Use a valve spring compressor and remove valve stem keys, caps, springs, and oil seals. Discard oil seals. Remove valves. Organize valves and springs so they can be installed in their original positions. 10. Remove valve rocker arms. See Figure 2. 11. Remove valve rocker arm supports. 12. Remove valve push rods.

CLEAN AND INSPECT 1. Clean carbon from valve ports and combustion chambers in cylinder head. 2. Clean carbon and oil from valves, push rods, and rocker arms. 3. Clean valve guides. 4. Clean surfaces of cylinder head where gaskets fit. 5. Inspect cylinder head for cracks in ports, combustion chambers, and external surfaces. 6. Measure cylinder head for warping with a straight edge and feeler gauge. Refer to Engine Specifications for tolerances.

600 SRM 590

Cylinder Head Repair valve faces and seats within the specifications. Make sure all of the lapping compound is removed from the valve and valve seat when the process is completed. Valves with minor pits in the valve faces can be machined to the proper angle. There are many different types of equipment for repairing valve faces. Follow the instructions of the manufacturer of the equipment that you are using. Valves must be machined to the proper specifications. See Figure 4.

1. VALVE ROCKER ARM 2. VALVE ROCKER ARM SUPPORT 3. PUSH ROD Figure 2. Remove Valve Rocker Arm and Push Rod (Year 2002 or Later Engine Models) 7. Inspect valves for burned or damaged areas in seat surfaces. Inspect for cracks and damaged or worn valve stems. Valve stems with excessive guide clearance must be repaired or replaced. Refer to Engine Specifications.

1. VALVE STEM 2. DIAL INDICATOR Figure 3. Valve Steam Clearance

VALVE GUIDES AND SEATS, REPAIRS Measure the clearance between the valve stem and the guide as shown in Figure 3. See Engine Specifications for maximum clearances. If the clearance is more than the maximum amount, oversize valves or new valve guides must be installed. Use a reamer of the correct size when installing new valve guides. Use normal service procedures when grinding the valve seats. See the Engine Specifications for dimensions.

VALVES, REPAIR NOTE: Before any work is performed on the valve faces and seats, make sure the clearance of the valve stems in their valve guides is within specifications. A correction for minimum wear and damage to the valve and seat can be done by a process called lapping. When the valve seats are lapped, keep the

NOTE: SEAT WIDTH DIMENSION APPLIES TO THE 46 FACE ONLY. 1. CYLINDER HEAD Figure 4. Valve Seat Specifications for Inlet and Exhaust Valves

Cylinder Head Repair Replace a valve if any of the following conditions are present: • Valve stem is worn below specifications. • Valve stem is bent. • Valve face is warped. • Any part of the valve is cracked. • Any wear or damage to the valve face that cannot be removed by resurfacing and still meet the specifications shown in Figure 5.

600 SRM 590 valve seats. Follow the instructions of the manufacturer of the equipment that you are using. The valve seats are ground at three different angles: 30 , 46 , and 60 . This method makes a valve seat that is the proper width and produces the correct contact line between the valve and valve seat. The specifications for the valve seats are shown in the Engine Specifications section and in Figure 4. • If the contact line is too high, it can be made lower by using a 30 stone. • If the contact line is too low, it can be raised using the 46 stone. • If the seat is too narrow, it can be made wider using a 46 stone. • If the seat is too wide, it can be made narrower using a 60 stone. The correct dimensions for the valve seat widths and valve/valve seat overlap are shown in Figure 6. The valve seat widths are the dimensions of the 46 face only. The valve/valve seat overlap is the distance from the edge of the seat to the outside edge of the valve.

Figure 5. Valve Head Measurements

VALVE SEATS, REPAIR NOTE: Before any work is done on the valve faces and seats, make sure the clearance of the valve stems in their valve guides is within specifications.

CAUTION The exhaust valve seats in these cylinder heads are induction-hardened. Removal of too much valve seat material will damage the valve seats which will require replacement of the cylinder head. Damaged valve seats can be resurfaced with a tool that is designed to repair valve seats. There are many different types of equipment for repairing

VALVE SPRINGS Measure the length of the valve springs. The correct length is 51.6 mm (2.03 in.).

WARNING Be careful when testing the valve springs. These springs can come loose with enough force to cause an injury. Always use equipment that was designed to test springs. Always wear eye and face protection while testing valve springs. Use a special tool to check the tension of the valve springs. Compress the spring to the correct height and check the tension. For the correct specifications, see Figure 7. Replace valve springs that are not within specifications.

600 SRM 590

Cylinder Head Repair

A. EXHAUST VALVE

B. INLET VALVE

1. CYLINDER HEAD

2. VALVE Figure 6. Valve Seat Widths and Valve/Valve Seat Overlap Legend for Figure 7 A. VARIATION FROM VERTICAL: LESS THAN 1.6 mm (0.063 in.) B. FREE LENGTH: 51.6 mm (2.03 in.) C. SPRING COMPRESSED TO 338 to 374 N (76 to 84 lbf) AT 43 mm (1.69 in.) D. INSTALLED HEIGHT EARLY MODELS : 42.92 to 43.43 mm (1.690 to 1.710 in.) LATE MODELS: INTAKE: 45.2 mm (1.78 in.) EXHAUST: 45.2 to 43.43 mm (1.780 to 1.710 in.)

Figure 7. Valve Spring Specifications

Cylinder Head Repair

ROCKER ARM STUDS (EARLY MODELS) These studs are pressed into the head. Replace a stud that has damaged threads or is loose in the cylinder head. New studs are available in the following oversizes: 0.003 in. and 0.013 in. 1. To remove old stud, install spacer, flat washer, and nut to damaged stud. Use a wrench to remove damaged stud. See Figure 8.

CAUTION

600 SRM 590

CAUTION Disposal of lubricants and fluids must meet local environmental regulations. Drain the cooling system before replacing the studs. The studs for late model engines have threads that hold them to the cylinder head. See Figure 10. A stud that has damaged threads must be replaced with a new stud. If the threads in the head are damaged, a thread repair kit can be used. If the damaged threads cannot be repaired with a thread repair kit, then the head must be replaced.

Do not attempt to install an oversized stud without reaming the stud hole to the new size. Installation of an oversized stud without reaming the stud hole can cause cracks in the cylinder head. 2. Use a reamer of the correct size for new oversized stud. Apply SAE 90 lubricant to new stud during installation. Install new stud as shown in Figure 9.

NOTE: EARLY MODELS ONLY. Figure 8. Rocker Arm Stud Removal

ROCKER ARM STUDS (LATE MODELS) NOTE: EARLY MODELS ONLY.

WARNING DO NOT remove a stud from the cylinder head when the engine is hot. Some of the studs fit into coolant passages and can release pressure and hot coolant when removed. The steam and boiling coolant can cause burns.

1. REAMER

2. INSTALLATION TOOL

Figure 9. Rocker Arm Stud Installation

600 SRM 590

Cylinder Head Repair Legend for Figure 11 A. VARIATION FROM VERTICAL: LESS THAN 1.6 mm (0.063 in.) B. FREE LENGTH: 51.6 mm (2.03 in.) C. SPRING COMPRESSED TO 338 to 374 N (76 to 84 lbf) AT 43 mm (1.69 in.) D. INSTALLED HEIGHT EARLY MODELS : 42.92 to 43.43 mm (1.780 to 1.710 in.) LATE MODELS: INTAKE: 45.2 mm (1.78 in.) EXHAUST: 45.2 to 43.43 mm (1.690 to 1.710 in.) 2. Clean surface of cylinder head and top of cylinder block. Make sure threads in block are clean.

NOTE: LATE MODELS ONLY. 1. STUD Figure 10. Studs With Threads

ASSEMBLE AND INSTALL 1. Install each valve in correct port. Install oil seal in lower groove. Install shim, damper, spring, shield, and cap or rotator. Using a spring compressor, compress assembly and install retainers. Measure height of valve spring as shown in Figure 11. Measure from top of shim to top of retainer cap. Install shims to get correct height shown in Figure 11. The installed height of valve spring must not be less than minimum height.

3. Install cylinder head gasket and cylinder head. Make sure cylinder head is aligned with pins in block. 4. Use a sealant on threads of capscrews for cylinder head. Install capscrews as follows: a. On 1995 and earlier engines, tighten capscrews in three steps. Tighten all capscrews to one torque specification, then use the next specification: 34 N•m (25 lbf ft), 61 N•m (45 lbf ft), and 90 N•m (65 lbf ft). Use sequence shown in Figure 12.

A. FAN END Figure 12. Cylinder Head Tightening Sequence

Figure 11. Valve Spring Specifications

b. On 1996 model and later engines, tighten all capscrews to 30 N•m (22 lbf ft). Use sequence shown in Figure 12. Next, tighten capscrews 11, 7, 3, 2, 6, 10 an additional 55 degrees. Tighten capscrews 12 and 13 an additional 65 degrees. Tighten capscrews 1, 4, 8, 5, 9 an additional 75 degrees.

Cylinder Head Repair 5. Apply RTV sealant (Hyster part number 280472) to front and rear surfaces between intake manifold and engine block. See Figure 13. The bead of sealant must be 5 mm (0.2 in.) thick and extend up sides of heads 13 mm (0.5 in.) to seal and retain gaskets.

600 SRM 590 8. Install valve push rods. See Figure 15.

1. EXTEND BEAD 13 mm (0.5 in.) UP HEADS (FRONT AND REAR). 2. REAR 3. FRONT Figure 13. Intake Manifold Sealant Locations 6. Install gaskets and intake manifold. Tighten capscrews in sequence shown in Figure 14. Tighten capscrews on early models to 48 N•m (35 lbf ft). On later models tighten capscrews on first pass to 3 N•m (27 lbf in). Tighten capscrews on second pass to 12 N•m (106 lbf in). Tighten capscrews on final pass to 15 N•m (133 lbf in).

A. EARLY MODELS B. LATE MODELS

C. FAN END

Figure 14. Inlet Manifold Tightening Sequence

NOTE: For year 2002 or later model engines, perform Step 8 through Step 18. For 2001 and earlier model engines, perform Step 7 and Step 14 through Step 18. NOTE: Install parts as marked during removal. 7. Install push rods, making sure they are in the seat of the valve lifter. Lubricate rocker arms and rocker arm balls with a molybdenum grease. Install rocker arms, balls, and nuts. The earlier and later models have different procedures to tighten rocker arms and adjust valves. The procedures are described in Valve Clearance Adjustment (Early Models) and Valve Clearance Adjustment (New Models).

Figure 15. Install Valve Push Rod

600 SRM 590

Cylinder Head Repair Legend for Figure 17

CAUTION Be sure that the arrow on the valve rocker arm support is in the up position. See Figure 16. 9. Install valve rocker arm supports.

1. 2. 3. 4.

VALVE PUSH ROD SOCKET ROLLER PIVOT VALVE STEM TIP ROCKER ARM BOLT

11. See Figure 18. Install the valve rocker arm assemblies as follows: a. Finger start the rocker arm bolt at location 1 in Figure 18. b. Finger start the rocker arm bolt at location 2 in Figure 18. c. Finger start the rocker arm bolt at location 3 in Figure 18. d. Finger start the remaining three valve rocker arm bolts.

Figure 16. Install Valve Rocker Arm Supports 10. Apply a molybdenum grease or equivalent to the following valve rocker arm contact surfaces: See Figure 17. • Valve push rod socket • Roller pivot • Valve stem tip

1. BOLT AT LOCATION 1 2. BOLT AT LOCATION 2 3. BOLT AT LOCATION 3 Figure 18. Install Valve Rocker Arm Assemblies 12. Rotate the crankshaft balancer to position the crankshaft balancer alignment mark 57 to 63 degrees clockwise or counterclockwise from the engine front cover alignment tab. See Figure 19. NOTE: Once the valve rocker arm assemblies are installed and properly torqued, no additional valve lash adjustment is required. 13. Tighten the valve rocker arm bolts to 30 N•m (22 lbf ft). See Figure 17. Figure 17. Lubricate Valve Rocker Arm Surfaces

14. Use new gasket and install valve covers. Tighten capscrews to 12 N•m (107 lbf in).

Piston Bore Preparation

600 SRM 590

15. Install spark plugs. 16. Install throttle body, air cleaner, and distributor. Install brackets for drive belt tensioner and alternator. Install drive belt(s). 17. Install exhaust manifolds. Tighten capscrews in two steps; first to 15 N•m (133 lbf in), then to 31 N•m (274 lbf in). If used, bend lock tabs against heads of capscrews. 18. Install coolant hose to housing for thermostat. Fill coolant system with coolant. See the Periodic Maintenance section for your lift truck.

1. CRANKSHAFT BALANCER ALIGNMENT MARK 2. ENGINE FRONT COVER ALIGNMENT TAB Figure 19. Rotate Crankshaft Balancer

Cylinder Block Cleaning and Inspection WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturer’s recommended safety procedures.

WARNING Compressed air can move particles so they cause injury to the user or to other personnel. Make sure the path of the compressed air is

away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes. After the engine is disassembled, clean cylinder block in solvent and dry with compressed air. Make sure all oil passages are clean. Remove gaskets from surface of block. Inspect bores for pistons for wear or damage. Measure bores and check dimensions shown in Engine Specifications. Repair cylinder block, as necessary.

Piston Bore Preparation NOTE: It is important that the piston bores are prepared correctly before new piston rings are installed. Incorrect preparation can cause the parts to wear quickly.

2. Move hone quickly (approximately 60 times per minute) up and down in bore. Make sure hone makes a cross pattern of 45 to 60 degrees. Use hone until entire length of bore has this pattern.

Use a hone in the piston bores when installing new rings. Use the hone as follows:

3. After using the hone, clean cylinder block with hot water and detergent. Make sure all metal particles are removed from block. Dry bores and lubricate them with engine oil.

1. Use a hone with a 280-grit stone. Make sure stone is clean and will not damage bore.

600 SRM 590

Lubrication System Repair

Engine Mounts Installation If the engine mount was removed from the cylinder block, install and tighten capscrews for mount as follows.

S/H3.50-5.00XL (S/H70-110XL)

31 N•m (23 lbf ft)

S/H6.00-7.00XL (S/H135-155XL)

50 N•m (37 lbf ft)

H3.50-5.50XM (H70-120XM)

52 N•m (38 lbf ft)

Lubrication System Repair OIL PUMP, REMOVE AND DISASSEMBLE 1. Remove oil sump. 2. Remove capscrew at mount for pump. Remove oil pump and shaft. See Figure 20. 3. Remove cover for oil pump. Put marks on gear teeth to show their correct location during assembly. 4. Do not remove tube and screen assembly unless it is damaged. The tube and screen must be replaced as an assembly. 5. Remove retaining pin, pressure regulator spring, and pressure regulator valve from pump cover.

CLEAN AND INSPECT WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturer’s recommended safety procedures.

1. 2. 3. 4. 5. 6.

CAPSCREW SCREEN DRIVEN GEAR DRIVE GEAR RETAINER SHAFT

7. 8. 9. 10. 11.

HOUSING SPRING RELIEF VALVE COVER PIN

Figure 20. Oil Pump

Clean parts of oil pump in solvent and dry with compressed air. Inspect gears, shaft, and body of pump for wear or damage.

Lubrication System Repair

OIL PUMP, ASSEMBLE AND INSTALL NOTE: There are some variations in the oil pumps installed during the years of manufacture of these engines, but the design is the same. The repair procedures are the same. See the Parts Manual for each oil pump.

600 SRM 590 a. Install new gasket(s) and oil sump. See Figure 22. Use a sealant on gasket(s) in the following locations: at front cover to block joint and rear seal retainer to block joint. The sealant must extend 25 mm (1 in.) in both directions at each of the four corners.

1. Install NEW pressure regulator valve and spring into pump cover. Install retaining pin. 2. Install gears in body of pump. Make sure to align identification marks. Install cover for oil pump and tighten capscrews to 12 N•m (106 lbf in). Turn shaft for oil pump and check for smooth operation. 3. Use a sealant when replacement of tube and screen assembly is necessary. The tube and screen assembly must have a good press fit into the oil pump body. Do not damage tube during installation. Make sure surface of screen assembly is parallel to bottom surface of cylinder block. See Figure 21.

Figure 21. Oil Pump Tube and Screen Installation 4. Install oil pump shaft and NEW retainer. 5. Install oil pump assembly to engine. Make sure shaft is aligned with slot in distributor shaft. On early models (1995 and older engines), tighten capscrew at mount to 47 N•m (35 lbf ft). On late models (1996 and later), tighten capscrew to 90 N•m (66 lbf ft).

OIL SUMP, INSTALL 1. Install oil sump on early models (1995 and earlier engines) as follows:

A. EARLY MODELS B. LATE MODELS

C. FAN END

1. OIL SUMP 2. GASKET

3. PLATE Figure 22. Oil Sump

b. Tighten capscrews for oil sump as follows: 1/4-20 capscrews, 10 N•m (89 lbf in); 5/16-18 capscrews, 19 N•m (168 lbf in). 2. Install oil sump on late models (1996 and later engines) as follows: a. Apply an RTV sealant to surfaces of engine block as shown in Figure 23.

600 SRM 590

Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters b. Install gasket and oil sump. Make sure vertical surfaces at back of engine block and oil sump are even. c. Tighten capscrews and nuts for oil sump in sequence shown in Figure 24 to 25 Nâ&#x20AC;˘m (221 lbf in).

Figure 24. Oil Sump Installation

A. FAN END Figure 23. Oil Sump Installation

Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters TIMING COVER Remove NOTE: For model H3.50-5.50XM (H70-120XM), refer to the section Cooling System 700 SRM 740.

vibration damper. Do not pull on outside diameter of vibration damper. 3. Remove crankshaft position sensor from timing cover. See Figure 26.

1. Remove fan assembly and belts.

4. Remove capscrews and stud for timing cover. Remove timing cover from engine. See Figure 27.

2. Remove crankshaft pulley and vibration damper. See Figure 25. Use a tool that pulls on center of

5. Remove crankshaft position sensor reluctor ring from crankshaft. See Figure 28.

Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters

1. TIMING COVER 2. VIBRATION DAMPER 3. TOOL FOR REMOVING VIBRATION DAMPER

600 SRM 590

1. TIMING COVER

2. ENGINE

Figure 27. Timing Cover

Figure 25. Timing Cover

1. CRANKSHAFT POSITION SENSOR BOLT 2. CRANKSHAFT POSITION SENSOR 3. TIMING COVER Figure 26. Crankshaft Position Sensor

1. CRANKSHAFT POSITION SENSOR RELUCTOR RING 2. CRANKSHAFT Figure 28. Crankshaft Position Sensor Reluctor Ring

600 SRM 590

Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters

Install

TIMING SPROCKETS

NOTE: The plastic timing cover can be used only once. When the engine has a plastic timing cover, always install a new one.

Remove

1. Install crankcase position sensor reluctor ring on crankshaft. See Figure 28. Make sure open side of seal is toward inside of cover. 2. Use a sealant on sump gasket in the following locations: at front cover to block joint and rear seal retainer to block joint. The sealant must extend 25 mm (1 in.) in both directions at each of the four corners. During installation of the cover, use a special tool to align oil seal with crankshaft. The vibration damper will damage the oil seal if it is not installed correctly. Tighten capscrews for cover to 12 N•m (106 lbf in). See Figure 27. 3. Install crankshaft position sensor. Tighten crankshaft position sensor bolt to 8 N•m (71 lbf in). See Figure 26. 4. Lubricate lips of seal with clean engine oil before vibration dampener is installed. Use a special tool to pull vibration damper onto crankshaft. See Figure 29. Tighten capscrew for damper to 95 N•m (70 lbf ft).

1. Remove timing cover. On late models, remove ring for crankshaft position sensor. See Figure 30. 2. Check timing chain for wear. If timing chain can be moved back and forth more than 16 mm (0.63 in.), install a new chain. 3. Remove capscrews for camshaft sprocket. Use a puller to remove crankshaft sprocket. Make sure timing chain is removed with sprockets.

Install 1. Install crankshaft sprocket. Install timing chain on camshaft sprocket. Install camshaft sprocket with chain. Make sure marks are aligned as shown in Figure 30. The number 4 cylinder will be at top dead center (TDC) on the compression stroke. Tighten capscrews to camshaft sprocket to 28 N•m (21 lbf ft). On late models, install ring for crankshaft position sensor. 2. Lubricate chain and sprockets with new engine oil. Install timing cover as described in section for Timing Cover.

5. Install crankshaft pulley, belts, and fan assembly.

1. SPECIAL TOOL

2. VIBRATION DAMPER

Figure 29. Timing Cover

1. TIMING MARKS 2. TIMING CHAIN

3. CAMSHAFT SPROCKET

Figure 30. Timing Marks

Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters

CAMSHAFT Remove 1. Remove intake manifold, push rods, lifter guides, and valve lifters.

600 SRM 590

on the surface of the bearing to see if they are round. If the difference of the readings for each bearing is more than 0.025 mm (0.001 in.), replace camshaft. Check for a bent camshaft or excessive camshaft runout. If runout exceeds 0.065 mm (0.0026 in.), the camshaft is bent and should be replaced.

2. Remove timing cover as described in section Timing Cover. Align timing marks. Remove timing chain, sprockets, and camshaft retainer. 3. Install two or three 5/16-18 capscrews that are 100 to 125 mm (4 to 5 in.) long into camshaft. See Figure 31. These capscrews will make the camshaft easier to control. Carefully remove camshaft from cylinder block. All camshaft bearings are the same size. Do not damage bearings or camshaft during removal.

1. TOOL FOR CAMSHAFT BEARINGS Figure 32. Camshaft Bearings

Install 1. Use a special tool as shown in Figure 32 to install camshaft bearings. See Figure 33. Install front and rear bearings first. Make sure oil holes in bearings are aligned with oil holes in block. Use a sealant on rear camshaft plug and install plug in block. Make sure plug is even with or 0.80 mm (0.03 in.) below surface of block. NOTE: LATE MODEL SHOWN, OTHER MODELS SIMILAR. Figure 31. Camshaft 4. If necessary, use a special tool as shown in Figure 32 to remove camshaft bearings. Remove front and rear bearings last.

Inspect Inspect entire camshaft for any signs of wear or damage. Measure diameter of each bearing surface on camshaft. Do the measurement at different positions

2. Lubricate camshaft lobes with a molybdenum lubricant. Lubricate camshaft bearings with engine oil. Install two or three 5/16-18 capscrews that are 100 to 125 mm (4 to 5 in.) long into camshaft. See Figure 31. These capscrews will make camshaft easier to control. Carefully install camshaft in cylinder block. 3. Lubricate and install retainer for camshaft. Tighten capscrews to 14 Nâ&#x20AC;˘m (125 lbf in). 4. Install gear for the balance shaft as described in procedures for Balance Shaft.

600 SRM 590

1. RETAINER

Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters

2. CAMSHAFT

Figure 33. Camshaft and Retainer 5. Install timing sprockets, chain, and cover as described in procedures for Timing Cover. 6. Lubricate valve lifters with a molybdenum lubricant. Install lifters in block. Install push rods and adjust valve mechanism as described in Valve Clearance Adjustment (Early Models) and Valve Clearance Adjustment (New Models).

BALANCE SHAFT Remove 1. Remove intake manifold. 2. Remove retainer for lifters.

1. SPROCKET, CAMSHAFT 2. DRIVE GEAR, CAMSHAFT

3. DRIVEN GEAR, BALANCE SHAFT 4. BALANCE SHAFT 5. RETAINER

Figure 34. Balance Shaft Components

3. Remove timing cover as described in section Timing Cover. Remove timing chain and sprocket from camshaft. 4. Remove driven gear from balance shaft. Remove retainer. See Figure 34. 5. Use a soft-faced hammer to remove balance shaft. See Figure 35. NOTE: The balance shaft and front bearing are serviced as a unit. 6. Use a special tool to remove rear bearing. A. FRONT Figure 35. Balance Shaft Removal

Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters

600 SRM 590

Install 1. Lubricate rear bearing with new engine oil. Use a special tool to push rear bearing into block. See Figure 34 and Figure 36.

1. ALIGNMENT OF TIMING MARKS 2. DRIVEN GEAR, BALANCE SHAFT 3. DRIVE GEAR, CAMSHAFT Figure 37. Balance Shaft Timing Marks

A. FRONT 1. HAMMER

2. BEARING DRIVER

Figure 36. Balance Shaft Installation

7. Install timing cover as described in section Timing Cover.

2. Lubricate front bearing with new engine oil. Use a driver to install balance shaft into engine block.

8. Make sure all lifters and guides for lifters are properly installed. Install retainer for lifters. Tighten bolts for retainer to 16 N•m (142 lbf in).

3. Install retainer for balance shaft. Tighten screws for retainer to 14 N•m (125 lbf in).

9. Install intake manifold as described in the section Cylinder Head Repair, Assemble and Install.

4. Install driven gear onto balance shaft. Tighten bolt to 20 N•m (177 lbf in), plus an additional 35 degrees of rotation. Rotate balance shaft by hand to make sure there is clearance between retainer and shaft. If the balance shaft does not rotate freely, check that retaining ring on the front bearing is in its seat.

HYDRAULIC VALVE LIFTERS

5. Temporarily install drive gear on camshaft. Turn camshaft until timing mark on drive gear is straight up. Remove drive gear and rotate balance shaft until mark on driven gear is straight down. Install drive gear on camshaft. Make sure timing marks are in the position shown in Figure 37. 6. Install timing chain and sprocket on camshaft. Make sure timing marks are in the position shown in Figure 30. Tighten capscrews that attach sprocket to camshaft to 28 N•m (21 lbf ft).

Remove 1. The hydraulic valve lifters normally do not need repair unless they become dirty, causing them to malfunction or the roller does not operate properly. The hydraulic valve lifters must be clean to operate correctly. If a hydraulic valve lifter must be disassembled, make sure small parts are handled carefully to prevent loss or damage. 2. Remove air bonnet, distributor, and intake manifold. 3. The push rods must be removed as described in Cylinder Head Repair, Remove and Disassemble. 4. Remove hydraulic valve lifters. Put lifters in a rack so they can be installed in their original positions.

600 SRM 590

Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters

Disassemble CAUTION The internal parts of a lifter are a precise fit to each lifter body. When servicing the lifters, make sure the parts from one lifter are not mixed with another lifter. If any part of the lifter or roller is worn or damaged, the lifter must be replaced. 1. Hold plunger down with a push rod. See Figure 38. Use blade of a small screwdriver to remove retainer for push rod seat.

Figure 39. Check Ball Assembly Removal

Clean and Inspect Clean all parts in a cleaning solvent and inspect them carefully. If any parts are damaged or worn, the complete hydraulic valve lifter must be replaced. If the body of the hydraulic valve lifter is worn, also inspect bore in cylinder block. If roller of hydraulic valve lifter is worn or damaged, inspect camshaft lobe for wear and damage.

Assemble 1. CHECK BALL ASSEMBLY 2. PLUNGER 3. METERING VALVE 4. PUSH ROD SEAT

5. 6. 7. 8.

RETAINER SPRING LIFTER BODY RETAINER

Figure 38. Hydraulic Valve Lifter 2. Remove push rod seat and metering valve. 3. Remove plunger, check ball assembly, and plunger spring. 4. Use a small screwdriver as a pry bar to remove check ball retainer from plunger. See Figure 39.

1. Assemble check ball assembly. Put check ball on small hole in bottom of plunger. Install check ball spring in seat of check ball retainer. Put check ball retainer over check ball so check ball spring is on check ball. Carefully press check ball retainer into position in plunger. See Figure 40. 2. Put plunger spring over check ball retainer and slide lifter body over spring and plunger. See Figure 38. 3. Fill assembly with SAE 10 engine oil. Put a 3 mm (0.125 in.) drift into plunger and push plunger until holes for oil are aligned. See Figure 41. Now put a 1.6 mm (0.0625 in.) drift through holes to hold plunger. Remove 3 mm (0.125 in.) drift and fill assembly again with SAE 10 oil.

Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters

600 SRM 590

(0.063 in.) drift and remove drift. The hydraulic valve lifter is now ready for installation.

Install 1. Lubricate all roller and lifter surfaces with new engine oil. Install lifters in their original positions. Make sure guides are in correct positions. See Figure 42. 2. Install retainer. Tighten capscrews to 16 Nâ&#x20AC;˘m (142 lbf in).

Figure 40. Check Ball Assembly Installation

3. Install push rods. Adjust valves. The old and new models use different procedures to tighten rocker arms and adjust valves. The procedures are described in Valve Clearance Adjustment (Early Models) and Valve Clearance Adjustment (New Models). 4. Install intake manifold and distributor.

1. 3 mm (0.120 in.) DRIFT PIN 2. OIL FEED HOLE

3. 1.6 mm (0.063 in.) PIN

Figure 41. Hydraulic Valve Lifter Assembly 4. Install metering valve and push rod seat. See Figure 38. Install retainer for push rod seat. Push down push rod seat to loosen 1.6 mm

1. 2. 3. 4.

ROCKER ARM CYLINDER HEAD CYLINDER BLOCK CAMSHAFT

5. 6. 7. 8.

LIFTER RETAINER GUIDE PUSH ROD

Figure 42. Cylinder Head

600 SRM 590

Crankshaft Repair

Crankshaft Repair REMOVE 1. Remove oil pan, oil pump, and flywheel. Remove rear seal retainer (late models).

bearing is round. The correct sizes are given in the Engine Specifications section.

2. Remove timing cover as described in the procedure Timing Cover, Remove. 3. Mark caps for connecting rods so they can be installed in their correct locations. Remove caps and bearing inserts for connecting rods. Make sure all parts from each rod assembly remain together. 4. Mark caps for main bearings so they can be installed in their correct locations. Remove caps for main bearings. Make sure all parts from each bearing assembly remain together. 5. Remove crankshaft with extreme care to prevent damage to journals and thrust flanges of crankshaft.

INSPECT AND REPAIR WARNING Commercial cleaning solvents can be flammable and toxic and can cause severe skin irritation. When using commercial cleaning solvents, always comply with the solvent manufacturerâ&#x20AC;&#x2122;s recommended safety precautions. Compressed air can move particles so they cause injury to the user or to other personnel. Make sure the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes. 1. Clean crankshaft with solvent and dry it with compressed air. Make sure oil passages are not plugged. 2. Inspect crankshaft for cracks or other damage. 3. Inspect bearing journals and thrust surfaces for scratches or damage caused by a lack of lubrication. 4. Inspect crankshaft for wear and damage. See Figure 43. Use a micrometer to measure journals for bearings of crankshaft. Do measurement at different positions to see if the surface of the

Figure 43. Crankshaft Inspection 5. If crankshaft journals must be repaired, they can be ground to the following diameters smaller (undersize) than the original size: 0.254 mm (0.010 in.) 0.508 mm (0.020 in.) NOTES ABOUT MAIN BEARINGS: Main bearings are an insert bearing that do not use shims for adjustment. Main bearings are available in a standard size and the following undersizes: 0.0254 mm (0.001 in.), 0.0508 mm (0.002 in.), 0.2286 mm (0.009 in.), 0.254 mm (0.010 in.), and 0.508 mm (0.020 in.). If a bearing on a journal is worn, both the upper and lower half of the bearing must be replaced. When the crankshaft is assembled by the manufacturer, the main bearings are specially selected to obtain close tolerances. For this reason, you can find one-half of a standard size insert with one-half of a 0.0254 mm (0.001 in.) undersize insert. This combination will decrease the clearance 0.0127 mm (0.0005 in.) from using a full standard bearing.

Crankshaft Repair When a production crankshaft cannot be fitted with this method, the main journal is then ground 0.2286 mm (0.009 in.) undersize. Only those main bearing journals that cannot be fitted with standard, 0.0254 mm (0.001 in.), or 0.0508 mm (0.002 in.) undersize main bearing will be ground. A 0.2286 mm (0.009 in.) and a 0.254 mm (0.010 in.) undersize bearings will be selected as described to obtain close tolerances. A production crankshaft that has been ground will have the following identification: • The crankshaft journal that has been ground will have a 9 marked in the metal of the crankshaft next to the journal. A spot of light green paint is also added to the crankshaft. • The main bearing cap is also marked with green paint.

HOW TO CHECK CLEARANCE BETWEEN MAIN BEARINGS AND THEIR JOURNALS 1. Use Plastigage® or equivalent to check clearance. The procedure is similar for both connecting rod bearings and main bearings. If engine has been removed from lift truck, put engine so crankshaft is up. The weight of the crankshaft is against the upper bearing half and the total clearance can be measured correctly. If the engine is still in the lift truck, the crankshaft must have a support to remove any additional clearance between the upper bearing half and its journal.

600 SRM 590 6. Remove main bearing cap. The Plastigage® will be compressed and wider and will adhere to either the bearing or its journal. Use scale on envelope for Plastigage® to measure width of plastic at its widest point. The scale will indicate the clearance in millimeters or thousandths of an inch. See Figure 47. 7. If the clearance is greater than the specifications, select a new undersize bearing set and install it. Measure clearance again. If clearance cannot meet specifications with the available undersize bearings, bearing journal must be ground to a new undersize. If bearing journal is already at maximum undersize, crankshaft must be replaced. 8. If clearance is within specifications, lubricate bearing with engine oil and install main bearing and bearing cap. Tighten capscrews on main bearing cap to correct specifications. 9. Turn crankshaft to make sure it rotates smoothly. 10. Check axial clearance between rear main bearing and thrust surface. Push crankshaft forward. See Figure 44. Measure clearance between crankshaft and thrust surface of rear bearing. See Engine Specifications for correct clearances.

2. All main bearing caps must be installed and their capscrews tightened to the specifications. 3. Check rear main bearing first. Remove cap for rear main bearing. The procedure for checking the clearance of the other bearings is similar. 4. Clean oil from bearing half and journal to be checked. Put a piece of Plastigage across full width of bearing journal as shown in Plastigage® on Bearing Journal. Do not rotate crankshaft when Plastigage is between main bearing and its journal. 5. Install main bearing cap and tighten capscrews. See Torque Specifications. The capscrews must be tightened to their final torque or there will be an error in the measurement.

A. FAN END 1. MEASURE CLEARANCE Figure 44. Measuring Crankshaft Axial Clearance

600 SRM 590

Crankshaft Repair

INSTALL 1. On engines with a two-piece rear seal, install seal halves so lips are toward fan end of engine. Apply sealant to ends of seal halves. Apply engine oil to seal during installation. Do not get any oil on ends of seal. NOTE: With the use of special tools, the main bearings and the rear crankshaft seal (two-piece) can be replaced without removing the crankshaft. 2. Install main bearings in cylinder block and bearing caps. Lubricate bearings with engine oil and carefully install crankshaft in cylinder block. 3. Install bearing caps. Make sure arrows on bearing caps are toward front (fan end) of engine. Push crankshaft forward and measure clearance at front side of rear main bearing. The correct clearance is 0.050 to 0.20 mm (0.002 to 0.008 in.). See Figure 44.

4. Tighten capscrews for bearing caps to 70 N•m (52 lbf ft). Move crankshaft forward and backward to align rear main bearing. Tighten capscrews for all bearing caps to 106 N•m (78 lbf ft). On late model engines, tighten capscrews for bearing caps to 20 N•m (177 lbf in) on the first pass. Move crankshaft forward and backward to align rear main bearing. Tighten capscrews for all bearing caps an additional 73 degrees on the final pass. 5. Install connecting rods, oil pump, and oil pan. Install flywheel and other parts. 6. On late model engines with a one-piece seal, install seal in retainer. Use new gasket and install seal retainer. See Figure 45. Tighten screws and nut to 15 N•m (133 lbf in).

A. SEAL REMOVAL NOTCHES 1. 2. 3. 4.

CRANKSHAFT OIL SEAL SEAL RETAINER ENGINE BLOCK

5. 6. 7. 8.

GASKET STUD SCREW NUT

Figure 45. One-Piece Rear Seal

Piston and Connecting Rod Assemblies Repair

600 SRM 590

Piston and Connecting Rod Assemblies Repair CONNECTING ROD BEARINGS, REPLACE NOTE: Connecting rod bearings are insert bearings that do not use shims for adjustment. These bearings are available in a standard size and the following undersizes: 0.025 mm (0.001 in.), 0.051 mm (0.002 in.), 0.254 mm (0.010 in.), and 0.508 mm (0.020 in.). If a bearing on a journal is worn, both the upper and lower half of the bearing must be replaced.

envelope for Plastigage® to measure width of plastic at its widest point. The scale will indicate the clearance in millimeters or thousandths of an inch. See Figure 47.

1. Remove oil sump and oil pump. 2. Mark caps for connecting rods so they can be installed in their correct locations and positions. 3. Push connecting rod away from crankshaft and remove upper bearing half. Wipe oil from bearing halves and bearing journal. Make sure all parts from each rod assembly remain together.

Figure 46. Plastigage® on Bearing Journal

4. Use a micrometer to measure bearing journal. The bearing journal must be within the following specifications: Out-of-round less than 0.0254 mm (0.001 in.) Taper less than 0.0254 mm (0.001 in.) If bearing journals are not within specifications, crankshaft must be removed and bearing journal ground to an undersize. If bearing journal cannot be repaired so bearing journal is a correct undersize, crankshaft must be replaced. See Engine Specifications, Crankshaft. 5. If bearing journal is within specifications, measure clearance between new bearing and crankshaft. Use Plastigage® or equivalent to check clearance: a. Put a piece of Plastigage® across the full width of the bearing journal as shown in Figure 46. Do not rotate crankshaft when Plastigage® is between bearing and its journal. b. Install bearing cap and tighten bearing cap nuts first to 27 N•m (240 lbf in) and then an additional 70 degrees. c. Remove bearing cap. The Plastigage® will be compressed and wider and will adhere to either the bearing or its journal. Use scale on

Figure 47. Measuring Plastigage® on Bearing Journal d. If clearance is greater than specifications, select a new undersize bearing set and install it. Measure clearance again. If clearance cannot meet specifications with available undersize bearings, bearing journal must be ground to a new undersize. If bearing journal is already at maximum undersize, crankshaft must be replaced. e. If clearance is within specifications, lubricate bearing with engine oil and install bearing and bearing cap. First tighten nuts on bearing caps to 27 N•m (240 lbf in). After this step, tighten nuts an additional 70 degrees.

600 SRM 590 6. When all rod bearings have been replaced, use the following procedure to check side clearances between connecting rods and crankshaft:

Piston and Connecting Rod Assemblies Repair 7. Push connecting rod and piston from cylinder. Temporarily install bearing cap on connecting rod to keep parts together.

a. Use a hammer to lightly hit connecting rod parallel to crankshaft journal to make sure there is clearance.

DISASSEMBLE

b. Measure side clearance between caps for connecting rods and crankshaft. See Figure 48 and Engine Specifications.

The pistons are aluminum alloy and can be damaged if they are hit with a hard object. The grooves for the piston rings are machined to close tolerances. Use a tool made to clean the grooves of the piston rings. Do not use a wire brush to clean a piston.

CAUTION

1. Remove piston rings from pistons. 2. Use a press to remove piston pins from piston. See Figure 49.

Figure 48. Measuring Connecting Rods Side Clearance

PISTON AND CONNECTING ROD ASSEMBLIES, REMOVE 1. Remove oil sump and oil pump. 2. Remove cylinder head as described in Cylinder Head Repair, Remove and Disassemble. 3. If engine has been in service for many hours, a ridge can be worn in the top of the cylinder. This ridge can be removed with a ridge reamer tool. Turn crankshaft to lower piston to bottom of stroke in its cylinder. Put cloth on top of piston for a collector of metal particles. Use a ridge reamer to remove ridge at top of cylinder. 4. Clean carbon from top of each cylinder. 5. Put an identification mark on top of each piston. 6. Remove caps and bearings from each connecting rod. Keep caps and bearings with their original piston assemblies. Mark caps so they will be installed again in their original positions. Do not mix parts.

Figure 49. Piston Pin Removal

Piston and Connecting Rod Assemblies Repair

600 SRM 590

PISTON, CLEAN AND INSPECT WARNING Commercial cleaning solvents can be flammable and toxic and can cause severe skin irritation. When using commercial cleaning solvents, always comply with the solvent manufacturerâ&#x20AC;&#x2122;s recommended safety precautions. Compressed air can move particles so they cause injury to the user or to other personnel. Make sure the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes. 1. Use solvent to clean pistons and connecting rods. Use compressed air to dry parts. 2. Clean piston ring grooves with a ring groove cleaning tool. 3. Clean piston oil lubrication holes and slots. 4. Inspect pistons for wear, cracks, and damage. Replace a piston that is worn or damaged.

Figure 50. Cylinder Bore Measurement Measure cylinder bore in positions from top to bottom to find any taper from wear. A normal wear pattern for a cylinder bore is shown in Figure 51. A cylinder that has a taper (measurement A that is 0.127 mm (0.005 in.) greater than measurement B) must have a new bore. A tool called a hone can be used to remove a small amount of taper from a cylinder bore. Use a boring machine to repair a badly worn cylinder. The boring machine will make a more accurate cylinder bore. The hone is then used to finish the surface of the cylinder bore.

NOTE: If the cylinder bore must be repaired, the piston must be changed to the correct oversize. Check clearance of piston in its cylinder after surface of cylinder bore has been finished with a hone. 5. Check clearance of piston pin in piston. The normal clearance is shown in the Engine Specifications. The piston pin will normally fall from the hole in the piston by its own weight. The piston pin is a press fit in the connecting rod. The piston and piston pin are a matched set and must be replaced as a unit if the clearances are greater than the specifications.

CYLINDER BORES, INSPECT AND REPAIR Inspect cylinder bores for wear and damage. Measure cylinder bores in several positions as shown in Figure 50. Measure cylinder bore at right angles to centerline to find any distortion from wear. A cylinder that is out-of-round greater than 0.05 mm (0.002 in.) must be repaired.

Figure 51. Pattern for Normal Cylinder Wear A cylinder bore that has been repaired with a hone or a boring machine must be fitted with a piston that is the correct size. Measure outer diameter of piston and inner diameter of cylinder bore as shown in Figure 52. Using different oversize pistons in the engine does not affect the dynamic balance of the engine. Replacement pistons from standard size to 0.508 mm (0.020 in.) oversize normally have the same weight. The clearance specifications between a piston and its cylinder bore is shown in Engine Specifications.

600 SRM 590

Piston and Connecting Rod Assemblies Repair

PISTON RINGS

clearances are shown in the Engine Specifications. Replace piston if clearances are greater than specifications.

NOTE: Check clearance of piston rings in cylinder after surface of cylinder has been finished with a hone. New piston rings are available for the following piston sizes: standard size, and 0.127 mm (0.005 in.), 0.254 mm (0.010 in.), 0.508 mm (0.020 in.), and 0.762 mm (0.030 in.) oversize. The piston rings must match the size of the piston on which they are installed. Check side clearance and end clearance of piston rings as described in the following paragraphs.

2. Measure end clearance of each piston ring as shown in Figure 54. The end clearances are shown in the Engine Specifications. Install piston ring into cylinder where it will be used. Use a thickness gauge to measure the amount of end clearance. Replace piston if clearances are greater than the specifications.

Each compression ring has a mark on one surface. This mark must be toward the top of the cylinder when the piston ring is installed. The No. 1 compression ring normally has a chrome or molybdenum surface.

Figure 53. Piston Ring and Groove Clearance Check

A. PISTON GAUGE POINT

B. BORE GAUGE POINT

Figure 52. Piston and Cylinder Bore Gauge Points The oil control ring has three pieces. There are two thin steel rings separated by a spacer. 1. Measure clearance between piston ring and groove in piston as shown in Figure 53. The

Figure 54. Piston Rings End Clearance Check

Piston and Connecting Rod Assemblies Repair

600 SRM 590

ASSEMBLE

Table 1. Piston Rings Arrangement on Piston

NOTE: There are notches cast in the top of all pistons to indicate the correct assembly and installation. The pistons must always be installed with this notch toward the fan end of the engine. See Table 1.

A Position of Gap for Spacer of Oil Ring

The connecting rods have a notch cast in the bearing journal as shown in Figure 55. This notch must be opposite the notch on the top of the piston when the piston and connecting rod are assembled. On later engines the flanges on the connecting rods and caps should face to the front of the engine on the left bank and to the rear of the engine on the right bank.

Fan End of Engine

B Position of Gap for Oil Ring C Position of Gap for Second Compression Ring D Position of Gap for First Compression Ring

PISTON AND CONNECTING ROD ASSEMBLIES, INSTALL 1. Lubricate assembly with engine oil during installation. Arrange piston rings on piston as shown in Table 1. Install ring compressor on piston. 2. Make sure notch in piston is toward fan end of engine. Install piston and connecting rod assemblies in cylinder bores.

1. NOTCHES ON ROD OPPOSITE NOTCH IN PISTON Figure 55. Connecting Rod Identification 1. Assemble connecting rod to piston. Make sure the orientation of connecting rod and piston are correct as described in the NOTE above. Use a press to install piston pin into piston and connecting rod. Lubricate piston pin with engine oil during installation. 2. Check clearances of piston rings as described in Piston Rings. Install piston rings on piston as shown in Table 1.

3. Install bearings and caps for connecting rods. Tighten nuts. See the procedure in Connecting Rod Bearings, Replace. 4. Check side clearance of each connecting rod after bearing cap is installed. See the procedure in Connecting Rod Bearings, Replace. 5. Install cylinder head as described in Cylinder Head Repair, Assemble and Install. 6. Install oil pump and oil sump.

600 SRM 590

Flywheel and Flywheel Housing Repair

Flywheel and Flywheel Housing Repair FLYWHEEL, REPAIR 1. Replace ring gear (if applicable) on flywheel. During removal or installation, do not heat gear to more than 230 C (450 F). 2. During installation, push ring gear fully against flywheel. 3. The bearing in the flywheel can be replaced. Push old bearing from flywheel and push in new bearing.

ENGINE ADAPTER H6.00-7.00XL (H135-155XL) The engine adapter is used on engines with a manual transmission. When the seal in the adapter is replaced, use a sealant (Hyster Part No. 246108) between seal and adapter. When installing adapter on engine, make sure O-rings are installed under washers. Tighten capscrews for adapter to 48 N•m (35 lbf ft). See Figure 56.

FLYWHEEL, INSTALL H3.50-5.00XL (H70-110XL), S3.50-5.50XL (S70-120XL), S6.00-7.00XL (S135-155XL) NOTE: For model H3.50-5.50XM (H70-120XM), refer to the section Cooling System 700 SRM 740 for hydraulic pump drive. When installing the flywheel on these units, refer to the section Hydraulic Pump Drive Assembly.

H6.00-7.00XL (H135-155XL) Make sure dowel pin is installed in crankshaft. Install flywheel. Units with a manual transmission: Make sure O-ring is installed between flywheel and crankshaft. Use a sealant (Hyster Part No. 246108) on heads of capscrews. Tighten capscrews for flywheel to 79 N•m (58 lbf ft). Units with a powershift transmission: Tighten capscrews to 79 N•m (58 lbf ft).

FLYWHEEL HOUSING H3.50-5.00XL (H70-110XL), H3.50-5.50XM (H70-120XM), S3.50-5.50XL (S70-120XL), S6.00-7.00XL (S135-155XL) The flywheel housing on these units has the parts for the hydraulic pump drive assembly. When doing any service to the housing, refer to section Hydraulic Pump Drive Assembly.

1. 2. 3. 4.

ENGINE ADAPTER ENGINE FLYWHEEL PILOT BEARING

5. 6. 7. 8.

SEAL CAPSCREW WASHER O-RING

Figure 56. Engine Adapter H6.00-7.00XL (H135-155XL)

Fan Mount Assembly Repair (Late Models)

600 SRM 590

Coolant Pump Repair If any parts of the coolant pump are worn or damaged, replace coolant pump. Parts for the coolant pump are not available separately. During installation, apply a sealant to gasket for coolant pump.

Tighten capscrews for coolant pump to 41 N•m (30 lbf ft). Adjust tension of belt as described in the Periodic Maintenance section for your lift truck.

Thermostat Replacement CAUTION DO NOT operate the engine without a thermostat. The engine and cooling system can be damaged.

When installing the thermostat, make sure flange is completely in its seat. Install gasket and housing. Tighten capscrews to 25 N•m (221 lbf in).

Fan Mount Repair (Early Models) The fan mount has the shaft and bearings for the fan. On some early units the mount has an idler pulley for adjustment of the fan belt. When the fan is installed, tighten capscrews to 20 N•m (177 lbf in). See Figure 57.

1. INNER SNAP RING 2. OUTER SNAP RING

3. BEARING 4. FAN MOUNT 5. SHAFT

Figure 57. Fan Mount (Early Models)

Fan Mount Assembly Repair (Late Models) NOTE: For model H3.50-5.50XM (H70-120XM), refer to the section Cooling System 700 SRM 740.

WARNING Do not try to disassemble the belt tensioner. There is a strong spring inside the tensioner that, if removed, can cause an injury.

The fan mount assembly includes brackets and mounts that hold fan, belt tensioner, alternator, and hydraulic pump (where used) to engine. When the fan is installed, tighten capscrews to 20 N•m (177 lbf in). See Figure 58.

600 SRM 590

Fan Mount Assembly Repair (Late Models)

NOTE: S/H6.00-7.00XL (S/H135-155XL) SHOWN, OTHERS SIMILAR. A. EARLY MODELS

B. LATE MODELS

1. 2. 3. 4. 5. 6. 7.

8. 9. 10. 11. 12. 13. 14.

MOUNT BEARING SNAP RING SHAFT HUB SPACER FAN PULLEY

FAN DRIVE BELT BELT TENSIONER CRANKSHAFT PULLEY BRACKET ALTERNATOR BRACKET TENSIONER BRACKET

Figure 58. Fan Mount Assembly

Drive Belt Installation

600 SRM 590

Drive Belt Installation NOTE: For model H3.50-5.50XM (H70-120XM), refer to the section Cooling System 700 SRM 740. 1. Check alignment of fan, alternator, and crankshaft pulleys. The pulleys must be aligned correctly to prevent damage to drive belt. See Figure 59.

1. BRACKET 2. UPPER HOLE 3. PULLEY

4. TENSIONER 5. ALIGNMENT LUG 6. LOWER HOLE

Figure 60. Drive Belt Tensioner Installation

CAUTION Do not use a pry bar to install the drive belt on the pulleys. The pry bar can damage the drive belt and pulleys. 3. Loosen top capscrew at alternator mount and move alternator toward engine. Install drive belt over fan and onto pulleys. NOTE: S/H3.50-5.50XL (S/H70-120XL) SHOWN, OTHERS SIMILAR. 1. ALTERNATOR PULLEY 2. FAN PULLEY 3. WATER PUMP PULLEY

4. CRANKSHAFT PULLEY 5. DRIVE BELT 6. TENSIONER PULLEY

Figure 59. Drive Belt Arrangement 2. Install drive belt tensioner on bracket and tighten bolts. See Figure 60. Make sure lug on back of tensioner fits into lower hole in bracket for new drive belts. Do not use the upper hole when installing a NEW drive belt. Putting the lug in the upper hole is only necessary to extend the life of a used drive belt.

4. Use a socket with a long handle on capscrew for the pulley (Figure 60) on belt tensioner. (The capscrew has left-hand threads and will not loosen.) Use the handle to pull the pulley away from drive belt. While holding pulley away from belt, pull alternator away from engine (as far as it will move) and tighten capscrew at mount. Release pulley for belt tensioner. 5. After installation is complete, check position of indicator on tensioner. When tension is correct, indicator will be in the area (3) as shown in Figure 61. If indicator is in the area as shown by (4), change position of tensioner to upper hole (Figure 60). Use the procedure described in Step 4. If tension on drive belt is still not correct, install new drive belt. Also check that brackets and pulleys are installed correctly.

600 SRM 590

Valve Clearance Adjustment (Early Models)

1. TENSIONER 2. INDICATOR

3. TENSION IS CORRECT 4. ADJUST TENSION OR REPLACE DRIVE BELT Figure 61. Drive Belt Tension Check

Valve Clearance Adjustment (Early Models) NOTE: The early models use rocker arm studs that are pressed into the head. 1. Disconnect negative cable at battery. Remove rocker covers. 2. Rotate engine until mark on vibration damper or crankshaft pulley is aligned with 0 timing mark on timing tab. Make sure valves for No. 1 cylinder are closed. If valves are moving as 0 timing mark is reached, engine is in firing position for No. 4 cylinder; rotate crankshaft one more turn to reach firing position for No. 1 cylinder. See Figure 62.

4. Adjust valve clearance by loosening nut for rocker arm until push rod is loose. Tighten nut for rocker arm until there is no clearance at push rod. Check clearance by rotating push rod while tightening nut. When there is no clearance at push rod, tighten nut for rocker arm one full turn. The additional turn of the nut will put the push rod in the seat of the valve lifter. 5. After the valves are adjusted in Step 3, rotate engine one full turn. Make sure timing marks are aligned. The valves on the No. 4 cylinder will be closed. When engine is in this position, adjust valves for the following cylinders:

3. When engine is in No. 1 firing position, adjust valves for the following cylinders:

Inlet Valves for Numbers. 4, 5, and 6 and Exhaust Valves for Numbers. 2, 3, and 4.

Inlet Valves for Numbers: 1, 2, and 3 and Exhaust Valves for Numbers: 1, 5, and 6.

6. Install valve covers. Connect battery cable. Start engine and check for correct operation.

Compression Check

600 SRM 590

NOTE: Early models shown.

Figure 62. Valve Clearance Adjustment

Valve Clearance Adjustment (New Models) NOTE: The new models use rocker arm studs screwed into the head. The new models have a valve system that is not adjustable. After the valve system has been assembled,

tighten nuts for rocker arms to 25 Nâ&#x20AC;˘m (221 lbf in). The hydraulic valve lifter acts as an automatic adjuster and maintains zero lash in the valve train.

Compression Check Check the compression as follows: 1. Remove all spark plugs.

b. Crank engine approximately ten revolutions to distribute oil.

2. Make sure battery is fully charged.

c. Install compression gauge and do the same tests as described in Step 3.

3. Install a compression gauge. Hold throttle open and crank engine with starter. The minimum pressure is 690 kPa (100 psi). The lowest pressure in a cylinder must not be less than 70% of the highest pressure.

d. If compression pressure increases to a normal reading, the low pressure was caused by worn or damaged piston rings. The cylinder bore can also be damaged.

4. If the readings are lower than the minimum readings, there is a problem with the valves, piston rings, or cylinder head gasket. Do the following tests to find the problem: a. Add approximately 30 ml (1 oz) of engine oil to each cylinder at spark plug hole.

e. If compression pressure does not increase, the low pressure was caused by worn valves, valve seats, or valve guides. f.

If low pressure readings are in two cylinders next to each other, the cylinder head gasket can be leaking.

600 SRM 590

Engine Specifications

Engine Specifications ENGINE DATA Number of cylinders

Firing order

1 6 5 4 3 2

Bore

101.62 to 101.64 mm (4.0008 to 4.0016 in.)

Stroke

88.39 mm (3.480 in.)

Compression Ratio

9.2:1

Displacement

4.3 liter (262.4 in. 3 )

Governor speed

See Periodic Maintenance section for each model of lift truck.

CYLINDER HEAD Valve seat specifications

See Figure 4 and Figure 6.

Valve seat width (inlet valves) Early Models

1.02 to 1.65 mm (0.040 to 0.065 in.)

Late Models

0.89 to 1.52 mm (0.035 to 0.060 in.)

Valve seat width (exhaust valves) Early Models

1.65 to 2.49 mm (0.065 to 0.098 in.)

Late Models

1.57 to 2.36 mm (0.062 to 0.093 in.)

Clearance between inlet valve and guide Early Models

0.02 to 0.09 mm (0.001 to 0.0035 in.)

Late Models

0.0254 mm (0.001 in.) max

Clearance between exhaust valve and guide Early Models

0.02 to 0.12 mm (0.001 to 0.0047 in.)

Late Models

0.0508 mm (0.002 in.) max

Valve spring, free length

See Figure 7.

Engine Specifications

600 SRM 590

HYDRAULIC VALVE LIFTER Leak rate

12 to 90 seconds with 50-lb load

Body diameter

21.3868 to 21.4046 mm (0.8420 to 0.8427 in.)

Plunger travel

3.175 mm (0.125 in.)

Clearance in bore

0.0635 mm (0.0025 in.)

Lifter bore diameter

21.425 to 21.450 mm (0.8435 to 0.8445 in.)

CAMSHAFT Variation from front to rear of a cam lobe

Taper with larger dimension away from No. 1 piston

Bearing journals, diameter (All engines)

47.45 to 47.48 mm (1.8681 to 1.8693 in.)

Bearing journals, clearance

0.01778 to 0.9685 mm (0.0007 to 0.0381 in.)

Variation of a bearing journal in either diameter or axial direction

0.03 mm (0.001 in.)

Axial clearance

0.10 to 0.30 mm (0.004 to 0.012 in.)

PISTONS Piston diameter (see gauge points in Figure 52) Cylinder Bore Out-of-round (see Figure 50)

0.0508 mm (0.002 in.)

Maximum cylinder taper

0.025 mm (0.001 in.)

Clearance at bottom of cylinder

0.068 mm (0.0027 in.)

Piston ring to groove clearance for piston rings (see Figure 53) Compression rings

0.107 mm (0.0042 in.)

Oil ring to groove clearance Early Models

0.203 mm (0.008 in.) max

Late Models

0.508 to 2.032 mm (0.02 to 0.08 in.)

Piston ring end clearance (see Figure 54) Compression rings Early Models

0.89 mm (0.035 in.)

Late Models

1.524 to 0.88 mm (0.06 to 0.035 in.)

Oil ring Early Models

1.65 mm (0.065 in.)

Late Models

0.23 to 1.65 mm (0.009 to 0.065 in.)

Piston pin to piston clearance

0.025 mm (0.001 in.)

Piston pin to connecting rod clearance

0.020 to 0.040 mm (0.0008 to 0.0016 in.)

600 SRM 590

Engine Specifications

CRANKSHAFT Diameter of main bearing journal Number 1

62.20 to 62.22 mm (2.4488 to 2.4496 in.)

Number 2, 3

62.20 to 62.21 mm (2.4488 to 2.4492 in.)

Number 4

62.18 to 62.20 mm (2.4480 to 2.4488 in.)

Out-of-round of main bearing journal (maximum)

0.0254 mm (0.001 in.)

Taper of main bearing journal (maximum)

0.0254 mm (0.001 in.)

Clearance between journals and main bearings Early Models Number 1

0.025 to 0.038 mm (0.0010 to 0.0015 in.)

Number 2, 3

0.025 to 0.064 mm (0.0010 to 0.0025 in.)

Number 4

0.064 to 0.090 mm (0.0025 to 0.0035 in.)

Late Models Number 1

0.0254 to 0.05 mm (0.0010 to 0.0020 in.)

Number 2, 3, 4

0.025 to 0.006 mm (0.0010 to 0.0002 in.)

Available undersize main bearings

0.0254 mm ( 0.001 in.) 0.0508 mm ( 0.002 in.) 0.2285 mm ( 0.009 in.) 0.25 mm ( 0.010 in.) 0.50 mm ( 0.020 in.)

Axial Clearance (crankshaft to thrust surface main bearing) Early Models

0.15 to 0.18 mm (0.006 to 0.007 in.)

Late Models

0.050 to 0.20 mm (0.002 to 0.008 in.)

CONNECTING RODS Diameter of connecting rod journals

57.12 to 57.14 mm (2.2488 to 2.2496 in.)

Out-of-round of bearing journal (maximum)

0.0254 mm (0.001 in.)

Taper of bearing journal (maximum)

0.0254 mm (0.001 in.)

Clearance between crankshaft journals and connecting rod bearings

0.076 mm (0.0030 in.)

Available undersize connecting rod bearings

0.0254 mm ( 0.001 in.) 0.0508 mm ( 0.002 in.) 0.254 mm ( 0.010 in.) 0.508 mm ( 0.020 in.)

Side clearance of connecting rod to crankshaft

Torque Specifications

600 SRM 590

Early Models

0.15 to 0.36 mm (0.006 to 0.014 in.)

Late Models

0.15 to 0.44 mm (0.006 to 0.017 in.)

BALANCE SHAFT Front bearing journal diameter

54.99 to 55.00 mm (2.1650 to 2.1654 in.)

Rear Bearing Journal Diameter

38.08 to 38.10 mm (1.4992 to 1.500 in.)

Rear Bearing Journal Clearance

0.025 to 0.091 mm (0.001 to 0.0036 in.)

COOLING SYSTEM Thermostat

82 C (180 F)

LUBRICATION SYSTEM Oil pressure @ 2500 rpm

170 to 241 kPa (25 to 35 psi)

Minimum oil pressure Early Model @ idle rpm

48 kPa (7 psi)

Late Model @ 1000 rpm

41.4 kPa (6 psi)

Oil pressure switch ON

20 to 39 kPa (2.9 to 5.7 psi)

Torque Specifications Alternator Pulley 61 N•m (45 lbf ft)

Cooling Fan to Pulley 24 N•m (212 lbf in)

Balance Shaft Gear Capscrew 20 N•m (177 lbf in) Plus 35 Degrees

Cylinder Head See Text

Balance Shaft Retainer Capscrews 14 N•m (124 lbf in)

Distributor Mount Capscrew 34 N•m (25 lbf ft)

Camshaft Retainer Screws 14 N•m (124 lbf in)

Exhaust Manifold 15 N•m (133 lbf in) - first step 30 N•m (22 lbf ft) - second step

Camshaft Sprocket Capscrews 28 N•m (21 lbf ft)

Flywheel 80 N•m (60 lbf ft)

Camshaft Sprocket Nut 28 N•m (21 lbf ft)

Flywheel Housing 48 N•m (35 lbf ft)

Chain Control Block for Hydraulic Pump Drive 19 N•m (168 lbf in) with Adhesive Sealant

Inlet Manifold to Cylinder Head (Early Models) 48 N•m (35 lbf ft)

Connecting Rod Cap See Text

Inlet Manifold to Cylinder Head (Late Models) 15 N•m (133 lbf in) - in three steps

Coolant Pump to Engine Block 41 N•m (30 lbf ft)

Main Bearing Cap 106 N•m (78 lbf ft)

600 SRM 590

Troubleshooting

Motor Mount to Engine S/H3.50-5.00XL (S/H70-110XL) 31 N•m (23 lbf ft) S/H6.00-7.00XL (S/H135-155XL) 50 N•m (37 lbf ft) Oil Pump Cover 14 N•m (124 lbf in)

Rocker Arm Cover 10 N•m (89 lbf in) Rocker Arm Nuts (Late Models) 25 N•m (18 lbf ft) Rocker Arm Studs 47 N•m (35 lbf ft)

Oil Pump to Crankcase 90 N•m (66 lbf ft)

Rocker Arm Bolts (Model Year 2002 or Later Engines) 30 N•m (22 lbf ft)

Oil Pressure Switch 27 N•m (20 lbf ft)

Thermostat Housing 25 N•m (18 lbf ft)

Oil Screen Support to Crankcase 50 N•m (37 lbf ft) Oil Sump to Crankcase (Early Models) (1/4-20) 10 N•m (89 lbf in) (5/16-18) 19 N•m (168 lbf in) Oil Sump to Crankcase (Late Models) Capscrews 25 N•m (18 lbf ft) Nuts 25 N•m (18 lbf ft)

Timing Cover 14 N•m (124 lbf in) Valve Lifter Retainer Capscrews 16 N•m (142 lbf in) Vibration Damper 95 N•m (70 lbf ft)

Rear Oil Seal Retainer Screws and Nut 15 N•m (133 lbf in)

Troubleshooting PROBLEM When the key switch is in the START position, engine does not crank.

POSSIBLE CAUSE

PROCEDURE OR ACTION

Battery is damaged.

Install new battery.

Battery is not fully charged.

Charge battery.

Connections at the battery are loose or they have corrosion.

Clean and tighten battery connections.

Key switch does not operate correctly.

Check operation of the key switch. Check electrical wiring. Install new key switch.

Starter or starter circuit is damaged.

Check starter, starter relay, and wiring. Install new parts as required.

There is a seizure of parts in the engine or ring gear is damaged.

Rotate crankshaft manually. If crankshaft will rotate, check ring gear, if not overhaul engine.

Troubleshooting

PROBLEM The engine will not start.

The engine does not run smoothly.

The engine does not have enough power.

600 SRM 590

POSSIBLE CAUSE

PROCEDURE OR ACTION

No fuel in fuel tank or fuel not entering engine.

Fill tank with correct fuel. If LPG, open shutoff valve. Check fuel delivery system (fuel pump, lines, etc.). Install new parts as required.

Cranking speed is too slow. Battery is not fully charged.

Charge battery or install new battery.

Valves are worn or damaged.

Grind valves. Install new valves.

Low compression. The piston rings are worn or damaged.

Install new piston rings. Overhaul engine.

Ignition system does not operate correctly.

Check spark delivery system. Repair or install new parts as required.

Ignition timing is not correct.

Adjust timing. Check timing chain and sprockets.

Valves are not adjusted correctly.

Adjust valves.

Head gasket is damaged.

Install new head gasket.

Cylinder head has cracks.

Install new cylinder head.

There is a leak in the intake system.

Repair leak.

Ignition timing is not correct.

Adjust timing.

Spark plugs are worn or damaged.

Install new spark plugs.

Ignition system does not operate correctly.

See sections for Electrical Systems for more information.

Restriction in air inlet. The air filter is dirty.

Check air restriction indicator. Clean or install new filter element.

Fuel is the wrong type or grade.

Drain fuel. Fill with correct fuel.

Ignition timing is not correct.

Check and adjust timing.

Valve mechanism is damaged.

Repair or install new parts.

Piston assemblies are damaged.

Repair or install new parts. Overhaul engine.

Valve timing is not correct.

Adjust valve timing.

Exhaust system has restrictions.

Remove restrictions. parts as necessary.

Install new

600 SRM 590

PROBLEM There is noise inside the engine.

The engine makes noise during acceleration.

Troubleshooting

POSSIBLE CAUSE

PROCEDURE OR ACTION

Main bearings are worn or damaged.

Install new main bearings or overhaul engine.

Bearings for the connecting rods are worn or damaged.

Install new rod bearings or overhaul engine.

Pistons or rings are worn or damaged.

Install new rings and piston or overhaul engine.

Engine is too hot.

Check thermostat. Check cooling system (radiator, fan, drive belt, etc.). Clean and repair as required.

Low oil pressure. Not enough oil in the engine.

Check oil level. Add oil to full mark on dipstick. Check oil pressure. Repair oil pump. Overhaul engine.

Flywheel is loose.

Tighten flywheel mounting bolts.

There is a leak in the exhaust system.

Repair leak.

Valve mechanism is damaged.

Repair or install new parts as required.

Valves are not adjusted correctly.

Check and adjust valve clearance.

Spark plugs are dirty.

Clean spark plugs and reinstall.

Spark plugs are the wrong type or heat range.

Install new spark plugs of correct type and heat range.

Ignition timing is not correct.

Check and adjust ignition timing.

Fuel is the wrong type or grade.

Drain fuel. Fill with correct fuel.

There is too much carbon in the combustion chamber (preignition).

Put truck in hard work cycle. Add engine cleaner to fuel. Do top engine overhaul.

Engine is too hot.

Check thermostat. Check cooling system (radiator, fan, drive belt, etc.). Clean or repair as required.

Fuel system is not adjusted correctly.

Adjust fuel system.

Troubleshooting

PROBLEM The engine is too hot during operation.

The bearings in the engine are damaged.

600 SRM 590

POSSIBLE CAUSE

PROCEDURE OR ACTION

There is not enough coolant in the cooling system.

Check coolant level in radiator and coolant recovery bottle. Add coolant to correct level.

Radiator is dirty.

Drain and flush radiator. Clean radiator fins with high pressure air or water in reverse direction of normal airflow. Refill with clean coolant.

Drive belt for water pump is not adjusted correctly, worn, or broken.

Check water pump drive belt. Adjust or install new belt as required.

Thermostat is wrong heat range or does not operate correctly.

Check heat range. Install new thermostat.

Cooling system has restrictions.

Drain and back-flush engine and radiator. Refill with clean coolant.

Water pump worn or damaged.

Install new water pump.

Exhaust system has restrictions.

Check the exhaust system. Remove restrictions.

There is not enough oil in the engine.

Add oil to full mark on dipstick.

Oil in the engine is dirty.

Make sure dirt is not entering engine through air inlet system. Drain and fill with clean oil. Reduce time interval for oil and filter change.

Oil in the engine is the wrong type.

Drain and fill with correct oil.

Oil pump is worn or damaged.

Install new oil pump.

Connecting rod(s) and bearings have damage.

Check and repair crankshaft. Install new connecting rods and bearings.

Camshaft and bearings have damage.

Install new camshaft and bearings.

Passages for oil have restrictions.

Remove restrictions or overhaul engine.

Bearings are not installed correctly.

Install new bearings or overhaul engine.

HIGH ENERGY IGNITION (HEI) SYSTEM GM ENGINES S30-120E, S40-50F, S3.50-5.50XL (S70-120XL), S3.50-5.50XM (S70-120XM), S6.00-7.00XL (S135-155XL), H30-60H, H60-110E, H110-150F, H3.50-5.00XL (H70-110XL), H6.00-7.00XL (H135-155XL), H3.50-5.50XM (H70-120XM), H150-250E, H150-275H, H250-300A, H300-350B, P150-200B, A66-80A, Z90A, S/H2.00-3.20XM (GM 3.0 LITER WHEN EQUIPPED WITH LPG), M200-400H, GM 6.0 LITER V8-366 ENGINE WHEN USED IN H8.00-12.00XL (H165-280XL), H13.00-16XL (H300-360XL), H10.00XL-12EC (H330XL-EC), H12.00XL-12EC (H360XL-EC)

PART NO. 899788

2200 SRM 107

High Energy Ignition (HEI) System

Table of Contents

TABLE OF CONTENTS Description ........................................................................................................................................................... Distributor Repair................................................................................................................................................ Remove ............................................................................................................................................................. Disassemble ..................................................................................................................................................... Assemble .......................................................................................................................................................... Install, If Crankshaft WAS NOT Rotated when Distributor was Removed ................................................. Install, If Crankshaft WAS Rotated when Distributor was Removed .......................................................... Ignition Coil Replacement ................................................................................................................................. Some Four- and Six-Cylinder Models ........................................................................................................... Remove....................................................................................................................................................... Install ......................................................................................................................................................... V8, Some Four- and Six-Cylinder Models .................................................................................................... Remove....................................................................................................................................................... Install ......................................................................................................................................................... Electronic Module Replacement........................................................................................................................ Remove ........................................................................................................................................................... Install ............................................................................................................................................................. Sensing Coil Replacement ................................................................................................................................. Remove ........................................................................................................................................................... Install ............................................................................................................................................................. Spark Plugs Replacement.................................................................................................................................. Remove ........................................................................................................................................................... Install ............................................................................................................................................................. Visual Check....................................................................................................................................................... High Voltage Wires Check ................................................................................................................................. Ignition Coil Check ............................................................................................................................................ Coil in Distributor Cap Design ..................................................................................................................... Separate Coil Design ..................................................................................................................................... Sensing Coil, Check ....................................................................................................................................... Electronic Module Check ................................................................................................................................... Ignition Timing Adjustment.............................................................................................................................. GM V8-366 (6-liter) Ignition System Check ..................................................................................................... GM V6-LPG (4.3 liter) GM V6-LPG (4.3 liter) Ignition Timing and Idle Speed Adjustment ........................ Specifications...................................................................................................................................................... Troubleshooting..................................................................................................................................................

1 3 3 3 8 9 9 10 10 10 11 11 11 12 13 13 13 14 14 14 14 14 15 15 15 16 16 16 17 17 17 19 19 19 20

This section is for the following models: S30-120E, S40-50F, S3.50-5.50XL (S70-120XL), S3.50-5.50XM (S70-120XM), S6.00-7.00XL (S135-155XL), H30-60H, H60-110E, H110-150F, H3.50-5.00XL (H70-110XL), H6.00-7.00XL (H135-155XL), H3.50-5.50XM (H70-120XM), H150-250E, H150-275H, H250-300A, H300-350B, P150-200B, A66-80A, Z90A, S/H2.00-3.20XM (GM 3.0 liter when equipped with LPG), M200-400H, GM 6.0 liter V8-366 engine when used in H8.00-12.00XL (H165-280XL), H13.00-16XL (H300-360XL), H10.00XL-12EC (H330XL-EC), H12.00XL-12EC (H360XL-EC)

2200 SRM 107

Description

Description This section has a description and the service procedures for the High Energy Ignition (HEI) system for General Motors engines. See Figure 1. The High Energy Ignition (HEI) system generates the spark which starts combustion. The main parts of the system are: the battery, key switch, distributor, ignition coil, spark plugs, and the wires. If the engine is starting or running, current flows from the battery to the key switch, primary winding of the ignition coil, electronic module and returns to the battery. A magnetic field is generated in the primary winding of the coil when current flows through it. The pole piece and sensing coil sends a signal to the electronic module to interrupt primary current. When the current flow in the primary windings are interrupted, the decreasing magnetic field generates a high voltage in the secondary windings of the coil.

of the ignition coil. The flow of current generates a magnetic field around both windings. When the sensing coil removes the voltage signal, the electronic module deactivates OFF. Current stops flowing in the primary winding. The magnetic field decreases quickly. This changing magnetic field generates a high voltage in the secondary winding.

The distributor rotor applies the secondary (high) voltage to the correct spark plug at the correct time. The secondary voltage is applied to the rotor. The rotor transfers this high voltage to one of the terminals in the distributor cap. When the high voltage is applied through the high voltage wire to the spark plug, the spark in the spark plug starts combustion in the cylinder. The parts that generate the voltage signal for the electronic module are shown in Figure 2. The timer core of the distributor shaft has a tooth for each cylinder in the engine. The pole piece also has a tooth for each cylinder. A permanent magnet is fastened under the pole piece. A sensing coil is put in the center of the magnet and pole piece. When the teeth are aligned, the magnetic field from the permanent magnet will have a path. The magnetic field generates a voltage signal in the sensing coil. When the teeth are not aligned, the magnetic path is removed. This disables the magnetic field and the voltage signal. The electronic module is an electronic switch which controls the current in the primary of the ignition coil. The basic circuit is shown in Figure 3. When the electronic module receives a voltage signal from the sensing coil, the electronic module activates ON. Current now flows through the primary winding

1. BATTERY 2. TIMER CORE 3. POLE PIECE/SENSING COIL 4. SPARK PLUG

5. ROTOR 6. DISTRIBUTOR CAP 7. ELECTRONIC MODULE 8. IGNITION COIL 9. KEY SWITCH

Figure 1. HEI System

Description

2200 SRM 107

A. TEETH ALIGNED

B. TEETH NOT ALIGNED

1. TIMER CORE 2. POLE PIECE

3. PERMANENT MAGNET 4. SENSING COIL

Figure 2. Voltage Signal

A. MODULE "ON"

B. MODULE "OFF"

1. ELECTRONIC MODULE 2. BATTERY

3. PRIMARY (IGNITION COIL) 4. SECONDARY (IGNITION COIL)

Figure 3. Electronic Module Operation

2200 SRM 107

Distributor Repair

Distributor Repair REMOVE WARNING Do not disconnect the spark plug wires when the engine is running. The high voltage can cause electric shock. 1. Disconnect wire from negative terminal of battery. 2. Disconnect primary wiring connector to distributor. Some distributors have the primary wiring connected to the coil and others are connected to the distributor. NOTE: Some four- and six-cylinder models have two latch screws. Some four- and six-cylinder models and all V8 models have four latch screws. 3. Unlock latch screws that fasten the cap to the housing. Remove cap and put it away from the distributor.

CAUTION Do not rotate the engine after making the alignment marks. 4. Make a mark on distributor housing which aligns with rotor. Make a double mark on housing and engine to use during assembly. 5. Remove capscrew and clamp that fastens distributor to engine. Clean area around base of distributor. 6. Lift distributor from engine.

DISASSEMBLE 1. Remove distributor from engine according to the above procedure. 2. If installed, remove two screws that fasten rotor to shaft assembly. Remove rotor.

CAUTION Do not clean the lubricant from the electronic module or the area where it is fastened.

3. If needed, remove electronic module as follows: a. Distributors shown in Figure 4, Figure 5, and Figure 6: Remove two screws which fasten electronic module to housing. Move electronic module to a position where connector can be removed from B and C terminals. Remove connector from electronic module. Carefully disconnect wires from W and G terminals. Remove electronic module. If installed, remove screw from capacitor. Disconnect capacitor from wire connector. Remove capacitor. b. Distributors shown in Figure 7: Remove three screws that fasten electronic module, wiring harness, and capacitor to housing. Disconnect connector for the green and white wire from the electronic module. Remove electronic module, wiring harness, and capacitor from the housing. 4. Make a mark on gear and shaft which can be aligned during assembly.

CAUTION Do not damage the shaft when removing the gear. Hold the gear on a block of wood while removing the pin. 5. Remove pin from gear. Remove gear, shim, and thrust washer if used.

CAUTION Make sure the roll pin area of the shaft is smooth before removing the shaft. 6. Remove shaft assembly from housing.

CAUTION Do not disassemble the pole piece/sensing coil. If damaged, replace as a unit. 7. Remove snap ring/retainer from top of sleeve in center of housing. Remove pole piece/sensing coil and shield, if installed from the sleeve.

Distributor Repair

2200 SRM 107

Figure 4. GM-V8, Some Models

2200 SRM 107

Distributor Repair Legend for Figure 4

A. DESIGN 1

B. DESIGN 2

1. 2. 3. 4. 5. 6. 7. 8. 9.

10. 11. 12. 13. 14. 15. 16. 17. 18.

PIN DRIVE GEAR SHIM THRUST WASHER O-RING WIRING HARNESS HOUSING WIRE RETAINER FELT WASHER

SHIM CAPACITOR SPACER RETAINER POLE PIECE/SENSING COIL SNAP RING ELECTRONIC MODULE IGNITION COIL SEAL SPRING

19. 20. 21. 22. 23. 24. 25.

WIRE RETAINER COIL COVER CAP ROTOR CENTRIFUGAL MECHANISM TIMER CORE SHAFT

Figure 5. GM Four-Cylinder and Six-Cylinder Models with Separate Coil

Distributor Repair

2200 SRM 107 Legend for Figure 5

1. 2. 3. 4. 5. 6.

PIN DRIVE GEAR O-RING WIRING HARNESS HOUSING WIRE RETAINER

1. 2. 3. 4. 5. 6.

SCREW DISTRIBUTOR CAP ROTOR SHAFT ASSEMBLY RETAINER SHIELD

7. 8. 9. 10. 11. 12.

7. 8. 9. 10.

FELT WASHER SHIM CAPACITOR POLE PIECE/SENSING COIL SNAP RING ELECTRONIC MODULE

SENSING COIL POLE (STATIONARY) BOLT ELECTRONIC MODULE 11. PIN

12. 13. 14. 15. 16. 17.

HOUSING THRUST WASHER SHIM GEAR PIN GASKET

Figure 6. GM V6 Models

13. CAP (FOUR-CYLINDER SHOWN) 14. ROTOR 15. TIMER CORE 16. SHAFT 17. CENTRIFUGAL MECHANISM

18. CLAMP 19. BOLT

2200 SRM 107

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

Distributor Repair

SCREW BRACKET CAPACITOR SCREW WIRING HARNESS ELECTRONIC MODULE SNAP RING POLE PIECE/SENSING COIL SCREW SPACER RETAINER* GREASE SEAL HOUSING

13. 14. 15. 16. 17. 18. 19. 20.

THRUST WASHER* SHIM* GEAR PIN SHAFT ASSEMBLY ROTOR SCREW DISTRIBUTOR CAP (V8 SHOWN) 21. RESISTOR BRUSH AND SPRING 22. SEAL

23. 24. 25. 26. 27.

IGNITION COIL SCREW COVER SCREW VACUUM ADVANCE UNIT

*V8 ONLY Figure 7. HEI, Some Models with Coil as Part of Distributor

Distributor Repair

CAUTION Do not remove the bushing from the center of the housing. 8. If needed, remove spacer retainer from housing. Remove other parts as follows: a. On distributors shown in Figure 4 and Figure 5, remove shim, felt washer, and wire retainer from housing. Remove wiring from housing. b. On distributors shown in Figure 7, remove plastic retainer that seals the grease.

2200 SRM 107 2. If removed, install spacer retainer and screws. Install pole piece/sensing coil and shield if used. Make sure hole in arm of pole piece connects to pin of retainer. Install snap ring/retainer on top of sleeve. Make sure ring fits in groove. 3. Install distributor shaft. Slowly rotate shaft. Check for equal clearance between pole piece and timer teeth of shaft. If wrong, loosen three screws fastening pole piece. Move pole piece until it is in center. Tighten three screws. 4. Install gear with teeth toward housing as follows: a. Install thrust washer and then shim, if used. Align marks and slide gear on shaft.

CAUTION

CAUTION Put a block under the gear to prevent damage when installing the gear pin. b. Align hole in gear with hole in shaft. Install pin to lock gear to shaft.

CAUTION

Do not use solvents with an oil base to clean electrical parts.

Make sure to put silicone grease (1198757) between the module and the fastening plate.

9. Wash housing, shaft assembly, and gear in solvent. Dry parts with compressed air.

5. Install electronic module as described in the following procedures:

10. Check all parts for damage. Replace damaged parts with new parts.

a. Distributors shown in Figure 4, Figure 5, and Figure 6: If used, install capacitor, but do not tighten screw. Connect wire connector to B and C terminals on electronic module. Apply silicone grease to bottom of electronic module. Fasten electronic module to housing with two screws. Make sure screws are tight. Put wiring grommet in the notch in the housing. Connect pink wire to capacitor terminal. If a black wire is used, connect it to screw that fastens capacitor. Tighten screw. Connect white wire from sensing coil to W terminal on electronic module. Connect green wire from sensing coil to G terminal on electronic module.

ASSEMBLE 1. Fill lubrication reservoir with correct lubricant. Install parts as follows:

CAUTION On four- and six-cylinder distributors shown in Figure 5, make sure the brown wire has a circle shape. a. On distributors shown in Figure 4, Figure 5, and Figure 6, install wiring in correct position in housing. Install wire retainer, felt washer, and shim in housing. b. On distributors shown in Figure 7, install plastic retainer on top of lubrication reservoir.

b. Distributors shown in Figure 7: Connect wiring connector to electronic module. Connect capacitor to wiring connector. Apply silicone grease to bottom of electronic module. Put wiring connector assembly into correct position in housing. Make sure wiring grommet fits into notch. Install three fastening

2200 SRM 107 screws and tighten. Install connector for green and white wires to electronic module.

CAUTION The notch on the rotor must fit into the tooth of the centrifugal mechanism. 6. Install rotor and two screws to shaft assembly. Tighten screws.

INSTALL, IF CRANKSHAFT WAS NOT ROTATED WHEN DISTRIBUTOR WAS REMOVED

Distributor Repair 7. Adjust ignition timing according to the procedure in Ignition Timing Adjustment.

INSTALL, IF CRANKSHAFT WAS ROTATED WHEN DISTRIBUTOR WAS REMOVED 1. Find ignition position of the number one cylinder as follows: a. Remove valve cover (left valve cover on V8 350). b. Rotate crankshaft until inlet valve closes.

1. Turn rotor 1/8 turn to the left, past the mark put on the housing during removal.

c. Rotate crankshaft 1/3 turn more. Stop crankshaft when timing mark on pulley aligns with TDC mark.

NOTE: If needed, turn rotor until gears align correctly. The rotor must align with the mark on the housing after installation.

2. Hold distributor just above the installation position. Rotate distributor rotor until it is aligned with number one terminal.

2. Push distributor into position in block. Turn housing until the double mark on the housing aligns with the marks on the engine.

NOTE: If needed, turn rotor until gears align correctly. If needed, rotate oil pump driveshaft with a screwdriver so distributor shaft aligns with oil pump drive. The rotor must align with the number one terminal of the distributor cap. (See Figure 8.)

3. Install distributor clamp and capscrew.

CAUTION The tooth on the bottom of the cap must fit into the notch in the housing. 4. Put distributor cap on housing. Lock cap to housing with four latch screws. The early fourand six-cylinder distributors use only two latch screws. 5. Connect primary wiring harness to distributor.

3. Push distributor into position in block. Turn housing until double mark on housing aligns with marks on engine. 4. Install distributor clamp and capscrew.

CAUTION The tooth on the bottom of the distributor cap must fit into the notch in the housing or the alignment will not be correct.

a. Some four- and six-cylinder models, connect connector to coil.

5. Put distributor cap in position on housing. Lock cap to housing with latch screws.

b. V8 350 and some four- and six-cylinder models, connect connector at side of distributor.

6. Connect primary wiring harness to distributor. (See Figure 4, Figure 5, Figure 6, and Figure 7.)

6. If removed, connect battery wire to negative terminal of battery. Tighten nut on capscrew.

7. Adjust ignition timing according to the procedure in Ignition Timing Adjustment.

Ignition Coil Replacement

2200 SRM 107

A. FIRING ORDER 1-3-4-2 B. FIRING ORDER 1-5-3-6-2-4

C. FIRING ORDER 1-8-4-3-6-5-7-2 D. FIRING ORDER 1-6-5-4-3-2

1. FOUR CYLINDER 2. SIX CYLINDER

3. V8 4. V6 Figure 8. Firing Order

Ignition Coil Replacement SOME FOUR- AND SIX-CYLINDER MODELS

2. Disconnect secondary wire from coil. See Figure 9 and Figure 10.

Remove

3. Remove dust cover from primary wiring.

1. Disconnect wire from negative terminal of battery.

4. Disconnect primary wiring harness from coil.

5. Remove nuts from studs that fasten coil to block.

2200 SRM 107

Ignition Coil Replacement 1. Turn coil so terminals are on top. See Figure 9 and Figure 10. Put coil frame on studs that fasten coil to engine. Install and tighten nuts. 2. Connect primary wiring harness to coil. Push connector until latches lock. 3. Install dust cover over primary wiring connector. 4. Connect secondary wire to coil. Push connector until latches lock. 5. If removed, connect battery wire to negative terminal of battery. Tighten nut on capscrew.

1. SECONDARY TERMINAL 2. TACHOMETER TERMINAL

3. PRIMARY TERMINAL 4. FRAME 5. BATTERY TERMINAL

Figure 9. Some Four- and Six-Cylinder Models Ignition Coil

V8, SOME FOUR- AND SIX-CYLINDER MODELS Remove 1. Disconnect wire from negative terminal of battery. 2. Unlock holder for secondary wires. See Figure 11. Remove secondary wires by carefully pulling on holder. 3. Disconnect wiring harness for primary wires from side of distributor. 4. Unlock four latch screws that fasten cap to housing. Remove distributor cap from distributor. NOTE: Some V8-350 models used three screws to fasten the cover. Some V8-350, four- and six-cylinder models use two screws to fasten cover. 5. Remove screws that hold coil cover to distributor cap. Remove cover.

1. SECONDARY TERMINAL 2. TACHOMETER TERMINAL

3. PRIMARY TERMINAL 4. FRAME 5. BATTERY TERMINAL

Figure 10. GM V6 Models Ignition Coil

Install NOTE: It is normal for a new coil to be loose in the frame.

CAUTION Do not damage the ground wires. 6. Remove four screws that hold coil to distributor cap. Loosen terminals of primary wires by pushing from connector side of cap. Carefully remove coil and primary wires. 7. Check rubber seal, spring, and resistor brush in cap for damage. Check cap for cracks or other damage. Replace parts that are damaged.

Ignition Coil Replacement

2200 SRM 107

Install NOTE: On some distributor models, the ground wire must be installed before the coil is installed. 1. If the ground wire was removed, install wire into position. 2. Install resistor brush, spring, and rubber seal in cap. See Figure 11. NOTE: If the coil is new, make sure the part number is correct. 3. Put coil in correct position in cap. Push terminals of primary wires into connector on side of cap. 4. Align terminal(s) of ground wire(s) to hole in coil frame. Install four screws in frame of coil. Tighten screws.

CAUTION Some V8 units use three screws to fasten the cover. Some V8, four- and six-cylinder models use two screws to fasten the cover. 5. Install coil cover and fastening screws. Tighten screws.

CAUTION The tooth on the bottom of the distributor cap must fit into the notch in the housing or the alignment will not be correct. 6. Put distributor cap in position on housing. Lock cap to housing with four latch screws.

A. DESIGN 1 B. DESIGN 2

C. DESIGN 3

1. TACHOMETER TERMINAL 2. PRIMARY WIRE

3. GROUND WIRE 4. BATTERY TERMINAL

Figure 11. V8 and Some Four- and Six-Cylinder Models Ignition Coil

7. Connect wiring harness for primary wires to side of distributor. Make sure connector is locked together. 8. Connect secondary wires and holder to cap. Make sure holder is locked to cap. 9. If removed, connect battery wire to negative terminal of battery. Tighten nut on capscrew.

2200 SRM 107

Electronic Module Replacement

Electronic Module Replacement REMOVE 1. Disconnect wire from negative terminal of battery. See Figure 12.

3. Unlock latch screws that fasten cap to housing. Remove cap. 4. If used, remove two screws that fasten rotor to shaft assembly. Remove rotor. 5. Remove electronic module as follows: a. Distributors shown in Figure 4, Figure 5, and Figure 6: Remove two screws which fasten electronic module to housing. Move electronic module so connector can be removed from B and C terminals. Remove connector from electronic module. Carefully disconnect other wires from W and G terminals. Remove electronic module from housing. b. Distributors shown in Figure 7: Remove three screws that fasten electronic module, wiring harness, and capacitor to housing. Disconnect connector for the green and white wire from the electronic module. Remove electronic module, wire connector, and capacitor from housing. Disconnect electronic module from connector.

INSTALL CAUTION Apply silicone grease (Part No. 1198757) between the electronic module and the fastening plate. 1. The following procedure is for installation of the electronic module:

1. WIRING HARNESS 2. CAPACITOR

3. SENSING COIL WIRES 4. ELECTRONIC MODULE

Figure 12. Electronic Module Installation 2. Disconnect primary wiring harness to distributor. (See Figure 4, Figure 5, Figure 6, and Figure 7.)

a. Distributors shown in Figure 4, Figure 5, and Figure 6: Connect wire connector to B and C terminals on electronic module. Apply silicone grease to bottom of electronic module. Fasten electronic module to housing with two screws. Make sure screws are tight. Put wiring grommet in notch in housing. Connect pink wire to capacitor terminal. If a black wire is used, connect it to screw that fastens the capacitor. Tighten screw. Connect white wire from sensing coil to W terminal on electronic module. Connect green wire from sensing coil to G terminal on electronic module.

Spark Plugs Replacement

2200 SRM 107

2. Install rotor and two screws to shaft assembly.

CAUTION The tooth on the bottom of the distributor cap must fit into the notch in the housing or the alignment will not be correct. 3. Put distributor cap in position on housing. Lock cap to housing with latch screws. 4. Connect primary wiring harness to distributor.

CAUTION The notch on the rotor must fit into the tooth of the centrifugal mechanism.

5. If removed, connect battery wire to negative terminal of battery. Tighten nut on capscrew.

Sensing Coil Replacement REMOVE 1. Remove distributor from engine. See the procedure for Distributor Repair, Remove.

Crankshaft WAS Rotated when Distributor was Removed.

CAUTION Do not disassemble the sensing coil/pole piece. Disassembly can change the polarity of the coil. If damaged, replace the sensing coil/pole piece with a new assembly. 2. Disassemble distributor. See the procedure for Distributor Repair, Disassemble. See Figure 13.

INSTALL 1. Assemble distributor. See the procedure for Distributor Repair, Assemble. 2. Install distributor to engine. See the procedures for Distributor Repair, Install, If Crankshaft WAS NOT Rotated when Distributor was Removed and Distributor Repair, Install, If

1. MAGNET 2. POLE PIECE

3. POSITION ARM 4. SENSING COIL

Figure 13. Pole Piece and Sensing Coil

Spark Plugs Replacement REMOVE WARNING Do not remove the wires to the spark plugs with the engine running. The high voltage can cause electric shock.

CAUTION Do not pull on the wires. The core can separate and cause ignition problems. 1. Disconnect wires by pulling on terminal cover. Turn cover to loosen it from spark plug.

2200 SRM 107

High Voltage Wires Check

INSTALL

CAUTION

1. Clean thread area where spark plugs screw into cylinder head. Make sure seat area is clean. 2. Check clearance between electrodes. Bend side electrode to get correct clearance.

CAUTION Do not use a gasket if the spark plug has a tapered seat. 3. Install spark plugs and if used, gaskets.

Use a deep socket for removing the spark plug. Make sure the insulator is not damaged.

Do not tighten the spark plugs to more than the specification.

3. Remove spark plugs. If used, remove gaskets. 4. Inspect spark plugs for normal operation. damaged, replace plugs.

CAUTION

4. Tighten plugs to correct torque. 5. Connect wires to spark plugs. Push wire terminal until wire locks to plug.

Visual Check WARNING Compressed air can move particles so they cause injury to the user or to other personnel. Make sure the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes. The HEI distributor will operate for a long time without causing problems. A visual inspection of the distributor when the spark plugs are changed is a good

check. Remove the distributor cap. Inspect the rotor and the inside of the cap for dust and carbon deposits. Clean the dust from the parts with compressed air. Inspect the rotor and cap for damage. If parts are damaged, replace with new parts. Remove the rotor. Inspect the pivot area of the centrifugal weights. If the pivot has a rust condition, put one drop of oil on the pivot. If the pivot is damaged, replace the damaged parts with new parts.

High Voltage Wires Check The high voltage wires must be handled very carefully. Do not pull on the wires. The core can separate and cause ignition problems. If the wires are causing a problem, do the following checks:

WARNING Do not remove the high voltage wires with the engine running. The high voltage can cause electric shock.

1. Disconnect each wire by pulling on terminal cover. Turn cover to loosen wire. 2. Connect wires from an ohmmeter to high voltage wire. Set ohmmeter to a high scale. 3. Move high voltage wire a little while looking at ohmmeter. If the ohmmeter indicates more than 2500 ohms, replace wire with a new part. If the ohmmeter indication changes from infinity to any value, replace wire with a new part.

Ignition Coil Check

2200 SRM 107

CAUTION Make sure the new wires have a diameter of 8 mm and have silicone insulation.

4. Check wire without moving it. Replace wire with a new part if the meter indications are not within specifications.

Ignition Coil Check COIL IN DISTRIBUTOR CAP DESIGN

SEPARATE COIL DESIGN

1. Disconnect wire from negative terminal of battery.

2. Disconnect primary wiring connector to distributor.

2. Disconnect secondary wire from coil.

3. Unlock four screws that fasten cap to housing. Carefully remove cap and turn it to the position shown in Figure 14.

3. Remove dust cover from primary wiring. 4. Disconnect primary wiring harness from coil. 5. Set ohmmeter to the high scale. Connect ohmmeter as shown in step 1 of Figure 15. If the meter indication is less than infinity, install new coil and repeat Step 5.

Figure 14. Ignition Coil Checks, V8 and Some Four- and Six-Cylinder Engines 4. Set ohmmeter to the low scale. Connect ohmmeter as shown in step 1 of Figure 14. The normal indication is less than 2 ohms. Replace coil if indication is infinity and repeat Step 4. 5. Set ohmmeter to the high scale. Connect ohmmeter as shown in steps A and B of step 2 of Figure 14. Install a new coil if both the indications are infinity and repeat Step 4 and Step 5. A resistance indication one way and an infinity indication the other way is normal.

Figure 15. Ignition Coil Checks, Some Fourand Six-Cylinder Engines 6. Set ohmmeter to the low scale. Connect ohmmeter as shown in step 2 of Figure 15. If it does not indicate zero to one ohm, install new coil and repeat Step 5 and Step 6. 7. Set ohmmeter to the middle scale. Connect ohmmeter as shown in step 3 of Figure 15. If the meter indication is infinity, install new coil and repeat Step 5 and Step 7.

2200 SRM 107

Ignition Timing Adjustment

SENSING COIL, CHECK 1. Disconnect wire from negative terminal of battery. 2. Disconnect primary wiring connector to distributor. 3. Unlock latch screws that fasten cap to housing. Carefully remove cap and put it away from distributor. NOTE: Some models use separate terminals. Some models use a double terminal. 4. Disconnect white and green wires from electronic module. 5. Set ohmmeter to a middle scale. Connect ohmmeter as shown in step 1 of Figure 16. If the ohmmeter indicates less than 500 ohms or more than 1500 ohms, install new part and Step 5. 6. Set ohmmeter to a high scale. Connect ohmmeter as shown in step 2 of Figure 16. Do step 2 for each wire. If the meter indication is less than infinity, install new coil and repeat Step 5 and Step 6.

1. GREEN WIRE 2. WHITE WIRE

3. HOUSING

Figure 16. Sensing Coil Checks

Electronic Module Check The electronic module can be tested only with a special tool. Use the procedure given by the manufacturer to test the electronic module. If needed, get tool number J-24642 from the Kent-Moore Tool Division, Jackson, Michigan.

Ignition Timing Adjustment 1. If equipped with vacuum advance, disconnect vacuum line at distributor and put a plug in the line.

CAUTION Not all tachometers will give the correct indication of speed when connected to the HEI system. Check with the manufacturer of the tachometer to make sure it will work with HEI. 2. Connect tachometer to tachometer terminal. a. Some four- and six-cylinder engines, connect at the ignition coil. (See Figure 9.)

(Also see GM V8-366 (6-liter) Ignition System Check.)

CAUTION Not all timing lights will give the correct indication when connected to the HEI system. Check with the manufacturer of the timing light to make sure it will work with HEI. 3. Connect timing light to spark plug wire that goes to number one cylinder. Make other connections described by the manufacturer.

b. V8-350, some four- and six-cylinder engines, connect at the distributor. (See Figure 11.)

Ignition Timing Adjustment

2200 SRM 107

WARNING Do not touch moving parts (fan, belt, shafts, pulleys). 4. Start engine and run at correct speed. Hold timing light so it illuminates timing plate and the mark on crankshaft pulley. See Figure 17. Check for correct timing. If timing is not correct, loosen clamp that holds distributor housing. Rotate housing right or left to get correct timing. Tighten clamp when timing is correct. Connect vacuum line to distributor. NOTE: Do not use a dwell meter to check the cam angle. The cam angle is set by the electronic module.

A. BEFORE

B. AFTER

1. FOUR AND SIX CYLINDER

2. V8-350

Figure 17. Timing Marks

2200 SRM 107

Specifications

GM V8-366 (6-liter) Ignition System Check Check spark plugs. Replace worn spark plugs and distributor contacts. The correct spark plug gap is 0.89 to 1.1 mm (0.035 to 0.043 in.). Check ignition timing. See Figure 18. Adjust timing according to specifications.

1. CRANKSHAFT DAMPER

2. TIMING TAB

Figure 18. GM V8 Timing Marks

GM V6-LPG (4.3 liter) GM V6-LPG (4.3 liter) Ignition Timing and Idle Speed Adjustment For ingnition timing and idle speed adjustment for the GM V6 (4.3-liter) with EPIC LPG System, see Carbureted Engine Management System Open Loop 2200 SRM 744. For ingnition timing and idle speed adjustment for the GM V6 (4.3-liter) on lift trucks equipped with MSTS, see MSTS GM V6-4.3L (Later Control Modules)2200 SRM 765

Specifications Item

Specifications

Spark Plugs Electrode gap ............................................................ Torque Gasket type ........................................................... Tapered seat..........................................................

See Parts Manual 0.89 to 1.1 mm (0.035 to 0.045 in.)

Firing Order Four cylinder............................................................. Six cylinder (in-line) ................................................. V-6 ............................................................................. V-8 .............................................................................

35 to 40 N•m (26 to 30 lbf ft) 14 to 27 N•m (10 to 20 lbf ft) 1-3-4-2 1-5-3-6-2-4 1-6-5-4-3-2 1-8-4-3-6-5-7-2

Troubleshooting

2200 SRM 107

Item

Specifications

Ignition Timing 4 cylinder................................................................... 6 cylinder (in-line)..................................................... V-6 ............................................................................. V8-350 ....................................................................... V8-366 .......................................................................

8 BTDC @ 600 rpm 8 BTDC @ 600 rpm 0 BTDC @ 650 rpm 6 BTDC @ 600 rpm (gasoline fuel) 10 BTDC @ 650 rpm (LPG fuel) 6 to 8 BTDC @ 725 to 750 rpm (LPG fuel)

Module Grease ..............................................................

Silicone Grease, Part No. 1198757

Sensing Coil Resistance................................................

500 to 1500 Ohms

High Voltage Wire Resistance 0 to 381 mm (0 to 15 in.)........................................... 381 to 635 mm (15 to 20 in.)..................................... 635 to 890 mm (25 to 35 in.).....................................

3000 to 10,000 Ohms 4000 to 15,000 Ohms 6000 to 20,000 Ohms

Troubleshooting PROBLEM The engine will not start.

POSSIBLE CAUSE

PROCEDURE OR ACTION

Open circuit between the battery and the distributor.

Repair or replace cable from battery to distributor.

Moisture or dirt in the distributor cap.

Clean and dry distributor cap.

New spark plugs are needed.

Replace spark plugs. Plugs Replacement.

High voltage wires are damaged.

Perform high voltage wire checks. See High Voltage Wires Check.

Open circuit between the distributor connector and the ignition coil.

Perform Ignition Coil Check and repair as required. See Ignition Coil Check and Ignition Coil Replacement.

Open circuit in the ignition coil.

Replace ignition coil. Coil Replacement.

Open circuit in the sensing coil.

Replace Sensing Coil. See Sensing Coil Replacement.

The electronic module is damaged.

Replace electronic module. See Electronic Module Replacement.

See Spark

See Ignition

2200 SRM 107

PROBLEM Engine does not run correctly.

Troubleshooting

POSSIBLE CAUSE

PROCEDURE OR ACTION

Ignition timing is not correct.

Perform proper timing procedures. See Ignition Timing Adjustment.

New spark plugs are needed.

Replace spark plugs. Plugs Replacement.

High voltage wires are damaged.

Perform high voltage wire checks. See High Voltage Wires Check.

Moisture or dirt in the distributor cap.

Clean and dry distributor cap.

Distributor cap is damaged.

Replace distributor cap.

Centrifugal mechanism is damaged.

Replace centrifugal mechanism. See Distributor Repair.

Ignition coil is damaged.

Replace ignition coil. Coil Replacement.

Sensing coil is damaged.

Replace Sensing Coil. See Sensing Coil Replacement.

The electronic module is damaged.

Replace electronic module. See Electronic Module Replacement.

See Spark

See Ignition

HYDRAULIC GEAR PUMPS H40.00-48.00XM-12 (H1050HD) [A917]; S3.50-5.50XL (S70-120XL) [D004]; S3.50-5.50XM (S70-120XM) [E004, F004]; H3.50-5.00XL (H70-110XL); S30-60E/ES; S40-50F; H40-60H; H2.00-3.00J (H40-60J); H16.00-30.00C (H360-650C); P40-50A [A119]; S6.00-7.00XL (S135-155XL, S135-155XL 2) [B024, C024]; S3.00-5.50E (S60-120E); H60-110E; H360-620B; H16.00-30.00C (H360-650C); H36.00-48.00C/E (H800-1050C/E) [D117]; H7.00-12.50H (H150-275H); H13.50-16.00B (H300-350B); H32.00-42.00B (H700-920B); J25-35A/AS; J40-60A; E20-50B; E3.00-5.50B (E60-120B); H6.00-7.00XL (H135-155XL, H135-155XL 2) [F006, G006]; H40-60H; R30XMS2 [D174]; H40.00-52.00XM-16CH (H1050HD-CH, 1150HD-CH) [E117, F117]; R30XM2, R30XMA2, R30XMF2 [G118]; H2.00-3.00J (H40-60J)

PART NO. 910091

1900 SRM 97

Hydraulic Gear Pumps

Table of Contents

1 2 2 3 3 3 4 4 5 8 10 10 10 11 12 13

This section is for the following models: H40.00-48.00XM-12 (H1050HD) [A917]; S3.50-5.50XL (S70-120XL) [D004]; S3.50-5.50XM (S70-120XM) [E004, F004]; H3.50-5.00XL (H70-110XL); S30-60E/ES; S40-50F; H40-60H; H2.00-3.00J (H40-60J); H16.00-30.00C (H360-650C); P40-50A [A119]; S6.00-7.00XL (S135-155XL, S135-155XL 2) [B024, C024]; S3.00-5.50E (S60-120E); H60-110E; H360-620B; H16.00-30.00C (H360-650C); H36.00-48.00C/E (H800-1050C/E) [D117]; H7.00-12.50H (H150-275H); H13.50-16.00B (H300-350B); H32.00-42.00B (H700-920B); J25-35A/AS; J40-60A; E20-50B; E3.00-5.50B (E60-120B); H6.00-7.00XL (H135-155XL, H135-155XL 2) [F006, G006]; H40-60H; R30XMS2; [D174]; H40.00-52.00XM-16CH (H1050HD-CH, 1150HD-CH) [E117, F117]; R30XM2, R30XMA2, R30XMF2; [G118]; H2.00-3.00J (H40-60J)

1900 SRM 97

Description

Description Gear pumps have several sections and are made with a single set (single stage) of gears or with multiple sets (tandem) of gears. See Figure 1. A single-stage pump has two covers and the gear housing with the gears. Seals are used to prevent leaks between the sections. Tandem pumps have a gear housing for each set of gears. Most tandem pumps also have a center section for the bearings. The inlet and outlet ports are normally on the gear housing or rear cover. The front cover has the seal for the input shaft. The input shaft is connected to a driven sprocket, coupling, or gear by splines or a key.

All the gear pumps have devices that keep the thrust clearance at a minimum when the pressure increases. When the pressure is low, the clearance increases to prevent wear. To prevent leakage when the pressure is high, the oil from the outlet side of the pump is transferred to a wear plate. The oil pushes the wear plate against the gears. Some pumps have bearing blocks that move closer to the gears when the pressure increases.

1. ONE-SECTION PUMP 2. DRIVE GEAR

3. TWO-SECTION PUMP 4. DRIVEN GEAR Figure 1. Types of Gear Pumps

Operation

1900 SRM 97

Operation Gear pumps have the teeth of the gears engaged in the center of the pump. When the input shaft is turned, the drive gear turns the driven gear. See Figure 2. The oil in the inlet chamber is moved out from the center by the teeth of rotating gears. See Figure 3. The oil between the teeth is moved around the pumping chamber to the outlet chamber. The oil is pushed from the outlet chamber by the gear teeth that are beginning to engage.

When the pressure increases to the spring setting, the ball moves from its seat and oil flows to the inlet chamber.

1. OIL ENTERS GROOVES IN BUSHINGS 2. OIL ENTERS INLET CHAMBER Figure 3. Check Valve

FLOW CONTROL VALVE 1. INLET 2. OUTLET

3. SEAL MADE BY GEAR TEETH

Figure 2. Gear Pump Operation The gears and bearings are lubricated by oil from the outlet side of the pump. A small amount of oil flows past the gears and into the bearings and to the front seal cavity. A check ball and spring are installed in some pumps to keep pressure on the oil in this passage. The oil pressure prevents air leaks through the front seal and makes sure there is oil to the bearings.

Some of the pumps have a flow control valve in the rear cover. See Figure 4. The flow control valve has either a piston and spring, or a cartridge with a piston and spring. The piston has an orifice that permits a constant volume of oil to flow to the controlled flow port. When the pump speed increases, the piston moves to partly open the passage to the main control valve. This action keeps constant the pressure difference across the orifice. A constant pressure difference between both sides of an orifice causes a constant flow through the orifice.

1900 SRM 97

Hydraulic Gear Pump Repair

RELIEF VALVE Some pumps have a relief valve installed in a cartridge or in a bore in the rear cover. See Figure 4. Relief valves in the pump prevent the pressure in the controlled flow system from increasing beyond the specifications. The relief valve in the cartridge has a poppet and spring, with the seat for the poppet in the cartridge. The relief valve and flow control valve on some pumps are installed in the same cartridge. Some of the relief valves that are installed in the pumps are adjustable only with shims. Replace the cartridge if the relief valve has a problem.

1. 2. 3. 4. 5.

INPUT SHAFT BEARING BLOCKS REAR COVER DRIVE GEAR CARTRIDGE, FLOW CONTROL AND RELIEF VALVE 6. DRIVEN GEAR 7. FRONT COVER Figure 4. Gear Pump Basic Parts

Hydraulic Gear Pump Repair NOTE: Worn or damaged seals are the most common cause of pump failure. The pump bearings, gears, and shafts also wear. Many service persons do not repair a worn pump because the cost of repairs can be greater than the cost of a new pump. The seals can be replaced in the hydraulic pump. If the pump will be rebuilt, the following general procedures are for repairing gear pumps.

prevents the tank from draining too fast when the inlet line is disconnected. 2. Disconnect hoses from pump. Put caps on all fittings. Be careful so inlet hose is not damaged during removal. 3. If the pump is driven by a drive shaft, disconnect drive shaft at pump.

REMOVE WARNING WARNING Make sure the carriage is lowered before disconnecting any parts of the hydraulic system. 1. If the lift truck is equipped with a valve on the tank, the valve must be closed before removing the pump. If there is no valve on the tank, remove breather and install a plug. This action

Some of the hydraulic pumps are very heavy. Use a lifting device when removing or installing the pump. 4. Remove capscrews holding pump housing to the mount. 5. Remove pump from lift truck.

Hydraulic Gear Pump Repair

DISASSEMBLE NOTE: See Figure 6, Figure 7, Figure 8, or Figure 9 for the illustration that is similar to the pump being repaired. The illustration can have parts that are different than those in the actual pump that is being repaired. 1. Remove gear or sprocket from input shaft. If equipped, remove pulley from input shaft. See Figure 5.

1900 SRM 97 passages in the housing sections. The oil passage for the thrust plates is in the outlet chamber. Make sure you make careful notes of the location and orientation of the parts and seals during disassembly. Some of the parts are similar, but not exactly the same and it can be difficult to make an identification if they are mixed. 3. Remove capscrews or nuts that hold housings together. Use a plastic hammer to separate housings. Do not damage machined surfaces. 4. Remove gears and thrust plates (if used). Make a note of the positions of the thrust plates, seals, and gaskets. Do not use a punch to mark the parts. Remove any springs and check valves. 5. Remove bearings with a puller. In some pumps, the bearing blocks or plates must be replaced with the bearings. 6. Remove front seal.

CLEAN WARNING NOTE: NOT ALL LIFT TRUCK MODELS HAVE A PULLEY ASSEMBLY ON THE GEAR PUMP. 1. PLATE 2. CAPSCREW 3. WASHER

4. LOCKWASHER 5. PULLEY 6. NUT

Figure 5. Pulley Assembly on Gear Pumps 2. Before disassembling the pump, make alignment marks on all housings. Some housings can be assembled in the wrong positions, which will cause failure or increased wear. Carefully clean the outside of the pump. NOTE: The inlet ports in most gear pumps are larger than the outlet ports. NOTE: If the pump is held in a vise for disassembly, make sure the vise does not hold the pump too tightly and cause distortion of the pump body. NOTE: The position of the seals is important. In some pumps the direction of pump rotation is changed by changing the position of the seals and housings. The holes in the seals must be aligned with the oil

Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturerâ&#x20AC;&#x2122;s recommended safety precautions.

CAUTION Any dirt that enters the hydraulic system can cause damage to the parts. Clean all parts of the pump with solvent. Use compressed air to dry the parts. Do not use a cloth to dry the parts. Pieces of the cloth can cause restrictions in the hydraulic system. Make sure the work area and tools are very clean.

1900 SRM 97

Hydraulic Gear Pump Repair

NOTE: THERE CAN BE A VARIATION OF INTERNAL PARTS ON DIFFERENT MODELS OF LIFT TRUCKS. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.

CAPSCREW WASHER REAR COVER DOWEL PIN SEAL GEAR HOUSING DRIVE GEAR SEAL SEAL SPACER SEAL RING FRONT COVER SHAFT SEAL BEARING BLOCKS DRIVEN GEAR BEARING BLOCKS DOWEL PIN

17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32.

SPACER O-RING CARTRIDGE RELIEF POPPET SPRING SPRING ADJUSTMENT SCREW O-RING PLUG SPRING FLOW CONTROL PISTON O-RING SNAP RING O-RINGS CAPSCREW AND WASHER CAPSCREW AND WASHER

Figure 6. Hydraulic Gear Pump Single-Stage

INSPECT 1. Inspect outside edges of gear teeth for grooves or scratches. If the edges of the gear teeth are sharp, use emery cloth to break the edges. Replace gears if there are deep grooves on the gears.

Wear on the seal area of the shaft indicates there is dirt in the oil or a hard seal. Inspect seal to see if it has been too hot. Look for small cracks in seal surfaces. If the seal was too hot or the wrong oil was used, the seal will be too hard or too soft. Inspect splines or key groove for damage.

2. If the gear shafts have grooves or are worn more than 0.05 mm (0.002 in.), they must be replaced.

Hydraulic Gear Pump Repair

1900 SRM 97

NOTE: THERE CAN BE A VARIATION OF INTERNAL PARTS ON DIFFERENT MODELS OF LIFT TRUCKS. 1. 2. 3. 4. 5. 6. 7. 8.

9. 10. 11. 12. 13. 14. 15. 16.

REAR COVER SEAL GLAND SEAL RETAINER REAR WEAR PLATE DRIVEN GEAR DRIVE GEAR GEAR HOUSING FRONT WEAR PLATE

FRONT COVER STUD WASHER NUT SEAL SNAP RING SEAL PIN

Figure 7. Hydraulic Gear Pump Single-Stage NOTE: Some pump bodies will show gear marks where the gears rotate because of the small clearances between the parts. These gear marks do not indicate a worn or damaged pump unless the pump will not supply the volume and pressure shown in the specifications.

chamber indicate dirt is in the oil. Small holes in the outlet side of the gear chamber indicate that cavitation has occurred. Make sure inlet hose, fittings, and tank have no restrictions. Cavitation can also occur when the engine speed is too high.

3. Inspect gear housing for wear or grooves. Most wear occurs on the inlet side of the gear chamber. Put a straight edge across the inlet side of the gear chamber. If a 0.13 mm (0.005 in.) thickness gauge fits between the straight edge and the housing, the gear housing must be replaced. If the gear housing is worn, inspect bearings for wear. If the system pressure is too high, the gear housings will wear quickly. Grooves in the gear

If the surfaces of the gear chamber or gear teeth have blue marks, the pump was too hot. Heat damage in the pump can be caused by hot oil or lack of oil. Check front seal surface to see if air was entering the pump through the front seal. Make sure the oil is the correct viscosity. The wrong viscosity oil can increase leakage within the pump. Leakage inside the pump increases the oil temperature.

1900 SRM 97

Hydraulic Gear Pump Repair

NOTE: THERE CAN BE A VARIATION OF INTERNAL PARTS ON DIFFERENT MODELS OF LIFT TRUCKS. 1. 2. 3. 4. 5. 6. 7.

SNAP RING BEARING SEAL FRONT COVER PLUG RING SEAL ROLLER BEARINGS

8. 9. 10. 11. 12. 13. 14.

SEALS THRUST PLATE DRIVE SHAFT AND GEARS HOUSING SEAL GEAR HOUSING BODY CONNECTOR SHAFT

15. 16. 17. 18. 19. 20.

GEAR SET GEAR HOUSING REAR COVER WASHER (4) STUD (4) NUT (4)

Figure 8. Hydraulic Gear Pump Tandem 4. Check thrust plates for wear or grooves. If the thrust plate is worn more than 0.05 mm (0.002 in.), it must be replaced. Replace thrust plate if it has grooves or holes. Dirty oil causes the thrust plate to wear near where the gears engage. Small holes on the outlet side the thrust plate are caused by cavitation. Lack of oil can also cause small holes in the thrust plates. If the color of the thrust plates has changed, the pump was too hot.

5. Inspect all machined surfaces for scratches or damage. Remove with emery cloth any metal that is above the flat surface. Check surfaces with a straight edge. Inspect grooves for the seals for dirt or scratches. 6. Inspect bearings for wear or damage. Replace bearings if there is any small hole on the bearing surface. Replace bushing if it is not round.

Hydraulic Gear Pump Repair

1. 2. 3. 4. 5. 6. 7. 8. 9.

1900 SRM 97

CAPSCREW (4) GEAR HOUSING PIN (4) DRIVE GEAR DRIVEN GEAR KEY (2) THRUST PLATE (2) PLASTIC GASKET (2) PAPER GASKET (2)

10. 11. 12. 13. 14. 15. 16. 17. 18.

SEAL (2) BODY GEAR HOUSING DRIVE GEAR AND SHAFT DRIVEN GEAR AND SHAFT SPRING BALL FRONT COVER SEAL

Figure 9. Hydraulic Gear Pump Tandem 7. Look for damage on seals. Replace all seals and O-rings, even if they are in good condition. Look for cuts or changes in shape that can cause damage. Find out what damage caused the pump to fail. A damaged seal for the thrust plate can cause the shaft seal to leak. A damaged shaft seal can cause air to enter the hydraulic system. 8. Inspect flow control valve and relief valve for dirt or scratches. Make sure piston moves freely in the bore. Look at poppet and seat for damage. The springs must not be broken or bent. Inspect O-rings for damage. Make sure orifices are open.

CAUTION Do not permit dirty oil to enter the gear pump. 9. If any parts of the pump have damage from dirt in the oil, inspect hydraulic tank. Drain tank, clean screen and tank, and replace filter.

10. Inspect inlet hose to the gear pump. Use a lamp to look inside the hose. Look for pieces of rubber that are separating from the hose. Inspect hose for restrictions at bends. Check for loose fittings or damaged O-rings.

ASSEMBLE CAUTION Make sure no dirt enters the pump during assembly. 1. Lubricate all parts with hydraulic oil before they are installed into the pump. 2. Put Loctite 290ÂŽ sealant around outside of front seal. Install seal in front cover. Make sure seal is installed straight. If pump has a ball bearing for the shaft, install it in the front cover. Install snap rings.

1900 SRM 97 3. Install needle bearings into front and rear covers. Use a press to push bearings into position. Push on end of bearings that has writing. If the pump has check valves, install them in cover.

CAUTION Make sure the holes in the gaskets and seals are aligned with the hole in the output side of the pump. The pump will not operate correctly if the oil from the outlet chamber cannot flow to the thrust plate. 4. Install seals for thrust plate. Install rubber seal with lips away from gears. Install paper gasket against the rubber seal. The plastic gasket is installed between the paper gasket and the thrust plate. Install thrust plate with the bronze side toward the gears.

Hydraulic Gear Pump Repair 7. Install seal and rear cover. Use a plastic hammer to join the sections. Apply a small mount of Loctite 290ÂŽ sealant to threads of capscrews or studs. Install capscrews or studs and tighten with your fingers. Rotate drive shaft to make sure pump is assembled correctly. Tighten capscrews or nuts to the specification using an "X" sequence. 8. Use a soft, blunt tool to install O-rings in bore of the flow and relief cartridge. See Figure 10. Install relief valve and flow control valve. Install fittings with new O-rings. 9. If a pulley was removed, install pulley on shaft and tighten nut to 72 Nâ&#x20AC;˘m (53 lbf ft). See Figure 5.

Some pumps have thrust plates with small grooves for the seals. The seals must be cut to the correct length. Cut two strips that are 5.5 mm (0.22 in.) long from seal strip. Put grease on seals and install them in grooves in center of thrust plate. Cut thrust plate on front cover. Hit thrust plate with a plastic hammer to 0.8 mm (0.031 in.) from machined surface. Cut four strips 6 mm (0.24 in.) from seal strip. Push strips into slots in thrust plate. Lightly hit thrust plate against the machined surface. Use a sharp blade to cut the seals even with the edge of the thrust plate. Install seal that has a W shape and spacer in groove in front cover. Do not bend metal seal. Install seal in outer groove in front cover. Install bearing blocks in the same positions from which they were removed. 5. Install gears and bearing blocks in pump chamber housing. Make sure gear housing is installed in the correct position. The small hole in some housings must be in the outlet chamber. The large channels in the inlet and outlet chambers must be toward the rear cover. The arrow indicating the direction of rotation on the gear housing must be toward the front cover. Align marks on gear housing with marks on covers. 6. Put connecting shaft in drive gear shaft on the pumps with two pump chambers. Install thrust plates and seals. Put gears and pump chamber housing on center bearing housing with the marks aligned.

1. ADJUSTMENT SCREW 2. SPRING 3. SPRING 4. RELIEF POPPET 5. CARTRIDGE 6. SPRING 7. O-RING

8. FLOW CONTROL PISTON 9. SNAP RING 10. RELIEF FLOW 11. CONTROLLED FLOW 12. MAIN FLOW

Figure 10. Flow Control and Relief Valve Cartridge

Pump Output Check

1900 SRM 97

INSTALL

CAUTION

CAUTION Before the gear pump is installed, loosen the lock nut on the adjustment screw for the relief valve. Loosen the adjustment screw until the spring is not compressed. If the relief valve was adjusted for a worn pump, the setting will not be correct for a new pump. Damage to the hydraulic system can occur if the setting of the relief valve is too high. Always install a new filter when repairs are made to the hydraulic system. Drain and replace the hydraulic oil if the oil is dirty or burned. 1. Install new gasket or O-ring on front cover of pump. Put a thin layer of Never-SeezÂŽ on splines of drive shaft. Fill inlet port of the pump with hydraulic oil. Turn drive shaft in the direction of rotation until oil comes out of the outlet port.

WARNING Some of the pumps are very heavy. Use a lifting device to help install the pump. 2. Install pump in lift truck.

Do not permit hot oil to enter a cold pump. Make sure the relief valve in each system is at the lowest setting. 4. Remove plug from breather on tank. Install breather. Open valve on tank. Fill tank with clean hydraulic oil. 5. Install a 0 to 20 MPa (0 to 3000 psi) pressure gauge to a tee fitting at the pump outlet port. Start engine and run it at idle speed for 3 minutes.

CAUTION Do not operate any valve until the pump has run for 3 minutes at low pressure and low speed. 6. Touch pump with your hand. If pump is hot, it has a problem. If pump is not hot, then increase engine speed to high limit. Momentarily increase pressure to relief setting. Repeat this procedure for 3 minutes. 7. Look at pressure gauge and adjust relief valve. See Checks and Adjustments for the lift truck for which you are making repairs.

3. Install and tighten capscrews. Remove caps from fittings. Connect hoses.

Pump Output Check Two methods are given for checking the volume of flow from the hydraulic pump. The first method uses a flow meter, a pressure gauge, and a needle valve. The second method uses a needle valve, a pressure gauge, a container, and a timer. NOTE: If the pump has two outlet ports, do separate flow tests. Add the results of both tests to find the total output rate.

METHOD NO. 1 WARNING Hydraulic oil can be hot. Do not touch the oil during the tests. 1. If the flow meter is available, install flow meter between needle valve and outlet port of pump.

See Figure 11. The pressure gauge must be between the needle valve and the pump. Make a separate check for each system if pump is tandem or if flow regulator is part of pump. When the hydraulic oil is at operating temperature, run engine at 2800 RPM with no load on hydraulic system. Note the reading of the flow meter. Compare output rate of pump with specification found in the Capacities and Specifications section of the Service Manual for your lift truck. 2. Run engine at high limit. Slowly close needle valve until gauge indicates pressure just below specification for relief valve setting. The pump output at high or pressure must be within 25% of the output with no load. If the output at high pressure is less than 75% of the low pressure output, the pump has a problem.

1900 SRM 97

1. 2. 3. 4.

Pump Output Check

HYDRAULIC PUMP INLET PORT OUTLET PORT HYDRAULIC TANK

5. 6. 7. 8.

PRESSURE GAUGE TEE FITTING FLOW METER NEEDLE VALVE

Figure 11. Hydraulic Pump Output Check with Flow Meter

METHOD NO. 2 WARNING Hydraulic oil can be hot. Do not touch the oil during the tests. 1. Another method of checking the pump output is to measure the amount of oil moved in a given amount of time. See Figure 12. Run engine until oil is 55 to 65 C (131 to 149 F). Disconnect line from outlet port of pump. Install a 0 to 20 MPa (0 to 3000 psi) pressure gauge on a tee fitting connected to a hose from the outlet port. Install needle valve on end of hose. Connect another hose to needle valve. Put the other end of the hose in a container with a 18 liter (5 gal) capacity. Make sure reservoir is full.

CAUTION This test must be done quickly to prevent the hydraulic tank from becoming empty. Do not

operate the engine when there is no oil in the hydraulic tank. 2. The needle valve must be fully open. Start engine and run engine at its governed rpm for 5 seconds. Stop engine. Measure volume of oil that entered container in 5 seconds. Multiply quantity in container by 12 to find output per minute. Compare pump output rate with the specifications found in the Capacities and Specifications section of the Service Manual for your lift truck. The pump output rate must be within 20% of the specifications. 3. Start engine and run engine at its governed rpm. Close needle valve until pressure increases to just below relief valve setting. Measure the volume of fluid the pump moves in 5 seconds. Compare this quantity with the results from the test of the pump output at low pressure. The output of the pump at high pressure must be within 25% of the volume of oil flow at low pressure.

Hydraulic System Air Check

1. 2. 3. 4. 5.

1900 SRM 97

HYDRAULIC PUMP INLET PORT OUTLET PORT HYDRAULIC TANK PRESSURE GAUGE

6. 7. 8. 9.

TEE FITTING NEEDLE VALVE CONTAINER TIMER

Figure 12. Hydraulic Pump Output Check

Hydraulic System Air Check If the pump makes noise or does not move the correct amount of oil, check for air in the system. Run the engine until the oil is warm. Remove the filter head and look into the tank. If there are bubbles in the oil, air is in the hydraulic system. The most common place of entry of the air is in the inlet hose to

the pump. Check for air leaks by pouring oil over the fittings and hose when the engine is running. If the noise decreases, the leak is in that area. See the Troubleshooting section for other causes of air in the hydraulic system.

1900 SRM 97

Troubleshooting

Troubleshooting PROBLEM The pump makes too much noise.

Low hydraulic pressure.

POSSIBLE CAUSE

PROCEDURE OR ACTION

Air in the hydraulic system.

Remove air from hydraulic system.

The bearings or gears are damaged.

Repair or replace hydraulic pump.

Outlet valve from the hydraulic tank is closed.

Open hydraulic tank outlet valve.

Low oil level in hydraulic tank.

Fill hydraulic oil tank to correct level.

Wrong oil.

Drain incorrect oil and fill hydraulic tank to correct level.

Supply hose is twisted or has a restriction.

Remove twist or remove restriction.

Breather on hydraulic tank has a restriction.

Replace hydraulic tank breather.

Seal for pump shaft is damaged.

Replace pump shaft seal.

Pump drive has a problem.

Repair pump drive.

Relief valve is set wrong or is damaged.

Adjust relief valve setting. Replace relief valve if it is damaged.

Screen in hydraulic tank has a restriction.

Clean hydraulic tank screen.

Pump is loose or not installed correctly in its mount.

Check pump installation and tighten bolts if necessary.

Relief valve is set wrong or is damaged.

Adjust relief valve setting. Replace relief valve if it is damaged.

Flow regulator valve is damaged.

Replace flow regulator valve.

Leak inside of a hydraulic cylinder.

Repair hydraulic cylinder.

Worn or damaged hydraulic pump.

Repair or replace hydraulic pump.

Air in the hydraulic system.

Remove air from hydraulic system.

Low oil level in hydraulic tank.

Fill hydraulic oil tank to correct level.

Wrong oil.

Drain incorrect oil and fill hydraulic tank to correct level with correct oil.

Supply hose is twisted or has a restriction.

Remove twist or remove restriction.

Troubleshooting

1900 SRM 97

PROBLEM Low hydraulic (Cont.)

pressure.

Pump has leaks, loose fittings, or damaged seals.

Pump is too hot. Relief valve is set wrong or is damaged.

POSSIBLE CAUSE

PROCEDURE OR ACTION

Breather on hydraulic tank has a restriction.

Replace hydraulic tank breather.

Seal for pump shaft is damaged.

Replace pump shaft seal.

Pump drive has a problem.

Repair pump drive.

Pump assembled wrong.

Reassemble pump correctly.

Screen in hydraulic tank has a restriction.

Clean hydraulic tank screen.

Housing capscrews are loose.

Tighten housing capscrews to correct torque.

Relief valve is damaged.

Replace relief valve.

Pump housing is damaged.

Replace hydraulic pump.

Worn seals and pump shaft.

Replace worn seals and pump shaft.

Flow regulator valve is damaged.

Replace flow regulator valve.

Leak inside of a hydraulic cylinder.

Repair hydraulic cylinder.

Worn or damaged hydraulic pump.

Repair or replace hydraulic pump.

Air in the hydraulic system.

Remove air from hydraulic system.

Low oil level in hydraulic tank.

Fill hydraulic oil tank to correct level.

Wrong oil.

Drain incorrect oil and fill hydraulic tank to correct level with correct oil.

Supply hose is twisted or has a restriction.

Remove twist or remove restriction.

Breather on hydraulic tank has a restriction.

Replace hydraulic tank breather.

Pump drive has a problem.

Repair pump drive.

Pump assembled wrong.

Reassemble pump correctly.

Screen in hydraulic tank has a restriction.

Clean hydraulic tank screen.

Replacement hydraulic hoses are wrong size.

Replace hydraulic hoses with correct size hoses.

1900 SRM 97

Troubleshooting

PROBLEM Hydraulic pump faster than normal.

POSSIBLE CAUSE wears

Air in the hydraulic system.

PROCEDURE OR ACTION

Dirt in the hydraulic system.

Drain hydraulic tank and clean thoroughly.

Wrong hydraulic oil.

Drain incorrect oil and fill hydraulic tank to correct level with correct oil.

Relief valve is set wrong or is damaged.

Adjust relief valve setting. Replace relief valve if it is damaged.

Cavitation from restriction in inlet hose.

Clear restriction from inlet hose.

Pump drive has a problem.

Repair pump drive.

Pump drive is not correctly aligned.

Realign pump drive.

Pump is not installed correctly in its mount.

Install pump drive correctly.

Pump is operating too hot.

Check hydraulic oil level and fill to correct level.

Low oil level in hydraulic tank.

Fill hydraulic oil tank to correct level.

Leak in inlet hose.

Replace inlet hose.

Loose inlet fitting.

Tighten inlet fitting.

Breather on hydraulic tank has a restriction.

Replace hydraulic tank breather.

Supply hose is twisted or has a restriction.

Remove twist or remove restriction.

Screen in hydraulic tank has a restriction.

Clean hydraulic tank screen.

Pump seal is damaged.

Replace pump seal.

Check valve in pump is damaged.

Replace check valve.

Pump housing capscrews are loose.

Tighten pump housing screws to correct torque.

Worn or damaged hydraulic pump.

Repair or replace hydraulic pump.

HYDRAULIC PUMP DRIVE ASSEMBLY S2.00-3.00XL (S40-60XL [GM engine only]) [A187, B187, C187]; H2.00-3.00XL (H40-60XL [GM engine only]) [B177, C177]; H3.50-5.00XL (H70-110XL) [F005, G005]; S3.50-5.50XL (S70-120XL) [D004]; S3.50-5.50XM (S70-120XM) [E004, F004]; S6.00-7.00XL (S135-155XL, S135-155XL 2, S155XLS) [B024, C024]

PART NO. 897121

1900 SRM 339

Hydraulic Pump Drive Assembly

Table of Contents

1 1 3 3 4 4 4 5

This section is for the following models: S2.00-3.00XL (S40-60XL [GM engine only]) [A187, B187, C187]; H2.00-3.00XL (H40-60XL [GM engine only]) [B177, C177]; H3.50-5.00XL (H70-110XL) [F005, G005]; S3.50-5.50XL (S70-120XL) [D004]; S3.50-5.50XM (S70-120XM) [E004, F004]; S6.00-7.00XL (S135-155XL, S135-155XL 2, S155XLS) [B024, C024]

1900 SRM 339

Description

General This section has the description and repair procedures for the chain drive assembly for the hydraulic pump(s).

Description The chain drive assembly transfers the power from the engine to the hydraulic pump for the hydraulic system. See Figure 1. On H3.50-5.00XL (H70-110XL) units, the chain drive assembly also operates the hydraulic pump for the oil clutch system. The assembly has a drive sprocket, a leaf chain and a driven sprocket. The drive sprocket fastens directly to the engine crankshaft. The driven

1. 2. 3. 4.

FLYWHEEL HOUSING OIL SEAL SHIMS DRIVE SPROCKET

5. 6. 7. 8.

sprocket rotates on ball bearings. One bearing for the driven gear is installed in the flywheel housing. The other bearing for the driven gear is installed in the housing for the torque converter or the oil clutch. The leaf chain connects the two sprockets. Splines in the driven sprocket engage with the splines on the shafts of the pumps. Special blocks in the flywheel housing prevent oscillations of the chain.

LEAF CHAIN SPECIAL BLOCK (TOP) SPECIAL BLOCK (BOTTOM) BEARING

9. SNAP RING (DIESEL ONLY) 10. DRIVEN SPROCKET 11. HYDRAULIC PUMP

Figure 1. Chain Drive Assembly

Description

1900 SRM 339

On H3.50-5.00XL (H70-110XL), S3.50-5.50XL (S70120XL), and S3.50-5.50XM (S70-120XM) units, oil from the powershift transmission circuit or the oil clutch system circuit lubricates the sprockets, bearings, and chain. On S3.50-5.50XM (S70-120XM) units, oil from the powershift transmission circuit lubricates the sprockets, bearings, and chain. On S/H2.00-3.00XL (S/H40-60XL) units with the GM engine, oil from the hydraulic system lubricates the

1. RETURN OIL FROM STEERING CONTROL UNIT 2. OIL LINE FOR LUBRICATION 3. TORQUE CONVERTER HOUSING

4. 5. 6. 7. 8.

sprockets, bearings, and chain. See Figure 2. The oil supply for the lubrication circuit comes from the return circuit of the steering system. From the steering control unit, the oil flows to fittings at the torque converter housing. One fitting supplies oil for lubrication. The other fitting supplies the oil to operate the jet pump at the bottom of the torque converter housing. The jet pump removes the oil from the torque converter housing and sends it back to the hydraulic tank. A hose at the top of the torque converter housing is used as a breather for the housing.

FITTING JET PUMP NOZZLE JET PUMP SPRING O-RING

9. RETURN TO HYDRAULIC TANK 10. BREATHER 11. JET PUMP FITTING

Figure 2. Lubrication Circuit S2.00-3.00XL (S40-60XL)

1900 SRM 339

Hydraulic Pump Drive Assembly Repair

Hydraulic Pump Drive Assembly Repair REMOVE AND DISASSEMBLE NOTE: The hydraulic pump(s) can be removed without removing or disassembling the pump drive assembly. The powershift transmission or oil clutch housing must be removed for disassembly of the pump drive assembly. See the service manual sections that apply to the Powershift Transmission - Repairs or Oil Clutch System for these units. The repair information for the hydraulic pumps is in the sections for the Hydraulic Pump, Hydraulic System, and the Oil Clutch System. 1. Remove the hydraulic pump as follows (see Figure 1): a. Put the lift truck on blocks. The hydraulic pump must be removed from the bottom of the lift truck. b. Remove the battery and battery tray. c. Remove the breather from the hydraulic tank and put a plug in the tank fitting. Disconnect the return line at the tank and put a cap on the fitting. d. Remove the hose between the hydraulic pump and the tank. Put a cap on the fitting at the tank. e. Disconnect the lines to the steering control unit and the main control valve. Put caps on the lines. f.

Remove the capscrews for the pump and remove the pump from the flywheel housing.

2. Remove the oil line for the bearings at the flywheel housing. 3. Remove two of the capscrews for the flywheel. Install alignment pins in these holes to keep the flywheel from falling. (Use capscrews with the heads removed.) Remove the remaining capscrews for the flywheel. Do not remove the drive sprocket. 4. Check that the leaf chain has not become too long. See Figure 3. The chain must be replaced if dimension X is more than 31.8 mm (1.25 in.).

1. 2. 3. 4. 5.

STRAIGHT EDGE LEAF CHAIN DRIVE SPROCKET DIMENSION X (CHAIN PUSHED DOWN) DRIVEN SPROCKET Figure 3. Chain Length

5. Remove the drive sprocket. Do not let the shims fall. Remove the shim set and keep the shims together. Remove the oil seal. 6. Remove the driven sprocket assembly and the leaf chain. If the bearings need replacing, use a puller to remove the bearings from the sprocket. 7. If the special blocks need replacing, remove the two capscrews that hold each block to the housing. 8. If necessary, disassemble the jet pump assembly [see Figure 2] on the S/H2.00-3.00XL (S/H4060XL) units as follows: a. Remove the jet pump fitting from the torque converter housing. b. Remove the spring and the jet pump. c. Remove the jet pump nozzle. d. Remove the oil line from the torque converter housing.

Hydraulic Pump Drive Assembly Repair

CLEAN WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the recommendations of the manufacturer. Clean all parts using solvent. Do not use steam or gasoline to clean parts.

INSPECT Inspect the sprockets and bearings for wear or damage.

ASSEMBLE AND INSTALL 1. If the flywheel housing was removed, install it on the engine. Install the capscrews with the O-rings. Tighten the capscrews to 50 N•m (45 lbf ft). Install the seal in the flywheel housing. Use a sealant on the outside diameter of the seal. Install the seal so that it is even with the inside edge (flywheel side) of the flywheel housing. See Figure 1, Figure 2, Figure 3, and Figure 4. 2. If new bearings are needed, install them on the driven sprocket. Install the special blocks in the flywheel housing. Tighten the capscrews for the blocks to 20 N•m (15 lbf ft). 3. Install the drive sprocket on the crankshaft without the flywheel. Use shims between the crankshaft and the drive sprocket so that the distance from the housing to the face of the sprocket is A as shown in Figure 4. 4. Install the driven sprocket and the chain. On diesel units, make sure the snap ring is on the

1900 SRM 339 bearing that fits in the torque converter or oil clutch housing. Install the flywheel on the drive sprocket. Use a gasket sealant on the threads and install the capscrews for the flywheel. On GM engines, tighten the capscrews to 80 N•m (60 lbf ft). On Perkins engines, tighten the capscrews to 120 N•m (90 lbf ft). Lubricate the chain and sprockets with hydraulic oil. 5. Connect the oil line for lubricating the chain drive assembly. Install the hydraulic pump. Use a sealant (Hyster Part No. 264159) on the flange of the pump. Connect the oil lines to the pump. 6. Install the powershift transmission as described in the section Powershift Transmission Repairs. Install the oil clutch assembly as described in the section for the Oil Clutch. 7. If removed, install the jet pump assembly (see Figure 2) for the S/H2.00-3.00XL (S/H40-60XL) units as follows: a. Clean the bottom of the torque converter housing and the jet pump nozzle. Use an adhesive sealant (Hyster Part No. 264159) and install the jet pump nozzle in the torque converter housing. b. Install the jet pump, spring, and O-ring in the torque converter housing. Make sure the jet pump fits over the jet pump nozzle. Install the fitting that holds the jet pump in the torque converter housing. c. Install the oil line for lubrication to the fittings on the torque converter housing.

1900 SRM 339

Troubleshooting Legend for Figure 4 NOTE: NOT ALL UNITS SHOWN. OTHERS SIMILAR. Model

Dimension A

S/H2.00-3.00XL (S/H40-60XL)

28.5 ±01 mm (1.12 ±0.004 in.) GM

H3.50-5.00XL (H70-110XL) S3.50-5.50XL (S70-120XL)

33.7 ±0.1 mm (1.33 ±0.004 in.) Gas & LPG

S3.50-5.50XM (S70-120XM)

33.7 ±0.1 mm (1.33 ±0.004 in.) Gas & LPG

S6.00-7.00XL (S135155XL, S135-155XL 2, S155XLS) (B024, C024)

29.7 ±0.1 mm (1.17 ±0.004 in.) DSL

1. 2. 3. 4. 5.

CRANKSHAFT SHIMS FLYWHEEL DRIVE GEAR DRIVEN GEAR ARRANGEMENT (WITH OIL CLUTCH) 6. DRIVEN GEAR ARRANGEMENT (WITH POWERSHIFT TRANSMISSION)

Figure 4. Chain Drive Assembly Parts

Troubleshooting Most problems that can occur in the chain drive assembly will cause noise that is not normal. Examples of these problems are as follows: (1) bearing wear, (2) sprocket wear, or (3) leaf chain wear. The leaf chain can also break. If the leaf chain breaks, there will be no pump output. To repair any of these problems, the drive assembly must be disassembled.

One of the hydraulic pumps can also be causing noise. With the unit running, actuate the system to put a load on the pump. If the noise is gone, the hydraulic pump is probably the cause of the noise and not the pump drive assembly.

INTRODUCTION GENERAL This section has the description and operation of the complete hydraulic system and brief descriptions of the components of the hydraulic system. The repair procedures for the hydraulic pump and a troubleshooting guide for the hydraulic system are also included.

DESCRIPTION AND OPERATION (See FIGURE 1.) The hydraulic system includes the circuits for the mast, steering system and the brake system. (There is a separate hydraulic pump for the oil clutch on the

H3.50–5.00XL (H70–110XL units.) The hydraulic pump is driven by a chain from the engine flywheel. The hydraulic pump for the oil clutch system is also driven by the chain arrangement from the engine flywheel.

Hydraulic Pump (See FIGURE 2.) The hydraulic pump has a flow divider and two outlet ports. Oil from the primary outlet port goes to the steering control unit. The priority flow is 12.25 to 14.24 litre/ min at 9.7 MPa (3.0 to 4.0 gal/min at 1400 psi). Oil from the secondary outlet port goes to the main control valve. The hydraulic pump gets its oil supply from the hydraulic tank.

11782

1. 2. 3. 4. 5.

HYDRAULIC TANK HYDRAULIC PUMP HYDRAULIC FILTER MAIN CONTROL VALVE MANIFOLD BLOCK FOR STEERING CONTROL UNIT

6. 7. 8. 9. 10.

BRAKE BOOSTER STEERING CYLINDER LIFT CYLINDER TILT CYLINDER TANK BREATHER

11. 12. 13. 14.

PRESSURE CHECK PORT MAIN RELIEF VALVE SECONDARY RELIEF VALVE STEERING SYSTEM CHECK PORT

FIGURE 1. HYDRAULIC SYSTEM DIAGRAM

valve is connected to the hydraulic filter. The filter has a by–pass valve so that oil can flow around the filter when the filter becomes restricted. Oil from the filter returns to the hydraulic tank.

11748

11779

1. MAIN CONTROL VALVE

FIGURE 3. MAIN CONTROL VALVE 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

INLET PRIORITY VALVE PRIORITY FLOW TO STEERING CONTROL UNIT FLOW DIVIDER SPOOL SECONDARY FLOW TO MAIN CONTROL VALVE END HOUSING CAP NUT LOCK NUT LOCK WIRE

11776

FIGURE 2. HYDRAULIC PUMP

Main Control Valve (See FIGURE 3.) The main control valve controls the lift, lower, tilt and attachment functions. The control valve receives oil from the hydraulic pump. The main relief valve (lift circuit) is set at 20.7 MPa (3000 psi) for the H3.50–5.00XL (H70–110XL) units and 21.4 MPa (3100 psi) for the S3.50–5.50XL (S70–120XL) units. The auxiliary relief valve for the tilt and attachment circuits is set at 15.5 MPa (2250 psi). The drain circuit from the main control 2

Oil flow in the main control valve goes first to the main relief valve and the lift/lower spool. If none of the spools are actuated, the oil flows past all of the spools and returns to the hydraulic tank. When the lift/lower spool is actuated to Lift, all of the oil flows to the lift cylinders. At this time the main relief valve controls the maximum pressure in the hydraulic system. If the tilt spool is actuated oil can still flow to the auxiliary spools. When the tilt or auxiliary spools are actuated, the secondary relief valve controls the maximum pressure in the hydraulic system. The S3.50–5.50XL (S70–120XL) lift trucks can have a solenoid operated valve to control an auxiliary hydraulic function. This valve is installed on the right side of the cowl. The oil supply for the solenoid valve and attachment comes from the main control valve. The solenoid valve is controlled by a switch on the knob of the control lever for the auxiliary functions. The button allows the lever to control three functions of an attachment. The button operates only when the lever is in the left position as follows:

2 3

1. 2. 3. 4. 6 5. 6.

7. 17 4

8. 9. 10. 11.

5 16

12.

13. 14. 15.

16. 17.

HYDRAULIC TANK BRAKE BOOSTER HYDRAULIC PUMP STEERING CONTROL UNIT MANIFOLD BLOCK STEERING CYLINDER MAIN CONTROL VALVE TILT CYLINDER LIFT CYLINDER OIL FILTER SOLENOID VALVE FOR AUXILIARY FUNCTION LIFT/LOWER SPOOL TILT SPOOL AUXILIARY SPOOL MAIN RELIEF VALVE SECONDARY RELIEF VALVE TEST PORT

15 11775

FIGURE 4. HYDRAULIC SYSTEM SCHEMATIC 3

Button not depressed: Push the lever forward to rotate the attachment to the left. Pull back on the lever to rotate the attachment to the right. Button depressed: Push the lever forward to swing the attachment to the left. Pull back on the lever to swing the attachment to the right. Push the lever to the right and forward to open the clamp. Push the lever to the right and pull back to close the clamp.

Brake Booster (See FIGURE 5.) The brake system on these lift trucks uses a hydraulic actuator (brake booster) to actuate the master cylinder. The operation of the brake booster decreases the foot pressure necessary to apply the brakes. The oil pressure from the outlet of the steering control unit is used to operate the brake booster. A relief valve in the brake booster is set at 1800 kPa (260 psi).

Steering Control Unit The steering control unit is a rotary valve that controls the movement of the steering cylinder. The control unit has a minimum restriction to oil flow when the steering wheel is not moved. The control unit has four ports. A manifold block is installed on the steering control unit over the four ports. The inlet port in the manifold block has a check valve and a relief valve and is connected to the hydraulic pump. The relief valve is set at 9.7 MPa (1400 psi). Two of the ports are connected to the steering cylinder. The port for the drain circuit is connected to the inlet of the brake booster. All of the oil that flows to the steering control unit flows to the brake valve.

11777

1. BRAKE BOOSTER 2. INLET

3. OUTLET 4. MASTER CYLINDER

FIGURE 5. BRAKE BOOSTER

REPAIRS See other sections of the Service Manual for making repairs to the main control valve, hydraulic cylinders, steering control unit and the brake booster.

Removal

HYDRAULIC PUMP

2. Remove the battery and battery tray.

NOTE: Worn or damaged seals are the most common cause of hydraulic pump repair. The pump bearings, gears and shafts also wear. Most service persons do not repair a worn pump because the cost of repairs can be greater than the cost of a new pump. The seals can be replaced in the hydraulic pump. Replace a worn or damaged hydraulic pump.

3. Remove the breather from the hydraulic tank. Put a plug in the tank fitting so that the tank has an air lock. Disconnect the return line at the tank and put a cap on the fitting.

1. Put the lift truck on blocks. The hydraulic pump must be removed from the bottom of the lift truck.

4. Remove the hose between the hydraulic pump and the tank. Put a cap on the fitting at the tank.

5. Disconnect the lines to the steering control unit and the main control valve. Put caps on the lines.

Assembly (See FIGURE 2. and FIGURE 6.)

6. Remove the capscrews for the pump and remove the pump from the flywheel housing.

1. Make sure the internal parts of the pump are clean. Lubricate the parts with hydraulic oil as they are installed into the pump.

Disassembly (See FIGURE 2. and FIGURE 6.)

2. Install the seals in the shaft housing. Install the seal in the seal retainer. Install the O–ring on the seal retainer, then install the seal retainer and snap ring.

NOTE: If the pump is held in a vise for disassembly, make sure the vise does not hold the pump too tightly and cause damage to the pump body. Make sure to take careful notes of the location of the parts and seals during disassembly. Some of the parts are similar but are not exactly the same. Use a punch to make alignment marks on the parts of the housing. 1. Remove the four capscrews that hold the pump together. Carefully separate the housing pieces.

3. Make sure the alignment pins are in the housings. Install the gears, thrust plates and gear housing to the shaft housing. Make sure the O–rings are installed between the housings and between the thrust plates and the housings. 4. Install the O–ring between the gear housing and the end housing. Install the end housing and the capscrews. 5. Install the spool and spring for the flow divider. Install the cap for the flow divider.

WARNING Be careful when removing the spool for the flow divider. The spool is under spring pressure and can move with high force and cause personal injury. 2. Remove the gears and thrust plates from the housing. Do not disassemble the priority valve as it is set at the factory. Remove the spool for the flow divider. 3. Remove the snap ring that holds the seal retainer in the shaft housing. Remove the seal retainer and seals for the drive shaft. Make a note of the arrangement of the seals.

Cleaning and Inspection Inspect the gear assembly and the housing parts for wear and damage. Replace a damaged or worn hydraulic pump. If just the gears are replaced, they must be replaced as a set. NOTE: Some pump bodies will show gear marks where the gears rotate because of the small clearances between the parts. These gear marks do not indicate a worn or damaged pump unless the pump will not supply the volume and pressure shown in the specifications.

11776

1. 2. 3. 4. 5. 6.

SHAFT HOUSING GEAR HOUSING END HOUSING SNAP RING* O–RING* SEAL RETAINER*

7. 8. 9. 10. 11. 12.

SEAL* SEAL BUSHING THRUST PLATE DRIVE SHAFT ALIGNMENT PIN

* NOT USED ON ALL UNITS

FIGURE 6. HYDRAULIC PUMP

Installation 1. Install the hydraulic pump on the flywheel housing. Use a sealant (Hyster Part No. 264159) on the flange of the pump. Connect the oil lines to the pump, hydraulic tank, steering control unit and the main control valve. 2. Fill the hydraulic tank with the oil shown in the section PERIODIC MAINTENANCE, 8000 SRM 341, for the H3.50–5.00XL (H70–110XL); 8000 SRM 393 for the S3.50–5.50XL (S70–120XL).

divider, check the steering time. Turn the steering wheel from stop to stop, full right to left or left to right. The correct steering time is 3.0 seconds at engine speeds above 1200 rpm. Steering time at idle will be more than 3.0 seconds and can vary. Adjust the flow divider if the steering time does not meet this specification. Adjust the flow divider as follows: 1. Remove the lock wire (11) and cap nut (9). 2. Loosen the lock nut (10) and turn the priority valve (2) clockwise with a screwdriver until it stops.

Adjust the Flow Divider (See FIGURE 2.) The hydraulic pump contains a flow divider with priority flow to the steering system. The flow divider can need adjustment when a new lift truck is first operated or when the main hydraulic pump is replaced. Adjustment is needed if the steering function is slow when trying to steer rapidly. To check for proper operation of the flow

3. Then, turn the priority valve counterclockwise one– quarter turn. 4. Hold the priority valve so that it cannot move and tighten the lock nut. 5. Install and tighten the cap nut. Install the lock wire.

SPECIFICATIONS ITEM

SPECIFICATION

HYDRAULIC SYSTEM CAPACITY ALL UNITS HYDRAULIC TANK CAPACITY H3.50–5.00XL (H70–110XL) S3.50–5.50XL (S70–120XL)

42.4 litre (11.2 gal) 37.0 litre (9.8 gal) 23.7 litre (6.3 gal)

RELIEF PRESSURES * MAIN CONTROL VALVE Lift Circuit – H3.50–5.00XL (H70–110XL) Lift Circuit – S3.50–5.50XL (S70–120XL)

20.7 MPa (3000 psi) 21.4 MPa (3100 psi)

Tilt and Auxiliary Circuit – All Units

15.5 MPa (2250 psi)

STEERING CIRCUIT BRAKE BOOSTER HYDRAULIC PUMP CAPACITY PRIORITY FLOW

9.3–10.0 MPa (1350–1450 psi) 1.8 MPa (260 psi) 89 litre/min at 20.7 MPa (23.5 gal/min at 3000 psi) 12.25 to 14.25 litre/min at 9.7 MPa (3.0 to 4.0 gal/min at 1400 psi)

* Oil temperature 50 to 100°C (120 to 210°F) and engine speed at 2500 rpm.

TROUBLESHOOTING PROBLEM

POSSIBLE CAUSE

Hydraulic functions will not operate.

There is no oil or not enough oil in the hydraulic tank. The hydraulic pump is damaged. The hydraulic pump drive arrangement is damaged.

Hydraulic pressure is above or below specifications.

Relief valve in main control valve is not adjusted correctly. There is a restriction in the hydraulic line(s). The hydraulic pump is worn or damaged. The priority valve or flow divider spool in the hydraulic pump does not operate correctly.

LIFT, LOWER AND TILT CIRCUIT Slow or no movement of cylinder(s).

Relief valve in main control valve is damaged or is not adjusted correctly. Large leaks between the spool and bore in the main control valve. Control valve spool not fully extended or retracted. Broken spring(s) for the spool(s). The hydraulic pump is damaged. The hydraulic pump drive arrangement is damaged. Air is in the hydraulic system. There is a restriction in the hydraulic line(s). The load is greater than the capacity of the system. The cylinder seals are damaged.

Lift cylinders retract when the spool is in the Neutral position.

Oil leaks between the spool and the bore. Cylinders seals or the check valves leak. Hydraulic line(s) to the cylinder leaks.

Tilt cylinder rods move forward when the spool is in the Neutral position.

Tilt control spool inside the tilt spool does not work correctly. Oil leaks between the spool and the bore. Hydraulic line(s) leak. Tilt cylinder seals have leaks.

Lift cylinder rods move down when the lift spool is moved to the Lift position.

The load check valve is damaged.

TROUBLESHOOTING PROBLEM

POSSIBLE CAUSE STEERING AND BRAKE SYSTEM

There is no action when the steering wheel is turned.

There is no oil or not enough oil in the hydraulic tank. Hydraulic lines to the steering cylinder are damaged or have a restriction. The priority valve or flow divider spool in the hydraulic pump does not operate correctly. The hydraulic pump drive arrangement is damaged. The steering control unit is damaged. There is air in the hydraulic system.

The lift truck steers slowly, or the steering wheel is hard to turn.

Hydraulic lines to the steering cylinder are damaged or have a restriction. The priority valve in the hydraulic pump does not operate correctly. The hydraulic pump is worn or damaged.

The steering wheel turns the tires in the wrong direction.

The steering control unit is worn or damaged.

The brake booster does not operate correctly.

The hydraulic line from the steering control unit has a restriction or a leak.

Hydraulic lines to the steering control unit or steering cylinder are not connected correctly.

The hydraulic line from the brake booster to the hydraulic tank has a restriction.

INSTRUMENT PANEL INDICATORS AND SENDERS H14.00-18.00XM-12 (H360-450H, EC5-6) [A214]; S6.00-7.00XL (S135-155XL, S155XLS) [B024, C024]; E3.50-5.50XL (E70-120XL) [C098]; S3.50-5.50XL (S70-120XL) [D004]; H13.00-16.00XL (H300-360, H330-360XL-EC) [D019]; H36.00-H48.00E (H800-1050E) [D117]; H8.00-12.00XL (H165-280XL) [E007]; H20.00-H32.00F (H440-700F, FS) [E008]; H6.00-7.00XL (H135-155XL) [F006, G006]

PART NO. 910110

2200 SRM 143

Instrument Panel Indicators and Senders

Table of Contents

TABLE OF CONTENTS General ............................................................................................................................................................... Description ......................................................................................................................................................... Steering Column Gauges, Meters, and Indicators....................................................................................... LED Display Panel ........................................................................................................................................ Battery Discharge Indicators.................................................................................................................... Brush Wear Indicators .............................................................................................................................. Motor Temperature Indicators ................................................................................................................. LX Series Display Panel................................................................................................................................ Hourmeter Functions ................................................................................................................................ Battery Indicator Function ....................................................................................................................... Status Code Function................................................................................................................................ ZX Series Display Panels .............................................................................................................................. Display Panel............................................................................................................................................. Basic Display Panels ................................................................................................................................. Performance Display ................................................................................................................................. Brush Wear Indicators .............................................................................................................................. Adjustments - General....................................................................................................................................... Replacement - General Information ................................................................................................................. Meter Replacement ............................................................................................................................................ Sender Replacement .......................................................................................................................................... Fuel Level Sender .......................................................................................................................................... Pressure and Temperature Sender ............................................................................................................... Seat Sensor, Operator Presence System (OPS)............................................................................................ Remove....................................................................................................................................................... Install ......................................................................................................................................................... Operator Presence System Module Replacement ........................................................................................ Remove....................................................................................................................................................... Install ......................................................................................................................................................... ITW Display Panel Replacement ...................................................................................................................... Remove ........................................................................................................................................................... Column Mount Display Panel (EV-100/200ZX Motor Controllers) Replacement .......................................... Remove ........................................................................................................................................................... Display Panel Assembly, Replace ................................................................................................................. Indicator LEDs .............................................................................................................................................. Battery Indicators.......................................................................................................................................... Digital Display (Performance Display Panel Only) ..................................................................................... Status Code or Performance Level Switches and Indicator LEDs (Performance Display Panel Only) ............................................................................................................................................................... Basic Display Panel, Replace Parts .............................................................................................................. Performance Display Panel, Replace Parts.................................................................................................. Dash Mount Display Panel (EV100/200ZX Motor Controllers) Replacement ................................................ Remove and Replace...................................................................................................................................... Specifications...................................................................................................................................................... Meter Specifications ...................................................................................................................................... Sender Specifications .................................................................................................................................... Troubleshooting.................................................................................................................................................. Troubleshooting for Operator Presence System ...............................................................................................

ÂŠ2007 HYSTER COMPANY

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Table of Contents

Instrument Panel Indicators and Senders

TABLE OF CONTENTS (Continued) This section is for the following models: H14.00-18.00XM-12 (H360-450H, EC5-6) [A214]; S6.00-7.00XL (S135-155XL, S155XLS) [B024, C024]; E3.50-5.50XL (E70-120XL) [C098]; S3.50-5.50XL (S70-120XL) [D004]; H13.00-16.00XL (H300-360, H330-360XL-EC) [D019]; H36.00-H48.00E (H800-1050E) [D117]; H8.00-12.00XL (H165-280XL) [E007]; H20.00-H32.00F (H440-700F, FS) [E008]; H6.00-7.00XL (H135-155XL) [F006, G006]

2200 SRM 143

General

General NOTE: Battery indicator meters, used on electric lift trucks, are described in the SRM section Battery Indicators 2260 SRM 138. The gauges and meters provide information to the operator on the condition of various systems. Gauges may be either direct reading (mechanical) or indirect (electrical). Unlike mechanical gauges, electrical gauges have electrical meter-movements, light emitting diode (LED) or digital displays inside the case. These meters, receive an electrical signal from a sender unit, usually in the engine or transmission case. The indicators of electric lift trucks receive an electrical signal from a sensor (motor temperature) or a control board. This section only describes the electrical "gauges," meters, senders and instrument

1. 2. 3. 4. 5. 6.

ENGINE TRANSMISSION GENERATOR OR AMMETER CURRENT OIL WATER

7. 8. 9. 10. 11. 12.

panel displays. "Gauges" will be referred to as meters. The meters and displays are used to provide operator information on the status of many systems including: (1) engine coolant temperature, (2) engine or transmission oil pressure or temperature, (3) fuel level, (4) battery current (ammeter), battery voltage (voltmeter), battery or state of charge (battery indicators), (5) motor temperature, (6) motor brush wear, (7) traction system status, and (8) elapsed time. See Figure 1, Figure 2, Figure 4, Figure 5, Figure 6, Figure 7, Figure 9, and Figure 10. However, every truck or piece of equipment is not equipped with each one of these meters.

TEMPERATURE PRESSURE HOURS FUEL FUEL LEVEL - FULL FUEL LEVEL - 1/2

13. FUEL LEVEL - EMPTY 14. BATTERY 15. BRUSH WEAR TRACTION MOTOR 16. BRUSH WEAR LIFT MOTOR 17. MAINTENANCE

Figure 1. International Meter Face Symbols

Description

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Description Many meters have meter-movements that move an indicating needle attached to a shaft (or pin). The shaft rotates to swing the needle when current flows through the movement. The movement operates on the same principle (electromagnetic) that rotates a motor shaft. However, shaft rotation of a meter is limited to much less than even one full revolution. The amount of rotation or deflection of the needle is directly related to the amount of current flow through the meter movement. Meter faces (or scales) are calibrated to indicate a range of values that are converted from a directly proportional current flow through the sender. See Figure 1 and Figure 2 for some typical examples of meter faces with various calibrations. Meters such as ammeters, voltmeters, and some hourmeters are able to convert this proportional current within the meter case. Many other meters and displays require a separate sender. See Figure 2. Senders convert a specific pressure, temperature or fluid level into a current flow that is directly related to a given voltage (electrical system voltage) applied. See Figure 3.

STEERING COLUMN GAUGES, METERS, AND INDICATORS Some lift trucks use a cluster of gauges, meters, and indicator lights at the base of the steering column. See Figure 4. The left side includes an hourmeter and engine coolant temperature gauge. For diesel and gasoline units, the right side has a fuel level gauge. Below the fuel level gauge is a four function indicator that has separate warning indicators for the alternator, engine and transmission oil pressure, and transmission oil temperature. For LPG units, the fuel gauge is replaced by a bezel with the Hyster emblem. The indicator with the gasoline pump symbol will now indicate low LPG tank pressure. However, the optional pressure switch must be installed in the LPG system. The indictor for oil pressure and temperature (oil clutch units or powershift transmissions) are combined in a two-function warning light in the lower right position.

LED DISPLAY PANEL Some lift trucks have a Light Emitting Diode (LED) warning display on the instrument panel. See Figure 7, Figure 9, and Figure 10. The following paragraphs describe how the circuit for each function operates and how to check its operation. The LED warning display must be replaced as a complete unit. The sensors for the LED warning display can be replaced as separate parts.

Battery Discharge Indicators NOTE: See the section Battery Indicators 2260 SRM 138 for a more complete description of the operation and the adjustment and repair procedures. Earlier units without the LX control card have a battery discharge indicator that is a scale with a series of 10 LEDs of different colors. See 1, 2, and 3 of Figure 7. The LEDs illuminate in a sequence (green, yellow, red) to indicate the discharge of the battery as the battery voltage decreases during operation. No more than two LEDs are illuminated at one time. When the battery is fully charged, the two green LEDs at the end of the scale are illuminated. When the battery discharges during operation, the illumination sequence moves to the left. The color changes from green to yellow to red. When the battery is discharged to the red section of the battery discharge indicator, the last two red LEDs begin to flash just before the "lift interrupt" is enabled. When the last two red LEDs are illuminated continuously, the controller for the battery discharge indicator stops the power to the hydraulic pump. This action prevents the lift truck from lifting. Enough battery power is normally available to move the lift truck to a battery charger or to a place where a charged battery can be installed.

2200 SRM 143

Description

Figure 2. Typical Meter Faces for Lift Trucks With Engines

Description

2200 SRM 143 Legend for Figure 2

NOTE: METER FACE NUMBERS, INCREMENTS, AND COLORED BANDS CAN BE DIFFERENT THAN SHOWN. 1. HOURMETER (ENGINE POWERED OR ELECTRIC LIFT TRUCKS) 2. AMMETER 3. COLORED BANDS 4. VOLTMETER 5. ENGINE COOLANT TEMPERATURE

6. 7. 8. 9. 10.

TRANSMISSION OIL TEMPERATURE HYDRAULIC OIL TEMPERATURE ENGINE OIL PRESSURE TRANSMISSION OIL PRESSURE FUEL LEVEL

1. FLUID TEMPERATURE SENDERS 2. FLUID PRESSURE SENDER 3. FUEL LEVEL SENDER Figure 3. Typical Senders for Lift Trucks With Engines Legend for Figure 4 A. B. C. D.

LEFT HAND - ALL UNITS WIRING DIAGRAM GAUGES ON STEERING COLUMN WIRING DIAGRAM

E. RIGHT HAND - LPG POWERED UNITS F. RIGHT HAND - DIESEL AND GASOLINE POWERED UNITS G. WIRING DIAGRAM

1. 2. 3. 4.

HOURMETER ENGINE COOLANT TEMPERATURE GAUGE 4-PIN CONNECTOR FUEL LEVEL GAUGE

5. INDICATOR LIGHTS 6. 8-PIN CONNECTOR 7. COVER WITH LOGO

2200 SRM 143

Description

Figure 4. Typical Meters on Steering Column Assembly for Lift Trucks With Engines

Description

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Figure 5. Steering Column Meters for H/S6.00-7.00XL (H/S135-155XL, S155XLS) (C024) (G006)

2200 SRM 143

Description Legend for Figure 5

A. LEFT HAND - ALL UNITS B. RIGHT HAND - DIESEL POWERED UNITS

C. RIGHT HAND GASOLINE POWERED UNITS D. RIGHT HAND - LPG POWERED UNITS

1. INSTRUMENT CLUSTER 2. HOURMETER 3. ENGINE COOLANT TEMPERATURE GAUGE

4. FUEL LEVEL GAUGE 5. INDICATOR LIGHTS

1. 2. 3. 4. 5.

6. 7. 8. 9.

ALTERNATOR INDICATOR ENGINE OIL PRESSURE FUEL LEVEL HOURMETER TRANSMISSION OIL PRESSURE

TRANSMISSION OIL TEMPERATURE COOLANT TEMPERATURE CHECK ENGINE INDICATOR TRANSMISSION OIL TEMPERATURE/PRESSURE WARNING LIGHT

Figure 6. Meter Face Symbols for H/S6.00-7.00XL (H/S135-155XL, S155XLS) (C024) (G006)

Description

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Brush Wear Indicators The brush wear indicators illuminate when the motor brushes must be replaced. The earlier units have two indicators for the traction motor and two for the pump motor. See Figure 7. The later display unit has one indicator for each motor. See Figure 9 and Figure 10. The sensor wires for the brush wear indicators are an insert in the brush material when the brush is made. The sensor wires are insulated from the brush material. When the brush wears within approximately 0.060 in. of the brush lead, the insulation between the sensor wire and the brush material is destroyed. The connection between the brush and the sensor wire causes the indicator to illuminate. The operation of the brush wear indicators can be checked during periodic maintenance. The battery must be removed from the lift truck for access to the motors. See Figure 8.

WARNING

A. TO DISPLAY PANEL 1. 2. 3. 4. 5. 6. 7. 8. 13. 71. 72. 74. 75. 76. 77. 78. 79.

BATTERY INDICATOR LED, GREEN (3) BATTERY INDICATOR LED, YELLOW (4) BATTERY INDICATOR LED, RED (3) TEMPERATURE ALARM, TRACTION MOTOR TEMPERATURE ALARM, (ILLUMINATES WITH 4 OR 6) TEMPERATURE ALARM, HYDRAULIC MOTOR BRUSH WEAR INDICATORS, TRACTION MOTOR BRUSH WEAR INDICATORS, HYDRAULIC MOTOR B - BATTERY POSITIVE BATTERY NEGATIVE BATTERY INDICATOR TRACTION MOTOR TEMP. TRACTION BRUSH WEAR TRACTION BRUSH WEAR PUMP MOTOR TEMP. PUMP BRUSH WEAR PUMP BRUSH WEAR

Figure 7. LED Display Panel (Some Earlier Electric Lift Trucks)

Lift truck movement can cause an injury or damage. Raise the drive wheels from the floor to prevent lift truck movement. Use the correct procedure in the Operating Manual or the Periodic Maintenance section for your lift truck to raise the drive wheels. Use a jumper cable so that the battery can be connected and still have motor access. Disconnect the sensor wires, one at a time, from the outside of the motor case. Touch the end of the sensor wire to battery negative. The LED indicator will illuminate if the circuit is operating correctly. The motor brushes must be replaced when they are worn. If equipped with brush wear indicators, the condition of the commutator and the motor brushes must still be checked during periodic maintenance.

Motor Temperature Indicators The traction motor and the hydraulic pump motor have thermal switches inside the motors. See Figure 7 and Figure 9. When the temperature increases to 300 F for Prestolite motors or 338 F for GE motors, the thermal switch closes and the LED (ZX or earlier units) on the instrument panel display illuminates. This temperature is set by the manufacturer of the motor and is below the temperature where the insulation in the motor will have reduced life.

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Description Legend for Figure 8 Connect the battery so that the motor can be operated. The battery must be removed for access to the motor. Use a jumper cable to connect the battery to the lift truck. Raise the drive wheels. See "How to Raise Drive Wheels" in the Periodic Maintenance section for your lift truck or the Operating Manual for your lift truck. 1. RAISE DRIVE WHEELS

2. JUMPER 3. BATTERY

Figure 8. Connect Battery so Motor can be Operated

Figure 9. GE Instrument Panel Display and Plug Connector (E40-60XL)

Description

2200 SRM 143 Legend for Figure 9

1. DISPLAY UNIT 2. FOUR DIGIT DISPLAY 3. FUNCTION INDICATOR, STATUS CODE (GREEN LED) 4. FUNCTION INDICATOR, BATTERY (GREEN LED) 5. FUNCTION INDICATOR, HOURMETER (GREEN LED) 6. MOUNT FOR DISPLAY UNIT 7. INSTRUMENT PANEL 8. CONNECTOR FOR MOTOR CONTROLLER, TRACTION

9. CONNECTOR FOR MOTOR CONTROLLER, LIFT PUMP 10. TO CONTROL CARD PLUG Y 11. RED* 12. WHITE 13. GREEN 14. BARE 15. GREEN

*TRACTION CARD PLUG ONLY

WARNING Lift truck movement can cause an injury or damage. Raise the drive wheels from the floor to prevent lift truck movement. Use the correct procedure in the Operating Manual or the Periodic Maintenance section for your lift truck to raise the drive wheels. The operation of the motor temperature indicators can be checked during periodic maintenance. The battery must be removed from the lift truck for access to the motors. See Figure 8. Use a jumper cable so that the battery can be connected and still have motor access. Disconnect the sensor wires from the outside of the motor case. Touch the ends of the sensor wires together. The LED indicator will illuminate if the circuit is operating correctly. The thermal switch can be replaced if it has a malfunction. However, the motor must be disassembled to replace the thermal switch.

LX SERIES DISPLAY PANEL WARNING Some adjustments can cause the lift truck to operate differently than normal. This different operation of the truck can result in personal injury or damage. Do NOT try to make adjustments for the instrument panel display without using the procedures in the section EV-100LXT/LX/LXP EV-200LXT/LX Motor Controller & Diagnostic Handset, Description, Checks, Repairs, Adjustments, and Troubleshooting 2200 SRM 460.

There are two instrument panel displays used on some electric lift trucks that have the EV-100/200 "LX" series control cards. Both instrument panel displays are shown in Figure 9 and Figure 10. These instrument panel displays are optional on some electric lift trucks with the EV-100 or EV-200 LX series motor controller. The early unit has a four digit display and three LED function indicators. The indicators show which function value is displayed by the digits. Not all functions are available on all lift truck models. Following is a list of the functions: Battery Indicator, Status Codes, Traction Hourmeter and Pump Hourmeter. Later units have the same digital display and the same function indicators with the additional motor brush wear indicator and temperature alarm indicator LEDs. The following paragraphs describe how the circuit for each function operates. The display panel must be replaced as a complete unit. The sensors for brush wear and motor temperature can be replaced as separate parts. The digits show the operating hours when the hourmeter function indicator is ON. When the battery indicator is ON, the digits show the charge condition of the battery. See Figure 9 and Figure 10. The status code indicator is ON when the digits show the status code number. The brush wear or temperature alarm indicators of the later units will be ON if the traction or pump motor brushes are too worn or the motor is too hot. Refer to the descriptions Brush Wear Indicators and Motor Temperature Indicators for a complete description of the operation of these indicators.

2200 SRM 143

Hourmeter Functions The hourmeter function on the instrument panel display is controlled by the EV-100/200 "LX" series control card. There can be a display for the operating time of the traction circuit. On some units, there can also be a display for the operating time of the pump circuit. Only those units that have the EV-100LXP pump control card can have the optional pump hourmeter function. The instrument panel display shows the operating time of 0000 to 9999 hours. The traction time is displayed for four seconds after the lift truck has been operating and the key is turned to the OFF position. If there is a pump hourmeter, the pump time will now be displayed for another four seconds.

Battery Indicator Function NOTE: See the SRM section Battery Indicators 2260 SRM 138 for a more complete description of the operation and the adjustment and repair procedures. The battery indicator reading is displayed on the four digit display when the green function indicator above the battery symbol is ON. See Figure 9 and Figure 10. This battery indicator uses the traction control shunt to measure the current during operation. This current and battery voltage are checked at the same time for an accurate reading of battery voltage with a load (during use). This method of checking voltage and current is much more accurate than other methods used by battery indicators on earlier lift trucks. This method allows more usage of the battery. Lift truck operation can be different than with other battery indicators when a battery is low or a different battery is connected.

Description The battery indicator function shows the battery charge by the numbers between 0 and 100. The digital display will flash when the display reads 19. At a display of 9 (80% discharged), the control will disable the lift pump circuit. After the circuit has disabled the lift pump, charge or change the battery. The control also checks the battery voltage each time a battery is connected. The traction control will prevent lift truck operation if the battery voltage is not correct as set by the traction function of the control card. A status code of -16 (voltage too high) or -15 (voltage too low) will show on the instrument panel display. The battery can have a voltage that is too high or too low. A battery with the correct voltage can also be over discharged from use or other reasons and have a voltage that is less than the minimum voltage range.

Status Code Function The status codes are code numbers for different symptoms that the control card can sense. The control card will show this code number on the digital display. The control card will flash the status code on the display. Every third display will show the battery charge instead of the status code. NOTE: See the section EV-100LXT/LX/LXP EV-200LXT/LX Motor Controller & Diagnostic Handset, Description, Checks, Repairs, Adjustments, and Troubleshooting 2200 SRM 460 for a description of the different status code displays.

Description

2200 SRM 143

9-Pin Connector Wiring Pin No.

Wire No.

1 2 3 4 5 6 7 8 9

95 96 93 94 98 99 13 10

Connection/Function Traction Motor Temperature Pump Motor Temperature Traction Motor Brush (A) Wear Traction Motor Brush (B) Wear Pump Motor Brush (A) Wear Pump Motor Brush (B) Wear Not Used Battery Negative Battery Positive from Key Switch

1. DISPLAY UNIT 2. BRUSH WEAR INDICATOR, HYDRAULIC MOTOR (YELLOW LED) 3. TEMPERATURE ALARM, HYDRAULIC MOTOR (RED LED) 4. TEMPERATURE ALARM (RED LED) (ILLUMINATES WITH 3 OR 5) 5. TEMPERATURE ALARM, TRACTION MOTOR (RED LED) 6. BRUSH WEAR INDICATOR, TRACTION MOTOR (YELLOW LED)

7. STATUS CODE FUNCTION INDICATOR (GREEN LED) 8. HOURMETER FUNCTION INDICATOR (GREEN LED) 9. FOUR DIGIT DISPLAY 10. BATTERY FUNCTION INDICATOR (GREEN LED) 11. CONNECTOR, HYDRAULIC PUMP CARD 12. CONNECTOR, TRACTION CARD 13. 9-PIN MOTOR CONNECTOR

Figure 10. ITW Instrument Panel Display (E40-60XL)

2200 SRM 143

Description

ZX SERIES DISPLAY PANELS Display Panel WARNING Some adjustments can cause the lift truck to operate differently than normal. This different operation of the truck can result in personal injury or damage. Do NOT try to make adjustments for the instrument panel display without using the procedures in the section EV-100ZX™ SCR Motor Controller, Parameter Tables 2200 SRM 595.

There are two display panels available on lift trucks with the EV-100ZX SCR motor controller. The lift trucks can only have one of the two display panels: • a basic display that gives the operator basic information about the operation of the lift truck • a performance display that includes diagnostic capabilities similar to the Handset.

Basic Display Panels The EV-100 ZX Series motor controller can have two Basic display panels that include one of two types of Battery Indicators. See Figure 11 and Figure 12.

Standard Display 18-Pin Connector Pin 1-11 12 13 14 15 16 17 18 1. 2. 3. 4. 5.

Function No Connection Battery Negative ( ) Parking Brake Switch Brake Fluid Switch Hydraulic Contactor Coil Seat Switch Key Switch (IGN) Battery Positive (+) (from Fuse 6)

HOURMETER BATTERY METER PARKING BRAKE INDICATOR BRAKE FLUID TOO LOW INDICATOR SEAT BELT INDICATOR

6. 7. 8. 9.

KEY SWITCH LEADS RED/BRN IGN TERMINAL BRN BAT TERMINAL 18-PIN CONNECTOR

Figure 11. Basic (Early) Display Panel for EV-100/200ZX Motor Controllers

Description

2200 SRM 143

1. BATTERY DISCHARGE INDICATOR 2. PARKING BRAKE SYMBOL AND LED

3. FASTEN SEAT BELT SYMBOL AND LED 4. DIGITAL DISPLAY

Figure 12. Basic (Later) Display Panel for EV-100/200ZX Motor Controllers EARLY DISPLAY PANEL When the key is turned to the ON position, a start program will cause each warning light to illuminate to show that the function is operating. This later display panel has the following functions: (1) Hourmeter. The hourmeter display shows the operating time of 0000 to 9999 hours. The time for the traction circuit is shown for four seconds after the lift truck has been operating and the key is turned to the OFF position. (2) Voltmeter. The earlier Basic Display Panel has a battery indicator without lift interrupt (voltmeter). This meter has a green, yellow, and red band on the meter face to indicate the voltage of the battery. The needle starts in the green band with a fully-charged battery and moves to the red band as the battery discharges. The battery must have a current draw (load) to check the battery charge. Hold the tilt lever in the tilt BACKWARD position or for the N30XMH, hold the rotate lever in the ROTATE position and look at the indicator. If the needle is in the red band, charge the battery. Operating the lift truck with the needle in the red band can decrease battery life. Continued operation with a discharged battery can damage the battery, motors, or the contactors. (3) Warning light, parking brake indicator. The red light is ON when the parking brake is applied and the seat switch is closed, and goes OFF when the parking brake is released. (4) Warning light, brake fluid reservoir is low (Early Only). The red light is ON for one second when the key is turned to the START position and

must go OFF after one second. If the warning light is ON during operation, the brake fluid level in the reservoir is too low. (5) Warning light, fasten seat belt. The red light is ON for eight to ten seconds after the key is turned to the ON position. LATER DISPLAY PANEL When the key is turned to the ON position, a start program will cause each warning light to illuminate to show that the function is operating. This later display panel has the following functions: (1) Battery Charge Indicator With Lift Interrupt. Later Basic display panels have a battery indicator that is a scale with a series of 5 round LEDs in three colors (green, orange, and red). See Figure 12. There are two green LEDs and bars at the top, two orange LEDs and bars in the center, and a red LED and bar at the bottom. As the battery voltage decreases during operation, different LEDs illuminate to indicate a discharged battery. No more than two LEDs are illuminated at one time. When the battery is fully charged, the two green LEDs of the scale are illuminated. When the battery discharges during operation, the LEDs illuminate from top to bottom (green to red). The red LED indicates that the battery is discharged. The battery must be charged or a charged battery must be installed before lift truck operation can continue. The battery charge indicator uses the traction control shunt to measure the current during operation. This current and battery voltage are checked at the same time for an accurate reading of battery voltage with

2200 SRM 143

Description

a load (during use). This method can make operation of the lift truck different when the battery is low or a different battery is connected. This method permits better use of the battery charge.

hourmeter (12) will also be illuminated during this time.

The controller also checks the battery voltage each time a battery is connected. The traction control will prevent lift truck operation if the battery voltage is not correct as set by traction function 15. A status code of -16 (voltage too high) or -15 (voltage too low) will indicate on the display panel. The battery can have a voltage that is too high or too low. A battery with the correct voltage can also be deeply discharged from use or other reasons and have a voltage that is less than the minimum of the voltage range.

When the key is turned to the ON position, a start program will cause each warning and indicator light to illuminate to show that the function is operating. The functions and operation of the indicators for these early and later display panels is the same. See Figure 13 and Figure 14. These display panels have the following functions:

Batteries that have different ampere hour ratings or are of different ages can sometimes be used in the same lift truck. It can be necessary to adjust traction Function 14 so that the weakest battery is not damaged. Follow the procedure for adjusting traction Function 14 in the Checks And Adjustments. (2) Warning light, parking brake indicator. The red light is ON when the parking brake is applied and the seat switch is closed, and goes OFF when the parking brake is released. (3) Warning light, fasten seat belt. The red light is ON for eight to ten seconds after the key is turned to the ON position. (4) Digital Display. This indicator is blank when the lift truck is operating correctly. The status codes and the hourmeter values are shown on this fourdigit LCD display. When a fault occurs, the status code will be shown with a dash ( ) in the left-digit position. The warning light, Service Interval (11) will also be illuminated when a fault occurs. When it is time for periodic maintenance, the warning light, Service Interval (11), will be illuminated and a status code -99 will be indicated. The register in the controller card must be reset by the service person before this warning light will go OFF. The hourmeter display shows the operating time of 0000 to 9999 hours. The time for the traction circuit is shown for four seconds after the lift truck has been operating and the key is turned to the OFF position. The indicator lights for the traction motor (8) and for the hourmeter (12) will also be illuminated during this time. If there is an SCR control card for the hydraulic pump motor, this time will then be shown on the hourmeter for another four seconds. The indicator lights for the hydraulic motor (9) and for the

Performance Display

(1) Battery Charge Indicator With Lift Interrupt. This battery charge indicator shows the battery charge with an LED bar graph. There are four green bars, four orange bars, and two red bars. When the battery is discharged during operation, the LED bar that is illuminated decreases sequentially from the top green bar through the orange bars to the red bars. When the battery is discharged to the red LED bars, the battery is 73% discharged and the lift interrupt function will not permit operation of the hydraulic motor. The battery must be charged or a charged battery must be installed before lift truck operation can continue. The top green bar will be illuminated when the battery is more than 90% charged. The battery charge indicator uses the traction control shunt to measure the current during operation. This current and battery voltage are checked at the same time for an accurate reading of battery voltage with a load (during use). This method can make operation of the lift truck different when the battery is low or a different battery is connected. This method permits better use of the battery charge. The controller also checks the battery voltage each time a battery is connected. The traction control will prevent lift truck operation if the battery voltage is not correct as set by traction function 15. A status code of -16 (voltage too high) or -15 (voltage too low) will indicate on the display panel. The battery can have a voltage that is too high or too low. A battery with the correct voltage can also be deeply discharged from use or other reasons and have a voltage that is less than the minimum of the voltage range. Batteries that have different ampere hour ratings or are of different ages can sometimes be used in the same lift truck. It can be necessary to adjust traction Function 14 so that the weakest battery is not damaged. Follow the procedure for adjusting traction function 14 in the Checks And Adjustments.

Description

2200 SRM 143

Enhanced Display 18-Pin Connector Pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Function Traction Card PY 5 Pump Card PY 5 No Connection Traction Card PY 14 Traction Card PY 13 Pump Card PY 14 Pump Card PY 13 No Connection Traction Card PY 4 Pump Card PY 4 Brush Wear Indicator & Temperature Jumper* * Parking Brake Switch Brake Fluid Switch No Connection No Connection Key Switch (IGN) No Connection

*Pin 11 to 12 Jumper (In Wire Harness). BWI and Temperature LEDs Disabled if Cut. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

BATTERY DISCHARGE INDICATOR DIGITAL DISPLAY FASTEN SEAT BELT INDICATOR BRAKE FLUID TOO LOW INDICATOR PARKING BRAKE INDICATOR STEERING PUMP MOTOR INDICATOR BRUSH WEAR INDICATOR TRACTION MOTOR INDICATOR LIFT PUMP MOTOR INDICATOR MOTOR TEMPERATURE INDICATOR

11. 12. 13. 14. 15. 16. 17. 18. 19.

STATUS CODE/MAINTENANCE INDICATOR HOURMETER INDICATOR STATUS CODE BUTTON PERFORMANCE LEVEL BUTTON PERFORMANCE LEVEL LEDS KEY SWITCH LEADS RED/BRN IGN TERMINAL BRN BAT TERMINAL 18-PIN CONNECTOR

Figure 13. Early Performance Display Panels for EV-100/200ZX Motor Controllers

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1. 2. 3. 4. 5. 6. 7. 8.

Description

9. 10. 11. 12. 13. 14. 15.

LIFT PUMP MOTOR INDICATOR MOTOR TEMPERATURE INDICATOR STATUS CODE/MAINTENANCE INDICATOR HOURMETER INDICATOR STATUS CODE BUTTON PERFORMANCE LEVEL BUTTON PERFORMANCE LEVEL LEDS

Figure 14. Later Performance Display Panels for EV-100/200ZX Motor Controllers (2) Digital Display. This indicator is blank when the lift truck is operating correctly. The status codes and the hourmeter values are shown on this fourdigit LCD display. When a fault occurs, the status code will be shown with a dash ( ) in the left digit position. The warning light, Service Interval (11) will also be illuminated when a fault occurs. The hourmeter display shows the operating time of 0000 to 9999 hours. The time for the traction circuit is shown for four seconds after the lift truck has been operating and the key is turned to the OFF position. The indicator lights for the traction motor (8) and for the hourmeter (12) will also be illuminated during this time. If there is an SCR control card for the hydraulic pump motor, this time will then be shown on the hourmeter for another four seconds. The indicator lights for the hydraulic motor (9) and for the hourmeter (12) will also be illuminated during this time. (3) Warning Light, Fasten Seat Belt. The red light is ON for eight to ten seconds after the key is turned to the ON position. (4) Warning Light, Brake Fluid Reservoir Is Low (Early Only). The red light is ON for one second when the key is turned to the START position and must go OFF when the key is in the ON

position. If the warning light is ON when the key is in the ON position, the brake fluid level in the reservoir is too low. (5) Warning Light, Parking Brake Indicator. The red light is ON when the parking brake is applied and the seat switch is closed, and goes OFF when the parking brake is released. A warning buzzer will make a noise if the operator leaves the seat (key moved to ON position) and the parking brake is not applied. (6) Indicator Light, Steering Pump Motor. This light will illuminate with another warning light if a fault occurs in the steering pump motor. If the brush wear sensor is activated in the motor, the warning light, brush wear (7) will go ON and the indicator light for the steering pump motor will show which motor has the problem. (7) Warning Light, Motor Brushes Are Worn. When the sensor for brush wear closes, this warning light and the indicator light for the motor that has the problem will both illuminate. (8) Indicator Light, Traction Motor. This light will illuminate with another warning light if a fault occurs in the traction motor. Example: If the brush wear sensor is activated in the motor, the warning

Description light, brush wear (7) will go ON and the indicator light for the traction motor will show which motor has the problem. (9) Indicator Light, Hydraulic Motor. This light will illuminate with another warning light if a fault occurs in the hydraulic pump motor. Example: If the temperature over limit switch closes in the motor, the warning light, motor temperature over limit (10) will go ON and the indicator light for the hydraulic motor will show which motor has the problem. (10) Warning light, Motor Temperature Over Limit. The traction motor and the hydraulic pump motor have thermal switches inside the motors. When the temperature increases to the limit set by the manufacturer of the motor, the thermal switch closes and the warning light on the display panel illuminates. The indicator light for traction motor (8) or for the hydraulic motor (9) will show which motor has the problem. (14, 15) Set Lift Truck Performance. The lift truck can be set to four performance levels by the operator. (If the customer does not want this function available to the operator, a service person can set all four levels to the same setting.) Each time the operator pushes the button (14), performance level will increase by one step. At the maximum (rabbit) level, the performance levels will begin at the lowest (turtle) level again. The four performance levels set by the manufacturer are: 1. Low performance for handling fragile loads. 2. Medium speed for less consumption of battery charge during a work shift. 3. Higher performance with higher consumption of battery charge during a work shift. 4. Maximum lift truck performance with maximum consumption of battery charge. The performance settings can be made with either the PC or the Handset (Functions 11, 12, and 13). The four performance levels can be set to any level up to the maximum limits. Two or more adjacent performance levels can be set to the same limits. The performance levels must be set at the same or in ascending order (from turtle to rabbit). The register interlocks will not permit a higher performance level setting toward the turtle than the adjacent registers toward the rabbit. Fault Code Memory. The control cards for the traction motor controller and hydraulic pump motor each

2200 SRM 143 have memory registers in which the last 16 status codes can be stored. Each status code is stored with the hourmeter time and the battery charge at the time of the fault. The status code for the last fault will be indicated on the Status Code Indicator (2). If the key is turned to OFF, the status code will be removed from the four digit display. The push button (13) will cause the status codes for the for the faults to be shown on the Status Code Indicator (2). When the button is pushed and held down, the indicator light for the traction motor (8) will illuminate. The status codes in memory for the detected faults will be displayed, starting with the most recent fault. If the push button is released, the display will stop. If the button is pushed again, the display will start from the beginning again. The hourmeter time and the battery charge at the time of the fault will not be shown. A Handset or a PC must be used to show this additional information. A Handset or a PC must be used to clear the status code from the register. If the button is pushed twice and then held down, the indicator light for the hydraulic pump motor (9) will illuminate. The status codes in memory for the detected faults will be displayed, starting with the most recent fault. If the push button is released, the display will stop. If the button is pushed twice to start the sequence again, the display will start from the beginning. The hourmeter time and the battery charge at the time of the fault will not be shown. A Handset or a PC must be used to show this additional information. A Handset or a PC must be used to clear the status code from the register. There can be 16 status codes in the memory for each system (traction or lift). Push and hold the push button to display all the status codes in the memory for detected faults of the traction system. The Traction Motor Indicator will be ON to show that the status codes are for the traction system. If the push button is released then pushed and held again, the digital display will start over showing all the status codes for the traction system. Push the button twice and hold the push button to display all the status codes in the memory for detected faults of the lift system. The Lift Pump Motor Indicator will be ON to show that the status codes are for the lift system. If the push button is released then pushed twice and held again, the digital display will start over showing all the status codes for the lift system.

2200 SRM 143

Replacement - General Information

Brush Wear Indicators The brush wear indicators illuminate when the motor brushes must be replaced. The sensor wires for the brush wear indicators are an insert in the brush material when it is made. The sensor wires are insulated from the brush material. When the brush wears within approximately 0.060 inch of the brush lead, the insulation between the sensor wire and the

brush material is destroyed. The connection between the brush and the sensor wire causes the indicator to illuminate. The operation of the brush wear indicators can be checked during periodic maintenance. The battery must be removed from the lift truck for access to the motors.

Adjustments - General There are no adjustments to perform except for some battery indicators. Refer to the section Battery Indicators 2260 SRM 138 to adjust the battery indicators. Refer to the section EV-100LXT/LX/LXP

EV-200LXT/LX Motor Controller & Diagnostic Handset, Description, Checks, Repairs, Adjustments, and Troubleshooting 2200 SRM 460 to adjust the I.T.W. display panel.

Replacement - General Information Before replacing any components, fully lower all parts of the mast and tilt it forward until the tips of the forks touch the ground. This action will prevent the mast from lowering suddenly if the control lever is accidently moved.

meters, indicators, or senders is direct replacement. The most common cause of failure is poor connections or damaged or improper wiring and not the meter indicator or sender. This section only has the replacement procedures. Before a meter, display panel, indicator, or sender is replaced, make the following checks:

ALWAYS disconnect the battery and remove the key before replacing components.

1. Check that other meters and electrical circuits operate correctly.

Never have any metal on your fingers, arms, or neck. These metal items can accidentally make an electrical connection and cause an injury.

2. Check that the battery is fully charged, has a good ground (diesel, gasoline and LPG units only), and the cable terminals are clean and tight.

WARNING

NOTE: None of the electrical components of this section can be repaired. All bad components must be replaced. Meters, display panels, most indicators, and senders are not repairable items. The most accurate and usually easiest checks for proper operation of individual

3. Check that the wiring and connections to the meter, indicator, or sender are tight and in good condition.

Meter Replacement

2200 SRM 143

Meter Replacement Meters are usually mounted to an instrument panel. See Figure 15. Access to the back of the panel or mounting surface is required for meter replacement. Replace a meter as follows: 1. Make sure the key is in the OFF position.

4. Remove the meter and install the replacement meter in the panel. Make sure the meter is in the correct position for reading by the operator. 5. Install the mounting bracket, washers, and nuts. Tighten the nuts.

WARNING

CAUTION

Meters normally have voltage at the terminals. A short circuit of this voltage can result in meter damage or personal injury. To prevent a short circuit during meter replacement, disconnect the battery negative cable at the battery negative terminal. Install a lock or tag on the connector to prevent connection.

A short circuit and damage can occur if wires are not installed correctly. Make sure wire connectors do not touch the other meter terminals or wire connectors, metal brackets, or the bracket mounting nuts. Make sure the wires are not pulled tight and are not touching other parts to damage the insulation.

2. Put tags on the meter wires for correct identification during installation. Remove the wires from the meter terminals.

6. Connect the wires to the meter electrical terminals. Tighten the nuts if the nuts are required for correct connection.

NOTE: If the meter is illuminated, remove bulb socket and bulb from the meter.

NOTE: If the meter is illuminated, install the socket with the bulb into the meter housing.

3. Remove the nuts and washers that fasten the mounting bracket to the meter housing.

1. 2. 3. 4.

HOURMETER AMMETER (FARIA) OIL TEMPERATURE (DATCON) (A.C.) METERS

5. 6. 7. 8.

AMMETER VOLTMETER TEMPERATURE OIL PRESSURE AND FUEL LEVEL

Figure 15. Meters and Mount Brackets

2200 SRM 143

Sender Replacement

Sender Replacement FUEL LEVEL SENDER

WARNING

WARNING All fuel vapors are extremely explosive. Do not allow sparks or flames around vehicles or fuel storage and service areas. Make sure there is no source of open flame or sparks in the vicinity. Use caution to prevent sparks from tools. The fuel level sending unit is mounted to the fuel tank surface (usually top surface) with screws through the sender plate and gasket. See Figure 16. Correct sender operation and screw hole alignment can only be obtained with the plate mounted in one position. Replace the sender as follows:

Electrical shock from voltage can cause personal injury. Put electrical tape on the wire connector to electrically insulate the connector if the wire is accidentally energized.

CAUTION Fuel level senders are not accurate if the arm is bent during removal and installation. There must also be clearance for operation. Do not bend the float arm. 3. Remove screws that fasten sender plate to fuel tank. Remove sender. 4. Carefully install new sender with new gasket. 5. Make sure screw holes are aligned and install screws. Tighten screws enough to partially compress gasket to prevent leaks. 6. Remove tape from wire connector. Install connector on sender terminal.

PRESSURE AND TEMPERATURE SENDER Pressure senders have a hollow threaded fitting fastened to the base. See Figure 17 and Figure 18. This makes it possible for the sender to sense the pressure and also to fasten the sender to the equipment. The sender can be tightened or loosened using a wrench on the flats of the hex shape of the fitting. The body of the temperature sender has threads to fit a threaded hole in the equipment. Replace either sender as follows: A. FULL POSITION

B. EMPTY POSITION

1. ELECTRICAL TERMINAL 2. PLATE

3. SENDER UNIT 4. FLOAT ARM 5. FLOAT

Figure 16. Fuel Level Sender 1. Turn key switch to OFF position and disconnect positive battery cable at battery. Install lock or tag on connector to prevent connection. 2. Disconnect sender wire at sender.

NOTE: Make sure the system fluid is drained to a level below the sender to prevent leakage when the sender is removed. 1. Turn key switch to OFF position. 2. Disconnect sender wire. 3. Turn sender counterclockwise with a wrench until free. Remove and discard old sender. 4. Install new sender and tighten with a wrench. 5. Connect sender wire.

Sender Replacement

2200 SRM 143 4. Disconnect the seat harness from the seat sensor. See Figure 19. 5. Remove two capscrews and seat sensor from the seat.

1. 2. 3. 4. 5.

ELECTRICAL TERMINAL HEX THREADED BODY SENSOR ELEMENT CASE OF ENGINE OR TRANSMISSION

Figure 17. Typical Pressure and Temperature Sender

1. 2. 3. 4. 5.

CAPSCREWS SEAT SENSOR SEAT SENSOR ELECTRICAL CONNECTOR SEAT GROUND WIRE TO CHASSIS HARNESS Figure 19. Seat Sensor Location

Install 1. 2. 3. 4. 5. 6.

ELECTRICAL TERMINAL SENDER HEX THREADED FITTING HOLE-TO-SENSOR ELEMENT CASE OF ENGINE OR TRANSMISSION Figure 18. Fluid Pressure Sender

SEAT SENSOR, OPERATOR PRESENCE SYSTEM (OPS)

1. Using two capscrews, install seat sensor on the bottom of the seat. See Figure 19. 2. Connect seat sensor to seat harness. 3. Install seat onto hood using four capscrews and washers. Tighten capscrews to 18 Nâ&#x20AC;¢m (156 lbf in). 4. Connect seat harness to chassis harness.

Remove

5. Connect battery.

1. Disconnect the battery.

OPERATOR PRESENCE SYSTEM MODULE REPLACEMENT

2. Disconnect seat harness from chassis harness. 3. Remove the four capscrews, washers, and seat from the hood.

NOTE: Remove the Operator Presence System Module only when directed to do so as a result of troubleshooting the Operator Presence System.

2200 SRM 143

Remove 1. Disconnect the negative battery terminal. 2. Remove the floorplates.

1. 2. 3. 4. 5.

STEERING COLUMN RIGHT HAND DASH PANEL FUSE PANEL HORN OPERATOR PRESENCE SYSTEM MODULE

Sender Replacement 3. Disconnect the Operator Presence System wiring harness from the Operator Presence System Module. See Figure 20 for lift truck model H6.00-7.00XL (H135-155XL) (G006) or Figure 21 for lift truck model S6.00-7.00XL (S135-155XL, S155XLS) (C024).

6. OPERATOR PRESENCE SYSTEM MOUNTING BRACKET 7. OPERATOR PRESENCE SYSTEM WIRING HARNESS 8. MAIN WIRING HARNESS 9. LEFT HAND DASH PANEL

Figure 20. Operator Presence System Module [H6.00-7.00XL (H135-155XL)]

Sender Replacement

1. STEERING COLUMN 2. RIGHT HAND DASH PANEL 3. OPERATOR PRESENCE SYSTEM MODULE MOUNTING BRACKET

2200 SRM 143

4. OPERATOR PRESENCE SYSTEM MODULE 5. OPERATOR PRESENCE SYSTEM WIRING HARNESS 6. LEFT HAND DASH PANEL

Figure 21. Operator Presence System Module [S6.00-7.00XL (S135-155XL, S155XLS)] NOTE: There are two washers on each mounting screw and nut combination. Note the location of the two washers during removal to aid in installation. 4. Remove the Operator Presence System Module from the Operator Presence System mounting bracket located on the cowl See Figure 20 for lift truck model H6.00-7.00XL (H135-155XL) (G006). 5. Remove the Operator Presence System Module from the Operator Presence System mounting bracket located on the cowl. See Figure 21 for lift truck model S6.00-7.00XL (S135-155XL, S155XLS) (C024).

Install 1. Install the Operator Presence System Module on the Operator Presence System mounting bracket located on the cowl. See Figure 21 for lift truck model S6.00-7.00XL (S135-155XL, S155XLS) (C024). 2. Install the Operator Presence System Module on the Operator Presence System mounting bracket located on the cowl. See lift truck model Figure 20 for H6.00-7.00XL (H135-155XL) (G006). 3. Connect the Operator Presence System wiring harness to the Operator Presence System

2200 SRM 143

Column Mount Display Panel (EV-100/200ZX Motor Controllers) Replacement

Module. See Figure 20 for lift truck model H6.00-7.00XL (H135-155XL) (G006) or Figure 21 for lift truck model S6.00-7.00XL (S135-155XL, S155XLS) (C024).

4. Install the floorplates. 5. Connect the negative battery terminal.

ITW Display Panel Replacement REMOVE The display panel is in the instrument panel. The display panel cannot be repaired and must be replaced if it has a malfunction. See Figure 10. 1. Move the lift truck to a safe, level area. Turn the key to the OFF position and remove the key. Put a DO NOT OPERATE tag on the steering wheel. Put blocks under the drive wheels to keep the lift truck from moving. See the section Periodic Maintenance or the Operating Manual for your lift truck to place the blocks.

WARNING Disconnect the battery and separate the connector before opening the compartment cover or inspecting or repairing the electrical system. If a tool causes a short circuit, the high current flow from the battery can cause an injury or parts damage.

3. If installed, remove the cowl cover under the instrument panel. 4. Install labels for correct connection during installation and disconnect all electrical plugs and wires from the back of the display panel. 5. Remove the screws or nuts that fasten the display panel assembly to the instrument panel. Lift the display panel up out of the instrument panel. 6. Install the replacement display panel and install the screws or nuts. Make sure the panel can be read by the operator. 7. Correctly connect all electrical plugs or wires according to the labels made during removal. 8. Remove the blocks from under the drive wheels, remove the DO NOT OPERATE tag, connect the battery, and install the key.

2. Disconnect and separate the battery connector.

Column Mount Display Panel (EV-100/200ZX Motor Controllers) Replacement REMOVE The display panel is in the instrument panel. The display panel cannot be repaired and must be replaced if it has a malfunction. The display panels must be replaced as a unit. NOTE: Most parts of the column-mounted display panel can be replaced. However, the LED indicators cannot be replaced separately. The LEDs are part of the circuit board assembly. The major replaceable parts of this display panel are: 1) key switch; 2) housing, top cover, and O-ring seal; 3) housing and light filter for LED warning lights; 4) hourmeter and gasket; 5) battery indicator; 6) buzzer and circuit board; and 7) jumper harness and the wires to the key switch.

NOTE: The only replaceable parts of the Performance display panel are the O-ring seal, key switch, wires to the key switch, and the housing that fastens to the steering column. All other parts of the panel must be replaced as a single unit. See Display Panel Assembly, Replace of this section.

DISPLAY PANEL ASSEMBLY, REPLACE Follow this procedure to replace the Basic or Performance display panel as an assembly: 1. Disconnect the battery and remove the key. 2. Remove the front steering column cover with the display panel assembly attached. Carefully disconnect the 18-pin connector, the key switch

Column Mount Display Panel (EV-100/200ZX Motor Controllers) Replacement wires and, on the Basic panel, the two-pin connector from inside the column cover. 3. Remove the four screws that fasten the display panel to the column cover.

2200 SRM 143

The display must be replaced as part of the Performance display panel. See Display Panel Assembly, Replace of this section.

4. Install the replacement display panel assembly to the cover of the steering column and tighten the screws. Install the connectors and the key switch wires. On the Basic panel, set the DIP switches near the connector for the panel to the voltage of the lift truck. See Figure 22. Move the DIP switch for the correct voltage to the up position and all others to the down position. Install the column cover on the steering column.

INDICATOR LEDS NOTE: The indicator LEDs of the Basic display panel are part of the circuit board and must be replaced as an assembly. See Basic Display Panel, Replace Parts of this section. The LED indicators of the Performance display panel cannot be replaced. If these LED indicators are bad, replace the display panel. See Display Panel Assembly, Replace of this section.

BATTERY INDICATORS There are two types of battery indicators for these trucks. One type is a meter movement with colored bands showing the battery charge (Basic display panel). The other type is a Light Emitting Diode (LED) display with LEDs of different colors showing battery charge (Performance display panel). NOTE: The battery indicator is replaced as one of the components of the display panel. See procedure under Basic Display Panel, Replace Parts of this section. The battery indicator of the Performance display panel cannot be replaced as a separate component. The indicator must be replaced as part of the Performance display panel. See Display Panel Assembly, Replace of this section. See the section Battery Indicators 2260 SRM 138 to adjust these battery indicators.

DIGITAL DISPLAY (PERFORMANCE DISPLAY PANEL ONLY) NOTE: The digital display of the Performance display panel cannot be replaced as a separate component.

NOTE: ON = UP AS SHOWN. 36V SW#1 ON, OTHERS OFF. 48V SW#2 ON, OTHERS OFF. NOTE: SET DIP SWITCHES TO TRUCK VOLTAGE. IF TRUCK VOLTAGE IS NOT KNOWN, SET 36/48V (U.S.) TRUCKS TO 48V. 1. DISPLAY PANEL 2. STEERING COLUMN 3. ELECTRICAL CONNECTOR

4. DIP SWITCHES 5. BROWN 6. RED/BROWN

Figure 22. Dip Switches

2200 SRM 143

Column Mount Display Panel (EV-100/200ZX Motor Controllers) Replacement

STATUS CODE OR PERFORMANCE LEVEL SWITCHES AND INDICATOR LEDS (PERFORMANCE DISPLAY PANEL ONLY) NOTE: These switches of the Performance display panel cannot be replaced as separate components. The switches must be replaced as part of the Performance display panel. See Display Panel Assembly, Replace of this section.

BASIC DISPLAY PANEL, REPLACE PARTS NOTE: The parts of the Basic Display Panel can be replaced with the display panel on the steering column. If the assembly housing will be replaced, remove the complete assembly from the steering column as described in Display Panel Assembly, Replace. NOTE: The following is a complete disassembly procedure. Do ONLY those steps necessary to replace the part you want replaced. Remove and replace the components of the Basic display panel as follows: 1. Disconnect the battery and remove the key. 2. Remove the eight screws that fasten the top cover to the panel housing. The screws are at the bottom of the housing. See Figure 23. The hourmeter is fastened to the top cover with the electrical connector on the circuit board inside the housing. Carefully lift the top cover up off the housing and the indicator LEDs without damaging the O-ring gasket. The gasket for the LED indicators can stick to the LED housing as the top cover is removed. Do not lose or damage the gasket. Disconnect the three wire connector for the hourmeter. 3. If the housing or filter for the indicators will be replaced, remove the screws that fasten the LED housing to the cover. If the hourmeter or hourmeter gasket will be replaced, remove the screws that fasten it to the top cover. Install the replacement parts to the top cover. Make sure that the hourmeter is installed so that it can be read after the cover is installed. 4. Remove the nut that fastens the key switch. Remove the key switch from the housing. Make a note of which wires are on which terminals and

disconnect the wires. Install the wires on the same terminals of the replacement switch. 5. Align the notch in the shaft housing of the key switch with the tab in the housing of the display panel. Install the replacement switch. Tighten the nut and connect the wires. NOTE: It is not necessary to do Step 6 if only the meter movement of the battery indicator will be replaced on the existing circuit board. Carefully lift the meter movement up off the pins of the circuit board without bending the pins. See Figure 23. Carefully install the replacement meter movement on the pins. Make sure the pins are correctly aligned on the back of the meter before pushing the meter on the pins. 6. If the battery indicator, circuit board for the hourmeter or the buzzer will be replaced, remove the screws that fasten the circuit board to the housing. Disconnect the connector from the circuit board. Remove the buzzer from the bottom of the circuit board. Make sure to install the fiber washer when installing the replacement buzzer on the replacement circuit board. If necessary, carefully lift the meter movement up off the pins of the circuit board without bending the pins. See Figure 23. Carefully install the replacement meter movement on the pins of the replacement circuit board. Make sure the pins are correctly aligned on the back of the meter before pushing the meter on the pins. Connect the electrical connector to the circuit board and install the circuit board assembly in the housing. 7. If the LED indicator assembly will be replaced, first remove the 18-pin connector. It is necessary to remove the front steering column cover with the display panel assembly attached for access to the connector. After removing the screws that fasten the front cover, carefully disconnect the connector. It can be necessary to disconnect the key switch wires (Step 4) and the two wire connector for enough clearance to disconnect the 18-pin connector. Remove the two screws that fasten the LED assembly to the housing. Install the replacement LED assembly, carefully connect all connectors and wires. Install the front steering column cover with the display panel assembly attached. Install the LED gasket over the LED indicators.

Column Mount Display Panel (EV-100/200ZX Motor Controllers) Replacement

Figure 23. Standard Display Panel

2200 SRM 143

Dash Mount Display Panel (EV100/200ZX Motor Controllers) Replacement Legend for Figure 23

1. 2. 3. 4. 5. 6. 7. 8.

TOP COVER FILTER FOR LED INDICATORS HOUSING FOR LED INDICATORS KEY SWITCH ASSEMBLY HOUSING O-RING GASKET BUZZER FIBER INSULATING WASHERS

8. If necessary, install a new O-ring gasket. Carefully install the O-ring gasket in the groove of the top cover. Carefully install the top cover assembly over the LED indicators and assembly housing without damaging either the LED gasket or O-ring gasket. Make sure the O-ring gasket is still correctly aligned with the cover and housing before installing the screws. Install the eight screws that fasten the top cover to the panel housing and tighten them in a cross pattern.

9. CIRCUIT BOARD (LH) FOR BATTERY INDICATOR 10. BATTERY INDICATOR 11. JUMPER HARNESS 12. HOURMETER 13. GASKET FOR HOURMETER 14. CIRCUIT BOARD FOR LED INDICATORS 15. GASKET FOR LED INDICATORS

PERFORMANCE DISPLAY PANEL, REPLACE PARTS NOTE: The only replaceable parts of the Performance display panel are the O-ring seal, key switch, wires to the key switch, and the housing that fastens to the steering column. All other parts of the panel must be replaced as a single unit. See Display Panel Assembly, Replace of this section.

Dash Mount Display Panel (EV100/200ZX Motor Controllers) Replacement REMOVE AND REPLACE The display panel is in the dash. See Figure 24. The display panel cannot be repaired and must be replaced if it has a malfunction. These display panels must be replaced as a unit. 1. Disconnect the battery. 2. Disconnect the plug connector on the back of the display panel. Access is under the dash. 3. Remove the four nuts that fasten the display panel and lift it up out of the dash. 4. Install the replacement display panel in the dash. 5. Install and tighten the nuts that fasten the display panel in the dash and install the plug connector.

1. DASH PANEL 2. DISPLAY PANEL 3. MOUNT NUTS

4. PLUG CONNECTOR

Figure 24. Dash Mount Display Panels

Specifications

2200 SRM 143

Specifications METER SPECIFICATIONS Item

Design Data

Operating Voltage Hourmeter Engine-Powered Equipment

12V, 24V

Electric Motor-Powered Equipment

12V, 24V, 36V, 48V, 72V, 80V or multiple 30 to 130V

All Other Meters Terminal Threads

12V, 24V #10-32 UNF or #6-32 UNC

Range of Meter Hourmeter

0.0 to 9.999.9 Hours

Ammeter

0 to Â±60 Amps

Voltmeter

10 to 16 Volts

Temperature Gauge (Range Based on Requirements)

38 to 104 C (100 to 220 F) 38 to 121 C (100 to 250 F) 38 to 182 C (100 to 360 F)

Pressure Gauge (Range Based on Requirements)

0 to 552 kPa (0 to 80 psi) 0 to 1380 kPa (0 to 200 psi) 0 to 2068 kPa (0 to 300 psi)

Method of Mounting

To Panel with Bracket

SENDER SPECIFICATIONS Item

Design Data

Operating Voltage All Senders

12-Volt System

Terminal Threads (Electrical) All Senders

#10-32 UNF-2A

Fastener Data (To Fit in a Threaded Hole) Temperature Sender Body Threads

1/2-14 Dryseal

Hex (Across Flats)

23.4 mm (0.92 in.) for a 15/16 in. Wrench

Pressure Sender Fitting Threads

1/8-27 Dryseal NPTF

Hex (Across Flats)

22.4 mm (0.88 in.) for a 7/8 in. Wrench

Fuel Sender Plate

Number of Holes

5 (Not Equally Spaced)

Hole Size

5 - 5.1 mm (0.196 - 0.200 in.)

2200 SRM 143

Troubleshooting

Troubleshooting PROBLEM

POSSIBLE CAUSE

PROCEDURE OR ACTION

METER No Indication - All Meters

No Indication - Only One Meter

Incorrect Indication

Battery disconnected.

Clean the battery terminals and battery cable connectors. Install connectors.

Battery malfunction or discharged.

Charge or replace battery.

Wiring group connector or connectors not connected.

Fasten the connector or connectors.

Meter wires damaged or not connected.

Replace the broken wires or connectors. Install connectors on proper meter terminals.

Separate sender wire damaged or not connected.

Replace broken wire or connector. Install connector on sender terminal.

Meter malfunction. Voltage is at terminal.

Replace meter.

Sender malfunction. terminal.

Replace sender.

Voltage is at

Battery is discharged.

Charge battery.

Meter movement or needle is damaged or has a malfunction.

Replace meter.

Separate sender malfunction.

Replace sender.

Sender will not sense because system has corrosion.

Clean and flush system.

Troubleshooting for Operator Presence System

2200 SRM 143

Troubleshooting for Operator Presence System NOTE: If a fuse is blown, always check the associated circuit(s) for short to ground before replacing the fuse. Table 1. Troubleshooting Procedure for Operator Presence Module Symptom

Cause

Check

Result

Investigate

Truck does not move with Operator Present.

No power to Operator Presence System (OPS)

With power ON and engine OFF. Unplug the Operator Presence System connector, and check for battery voltage on Operator Presence System connector pin 2 (+) and pin 1 ( ).

Battery voltage >No > Battery voltage >Yes > (Next step below).

Check ground and power wiring, connectors and left hand instrument cluster fuse for open circuit. Repair or replace.

Truck does not move with Operator Present.

Circuit disconnected from the module to the transmission solenoidâ&#x20AC;&#x2122;s power source.

With power ON and engine OFF. Unplug Operator Presence System connector, release the park brake and select a direction. Check for battery voltage on Operator Presence System connector pin 6 (+) and pin 5 ( ). Repeat for other direction selection.

Battery Voltage > No > Battery voltage >Yes> (Next step below).

Check Wiring, connectors, park brake switch, and left hand instrument cluster fuse for open circuit between battery and pin 6. Check wiring, connectors, direction switches, and direction solenoids for open circuit between pin 5 and ground. Repair or replace.

Truck does not move with Operator Present.

Operator presence not detected.

With power ON and engine OFF. Plug the Operator Presence System connector in, and check for 5 volts on Operator Presence System connector pin 10 (+) and pin 12 ( ).

5 volts > no > 5 volts > yes > (Next step below).

Check circuit SA for short to ground. If there is no short to ground, replace Operator Presence System module.

Truck does not move with Operator Present.

With power ON and engine OFF. Plug the Operator Presence System connector in, and with no operator in the seat, check for approximately 0.5 volts on Operator Presence System connector pin 11 (+) and pin 12 ( ).

0.5 volts > No > 0.5 volts > yes> (next step below).

Check circuit SB for short to ground or open circuit. If there is a short to ground or open circuit, repair. If there is no short to ground, or open circuit, replace faulty seat sensor.

Truck does not move with Operator Present.

With power ON and engine OFF. Plug the Operator Presence System connector in, and with operator in the seat, check for approximately 3.0 to 4.5 volts on Operator Presence System connector pin 11 (+) and pin 12 ( ).

3 to 4.5 volts > No> 3 volts or more > yes > (next step below)

Faulty seat sensor.

2200 SRM 143

Troubleshooting for Operator Presence System

Table 1. Troubleshooting Procedure for Operator Presence Module (Continued) Symptom

Truck does not move with Operator Present.

Truck can move without Operator Present.

Cause

Operator Presence System does not reset.

Operator Presence System is detecting a false seat presence signal.

Check

Result

Investigate

Greater than 4.5 volts > Yes> 3 to 4.5 volts > yes > (next step below)

Check circuit SB for short to 5 volts or short to battery. Repair or replace.

With power ON, engine OFF, service brake applied, and the Operator Presence System connector unplugged, check for battery voltage on Operator Presence System connector pin 3 and pin 1.

Battery voltage >No> Battery voltage >yes> (next step below)

Check ground and power wiring for open circuits. Check connectors, service brake switch, and brake light relay for an open circuit. Check left hand instrument cluster fuse for an open circuit. Repair or replace.

With power ON, engine OFF, service brake not applied, and the Operator Presence System connector unplugged, check for battery voltage on Operator Presence System connector pin 3 and pin 1.

Battery voltage >yes>

Check power wiring or connectors for short to battery. Service Brake switch circuit shorted. Repair or replace.

With power ON and engine OFF. Plug the Operator Presence System connector in with no operator in the seat, check for approximately 3.0 to 4.5 volts on Operator Presence System connector pin 11 (+) and pin 12 ( ).

3 to 4.5 volts > Yes> 3 to 4.5 volts > No> (next step below)

Stuck seat mechanism Repair Stuck seat sensor Replace

Troubleshooting for Operator Presence System

2200 SRM 143

Table 1. Troubleshooting Procedure for Operator Presence Module (Continued) Symptom

Cause

Check

Result

Investigate

Truck can move without Operator Present.

Direction solenoids can be operated.

With power ON and engine OFF. Unplug Operator Presence System connector, release the park brake and select a direction. Check for battery voltage on Operator Presence System connector pin 5 (+) and pin 1 ( ). Repeat for other direction selection.

Battery voltage >Yes> Battery voltage >No> (next step below)

Circuit XM short to battery Repair or replace.

Truck can move without Operator Present.

No Operator Presence System Interlock.

With power ON and engine OFF. Plug the Operator Presence System connector in, with no operator in the seat, check for battery voltage on Operator Presence System connector pin 5 (+) and pin 1 ( ).

Battery voltage >Yes>

Operator Presence System faulty. Replace

LIFT CYLINDERS ALL MODELS, EXCEPT H8.00-12.00XM (H170-280HD) [F007, G007]; H13.00-16.00XM (H300-360HD) [E019, F019]; H10.00-12.00XM-EC (H360HD-EC) [E019, F019]; H20.00-32.00F (H440-700FS) [E008]; H36.00-48.00E (H800-1050E) [D117]; H3.50-5.50XM (H70-120XM) [K005, L005]; S3.50-5.50XM, S5.50XMS (S70-120XM, S120XMS) [E004, F004]

PART NO. 910119

4000 SRM 135

Lift Cylinders

Table of Contents

TABLE OF CONTENTS Safety Procedures When Working Near Mast.................................................................................................. General ............................................................................................................................................................... Description ......................................................................................................................................................... Lowering Control Valve ................................................................................................................................. Cylinders (General) ....................................................................................................................................... Cylinders (H520-620B, H700-800A) ............................................................................................................. Retainer, Install......................................................................................................................................... Cylinders (H360-460B) .................................................................................................................................. Cylinders (Two-Speed)................................................................................................................................... Lift Cylinder Repair........................................................................................................................................... Lift Cylinder Removal Without Removing Mast.......................................................................................... Standard Masts With Main Lift Cylinder Fastened to Crossmember of Inner Mast............................ Standard and Full Free-Lift Masts With Lift Cylinder Fastened to Crosshead ................................... Masts That Have Two Cylinders, Main Lift Cylinder and Free-Lift Cylinder ...................................... Disassemble ................................................................................................................................................... Assemble ........................................................................................................................................................ Lift Cylinder Installation in Mast ................................................................................................................ Standard Masts With Main Lift Cylinder Fastened to Crossmember of Inner Mast............................ Standard and Full Free-Lift Masts With Lift Cylinder Fastened to Crosshead ................................... Chevron-Style Packing .................................................................................................................................. Chevron-Style Packing Installation on Piston......................................................................................... Chevron-Style Packing Installation in Packing Gland ........................................................................... Lift Cylinders for VISTA® Masts....................................................................................................................... Description ..................................................................................................................................................... Lowering Control Valve............................................................................................................................. Remove ........................................................................................................................................................... Disassemble ................................................................................................................................................... Assemble ........................................................................................................................................................ Install ............................................................................................................................................................. Main Lift Cylinders ................................................................................................................................... Free-Lift Cylinder ..................................................................................................................................... Lift System Leak Check .................................................................................................................................... Specifications...................................................................................................................................................... Troubleshooting..................................................................................................................................................

1 5 5 5 8 8 8 10 12 14 14 14 14 14 16 16 18 18 18 18 19 21 22 22 22 24 25 26 27 27 27 28 29 30

This section is for the following models: All Models, ExceptH8.00-12.00XM (H170-280HD) [F007, G007]; H13.00-16.00XM (H300-360HD) [E019, F019]; H10.00-12.00XM-EC (H360HD-EC) [E019, F019]; H20.00-32.00F (H440-700FS) [E008]; H36.00-48.00E (H800-1050E) [D117]; H3.50-5.50XM (H70-120XM) [K005, L005]; S3.50-5.50XM, S5.50XMS (S70-120XM, S120XMS) [E004, F004]

4000 SRM 135

Safety Procedures When Working Near Mast

Safety Procedures When Working Near Mast The following procedures must be used when inspecting or working near the mast. Additional precautions and procedures can be required when repairing or removing the mast. See the correct Service Manual section for the specific mast being repaired.

WARNING Mast parts are heavy and can move. Distances between parts are small. Serious injury or death can result if part of the body is hit by parts of the mast or the carriage. • Never put any part of the body into or under the mast or carriage unless all parts are completely lowered or a safety chain is installed. Also make sure that the power is OFF and the key is removed. Put a DO NOT OPERATE tag in the operator’s compartment. • Be careful of the forks. When the mast is raised, the forks can be at a height to cause an injury. • Do NOT climb on the mast or lift truck at any time. Use a ladder or personnel lift to work on the mast. • Do NOT use blocks to support the mast weldments nor to restrain their movement. • Mast repairs require disassembly and removal of parts and can require removal of the mast or carriage. Follow the repair procedures in the correct Service Manual for the mast.

OR 2. If parts of the mast must be in raised position, install a safety chain to restrain the moving parts of the mast. Connect moving parts to a part that does not move. Follow these procedures: a. Put the mast in a vertical position. b. Raise the mast to align the bottom crossmember of the inner weldment with a crossmember on the outer weldment. See Figure 1, Figure 2, and Figure 3. c. Use a 12 mm (0.5 in.) minimum safety chain with a hook to fasten the crossmembers together so that the movable member cannot lower. Put the hook on the back side of the mast. Make sure the hook is completely engaged with a link in the chain. Make sure the safety chain does not touch lift chains or chain sheaves, tubes, hoses, fittings or other parts on the mast. d. Lower the mast until there is tension in the safety chain. If running, stop the engine. Apply the parking brake. Install a DO NOT REMOVE tag on the safety chain(s). e. Install another safety chain 12 mm (0.5 in.) minimum between the top or bottom crossmember of the carriage and a crossmember on the outer weldment.

WHEN WORKING NEAR THE MAST ALWAYS: 1. Lower the mast and carriage completely. Push the lift/lower control lever forward and make sure there is no movement in the mast. Make sure that all parts of the mast that move are fully lowered.

3. Apply the parking brake. After lowering or restraining the mast, shut off the power and remove the key. Put a DO NOT OPERATE tag in the operator’s compartment.

Safety Procedures When Working Near Mast

1. INNER WELDMENT 2. OUTER WELDMENT

4000 SRM 135

3. HOOK 4. CARRIAGE Figure 1. Mast

4000 SRM 135

1. INNER WELDMENT 2. TILT CYLINDERS

Safety Procedures When Working Near Mast

3. HOOK Figure 2. Mast

Safety Procedures When Working Near Mast

Figure 3. Two-Stage, Free-Lift, Three-Stage, and Four-Stage Masts

4000 SRM 135

Description Legend for Figure 3

A. TWO-STAGE MAST B. FREE-LIFT MAST

C. THREE-STAGE MAST D. FOUR-STAGE MAST

1. 2. 3. 4.

5. 6. 7. 8.

OUTER WELDMENT INNER WELDMENT INTERMEDIATE WELDMENT FIRST INTERMEDIATE WELDMENT

HOOK FREE-LIFT CYLINDER CROSSMEMBER CROSSMEMBER

General This section has the description for lift cylinders used in masts and the instructions for their repair. There are many different sizes of lift cylinders used in Hyster Company lift trucks. The operation and repair procedures for the different lift cylinders are similar. The illustrations in this section are for typical

lift cylinders. All of the variations in lift cylinders used in lift trucks are not shown. A section for Lift Cylinders for VISTAÂŽ Masts is included later in this section.

Description All lift cylinders are single-acting cylinders. See Figure 4. The hydraulic force is applied only in one direction. When hydraulic oil enters one end of the lift cylinder, the hydraulic force extends the piston rod. When the force is removed, the weight of the carriage and inner mast retracts the piston rod. A common maintenance problem is the repair of oil leaks from the seals and wiper around the piston rod. If the bore of the shell of the lift cylinder is damaged and cannot be repaired, the lift cylinder must be replaced.

LOWERING CONTROL VALVE A lowering control valve is installed in the inlet port. See Figure 5. It permits easy entry of hydraulic oil into the cylinder, but gives a restriction when the rod is retracted. This restriction gives limits to the speed that a load on the forks can be lowered. There are two types of lowering control valves. Both types have the same function and similar operation. The most common type of valve has a design that has good operation using large flows and lower pressures. Some lift trucks have a lift system design using higher pressures and a lower flow. These systems need a different type of lowering control valve.

The most common type of lowering control valve uses these parts: (1) a special fitting for the valve body, (2) a spring, and (3) a special washer. There is a variation in the shapes of the special washer. Different lift cylinders use different shapes of special washers. The volume of the hydraulic oil flowing through the inlet port controls the shape of the special washer. (A typical shape of a special washer is shown in Figure 5.) When the piston rod is lowered, the oil flow pushes against the special washer and spring. When the oil flow reaches the limit, the special washer is moved against the special fitting. The oil then flows only through the hole in the center of the special washer. This restriction permits the piston rod to lower only at a maximum controlled speed. The other type of lowering control valve uses these basic parts: (1) valve body, (2) spring, (3) washer, (4) cylinder, (5) orifice sleeve, (6) plunger, and (7) main sleeve. The orifice sleeve position is controlled completely by oil flow. The plunger position is controlled by oil pressure and spring tension. During lifting, oil entering the lift cylinder goes through the center of the main sleeve to the large holes. The oil flow through the plunger and bore moves the orifice sleeve to the end of the plunger. The flange of the orifice sleeve is then aligned with the large part of the bore in the body. This alignment lets the oil flow past the orifice sleeve to the cylinder.

Description

4000 SRM 135

A. INSTALLED

B. NOT INSTALLED

1. 2. 3. 4. 5. 6.

7. 8. 9. 10. 11. 12.

LOWERING CONTROL VALVE PISTON BEARING CHECK VALVE SHELL NYLON RING

RETAINER WIPER SEAL BACKUP RING O-RING ROD SINGLE-LIP SEAL

Figure 4. Two-Speed Lift Cylinder During lowering, oil from the lift cylinder moves the orifice sleeve. The orifice sleeve moves away from the larger inner diameter area of the bore in the valve body. This movement makes a restriction to the oil flow. As the pressure increases, the plunger begins to move against the spring. The movement begins to close the openings of the large holes in the main

sleeve. Additional pressure will push the plunger against the main sleeve to close the large holes completely. All the oil must then go through the small holes to the center of the main sleeve. This restriction permits the piston rod to lower only at a maximum controlled speed.

4000 SRM 135

Description

A. LOW PRESSURE DESIGN B. LOWERING C. RESTRICTED FLOW

D. HIGH PRESSURE DESIGN E. LIFTING F. FREE FLOW

1. 2. 3. 4.

5. ORIFICE SLEEVE 6. PLUNGER 7. MAIN SLEEVE

SPECIAL FITTING OR VALVE BODY SPRING SPECIAL WASHER CYLINDER

Figure 5. Lowering Control Valves

Description

CYLINDERS (GENERAL) Standard masts use a single-stage lift cylinder. Most three-stage and four-stage masts use two single-stage lift cylinders. A single-stage lift cylinder has one piston rod. See Figure 6. Most full free-lift masts and some three-stage masts use a two-stage lift cylinder. A two-stage lift cylinder has two telescopic piston rods. See Figure 7. The two-stage lift cylinder operates similar to a one-stage lift cylinder. Hydraulic pressure pushes the primary (larger) piston rod from the cylinder first because it has a larger diameter. The secondary piston rod moves with the primary piston rod. When the primary piston rod reaches the limit of its stroke, the secondary piston rod extends from the primary piston rod. Spacers are used in some cylinders to give a limit to the stroke of the piston rod. Worn spacers must be replaced with the same size spacer. Most of the lift cylinders use a single-lip seal assembly to prevent hydraulic oil leaks past the piston and past the retainer. See Figure 4. There are many lift cylinders in use that have an older design chevron-style packing. The chevron-style packing can be replaced with a seal kit that has the newer single lip seal and an adaptor. There are no replacements of single lip seals for chevron-style packing for lift trucks over 7,000 kg (15,000 lb) capacity. Lift cylinders and other hydraulic parts can have internal leaks. Internal leakage will increase as the temperature of the hydraulic oil increases. The internal leak rate of the hydraulic system is normally checked after every 1000 hours of operation. See Lift System Leak Check for test procedures and leakage rates within the specifications. During operation, some leakage of hydraulic oil can move past the piston seal to the rod side of the piston. A small leakage is permitted if the internal leak rate of the hydraulic system is not greater than the specification. An internal check valve is installed in

4000 SRM 135 the piston of many of the lift cylinders. When the rod extends, the pressure increases more quickly on any oil in the rod end of the cylinder. The hydraulic oil transfers through the check valve to the piston end of the cylinder. This action prevents hydraulic damage to the wiper seal. See Figure 8. Lift cylinders that do not have an internal check valve have a drain line on the outside of the cylinder shell.

CYLINDERS (H520-620B, H700-800A) The rod side of the lift cylinder is used for the storage of hydraulic oil on the H520-620B and H700-800A lift trucks. This storage decreases the required size of the hydraulic tank. When the piston raises in the cylinder, the oil on the rod side of the piston transfers to the hydraulic tank. When the piston lowers in the cylinder, some of the oil transfers to the rod side of the cylinder. Approximately one half of the oil in the bottom of the cylinder goes through the main control valve to the rod side of the cylinder. See the Main Control Valve of Service Manual for more information. See Figure 9.

Retainer, Install 1. Install the retainer over the piston and into the cylinder. Make sure the single-lip seal assembly, the O-ring, and the backup ring are not damaged. See Figure 9. 2. Turn the retainer ring into the threads in the cylinder. Turn the retainer ring until it is even with the top of the cylinder. 3. Install the capscrews loosely. 4. The stroke of the cylinder rod can be adjusted by turning the retainer ring one-half turn in either direction. 5. Install and tighten the setscrew. 6. Tighten the capscrews to 36 to 46 Nâ&#x20AC;˘m (27 to 34 lbf ft).

4000 SRM 135

Description

A. MAIN LIFT CYLINDER

B. FREE-LIFT CYLINDER

1. 2. 3. 4. 5. 6. 7. 8.

9. ROD ASSEMBLY 10. SPACER 11. TO SENSING PORT FOR PHASING VALVE PRESSURE 12. LOWERING CONTROL VALVE (ALL CYLINDERS) 13. PISTON RING 14. CUSHION RING

WIPER RING SINGLE-LIP SEAL BEARING O-RING RETAINER CHAIN ANCHOR MOUNT HYDRAULIC LINE MOUNT INTERNAL CHECK VALVE

Figure 6. Single-Stage Lift Cylinders

Description

4000 SRM 135

CYLINDERS (H360-460B) The lift cylinders used in the H360-460B lift trucks are displacement cylinders. The design and repairs for these cylinders are similar to the other lift cylinder in this section. A displacement cylinder does not have a piston or piston seal. The rod diameter is almost the same as the inside diameter of the cylinder. There are wear rings on the rod that are the bearings between the rod and the walls of the cylinder. The wiper seal at the top of the cylinder is also the high-pressure seal for these cylinders. The wiper seal has chevron-style packing. See Figure 10.

1. 2. 3. 4.

WIPER RING RETAINER SEAL SCREW (DO NOT CHANGE LENGTH) 5. PRIMARY ROD ASSEMBLY 6. SPACERS 7. BEARING

8. PISTON HALF (1 OF 2) 9. INTERNAL CHECK VALVE 10. SINGLE-LIP SEAL 11. SECONDARY ROD ASSEMBLY 12. O-RING 13. PLUG

Figure 7. Two-Stage Lift Cylinder

A. INSTALLED

B. NOT INSTALLED

1. 2. 3. 4.

5. SINGLE-LIP SEAL 6. O-RING 7. NYLON BACKUP RING

POPPET SPRING SEAL INLET AND OUTLET PORT

Figure 8. Internal Check Valve and Single-Lip Seal

4000 SRM 135

Description

A. LOWERING CONTROL VALVE 1. 2. 3. 4.

SETSCREW (1) CAPSCREW (2) RETAINER RING SINGLE-LIP SEAL ASSEMBLY

5. 6. 7. 8. 9.

RETAINER BACKUP RING O-RING CYLINDER SHELL ROD

10. 11. 12. 13. 14.

SPACER PISTON PISTON RING NUT NYLON SETSCREW SPRING

15. 16. 17. 18. 19.

FLANGE SPACER PLATE SPACER VALVE BODY SPECIAL WASHER

Figure 9. Lift Cylinder for H700-800A

Description

4000 SRM 135 Legend for Figure 10 NOTE: OIL LEAKAGE IS NOT CONTROLLED BY THE TORQUE ON THE PACKING GLAND. TIGHTEN THE PACKING RETAINER TO STOP OIL LEAKS. REPLACE CHEVRON-STYLE PACKING WHEN PACKING RETAINER CANNOT COMPRESS PACKING FURTHER TO CONTROL OIL LEAKS. DO NOT TIGHTEN MORE THAN NECESSARY TO STOP OIL LEAKS. 1. WIPER 2. NYLON RING 3. CHEVRON-STYLE PACKING 4. BACKUP RING 5. O-RING 6. ROD HEAD

7. PACKING RETAINER 8. PACKING GLAND 9. CYLINDER SHELL 10. INLET AND OUTLET PORT 11. WEAR RING

CYLINDERS (TWO-SPEED) Two-speed lift cylinders are single-stage lift cylinders with a special valve and path for the hydraulic oil. The lift cylinder is filled with oil on both sides of the piston. For loads less than 45% of the rated capacity, the cylinder rod can be extended at high speed. When the cylinder rod extends, the oil on the rod side of the piston transfers to the bottom of the piston. When the oil transfers, the increase almost doubles the flow of oil to the base of the cylinder. The pump pressure is applied to both sides of the piston. The area on the bottom of the piston is greater than the rod side of the piston. The difference in force pushes the piston up the cylinder. See Figure 11. For loads greater than 45% of capacity, the cylinder rod extends at normal speed. A special valve senses the increased oil pressure caused by the load. The oil is returned from the rod side of the lift cylinder to the hydraulic tank. All of the pump pressure is applied to the bottom side of the piston. The cylinder rod extends at a slower speed, but can lift a greater load. The two-speed lifting system is used only with standard masts. A two-speed lift system is used on the following lift trucks:

Figure 10. Displacement Cylinders

S60-80B

H150-250E

S125-150A

H150-275H

H60-80C

H250-300A

H300-350B

P125-180A

H110-150F

P150-200B

4000 SRM 135

Description

A. HIGH-SPEED OPERATION FOR NO LOAD OR LIGHT LOADS B. NORMAL OPERATION FOR RATED CAPACITY LOAD OR HEAVY LOADS 1. FORCE 2. FROM HYDRAULIC PUMP

3. GREATER LIFTING FORCE 4. TO HYDRAULIC TANK Figure 11. Two-Speed Lift Cylinders

NOTE: The maximum loads that the above models will lift at high speed are shown on Table 1. Table 1. Lift Trucks with Two-Speed Lift Cylinders Model

Load

S60-100B

1589 to 2043 kg (3500-4500 lb)

H60-80C

1589 to 2043 kg (3500 to 4500 lb)

H110-150F

1589 to 2043 kg (3500 to 4500 lb)

S125-150A

2270 to 2724 kg (5000 to 6000 lb)

H150-200ES, Standard Masts

2270 to 3087 kg (5000 to 6800 lb)

P125-180A, Standard Masts

2270 to 3087 kg (5000 to 6800 lb)

H150-250E, Heavy Duty Masts

3133 to 4041 kg (6900 to 8900 lb)

P125-180A, Heavy Duty Masts

3133 to 4041 kg (6900 to 8900 lb)

H250-300A

4540 to 4994 kg (10,000 to 11,000 lb)

This table shows the approximate maximum load that the mast will lift at high speed. Loads greater than those shown will cause the mast to lift at normal speed. These loads will have a variation because of the different attachments that can be installed on the lift truck.

Lift Cylinder Repair

4000 SRM 135

Lift Cylinder Repair LIFT CYLINDER REMOVAL WITHOUT REMOVING MAST

7. Remove the capscrew and the plate from the lower side of the cylinder.

Remove the carriage before the lift cylinder. See the procedure described in the Masts section. If the mast must be removed for repairs, then remove the lift cylinder when the mast is disassembled. Remove the lift cylinder from the mast as described in the following paragraphs.

8. Raise the cylinder and move it away from the mast. Move the lift cylinder to a position where it can be disassembled.

Standard Masts With Main Lift Cylinder Fastened to Crossmember of Inner Mast

1. Remove the lift chains and chain anchors from the mast and the lift cylinder. Connect a sling to the upper area of the lift cylinder. Raise the lifting mechanism until the sling is tight. See Figure 12 and Figure 13.

1. Fully lower the mast. Loosen, but do not disconnect the capscrew that fastens the cylinder rod to the crossmember of the inner mast. 2. Clean the area next to the fittings that connect the hydraulic lines to the lift cylinder. Put a drain pan under the area where the hydraulic lines will be disconnected. Disconnect the hydraulic lines and put a cap on each open fitting.

WARNING Make sure the lifting mechanism has enough capacity to lift the loads. See the Weight Guide for lift cylinders in Table 2. 3. Connect a lifting mechanism to the inner mast. Lift the inner mast approximately 300 mm (12 in.). Fasten the inner and outer masts together at the crossmembers with a heavy chain. Make sure that the inner mast cannot move. Remove the lifting mechanism. 4. Connect a heavy-duty sling to the upper part of the cylinder. Raise the lifting mechanism until the sling is tight. Make sure the sling will not slide. 5. Remove the capscrew and washer connecting the piston rod to the inner mast. Remove the spacer.

CAUTION Oil can come out of the cylinder fittings with pressure when retracting the rod. 6. Loosen the cap on the lower fitting of the cylinder. Manually retract the piston rod.

Standard and Full Free-Lift Masts With Lift Cylinder Fastened to Crosshead

2. Remove the capscrews that connect the piston rod to the crosshead. 3. Disconnect and remove the crosshead assembly from the mast. Make a note of the shim arrangement on the crosshead guide. 4. Clean the area next to the fittings that connect the hydraulic lines to the lift cylinder. Put a drain pan under the area where the hydraulic lines will be disconnected. Disconnect the hydraulic lines and put a cap on each open fitting. 5. Remove the snap ring that connects the bottom of the lift cylinder to the outer mast. 6. Raise the lift cylinder and move it away from the mast. Move the lift cylinder to a position where it can be disassembled.

Masts That Have Two Cylinders, Main Lift Cylinder and Free-Lift Cylinder 1. Remove the free-lift cylinder as described in the section above for removing a lift cylinder fastened to a crosshead. 2. Remove the main lift cylinder as described in the section above for removing a lift cylinder fastened to an inner mast.

4000 SRM 135

Lift Cylinder Repair

1. 2. 3. 4. 1. CHAIN GUARD 2. CROSSHEAD ASSEMBLY 3. SNAP RING 4. SHEAVE 5. BEARING

6. 7. 8. 9. 10. 11.

CHAIN ANCHOR SPECIAL WASHER LOCK NUT SPACER WEAR PLATE PAD

SHEAVE SNAP RING CROSSHEAD CYLINDER GUIDE ASSEMBLY

5. 6. 7. 8. 9.

CHAIN ANCHOR WASHER AND NUT SHIM GUIDE SHOE BEARING

Figure 13. Free-Lift Cylinder and Crosshead

Figure 12. Standard Mast Cylinder and Crosshead

Lift Cylinder Repair

DISASSEMBLE WARNING Use slings and a crane to handle and disassemble the lift cylinders of most lift trucks. Make sure that the crane and slings can lift the load. See Table 2.

CAUTION

4000 SRM 135 The spacers control the maximum stroke of the piston rod assembly. If a new spacer is necessary, make sure the same size spacer is installed. 1. Install the internal check valve. Make sure the arrow on the internal check valve is toward the base of the piston.

CAUTION

Carefully disassemble and assemble the lift cylinders so that the rods and sliding surfaces are not damaged.

A difficult and important step in assembling cylinders is the correct installation of the seals without damage. Most cylinder maintenance is caused by seal leakage.

NOTE: Disassembly of single-stage and two-stage lift cylinders is the same except the two-stage lift cylinder has a second piston rod assembly. The disassembly of the secondary piston rod assembly is similar to the disassembly of the primary piston rod assembly.

2. Install the seal and bearing (and spacer if equipped) on the rod piston. Use shim material and a band clamp as a guide to move the single-lip seal past the threads of the shell.

1. Loosen the retainer with a spanner. Disconnect the retainer from the shell. See Figure 14 and Figure 15. 2. Remove the cap from the inlet and slide the piston rod assembly from the shell. Use drain pans for the hydraulic oil. 3. Remove the retainer from the piston rod. Remove and discard the O-rings, seals, and bearings. 4. Remove the internal check valve. 5. Remove the lowering control valve. 6. Clean all the parts. Check the sliding surfaces for damage. Repair or replace any damaged parts.

ASSEMBLE NOTE: Lubricate all internal parts of the lift cylinder with hydraulic oil during assembly. Use new O-rings, seals and bearings. Apply lubricant during assembly. Packing lubricant (Part Number 186061) is available. Make sure the single-lip seal assemblies are installed with the O-ring toward the base of the lift cylinder. See Figure 8.

3. Carefully push piston and piston rod into the shell. Release the band clamp on the seal when the seal travels past the threads of the shell. 4. Install the seals, O-rings, and bearings (when used) in the retainer. If the wiper seal has a spring backup ring, the spring must be toward the base of the lift cylinder. 5. Carefully install the retainer on the piston rod. 6. Engage the threads and tighten the retainer in the shell to the correct torque. Use a correct spanner. Do not hit the retainer with a hammer and driver.

CAUTION When the screw is installed on two-stage cylinders, never use a screw longer than 9.5 mm (0.375 in.). A longer screw will touch and damage the primary piston rod. Always install a seal under the head of the screw. If you do not install the screw and seal, the cylinder will have leaks. 7. Install the lowering control valve. Make sure the special washer and the spring are installed correctly. A wrong installation can cause the load to lower too fast.

4000 SRM 135

1. 2. 3. 4. 5. 6.

Lift Cylinder Repair

7. 8. 9. 10. 11. 12.

PLUG O-RING RETAINER WIPER RING SINGLE-LIP SEAL BEARING

O-RING CYLINDER SHELL CYLINDER ROD SPACER INTERNAL CHECK VALVE O-RING

13. 14. 15. 16. 17.

WASHER SNAP RING BACKUP RING SINGLE-LIP SEAL BEARING

Figure 14. Single-Stage Lift Cylinder

1. 2. 3. 4. 5. 6. 7. 8.

PLUG RETAINER BEARING O-RING SINGLE-LIP SEAL WIPER RING RETAINER SECONDARY CYLINDER ROD

9. 10. 11. 12. 13. 14. 15. 16.

SPACER BEARING SINGLE-LIP SEAL BACKUP RING PRIMARY CYLINDER ROD SPACER O-RING PISTON RING HALF (2)

17. 18. 19. 20. 21. 22.

SNAP RING WASHER INTERNAL CHECK VALVE CYLINDER SCREW SEAL

Figure 15. Two-Stage Lift Cylinder

Lift Cylinder Repair

LIFT CYLINDER INSTALLATION IN MAST Standard Masts With Main Lift Cylinder Fastened to Crossmember of Inner Mast 1. Put the lift cylinder into position in the mast. Make sure the base of the lift cylinder is aligned correctly on its mount. 2. Connect a chain to the upper section of the lift cylinder and the overhead guard. Make sure the chain will hold the lift cylinder in position until it can be fastened to the mast. 3. Connect a lifting mechanism to the inner mast.

CAUTION Do not connect a wrench to the sliding surface of the piston rod. Any damage to the sliding surface will cause leaks. 4. Disconnect the inner mast from the outer mast. Lower the inner mast until it touches the piston rod. Align the holes of the inner mast and the piston rod. 5. Install capscrews, washer, and spacer to fasten the lift cylinder to the crossmember of the inner mast. 6. Fasten the base of the lift cylinder to the crossmember of the outer mast with a capscrew and plate. 7. Connect the hydraulic lines. 8. Install the carriage.

Standard and Full Free-Lift Masts With Lift Cylinder Fastened to Crosshead 1. Put the lift cylinder into position in the mast. Align the guide pin with the hole in the bottom crossmember.

4000 SRM 135 2. Install the crosshead assembly in the mast. Align the holes in the piston rod and the crosshead. 3. Fasten the crosshead to the piston rod with capscrews. 4. Fasten the base of the lift cylinder to its mount with a snap ring. 5. Connect the hydraulic lines. 6. Install the chain anchors. 7. Install the lifting chains. 8. Install the carriage. See masts section for checks and adjustments.

CHEVRON-STYLE PACKING The replacement seal kits for chevron-style packing have a single-lip seal and an aluminum spacer. The seal kits also have one or two backup rings. If one backup ring is in the seal kit, install it as shown in B of Figure 16. Two backup rings are installed as shown in C of Figure 16. Make sure the single-lip seal is always installed correctly against the direction of pressure. The installation of chevron-style packing on a piston is shown in Chevron-Style Packing Installation on Piston. The installation of chevron-style packing in a packing gland nut used at the top of the cylinder is shown in Chevron-Style Packing Installation in Packing Gland. There will be some variation in the design of the different lift cylinders. The principles of installation of the chevron-style packing is similar. Lubricate the parts with hydraulic oil or packing lubricant (Part No. 186061) before assembly.

4000 SRM 135

Lift Cylinder Repair

A. MANY EARLIER PRODUCTION LIFT TRUCKS WITH LESS THAN 7000 kg (15,000 lb) CAPACITY THAT HAVE CHEVRON-STYLE PACKING CAN BE CHANGED TO SINGLE-LIP SEALS. B. THE PARTS ARE INSTALLED IN THE ARRANGEMENT SHOWN. C. IF TWO BACKUP RINGS ARE IN THE SEAL KIT, THE PARTS ARE INSTALLED IN THE ARRANGEMENT SHOWN. 1. CHEVRON-STYLE PACKING 2. ALUMINUM SPACER

3. BACKUP RING 4. SINGLE-LIP SEAL ASSEMBLY

5. DIRECTION OF OIL PRESSURE

Figure 16. Chevron-Style Packing Replacement Seal Kits

Chevron-Style Packing Installation on Piston STEP 1. Lubricate the new O-ring with hydraulic oil and then install it on the piston end of the cylinder rod.

STEP 2. Install a new packing assembly on the piston half. The packing must extend approximately 3 mm (1/8 in.) beyond the end of the piston half.

1. THIS RING MUST EXTEND 3 mm (1/8 in.) BEYOND END OF PISTON HALF.

Lift Cylinder Repair

4000 SRM 135

STEP 3. Install the piston half and snap ring.

STEP 4. Install the nylon spacer.

STEP 5. Install the piston in the lift cylinder. Carefully push the piston and piston rod into the lift cylinder. Release the clamp on the packing when the packing moves past the threads of the cylinder.

1. PISTON 2. SPECIAL TOOL OR BAND CLAMP TO INSTALL PACKING

4000 SRM 135

Lift Cylinder Repair

Chevron-Style Packing Installation in Packing Gland STEP 1. Assemble the packing gland nut using new packing, O-ring, and backup ring.

1. PACKING ASSEMBLY 2. BACKUP RING 3. O-RING

4. PACKING RING MUST EXTEND 3 mm (1/8 in.) BEYOND EDGE OF BUSHING.

STEP 2. Assemble the gland nut using a new O-ring, backup ring, and inner seal.

NOTE: Install inner seal (if equipped). STEP 3. Install the bushing assembly and gland nut assembly in the rod.

Lift Cylinders for VISTA速 Masts

4000 SRM 135

STEP 4. Install a new wiper ring and spring on the retainer. Install the retainer against the packing gland nut. Lightly hit the retainer to move against the internal threads in the cylinder shell. Use a spanner to tighten the retainer.

1. O-RING

Lift Cylinders for VISTA速 Masts DESCRIPTION All lift cylinders for Vista速 masts are single-action hydraulic cylinders. The hydraulic force is applied only in one direction. When hydraulic oil enters one end of the lift cylinder, the hydraulic force extends the piston rod. When the force is removed, the weight of the carriage and inner mast causes the piston rod to retract. The most common maintenance problem is the repair of oil leaks. If the bore of the shell of the lift cylinder is damaged and cannot be repaired, the lift cylinder must be replaced. VISTA速 two-stage, three-stage, and four-stage masts have two main lift cylinders. The free-lift mast has two main lift cylinders and a shorter free-lift cylinder. See Figure 17 and Figure 18. Spacers are used in some cylinders to limit the stroke of the piston rod. Worn spacers must be replaced with the same size spacer. The free-lift cylinder has a single-lip seal on the piston to prevent hydraulic oil leaks past the piston and

retainer. The piston rod is a smaller diameter than the piston. During operation, some hydraulic oil will leak past the piston area to the rod end of the lift cylinder. Small leaks are permitted if the internal leak rate of the hydraulic system is not greater than the specification. An internal check valve is installed in the piston of the free-lift cylinders. When the piston rod extends, the pressure increases more quickly on any oil in the rod end of the lift cylinder. The hydraulic oil transfers through the check valve to the piston end of the free-lift cylinder. This action prevents hydraulic damage to the single lip seal and the wiper ring. See Figure 19.

Lowering Control Valve A lowering control valve is installed in the hydraulic line to the bases of the lift cylinders. See Figure 20. The lowering control valve permits easy entry of hydraulic oil into the cylinders, but gives a restriction when the rods retract. This restriction controls the

Lift Cylinders for VISTAÂŽ Masts

4000 SRM 135 maximum speed at which a load on the forks can be lowered. The lowering control valve prevents a load

on the forks from freely falling if a hydraulic hose breaks.

Figure 17. VistaÂŽ Masts Typical Lift Cylinders

Lift Cylinders for VISTAÂŽ Masts

4000 SRM 135 Legend for Figure 17

1. 2. 3. 4. 5.

SHELL BEARING PISTON PISTON ROD SNAP RING

6. 7. 8. 9. 10.

1. 2. 3. 4. 5. 6. 7.

SNAP RING INNER PISTON BEARING SINGLE-LIP SEAL BACKUP RING SPACER ROD

8. 9. 10. 11. 12.

WASHER INNER PISTON CHECK VALVE O-RING SINGLE-LIP SEAL

SHELL O-RING BACKUP RING SEAL RING RETAINER [TIGHTEN 340 to 410 Nâ&#x20AC;˘m (250 to 300 lbf ft)] 13. WIPER SEAL

11. BACKUP RING 12. WIPER SEAL 13. RETAINER

14. PISTON 15. 7.9 mm (0.31 in.) DIAMETER HOLE 16. WRENCH FLATS

Figure 18. Free-Lift Mast Main Lift Cylinder The lowering control valve includes the following parts: (1) valve body, (2) spring, (3) washer, (4) cylinder, (5) orifice sleeve, (6) plunger, and (7) main sleeve. The orifice sleeve position is controlled by oil flow. The plunger position is controlled by oil pressure and spring tension. During lifting, oil entering the lift cylinder goes through the center of the main sleeve to the large holes. The oil continues between the plunger and bore to move the orifice sleeve to the end of the plunger. The flange of the orifice sleeve is then aligned with the large part of the bore in the body. This alignment lets the oil flow around the orifice sleeve to the inlet port of the lift cylinder. During the lowering operation, oil from the lift cylinder moves the orifice sleeve. The sleeve moves away from the larger area of the bore in the valve body. This movement makes a restriction to the oil flow. When the pressure increases, the plunger begins to move against the spring. The movement begins to close the openings of the large holes in the main sleeve. Additional pressure will push the plunger against the main sleeve to close the large

holes completely. All the oil must go through the small holes to the center of the main sleeve. This restriction permits the piston rod to lower only at a maximum controlled speed.

REMOVE NOTE: Remove the carriage before removing the lift cylinder. See the procedure described in the Masts section. If the mast assembly must be removed for repairs, then remove the lift cylinders when the mast assembly is disassembled. When only the lift cylinders must be removed for repairs, then remove the lift cylinders from the mast as described in the following paragraphs. 1. Clean the area around the hydraulic fittings for the lift cylinders. Disconnect the fittings at the lift cylinders and put caps on the open lines. 2. On the free-lift mast, remove the capscrews, washers, and cylinder clamp from the mount for the free-lift cylinder. Remove the free-lift cylinder.

Lift Cylinders for VISTAÂŽ Masts

4000 SRM 135 3. Remove the snap rings and washers from the top of each main lift cylinder. Remove the cylinder clamps near the top of each lift cylinder. Each cylinder clamp is fastened to the top crossmember of the inner mast by two capscrews and washers. 4. Support the cylinder. Connect a crane to the top of the inner mast using chains. Raise the inner mast from the outer mast approximately 30 cm (12 in.). Disengage the piston rod ends of lift cylinders from the top crossmember of the inner mast. Remove the lift cylinders from the mount plates at the bottom of the outer mast.

DISASSEMBLE WARNING Use slings and a crane to handle and disassemble the lift cylinders of most lift trucks. Make sure that the crane and slings can lift the load correctly. See Table 2 for weight guide.

CAUTION Carefully disassemble and assemble the lift cylinders so that the piston rods and sliding surfaces are not damaged. NOTE: Disassembly of the main lift cylinders and the free-lift cylinder is similar. All of the lift cylinders are disassembled from the rod end of the cylinder shell. 1. Loosen the retainer with a spanner. Disconnect the retainer from the shell. 2. Remove the protective cap from the inlet and slide the rod and piston assembly from the shell. Drain the hydraulic oil into a container. NOTE: To remove the retainer, the piston rod and piston assembly must be disassembled if the lift cylinder is the type shown in Figure 18. Use the following procedure: a. Put a round bar through the 7.9 mm (0.31 in.) hole in the piston. Hold the rod in a vise or clamp so that it does not turn. Use the round bar and turn the threaded piston from the piston rod. b. If an adhesive was used on the threaded rod and piston, heat the rod to a maximum of 170 to 225 C (300 to 400 F) to loosen the adhesive.

A. INSTALLED

B. NOT INSTALLED

3. Remove the retainer from the piston rod. Remove and discard the O-rings, seals, and bearings.

1. PISTON AND ROD ASSEMBLY 2. CHECK VALVE 3. O-RING

4. INLET AND OUTLET PORT 5. SINGLE-LIP SEAL 6. O-RING 7. BACKUP RING

4. Remove the internal check valve from the base of the lift cylinder.

Figure 19. Internal Check Valve and Single-Lip Seal

5. Clean all the parts. Check the sliding surfaces for damage. Repair or replace any damaged parts.

Lift Cylinders for VISTA® Masts

4000 SRM 135

ASSEMBLE NOTE: • Lubricate all internal parts of the lift cylinder with hydraulic oil during assembly. • Use new O-rings, seals, and bearings. Apply lubricant (hydraulic oil) during assembly. Packing lubricant (Part No. 186061) is also available. • Make sure the single-lip seal assemblies are installed with the O-ring toward the base of the lift cylinder. (See Figure 19.)

CAUTION A difficult and important step in assembling lift cylinders is the correct installation of the seals. Most lift cylinder maintenance is caused by seal leaks. 1. Install the internal check valve, if installed. Make sure the arrow on the internal check valve is toward the base of the piston.

2. Install the wear ring, single lip seal, and backup ring onto the piston assembly. If a spacer sleeve is used, install it. Use shim material and a clamp as a guide to move the single-lip seal over the threads of the shell. 3. Carefully push the piston and rod assembly into the shell. Release the clamp on the seal when the seal travels past the threads of the shell. NOTE: When a main lift cylinder of the type shown in Figure 18 is assembled, use the following procedure: a. Install the seal ring and wiper ring into the retainer. Assemble the retainer onto the piston rod. b. Install the piston to the threaded part of the piston rod. Use a round bar through the hole in the piston and tighten the piston to the piston rod. Hold the piston rod in a vise or clamp by the two flats on the top end of the piston rod.

A. FREE FLOW B. LIFTING

C. RESTRICTED FLOW D. LOWERING

1. 2. 3. 4.

5. ORIFICE SLEEVE 6. PLUNGER 7. MAIN SLEEVE

VALVE BODY SPRING WASHER CYLINDER

Figure 20. Lowering Control Valve

4000 SRM 135 NOTE: Do not use an adhesive on the threads of the piston rod and piston. 4. Install the seal, O-ring, wear ring, and wiper ring in the retainer. If the wiper seal has a spring for a backup ring, the spring must be toward the base of the lift cylinder. 5. Carefully install the retainer on the piston rod. 6. Engage the threads and tighten the retainer in the shell until it is tight. Use a correct spanner. Do not hit the retainer with a hammer and driver. 7. Install the lowering control valve. Make sure the special washer and the spring are installed correctly. A wrong installation can cause the load to lower too fast.

Lift Cylinders for VISTAÂŽ Masts of the inner mast. Install the washers and snap rings, or other locking device, at the top of the lift cylinders. Install the cylinder clamps near the top of each cylinder. Fasten the clamps, if used, to the top crossmember of the outer mast with the capscrews and washers. 2. Install the lowering control valve on the outer mast. Connect the hydraulic lines and fittings between the lowering control valve and the lift cylinders. 3. Install the chain sheaves and brackets. Connect the lift chains to the chain anchors on the inner mast. Fasten wires between the ends of the lift chains so that they can be controlled during installation of the carriage. 4. Install the carriage. Connect the lift chains.

INSTALL

Free-Lift Cylinder

Main Lift Cylinders

1. When the inner mast is lowered, install the freelift cylinder in the inner mast. A pin in the base of the lift cylinder will fit into the cylinder mount at the base of the inner mast. Fasten the upper end of the cylinder to the center crossmember with the bracket, washers, and capscrews. Install the chain sheave and brackets to the top of the free-lift piston rod.

WARNING Connect slings and a crane to the top of the inner mast [and intermediate mast(s), if it is a 3-stage (4-stage) mast] using chains. If it is a 3-stage mast, make sure that all masts are fastened together. Make sure that the chains will not damage the sheaves, tubing or other parts of the mast. Make sure the crane and slings can lift the load correctly. See Table 2 for weight guide. 1. Install the main lift cylinders to the mounts at the base of the outer mast. Use a crane and lower the inner mast to engage the piston rods of the lift cylinders to the holes in the top crossmember

2. Install the tubes and fittings at the bottom of the main lift cylinders. Install the lowering control valve. Install the hydraulic fitting in the end of the rod at the top of the left main cylinder. Install the tube between the top of the main lift cylinder and the base of the free-lift cylinder. 3. Install the carriage. Install the lift chain.

Lift System Leak Check

4000 SRM 135

Lift System Leak Check WARNING Never allow anyone under a raised carriage. Do not put any part of your body through the lift mechanism unless all parts of the mast are completely lowered and the engine is stopped. Before making any repairs, use blocks and chains on the mast and carriage so that they cannot move. Make sure the moving parts are attached to the parts that cannot move. Do not try to find hydraulic leaks by putting hydraulic components under pressure. Hydraulic oil can be injected into the body by pressure.

neutral position, there are leaks inside the hydraulic system. The maximum speed that the carriage is allowed to lower is 50 mm (2 in.) per 10 minutes when the hydraulic oil is 30 C (90 F). If the oil temperature is 70 C (160 F), the maximum speed that the carriage can lower is 150 mm (6 in.) per 10 minutes. 3. Check the lift cylinder for internal leaks. Remove the load from the forks. Install a gate valve in the supply line between the main control valve and the mast. Put a capacity load on the forks again. Raise the carriage 1 m (3 ft). Close the gate valve. If the carriage or mast lower slowly, the seals in the lift cylinders have leaks.

During the test procedures for the hydraulic system, fasten the load to the carriage with chains to prevent it from falling. Keep all personnel away from the lift truck during the tests.

4. If the carriage does not move, open the gate valve and check the movement again. If the carriage lowers when the gate valve is open, check for leaks in the hydraulic lines and fittings. If no leaks are found, the main control valve can have a defect. Remove the load from the forks.

1. Operate the hydraulic system. Put a capacity load on the forks and raise and lower the load several times. Lower the load and tilt the mast forward and backward several times. Check for leaks.

NOTE: See the procedures in the mast repair sections for lift chain adjustments, mast adjustments, carriage adjustment, and header hose roller adjustment.

2. Raise the carriage and the load 1 m (3 ft). If the carriage lowers slowly with the control valve in a

4000 SRM 135

Specifications

Specifications Table 2. Cylinder Retainer Torque Specifications and Weight Guide Rod Diameter

Typical Outer Retainer Torque Values

Nâ&#x20AC;˘m

in.

Lifting Mechanism

lbf ft

One-Stage Cylinders for Lift Trucks with Less than 7000 kg (15,000 lb) Capacity 57.2

2.25

373-441

275-325

63.5

2.50

203-271

150-200

69.9

2.75

373-441

275-325

76.2

3.00

407-475

300-350

81.3

3.20

407-475

300-350

88.9

3.50

475-452

350-400

101.6

4.00

407-475

300-350

114.3

4.50

610-678

450-500

Use crane and slings with at least 500 kg (1000 lb) capacity to lift the cylinder.

One-Stage Cylinders for Lift Trucks with More than 7000 kg (15,000 lb) Capacity 108.0

4.25

113.4

5.25

241.3

9.50

254.0

10.00

Tighten retainer or packing gland nut. Oil leakage is not controlled by the torque on the retainer.

Use crane and slings with at least 1000 kg (2000 lb) capacity to lift the cylinder.

Use crane and slings with at least 2000 kg (4000 lb) capacity to lift the cylinder.

Two-Stage Cylinders for Lift Trucks with Less than 5000 kg (10,000 lb) Capacity 82.6

3.25

373-509

325-375

95.3

3.75

271-305

200-225

101.6

4.00

271-339

200-250

114.3

4.50

339-407

250-300

122.0

5.00

407-475

300-350

Use crane and slings with at least 500 kg (1000 lb) capacity to lift the cylinder.

Inner retainer torque value is 122 Nâ&#x20AC;˘m (90 lbf ft).

Troubleshooting

4000 SRM 135

Troubleshooting PROBLEM No movement of lift cylinders or tilt cylinders.

Slow movement of lift or tilt cylinders.

Rough movement of the mast assembly.

POSSIBLE CAUSE

PROCEDURE OR ACTION

Pilot line(s) to control valve are disconnected or leaking.

Tighten or connect fittings.

No oil or not enough oil in the hydraulic tank.

Fill tank. Check for leaks.

Relief valve(s) not set correctly.

Adjust or install new relief valve.

Hydraulic pump does not operate or has damage.

Repair or install new pump.

Remote control valve does not operate.

Check and repair valve.

No oil or not enough oil to lift or tilt cylinders.

Fill tank. Check for leaks.

Cylinders have internal or external leaks.

Repair leaks. Install new parts.

Relief valve is not set correctly.

Adjust or install new relief valve.

There is a restriction in a hydraulic line.

Remove restriction. parts.

Load is more than capacity.

Reduce load.

There is air in the hydraulic system.

Remove air. Check for loose connections or breaks in lines.

Lift cylinder(s) is damaged.

Repair or install new lift cylinder.

Mast weldments are damaged or not aligned.

Align weldments. Install new parts.

Mast weldments are not lubricated.

Lubricate correctly.

Load rollers or bearing blocks are damaged or not adjusted correctly.

Repair or adjust the parts.

Lift chains are damaged.

Replace lift chains.

Install new

LPG FUEL SYSTEM H3.50-5.00XL (H70-110XL) [G005]; H6.00-7.00XL (H135-155XL) [F006]; S3.50-5.50XL (S70-120XL) [D004]; S6.00-7.00XL (S135-155XL) [B024]; S3.50-5.50XM (S70-120XM) [E004]

PART NO. 897129

900 SRM 348

LPG Fuel System

Table of Contents

TABLE OF CONTENTS General ............................................................................................................................................................... Description and Operation ................................................................................................................................ Fuel Tank ....................................................................................................................................................... Fuel Filter and Fuel Valve Unit.................................................................................................................... Vaporizer ........................................................................................................................................................ Carburetor...................................................................................................................................................... Governor......................................................................................................................................................... LPG Tank Repair ............................................................................................................................................... Remove ........................................................................................................................................................... LPG Tanks with Fixed Mounting Bracket ............................................................................................... LPG Tanks with EZ Lift Mounting Bracket ............................................................................................ Install ............................................................................................................................................................. LPG Tanks with Fixed Mounting Bracket ............................................................................................... LPG Tanks with EZ Lift Mounting Bracket ............................................................................................ Hydrostatic Relief Valve Repair ........................................................................................................................ Remove and Install........................................................................................................................................ Filter Unit Repair .............................................................................................................................................. Fuel Filter Element, Replace ........................................................................................................................ Diaphragm and Fuel Valve, Replace ............................................................................................................ Hoses Replacement ............................................................................................................................................ Vaporizer Repair ................................................................................................................................................ Remove ........................................................................................................................................................... Disassemble ................................................................................................................................................... Clean .............................................................................................................................................................. Inspect ............................................................................................................................................................ Assemble ........................................................................................................................................................ Install ............................................................................................................................................................. Carburetor Repair.............................................................................................................................................. Remove ........................................................................................................................................................... Disassemble ................................................................................................................................................... Clean .............................................................................................................................................................. Assemble ........................................................................................................................................................ Install ............................................................................................................................................................. Governor Repair................................................................................................................................................. Filter Unit Check ............................................................................................................................................... Vaporizer Check ................................................................................................................................................. Pressure Reducer Valve................................................................................................................................. Vapor Valve .................................................................................................................................................... Carburetor Adjustment ..................................................................................................................................... Idle Mixture ................................................................................................................................................... Idle Speed....................................................................................................................................................... Power Mixture ............................................................................................................................................... Throttle Linkage Adjustment............................................................................................................................ Troubleshooting..................................................................................................................................................

ÂŠ2002 HYSTER COMPANY

1 3 3 4 5 6 8 9 9 9 9 10 10 11 12 12 12 12 12 14 14 14 14 14 14 16 19 20 20 20 20 20 20 21 23 23 23 23 23 23 23 24 24 26

Table of Contents

LPG Fuel System

TABLE OF CONTENTS (Continued) This section is for the following models: H3.50-5.00XL (H70-110XL) [G005]; H6.00-7.00XL (H135-155XL) [F006]; S3.50-5.50XL (S70-120XL) [D004]; S6.00-7.00XL (S135-155XL) [B024]; S3.50-5.50XM (S70-120XM) [E004]

900 SRM 348

General

General This section has the description, operation, and repair procedures for the parts of the LPG fuel system used on the GM V-6 engines. See Figure 1.

1. 2. 3. 4. 5.

FUEL TANK CARBURETOR BALANCE LINE GOVERNOR FUEL VALVE ON TANK

6. 7. 8. 9. 10.

HYDROSTATIC RELIEF VALVE TO COOLING SYSTEM VAPORIZER (IMPCO) FILTER UNIT VACUUM LINE

General

900 SRM 348

11. TO PCV VALVE Figure 1. LPG System

900 SRM 348

Description and Operation

Description and Operation The LPG fuel system (see Figure 1) has the following parts: • Fuel Tank with Hydrostatic Relief Valve • Fuel Filter and Fuel Valve Unit • Vaporizer (IMPCO) • Carburetor • Governor

FUEL TANK The fuel tank is the reservoir for the LPG system. See Figure 2 and Figure 3.

NOTE: SOME LPG TANKS HAVE AN AUXILIARY FILL FITTING INSTEAD OF A PLUG FOR ITEM 4. NOTE: FIXED MOUNTING BRACKET SHOWN. 1. SHUT-OFF VALVE 2. QUICK-DISCONNECT FITTING 3. FUEL GAUGE 4. PLUG 5. LIQUID LEVEL INDICATOR

6. RELIEF VALVE 7. ALIGNMENT PIN 8. TANK RELIEF VALVE 9. TANK LATCH 10. MOUNTING BRACKET

Figure 3. LPG Tank

A. HIGH-PRESSURE LIQUID FUEL B. LOW-PRESSURE VAPORIZED FUEL C. VACUUM 1. FUEL TANK 2. HYDROSTATIC RELIEF VALVE 3. FILTER UNIT (WITH FUEL VALVE) 4. ENGINE COOLING SYSTEM 5. VAPORIZER

6. CARBURETOR 7. GOVERNOR 8. INTAKE MANIFOLD FOR ENGINE 9. VACUUM ADVANCE LINE FOR DISTRIBUTOR

Figure 2. LPG System Schematic

The fuel tank keeps the fuel in the liquid condition. The pressure of the fuel is 1.7 MPa (240 psi) when the tank is full at an ambient temperature of 27 C (81 F). The tank has a pressure relief valve that is set at 3.4 MPa (480 psi). The inlet tube for the pressure relief valve is in the vapor area at the top of the tank. The tank has a fuel gauge that measures the percentage of fuel that is in the tank. A liquid level valve near the pressure relief valve is used to indicate the maximum liquid level that is permitted. The tank is filled until liquid fuel flows from the liquid level valve. One end of the outlet tube inside the tank is near the lower surface of the tank. The other end of the tube is fastened to the outlet port. A fuel valve is connected to the outlet port of the tank. The fuel valve can prevent fuel from leaving the tank when the outlet line is disconnected. A quick disconnect fitting is installed for easy tank removal. The tank has a guard to protect the valves and fittings from damage. The guard has a hole for the alignment dowel on the mount. The tank is fastened to the lift truck by metal straps with latches.

Description and Operation

900 SRM 348

FUEL FILTER AND FUEL VALVE UNIT A fuel line connects the fuel tank to the fuel filter. See Figure 4. The fuel filter prevents dirt from entering the vaporizer and has a fuel valve that is operated by engine vacuum. The fuel valve prevents fuel from entering the vaporizer unless the engine is being started or is running. The fuel valve has a leaf spring that holds a polyurethane pad against the seat. A diaphragm is used to open the fuel valve. Air

1. 2. 3. 4. 5. 6. 7. 8. 9.

DIAPHRAGM FULCRUM VACUUM INLET O-RING WASHER PIN FUEL OUTLET VALVE PAD FILTER COVER

pressure pushes on the vent side of the diaphragm. The other side of the diaphragm has inlet manifold vacuum and a lever and plunger that open the fuel valve. When the engine starts, the air pressure on the lever side of the diaphragm decreases. Then the air pressure on the vent side of the diaphragm moves the diaphragm, lever and pin to move the valve pad from the seat. Liquid LPG then flows through the fuel valve to the vaporizer.

10. 11. 12. 13. 14. 15. 16. 17.

FILTER ELEMENT AND SCREEN FUEL INLET LEAF SPRING GASKET BODY DIAPHRAGM COVER AIR INLET LEVER

Figure 4. Fuel Filter and Fuel Valve

900 SRM 348

VAPORIZER The function of the vaporizer is to change the liquid fuel to a vapor (gas) and to control the pressure of the vapor. See Figure 5 and Figure 6. The LPG fuel changes from a liquid to a vapor inside the expansion chamber. A liquid needs heat to change to a gas. Heat is removed from the vaporizer when the pressure of the liquid LPG is quickly decreased in the expansion chamber. The vaporizer must be heated by the engine coolant to replace the heat that is lost to the fuel. Coolant passages in the vaporizer prevent the vaporizer from being too cold to operate. The vaporizer also controls the pressure of the gas that goes to the carburetor. The pressure reducer valve keeps the pressure of the gas in the expansion chamber at 38 mm (1.5 in.) of water. When gas is required at the carburetor, there is a vacuum in the vapor chamber. The vacuum opens the vapor valve and permits the gas to flow to the carburetor.

Description and Operation When the carburetor throttle is closed, the vacuum in the vapor chamber decreases and the vapor valve closes. The pressure in the vapor chamber stays at 10.3 kPa (1.5 psi). A balance line connects the air pressure side of the vapor diaphragm to an air inlet port at the carburetor. If the air filter has a restriction, the pressure decreases in the carburetor and in the vapor chamber of the vaporizer. When a balance line is not installed, this decrease can cause the diaphragm to move and open the vapor valve. When a balance tube is connected, the restriction causes an equal decrease on both sides of the diaphragm. The balance line prevents an increase in the fuel mixture in the carburetor. A button in the housing can be used to manually open the vapor valve. LPG vapor then flows to the carburetor for starting the engine.

Liquid fuel enters the vaporizer inlet from the filter unit. The pressure reducer valve has a polyurethane pad and a seat. When the pad is against the seat, the liquid fuel cannot enter the expansion chamber. When the liquid fuel enters through the pressure reducer valve, the pressure of the fuel pushes on the diaphragm. The diaphragm immediately moves and closes the valve. Because only a very low pressure is needed to close the valve, the fuel pressure in the expansion chamber is very low. The sudden decrease in pressure causes the fuel to change from a liquid to a vapor. This change of condition takes heat from the surfaces of the expansion chamber. Warm coolant flows next to the surfaces of the chamber to replace the heat. The LPG vapor is kept in the expansion chamber by the vapor valve. When the engine starts, the gas in the vapor chamber leaves the vapor chamber to flow through the carburetor. The pressure on the vapor diaphragm then decreases. Air pressure on the other side of the vapor diaphragm pushes on the diaphragm and opens the vapor valve. The gas flows from the expansion chamber to the vapor chamber and then to the carburetor. The pressure in the expansion chamber decreases, and again the pressure reducer valve opens to repeat the operation.

1. FUEL INLET 2. COOLANT PORTS 3. BUTTON FOR LOW PRESSURE VALVE

4. FUEL OUTLET 5. BALANCE LINE PORTS

Figure 5. Vaporizer

Description and Operation

1. VAPOR CHAMBER 2. COVER 3. DIAPHRAGM FOR VAPOR VALVE

900 SRM 348

4. 5. 6. 7.

VAPOR VALVE LEVER VAPOR VALVE EXPANSION CHAMBER COOLANT PASSAGE

8. DIAPHRAGM FOR PRESSURE REDUCER VALVE 9. PRESSURE REDUCER VALVE 10. OUTLET

Figure 6. Inside the Vaporizer

CARBURETOR The carburetor has one moving part, a diaphragm with the fuel metering valve. See Figure 7. The fuel tube in the center of the air tube is the seat for the fuel metering valve. When the engine starts, the air in the air tube and in the vacuum chamber flows to the engine. See Figure 8 and Figure 9. Air pressure on the outside of the air tube pushes the diaphragm against the metering spring. The fuel metering valve moves from its seat. Air then flows from the outside of the air tube to the inside of the air tube. The fuel pressure moves the LPG vapor past the fuel metering valve to mix with the air flowing through the air tube. Because the diaphragm causes a restriction, the pressure in the inside of the air tube is always less than on the outside of the tube. The difference in pressure changes when the amount of air flowing through the air tube changes. The diaphragm moves according

to the air flow. The amount of fuel that can flow past the fuel metering valve is controlled by the amount of air flowing into the air tube. When the throttle plates in the governor are near the closed position, the pressure difference decreases. The metering spring pushes the fuel metering valve toward its seat. Flow around the fuel metering valve decreases. An idle mixture screw permits adjustment of the air supply at low engine speed. When the throttle plates are fully open at high engine speeds, the fuel metering valve is at the top of its travel. The carburetor has an adjustable valve that controls the amount of LPG vapor that goes to the fuel metering valve. The restriction in fuel flow by this valve is small when the fuel flow is low. When more fuel flows through the valve, the valve becomes an orifice. Adjusting the valve opening changes the mixture of fuel and air when the engine is operated at high speed with a load.

900 SRM 348

Description and Operation

A. AIR 1. 2. 3. 4. 5.

AIR INLET PLATE DIAPHRAGM BACK-UP PLATE FUEL METERING VALVE 6. FUEL TUBE 7. POWER MIXTURE VALVE 8. VACUUM LINE FOR FUEL VALVE

9. BALANCE LINE PORT 10. AIR TUBE 11. METERING SPRING 12. VACUUM CHAMBER 13. IDLE MIXTURE SCREW

B. FUEL

Figure 8. Normal Operation of Carburetor

Figure 7. Carburetor Parts

A. AIR

B. FUEL

Figure 9. Air and Fuel Flow at Idle

Description and Operation

900 SRM 348

GOVERNOR The governor is installed between the carburetor and the intake manifold. See Figure 10 and Figure 11. The solenoid valve is installed to the body of the governor. The governor controller is on the cowl in the operatorâ&#x20AC;&#x2122;s compartment. Vacuum lines connect the diaphragm of the governor to the solenoid valve and the throttle body of the governor. The governor controller is electrically connected to the solenoid valve and the ignition distributor. The operation of the governor is controlled by an electronic controller. Manifold vacuum provides the force to actuate the governor while the controller regulates this force. The governor has two throttle plates that are connected to a diaphragm. Linkage from the diaphragm closes the throttle plates. A spring in the governor opens the throttle plates. The electronic controller is connected to the distributor and controls the operation of the solenoid valve. The solenoid valve controls the vacuum at the diaphragm in the governor. When the solenoid valve is not energized, it is open and manifold vacuum does not affect the governor. During operation, the electronic controller receives engine speed (rpm) signals from the distributor. The controller compares these signals with an internal reference in the circuit for the controller. When the engine speed signal is more than the internal reference, current flows to the solenoid valve. The solenoid valve closes, causing manifold vacuum to operate the diaphragm. When actuated, the diaphragm works against the governor spring to close the throttle plates and decrease engine speed. The solenoid valve opens and closes as necessary to keep the engine speed within the governor limits.

1. DIAPHRAGM ASSEMBLY

2. GOVERNOR BODY 3. CONTROL SPRING

Figure 10. Governor

1. DISTRIBUTOR 2. GOVERNOR CONTROLLER 3. SOLENOID VALVE Figure 11. Governor Circuit

900 SRM 348

LPG Tank Repair

LPG Tank Repair REMOVE NOTE: The LPG tank on your lift truck can be mounted with either a fixed mounting bracket or an EZ Lift mounting bracket. Follow the procedures below for the mounting bracket used on your lift truck to remove the LPG tank.

LPG Tanks with Fixed Mounting Bracket WARNING • LPG tanks can cause an explosion even when the tanks are empty. When replacing the tanks, do not weld, cause sparks or permit flammable material on or near the tanks. Do not change tanks when the engine is running. Tanks must be filled by authorized personnel. Follow all the safety rules. Do not remove any parts from the tank. Use a cloth to protect your hands from cold metal. • LPG is heavier than air. LPG can stay in low places and cause an explosion when a spark occurs. • Before disconnecting any part of the LPG fuel system, close the valve on the fuel tank. Run the engine until the fuel lines are empty and the engine stops. If the engine will not run, close the valve on the fuel tank and release the fuel slowly in a non-hazardous area. 1. Move lift truck to area where tanks are changed. 2. Turn the tank shut-off valve clockwise until the valve is completely closed. See Figure 3. 3. Run engine until it stops. Turn the key to OFF position.

WARNING LPG is very cold in the atmosphere. Always wear gloves to protect your hands from the cold fittings. Do not permit LPG to contact the skin. 4. Disconnect the quick-disconnect fitting.

LPG Tanks with EZ Lift Mounting Bracket WARNING • LPG tanks can cause an explosion even when the tanks are empty. When replacing the tanks, do not weld, cause sparks or permit flammable material on or near the tanks. Do not change tanks when the engine is running. Tanks must be filled by authorized personnel. Follow all the safety rules. Do not remove any parts from the tank. Use a cloth to protect your hands from cold metal. • LPG is heavier than air. LPG can stay in low places and cause an explosion when a spark occurs. • Before disconnecting any part of the LPG fuel system, close the valve on the fuel tank. Run the engine until the fuel lines are empty and the engine stops. If the engine will not run, close the valve on the fuel tank and release the fuel slowly in a non-hazardous area. 1. Move lift truck to area where tanks are changed. 2. Turn the tank shut-off valve clockwise until the valve is completely closed. See Figure 3. 3. Run engine until it stops. Turn the key to OFF position.

WARNING LPG is very cold in the atmosphere. Always wear gloves to protect your hands from the cold fittings. Do not permit LPG to contact the skin. 4. Disconnect the quick-disconnect fitting. See Figure 12. 5. Grab tank handle on mounting bracket and swing tank out to left side of truck. 6. Tilt mounting bracket to position tank vertically. 7. Release tank strap and lift tank from mounting bracket.

5. Release tank latches and remove tank from bracket.

LPG Tank Repair

1. TANK HANDLE 2. QUICK-DISCONNECT FITTING

900 SRM 348

3. ALIGNMENT PIN 4. TANK STRAP 5. LPG TANK

6. EZ LIFT MOUNTING BRACKET 7. FUEL LINE

Figure 12. EZ Lift Mounting Bracket

INSTALL NOTE: The LPG tank on your lift truck can be mounted with either a fixed mounting bracket or an EZ Lift mounting bracket. Follow the procedures below for the mounting bracket used on your lift truck to install the LPG tank.

LPG Tanks with Fixed Mounting Bracket WARNING Do not use any LPG tank that is damaged. Damaged tanks must be removed from service. 1. Before the tank is installed on lift truck, check the operation of the fuel gauge. Look at the fuel gauge and move the tank. The needle of the gauge must move when the fuel moves. If the needle does not move, a new tank must be installed.

WARNING The tank must be installed in the correct position or the relief valve will not operate correctly. If the tank is not installed in the correct position, vapor instead of liquid fuel can go out the fuel valve. Also, liquid fuel can flow from the relief valve on the tank. The relief valve can close because of the freezing caused by the change of the liquid to vapor. 2. Put tank in tank bracket. Make sure alignment pin is in the hole in the bracket. Close latches. See Figure 3. 3. Connect the quick-disconnect fitting to the fuel valve on tank. Use your hand to tighten the fitting. Do not open fuel valve until the quick-disconnect fitting is completely tightened. To open fuel valve, slowly turn it counterclockwise.

900 SRM 348

LPG Tank Repair can close because of the freezing caused by the change of the liquid to vapor.

WARNING Make sure bracket assembly is locked in closed position.

b. Smell - LPG has a very distinctive odor. If you smell LPG, DO NOT start the engine.

2. Make sure mounting bracket is in a vertical position on left side of truck. Place tank into mounting bracket. Make sure alignment pin is in the hole in the bracket. Secure tank to mounting bracket by fastening tank strap. Move tank and bracket into horizontal position and swing tank into place behind seat. See Figure 12.

c. Soapy water - This method is used in conjunction with Step B above. If the odor of LPG is present but escaping fuel cannot be heard, apply soapy water to the fittings and observe for bubbles.

3. Connect the quick-disconnect fitting to fuel valve on tank. Use your hand to tighten fitting. Do not open fuel valve until the quick- disconnect fitting is completely tightened. To open fuel valve, slowly turn it counterclockwise.

a. Sound - Listen for the sound of LPG escaping from a tank fitting or hose connection.

d. Frost - If the amount of LPG escaping is sufficient, frost may appear on the fittings.

LPG Tanks with EZ Lift Mounting Bracket WARNING Do not use any LPG tank that is damaged. Damaged tanks must be removed from service. 1. Before the tank is installed on the lift truck, check the operation of the fuel gauge. Look at the fuel gauge and move the tank. The needle of the gauge must move when the fuel moves. If the needle does not move, a new tank must be installed.

WARNING The fuel valve on the tank must be closed when the truck is not being used. 4. Inspect fuel system for leaks when fuel valve is open. Make sure liquid level valve is closed. There are 4 methods used to inspect the fuel system for leaks: a. Sound - Listen for the sound of LPG escaping from a tank fitting or hose connection. b. Smell - LPG has a very distinctive odor. If you smell LPG, DO NOT start the engine. c. Soapy water - This method is used in conjunction with Step B above. If the odor of LPG is present but escaping fuel cannot be heard, apply soapy water to the fittings and observe for bubbles. d. Frost - If the amount of LPG escaping is sufficient, frost may appear on the fittings.

Filter Unit Repair

900 SRM 348

Hydrostatic Relief Valve Repair REMOVE AND INSTALL

WARNING

WARNING LPG can cause an explosion. Do not cause sparks or permit flammable material near the LPG system. Close the fuel valve on the tank. Disconnect the negative battery cable to prevent sparks.

LPG is flammable. Make sure there are no sparks or open flames in the area when the fuel lines are drained. 2. Slowly loosen hose fitting for relief valve. Let fuel drain from fitting before removing relief valve. See Figure 3. 3. The valve cannot be repaired. If the valve has a defect, install a new valve. After installation, open the fuel valve slowly and inspect the system for leaks.

1. Close shut-off valve on tank.

Filter Unit Repair FUEL FILTER ELEMENT, REPLACE WARNING LPG is flammable. Make sure there are no sparks or open flames in the area when the fuel lines are drained. 1. Close shut-off valve on tank. See Figure 13. Slowly loosen hose fitting to filter. Let fuel drain from fitting before disassembling filter unit. 2. Remove 10 screws and filter cover. Replace filter element. 3. Install cover and gasket. Tighten screws for cover. Tighten hose fitting.

DIAPHRAGM AND FUEL VALVE, REPLACE 1. Close shut-off valve on tank. Slowly disconnect fittings for inlet and outlet hoses and let LPG drain from lines. Remove vacuum hose and mount capscrews. See Figure 13. 2. Remove 10 screws from filter cover. Remove filter and screen. Remove 6 screws from diaphragm cover. Remove covers and gaskets.

3. Remove diaphragm. Remove filter and screen. Remove screw for leaf spring. Remove valve pad. Pull pin from its bore. 4. Remove fitting from fuel outlet port. Remove washer and O-ring through outlet port. 5. Install new O-ring in its bore. Align washer with O-ring and install pin through washer and O-ring. 6. Install valve pad with the polyurethane pad side toward the bore. Install leaf spring, lockwasher, and screw. 7. Install screen and filter element. Put gasket on body and install filter cover and 10 screws and lockwashers. 8. Replace diaphragm. Install diaphragm so the large plate is toward valve. Install cover and tighten 6 screws and lockwashers. 9. Install capscrews for mount. Connect vacuum line. Connect lines for tank and vaporizer. 10. Open fuel shut-off valve on tank and check for leaks in the line to filter unit. Start engine and inspect for leaks on outlet side of filter unit.

900 SRM 348

1. 2. 3. 4. 5. 6. 7.

SCREW DIAPHRAGM COVER DIAPHRAGM FULCRUM LEVER WASHER BODY

Filter Unit Repair

8. 9. 10. 11. 12. 13. 14.

O-RING PIN VALVE PAD SCREEN FILTER GASKET FILTER COVER

Figure 13. Fuel Valve and Fuel Filter

Vaporizer Repair

900 SRM 348

Hoses Replacement The hoses installed on LPG systems are special. Hoses that are made for use with hydraulic oil are damaged by LPG. When replacing the LPG hoses, make sure to use only Hyster Approved LPG hoses. Make sure to use the correct size of hose.

When replacing the hose to the quick-disconnect fitting, make sure it is the same length as the hose it replaces. A longer hose permits the tank to be installed in an incorrect position. If a fuel hose has a restriction, it is coldest around the restriction.

Vaporizer Repair REMOVE WARNING LPG can cause an explosion. Do not permit any sparks or open flames in the work area. 1. Close fuel valve on tank. Run engine until it stops. Slowly disconnect fitting from filter unit on vaporizer. Disconnect hose to carburetor. 2. Put a drain pan under the drain valve for the radiator. Open drain valve and drain coolant into pan. 3. Disconnect coolant fittings to vaporizer. Remove balance line from vaporizer. Remove capscrews at the mount for the vaporizer.

DISASSEMBLE 1. Remove the 7 screws holding the primary cover and plate to vaporizer body. Remove primary cover and primary diaphragm. Remove actuating pin, spring, and seal from plate. See Figure 14. 2. Remove plate and gasket. Remove pressure reducer valve. 3. Remove the 6 screws holding the cover for the vapor chamber to the vaporizer body. Remove cover. Move secondary diaphragm toward the inlet port to release it from the lever.

4. Remove screw that holds secondary lever pin. Cut wire that holds vapor valve pad to lever. Remove pad.

CLEAN WARNING Cleaning solvents can be flammable and toxic, and can cause skin irritation. When using cleaning solvents, always follow the recommendations of the manufacturer.

WARNING Compressed air can move particles so that they cause injury to the user or to other personnel. Make sure that the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes. Wash all parts of the assembly, except the diaphragms, in solvent. Use compressed air to dry the parts. Clean diaphragms in warm, soapy water and air dry. Do not use compressed air to dry diaphragm.

INSPECT Make sure vaporizer housing does not have cracks or damage. Inspect the threads for damage. The diaphragms, valve pads, and gaskets are included in the repair kit.

900 SRM 348

1. 2. 3. 4. 5. 6. 7.

VAPORIZER BODY VAPOR CHAMBER COVER DIAPHRAGM (SECONDARY) DIAPHRAGM (PRIMARY) COVER (PRIMARY) GASKET LEVER (SECONDARY)

Vaporizer Repair

8. 9. 10. 11. 12. 13. 14.

PIN PIN PLATE PLUG PLUG SCREW SCREW

15. 16. 17. 18. 19. 20. 21.

SCREW SCREW SPRING SPRING SEAL VAPOR VALVE PAD SCREEN

Figure 14. Vaporizer Parts

Vaporizer Repair

900 SRM 348

ASSEMBLE Assemble the vaporizer as follows. Always use a Hyster Approved repair kit when assembling the vaporizer. STEP 1. Install pad for pressure reducer valve. Make sure polyurethane surface is against the seat.

STEP 2. Install a new gasket. Install plate with pin guide over the pressure reducer valve.

900 SRM 348

Vaporizer Repair

STEP 3. Install actuating pin, spring, and seal.

STEP 4. Install a new diaphragm.

Vaporizer Repair STEP 5. Install the cover. (21 lbf in).

900 SRM 348

Tighten screws to 2.4 Nâ&#x20AC;˘m

STEP 6. Remove vapor valve pad from valve lever. Install a new valve pad in the lever. Leave pad loose enough against lever so that pad can tilt for alignment against the seat. Bend and cut the pin shown.

STEP 7. Put valve spring in position on housing. Put lever assembly over spring. Install screw so that head of screw is holding the pivot pin.

900 SRM 348

Vaporizer Repair

STEP 8. Tighten screw. Make sure lever moves freely.

STEP 9. Slide lever into slot in diaphragm bracket. Install diaphragm.

STEP 10. Install cover and tighten screws to 2.4 Nâ&#x20AC;˘m (21 lbf in).

INSTALL Install mount capscrews. Connect all lines to fittings. Fill radiator with coolant. Check for leaks. See Figure 1.

Carburetor Repair

900 SRM 348

Carburetor Repair REMOVE 1. Remove hose from air cleaner to carburetor inlet. Remove balance line from carburetor. Remove fuel inlet hose and vacuum hose. 2. Remove carburetor from governor.

DISASSEMBLE Disassemble the carburetor using Figure 15 as a reference.

CLEAN WARNING Cleaning solvents can be flammable and toxic, and can cause skin irritation. When using cleaning solvents, always follow the recommendations of the manufacturer.

WARNING Compressed air can move particles so that they cause injury to the user or to other personnel. Make sure that the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes. Wash all parts, except diaphragm, in solvent. Use compressed air to dry all parts. Make sure air passages in metering valve are clean. Clean diaphragm in warm, soapy water and air dry. Do not used compressed air to dry diaphragm.

ASSEMBLE See Figure 15 for the procedures for assembling the carburetor. Use only Hyster Approved repair kits.

INSTALL Install a new gasket on the governor. Install the carburetor on the governor. Install the balance line, the fuel hose, and the hose to the air cleaner.

1. 2. 3. 4.

INLET HOUSING SCREW COVER METERING SPRING 5. SCREW 6. BACK-UP PLATE 7. DIAPHRAGM

8. PLATE 9. FUEL METERING VALVE 10. BODY 11. SPRING 12. IDLE MIXTURE SCREW

Figure 15. Carburetor

900 SRM 348

Governor Repair

Governor Repair If the governor is removed or replaced, adjust throttle linkage as described in Throttle Linkage Adjustment. If the governor is not operating correctly, check the parts of the system as follows: (see Figure 16) NOTE: The vacuum hoses installed on the carburetor and governor are made of special high-temperature material. If any of the hoses are replaced, make sure the correct hoses are installed. 1. Check vacuum hoses and diaphragm in governor for damage. Remove the plate on the side of the governor and check that the linkage and spring move freely. 2. Check vacuum hoses for restrictions. Check teefitting at diaphragm for restrictions. Make sure tee-fitting is correctly installed. There are orifices in the fitting. The black (VAL) side is for the solenoid valve. The brass (GOV) side is for the governor. 3. Use an ohmmeter to check solenoid valve. Disconnect wire at solenoid valve. Measure resistance between terminals of solenoid valve. Correct resistance is 25-35 ohms. Measure resistance between one of the terminals and the body of the solenoid valve. Correct resistance is 800 ohms or higher. If readings are not correct, replace solenoid valve. If solenoid valve is defective, governor controller must also be checked.

A defective solenoid valve can damage the electronic controller. 4. Use a volt/ohmmeter to check the governor controller. a. Disconnect wiring harness at controller. Measure resistance between ground terminal in harness connector and cowl. Correct resistance is less than 3 ohms. If circuit is open or resistance is high, check for a defective wire. Correct the problem before doing Step b. b. Turn key switch to ON position (do not start engine). Use voltmeter to check for battery voltage at the terminals in the connector for the battery (red) and the solenoid (yellow). Check for defective wires if readings are not correct. c. Turn key switch to OFF position. Use an ohmmeter to check continuity of the signal input wire (black). Check wire between distributor (tachometer connector) and harness connector. 5. After checking the solenoid valve, wiring, hoses, and governor, if the governor does not operate correctly, replace electronic controller.

Governor Repair

1. 2. 3. 4. 5. 6.

900 SRM 348

IDLE MIXTURE ADJUSTMENT BALANCE LINE PORT FUEL INLET POWER MIXTURE ADJUSTMENT VACUUM PORT FOR FUEL VALVE PORT FOR PCV VALVE

7. 8. 9. 10. 11.

VACUUM PORT FOR GOVERNOR BRASS ORIFICE BLACK ORIFICE SOLENOID VALVE VACUUM HOSE

Figure 16. Carburetor and Governor

900 SRM 348

Carburetor Adjustment

Filter Unit Check WARNING LPG can cause an explosion. Do not permit any sparks or open flames in work area. 1. Check for leaks in the fuel valve by disconnecting the fuel inlet hose at the vaporizer. Put the end of the hose in a container of water. There must be no bubbles in the water. If there are bubbles in the water, install a new valve pad in the filter unit.

WARNING

2. If there are no bubbles in the water, remove the primary wire to the distributor or cause a short circuit in coil secondary wire. 3. Turn the key momentarily to the START position to cause a vacuum in the inlet manifold. Bubbles must appear in the container of water. 4. If there are no bubbles seen in Step 3, check the vacuum hose for a restriction. If there is vacuum to the filter unit, inspect the diaphragm for holes or cracks. Make sure the tank has fuel and that the tank valve is open.

Do not remove the coil secondary wire. Removing the coil secondary wire can cause an open circuit. A spark can cause an explosion.

Vaporizer Check PRESSURE REDUCER VALVE Connect a pressure gauge that can measure with accuracy a pressure below 35 kPa (5 psi) to the test port of the vaporizer. The gauge must indicate 10.5 kPa (1.5 psi) when the engine is at idle. If the gauge indicates a pressure greater than 10.5 kPa (1.5 psi), the pressure reducer valve inside the vaporizer is defective and the vaporizer must be replaced.

VAPOR VALVE 1. Run the engine until it is warm.

2. To check for leaks, stop the engine and disconnect the hose from the fuel inlet port at the carburetor. Put the end of the hose just below the surface of water in a container. If bubbles are seen, the vapor valve has a defect or is dirty. 3. To check the vapor diaphragm, remove the inlet hose to the vaporizer. Remove the inlet hose at the carburetor. Put the end of the hose below the surface of the water in a container. Remove the balance line from the carburetor and apply air pressure to the line. If bubbles continue to be seen in the water, the diaphragm has a defect.

Carburetor Adjustment IDLE MIXTURE 1. When the engine is not running, turn the idle mixture screw clockwise until it stops. In this position, the idle mixture screw prevents air from entering the air tube through the idle air port. See Figure 16. 2. Turn idle mixture screw 4 turns counterclockwise. Start engine. Adjust idle screw as needed until idle is smooth. Turning screw counterclockwise increases the ratio of air to fuel.

3. Stop and restart engine. If engine does not start easily, turn idle mixture screw clockwise turn and restart the engine. Continue this procedure until engine starts easily.

IDLE SPEED Turn idle speed screw until idle speed of engine is at 650 rpm. See Figure 16.

Throttle Linkage Adjustment

900 SRM 348

POWER MIXTURE The power mixture valve controls flow of fuel to the carburetor when engine is running at or near full capacity. Set power mixture valve to full rich position.

This setting will be satisfactory for most conditions. If further adjustment is required, proceed as follows: when adjusting the power mixture valve, the engine RPM must not be permitted to increase to the governor limit. See Figure 16.

Throttle Linkage Adjustment NOTE: The following throttle linkage adjustment procedure is for lift truck models H70-110XL (H3.50-5.00XL) (G005), H135-155XL (H6.00-7.00XL) (F006), S70-120XL (S3.50-5.50XL) (D004), and S135-155XL (S6.00-7.00XL) (B024). See Figure 17. 1. Adjust the idle speed as described in the Idle Speed section. 2. Make sure throttle linkage at pedal assembly is in correct position. See Figure 17.

4. Adjust pedal stop so that pedal and throttle lever reach full return positions at the same time. NOTE: The throttle linkage procedure listed below is for lift truck model S70-120XM (S3.50-5.50XM) (E004). See Figure 18. NOTE: Each time the throttle system is disassembled, the throttle cables must be readjusted to ensure proper operation of the cables, linkage, and throttle plates.

3. Depress throttle pedal until it stops against the floor plate. Adjust throttle cable so that pedal stops on the floor plate as throttle plates reach wide open position. Use nuts at both ends of cable housing to change the adjustment of the cable.

1. Adjust idle speed as described in the Idle Speed section.

1. LINKAGE FOR LPG CARBURETOR 2. THROTTLE CABLE 3. CABLE ADJUSTMENT NUTS

4. PEDAL ASSEMBLY 5. PEDAL STOP 6. THROTTLE LINKAGE

2. Adjust throttle cable length to allow for a 3 mm (0.12 in.) maximum of freeplay with the engine in idle position. See Figure 18 for the idle position the throttle linkage must be in before making adjustments to the throttle cable.

Figure 17. Throttle Linkage Adjustment 24

900 SRM 348

Throttle Linkage Adjustment

3. Depress throttle pedal until it stops against the floor plate. Adjust throttle cable so that pedal stops as throttle plates reach wide open position. Turn lock nuts at cable housing to change cable adjustment.

4. Adjust pedal stop so that pedal and throttle lever reach full return positions at the same time.

1. 2. 3. 4.

5. 6. 7. 8.

THROTTLE CABLE CABLE ADJUSTMENT JAM NUTS PEDAL STOP PEDAL ASSEMBLY

ROD END THROTTLE LINKAGE LPG CARBURETOR LINKAGE THROTTLE CABLE INSTALLATION JAM NUTS

Figure 18. Throttle Linkage Adjustment (S70-120XM Models Only)

Troubleshooting

900 SRM 348

Troubleshooting PROBLEM Engine will not start easily. Vaporizer is freezing.

Engine idle speed is too high.

POSSIBLE CAUSE

PROCEDURE OR ACTION

Low coolant level.

Check coolant level at radiator and coolant recovery reservoir. Fill to correct level.

Water hoses have a restriction or are too small.

Make sure there is adequate water flow to vaporizer. Install larger hoses.

Air lock in coolant line to the vaporizer.

Remove air from coolant line.

Belt for water pump is loose or broken.

Adjust tension. belt.

Hose from vaporizer to carburetor has a leak.

Find and repair leak. hose.

Thermostat is not operating correctly.

Install new thermostat.

Ignition system does not function correctly. Starter is damaged.

See Microprocessor Spark Timing System (MSTS) - Late Model GM 3.0L and 4.3L Engines 2200 SRM 765.

Idle mixture screw is not adjusted correctly.

Adjust idle mixture screw.

Fuel valve in carburetor is damaged.

Install new fuel valve. Overhaul carburetor. Install new carburetor.

Solenoid valve is disconnected or does not operate correctly.

Connect wire to solenoid. Install new solenoid valve.

Air filter is dirty.

Check air restriction indicator. Clean or install new filter element.

Balance line is disconnected.

Connect balance line.

Truck accelerates too soon after engine is started.

Allow longer warm-up time before starting operation.

Idle mixture screw is not adjusted correctly.

Adjust idle mixture screw.

Idle speed screw is loose.

Tighten screw and adjust idle speed.

Idle control actuator is not adjusted correctly or the vacuum hose is disconnected.

Connect vacuum hose. idle control actuator.

Install new drive Install new

Adjust the

900 SRM 348

Troubleshooting

PROBLEM Engine does smoothly.

Engine does smoothly.

not

POSSIBLE CAUSE run

idle

PROCEDURE OR ACTION

The governor is damaged.

Install new governor.

Low pressure diaphragm or valve in vaporizer is damaged.

Repair or install new vaporizer.

Wrong or damaged fuel valve in carburetor.

Repair or install new carburetor.

PCV system has a restriction.

Remove restriction. Install new PCV valve.

Air leaks in the intake manifold.

Repair leaks.

Balance line has a restriction.

Remove restriction.

Idle mixture screw is not adjusted correctly.

Adjust idle mixture screw.

Diaphragm in carburetor is damaged.

Install new diaphragm or carburetor.

Air leak between carburetor and governor or between governor and intake manifold.

Fix air leak.

PCV system has a restriction.

Remove restriction. Install new PCV valve.

Air leak at throttle shaft.

Repair or install new carburetor.

Hose from vaporizer to carburetor is damaged.

Install new hose.

Balance line is disconnected.

Connect balance line.

Pressure reducer diaphragm has a hole.

Install new diaphragm.

Low pressure valve in vaporizer is damaged.

Install new low pressure valve or new vaporizer.

Idle speed is too low.

Adjust idle speed.

Idle speed screw is loose.

Tighten screw and adjust idle speed.

Water in fuel.

Check fuel supply and tank filling procedure. Clean system.

Fuel tank is installed in the wrong position.

Install fuel tank in correct position.

Troubleshooting

900 SRM 348

PROBLEM Engine does not smoothly. (Cont.)

Loss of power.

Engine stops running.

POSSIBLE CAUSE idle

PROCEDURE OR ACTION

Fuel valve on the tank is in the wrong port.

Install fuel valve in the correct port.

Idle control actuator is not adjusted correctly or the vacuum hose is disconnected.

Connect vacuum hose. idle control actuator.

Air filter is dirty.

Check air restriction indicator. Clean or install new filter element.

PCV system has a restriction.

Remove restriction. Install new PCV valve.

Governor is damaged.

Install new governor.

Power mixture valve is not adjusted correctly.

Adjust power mixture valve.

Hose from vaporizer to carburetor has leaks.

Repair leak or install new hose.

Diaphragm in carburetor is damaged.

Install new diaphragm.

Wrong type of fuel.

Clear system of wrong fuel. Fill tank with correct fuel.

Hose from vaporizer to carburetor has a restriction or is too small.

Remove restriction or install new or larger hose.

Vaporizer is damaged.

Repair or install new vaporizer.

Valve on fuel tank is closed.

Open fuel valve at the tank.

Fuel tank is empty.

Install tank that has fuel.

Hose from fuel tank is too close to the exhaust pipe.

Locate new hose away from heat source.

Vacuum line to filter unit is disconnected.

Connect vacuum line.

Filter unit is damaged.

Install new filter unit.

Vaporizer is damaged.

Repair or install new vaporizer.

Carburetor is damaged.

Install new carburetor.

Hose to carburetor is damaged.

Install new hose.

Adjust the

900 SRM 348

Troubleshooting

PROBLEM Engine (Cont.)

stops

running.

POSSIBLE CAUSE

PROCEDURE OR ACTION

Idle speed is too low.

Adjust idle speed.

Water in the fuel.

Check fuel supply and tank filling procedure. Clean system.

Fuel filter is dirty.

Clean fuel filter.

Governor is damaged.

Repair or install new governor.

Air leak at the intake manifold.

Repair leak.

Solenoid valve is disconnected or does not operate correctly.

Connect wire to solenoid. install new solenoid valve.

MANUAL HYDRAULIC CONTROL VALVE S/H/E1.25-1.75XL (S/H/E25-35XL); S/H/E/J2.00-3.00XL (S/H/E/J40-60XL); H3.50-5.00XL (H70-110XL); S/E3.50-5.50XL (S/E70-120XL, E70-120XL 3) [D004, C098]; E30-40CR; E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) [D098/E098]

PART NO. 899782

2000 SRM 77

Manual hydraulic Control Valve

Table of Contents

1 1 2 2 4 4 6 6 6 8 8 9 9 9 10 10 10 12 12 12 13 14 16 17

This section is for the following models: S/H/E1.25-1.75XL (S/H/E25-35XL) S/H/E/J2.00-3.00XL (S/H/E/J40-60XL) H3.50-5.00XL (H70-110XL) S/E3.50-5.50XL (S/E70-120XL, E70-120XL 3) [D004, C098]; E30-40CR E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) [D098/E098]

2000 SRM 77

Description

General This section has a description and the repair procedure for the main control valve and the auxiliary solenoid valve used in the hydraulic system.

Description The main control valve controls the operation of the lift, tilt, and auxiliary cylinders. The main control valve is fastened to the cowl of the lift truck. Each main control valve has the following sections (see Figure 1): • Inlet and drain section with the primary relief valve • Lift and lower section (with or without secondary relief valve) • Tilt section

• Auxiliary section • End section The sections are held together with three through bolts. Each function of the main control valve is made as a separate section having a spool and valve body. Each valve body casting is the same. The control spools are different for each function.

Figure 1. Main Control Valve (Typical)

Operation

2000 SRM 77 Legend for Figure 1

1. 2. 3. 4. 5. 6. 7.

INLET AND DRAIN SECTION PRESSURE RELIEF VALVE LIFT SPOOL TILT SECTION CHECK VALVE OPEN CENTER PASSAGE END CAP

8. 9. 10. 11. 12. 13.

Other sections are added to the main control valve to control optional auxiliary functions. On some lift trucks, a solenoid valve is used with one of these sections to give another auxiliary function.

END COVER SUPPLY CAVITY DRAIN CAVITY RETURN TO HYDRAULIC TANK PARALLEL PASSAGE FROM HYDRAULIC PUMP

Each control section has a check valve in the valve body. The check valve and spring is held in the valve body by the next section.

Each spool has a spring that returns the spool to the neutral position when the control lever is released.

Operation The main control valve is an open center, parallel circuit valve. See Figure 2. When open center valve spools are in the neutral position, the hydraulic oil flows through the valve with minimum restriction. The oil returns through the drain passage and returns to the hydraulic tank. In a parallel circuit valve, each spool can be operated without preventing the flow of oil to another spool. This valve has three parallel passages through the valve. See Figure 3. When the spools are in the neutral position, the oil flows through the open center passage. At the end of the valve, the oil returns through the drain passage and returns to the hydraulic tank. A spool makes a restriction in the open center passage when the spool is moved from the neutral position. This restriction causes an increase in pressure in the parallel passage. The parallel passage is common to all sections of the valve, but oil

cannot flow freely through it. The increased pressure in the parallel passage causes the oil to flow through a check valve into a supply cavity in the valve body. The spool gives a path from the supply cavity to the hydraulic cylinder to do work.

LIFT SECTION When the spool is moved to the Lift position, the spool makes a restriction in the open center passage. See Figure 3. The increased pressure in the parallel passage causes oil to flow through the check valve to the supply cavity. The oil flows from the supply cavity through a section of the spool to the lift cylinder. When the spool is in the Lower position, the spool opens a path from the lift cylinder to the drain cavity. The spool is made so the oil flow through the open center passage is not stopped.

2000 SRM 77

Operation

A. FORWARD B. BACKWARD

C. LOWER D. LIFT

1. 2. 3. 4. 5. 6.

7. AUXILIARY SPOOL 8. TO HYDRAULIC TANK 9. AUXILIARY FUNCTION SOLENOID VALVE S3.50-5.50XL (S70-120XL) ONLY 10. TO LIFT CYLINDERS 11. TILT CYLINDER

FLOW FROM HYDRAULIC PUMP MAIN CONTROL VALVE PRIMARY RELIEF VALVE SECONDARY RELIEF VALVE LIFT/LOWER SPOOL TILT SPOOL

Figure 2. Control Valve Schematic

Operation

2000 SRM 77

A. LIFTING

B. LOWERING

1. LIFT SPOOL 2. CHECK VALVE 3. OPEN CENTER PASSAGE

4. PARALLEL PASSAGE 5. DRAIN PASSAGE 6. SUPPLY CAVITY

7. DRAIN CAVITY 8. TO LIFT CYLINDER

Figure 3. Lifting and Lowering

TILT SECTION

Tilt Backward

The basic operation of the tilt spool is the same as the other spools in this control valve. The tilt control spool that is inside the tilt spool adds an additional sequence to the tilt forward function.

When the spool is moved to the Back tilt position, the tilt spool causes a restriction of the oil flow through the open center passage. See Figure 4. The increased pressure in the parallel passage causes the oil to flow through the check valve to the supply cavity. The oil

2000 SRM 77

Operation

flows from the supply cavity through a section of the spool to the rod side of the tilt cylinders. The check valve prevents the movement of the load until the

system pressure is great enough to control the load. Oil from the piston end of the tilt cylinders returns through the main control valve to the hydraulic tank.

A. TILT BACKWARD

B. TILT FORWARD

1. 2. 3. 4.

5. TILT SPOOL 6. TO/FROM ROD END OF TILT CYLINDERS 7. TILT CONTROL SPOOL

OPEN CENTER PASSAGE SUPPLY CAVITY TO/FROM PISTON END OF TILT CYLINDERS DRAIN CAVITY

Figure 4. Tilt Spool Operation

Operation

Tilt Forward The tilt control spool that is inside the tilt spool operates during the Forward tilt function. See Figure 4. The tilt control spool prevents cavitation in the piston end of the tilt cylinders. Cavitation occurs when the available fluid does not fill the space in a closed system. The high vacuum causes some of the fluid to change to bubbles of gas. When cavitation occurs in the tilt cylinders, the tilt forward function is not smooth. The tilt control spool permits the regulation of the tilt speed by using the pressure from the hydraulic pump. The pressure must be 550 kPa (80 psi) on the piston end of the tilt cylinders. The tilt control spool prevents oil flow from the rod end of the tilt cylinders until the pressure is 550 kPa (80 psi). This action makes sure that a vacuum cannot occur at the piston end of the tilt cylinders.

Relief Valve The relief valve limits the maximum pressure within the hydraulic system. The control valve can have one or two relief valves. The primary relief valve is installed in the inlet section of the control valve and is for the lift circuit. The secondary relief valve is for the tilt and auxiliary circuits and is installed in the section of the control valve with the lift/lower spool. Both relief valves are the same in description and operation. When the secondary relief valve is installed,

2000 SRM 77 it is set at a lower pressure than the primary relief valve. When the pressure in one of the hydraulic circuits reaches the relief valve setting, the relief valve opens a path between the inlet and drain circuits. The relief valve is a poppet valve that is pilot operated. There are four poppet spools in this valve. Spools C, D, and E are used for pressure relief. (Spool K is for vacuum relief and is not used in this application.) This relief valve gives almost constant relief pressure over the range of the hydraulic pump flow. The sequence of operation is described in Figure 5.

SOLENOID VALVE FOR AUXILIARY FUNCTION When used, this valve is installed on the front of the cowl. See Figure 6. Together with one of the auxiliary sections of the main control valve, the solenoid valve provides a fifth function. Header hoses are used to connect the attachment to the solenoid valve. The solenoid valve is electrically actuated by a button on the lever for the optional hydraulic functions. The button operates only when the lever is in the left position. (The lever is spring-loaded to the left position.) When the button is not depressed, the lever operates the third function the same as without the button. When the button is depressed with the lever in the left position, the solenoid valve controls the fourth function. When the lever is moved to the right, it operates the fifth hydraulic function.

2000 SRM 77

Operation

1. STEP 1 = THE RELIEF VALVE IS CLOSED BETWEEN THE HIGH PRESSURE INLET (HP) AND THE LOW PRESSURE (LP) DRAIN. HIGH PRESSURE OIL ENTERS THE PASSAGE AT C. THE DIFFERENCE IN AREA BETWEEN DIAMETERS A AND B HOLDS THE POPPET SPOOL D AGAINST THE VALVE SEAT. 2. STEP 2 = THE OIL PRESSURE IN THE HIGH PRESSURE INLET BECOMES GREATER THAN THE SPRING FORCE OF THE PILOT POPPET E. THE PILOT POPPET E IS PUSHED FROM ITS SEAT. OIL FLOWS AROUND THE POPPET E AND THROUGH THE PASSAGES TO THE DRAIN. 3. STEP 3 = WHEN PILOT POPPET E OPENS, THE LOSS OF OIL PRESSURE BEHIND POPPET C CAUSES POPPET C TO MOVE AGAINST POPPET E. THIS MOVEMENT STOPS THE FLOW OF OIL THROUGH C AND CAUSES A LOWER PRESSURE BEHIND RELIEF VALVE POPPET D. 4. STEP 4 = THE DIFFERENCE IN PRESSURE ON EACH SIDE OF POPPET D CAUSES POPPET D TO OPEN. THE HIGH PRESSURE OIL THEN HAS A DIRECT PATH TO THE LOW PRESSURE DRAIN. Figure 5. Relief Valve Operation

Main Control Valve Repair

2000 SRM 77 Legend for Figure 6 1. SOLENOID VALVE 2. SUPPLY/RETURN HOSES 3. COWL

Figure 6. Solenoid Valve Installation

Main Control Valve Repair REMOVE AND DISASSEMBLE WARNING Lower the mast before disconnecting lines from the control valve to prevent the mast from lowering suddenly. 1. Disconnect lines at control valve. Put caps on open lines. 2. Disconnect linkage at spools. 3. Remove bolts that hold main control valve to frame. NOTE: Disassemble the main control valve as necessary for repairs. Most repairs to the main control

valve are the adjustment of the linkage and the replacement of O-rings to stop leaks. The passages in the tilt spool are small and can need cleaning if the hydraulic oil becomes dirty. The section normally must be replaced if the spool or valve section is damaged. 4. Remove end cap from valve section. Carefully pull spool from valve section. Do not remove spring retainers unless a spring must be replaced. 5. The valve sections can be separated when the three through bolts are removed. The check valves are held in the valve body by the next section.

2000 SRM 77

WARNING The special screw in the end of the tilt spool also holds the spring retainers. The spring is compressed. 6. Remove tilt control spool by removing special screw in end of tilt spool. 7. Carefully remove tilt control spool from tilt spool. 8. The relief valve is normally replaced if it is damaged.

CLEAN AND INSPECT WARNING Compressed air can move particles so that they cause injury to the user or to other personnel. Make sure that the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to eyes.

WARNING Cleaning solvents can be flammable and toxic, and can cause skin irritation. When using cleaning solvents, always follow the recommendations of the manufacturer. Clean all parts of control valve with solvent. Dry parts with compressed air. 1. Check spools and bores for defects. If a spool or the bores have damage, the complete control valve must be replaced. Make sure spools move freely in bores. 2. Check the check valves and relief valve for damage. Replace parts as necessary.

Main Control Valve Repair

ASSEMBLE CAUTION Before installing the parts into the valve body, make sure all parts are clean. Replace all the seals and the O-rings. Lubricate all the parts with clean hydraulic oil during assembly. 1. Install new seals in bores of sections. Install new O-ring seals between sections. Install check valves and springs and assemble the sections. Tighten nuts on the 3/8 inch through bolts to 45 Nâ&#x20AC;˘m (35 lbf ft). Tighten nuts on the 5/16 inch through bolts to 20 Nâ&#x20AC;˘m (15 lbf ft). 2. If return springs were removed from control spools, install spring retainers. During assembly, use new O-rings for parts of tilt control spool. Do not damage O-rings during installation. 3. Lubricate spools with clean hydraulic oil. Make sure dirt does not get on any of the parts. Carefully install spools in valve body. Install seal retainers and covers for return springs. 4. Install relief valve. Adjust relief setting for hydraulic system as described in Pressure Relief Valve Check and Adjustment.

INSTALL 1. Install control valve to frame. 2. Connect linkage at spools. 3. Connect hydraulic lines to control valve. 4. Add hydraulic oil to tank. See the section Periodic Maintenance for correct specifications. 5. Operate system and check for leaks and correct operation. Adjust relief valve as described in Pressure Relief Valve Check and Adjustment.

Solenoid Valve for Auxiliary Function Repair

2000 SRM 77

Solenoid Valve for Auxiliary Function Repair REMOVE AND DISASSEMBLE

ASSEMBLE AND INSTALL

NOTE: Step 1 through Step 3 provide access to the coil without removing the solenoid valve. To test the coil, see Troubleshooting for the solenoid valve.

1. To install a coil on the solenoid valve, proceed with Step 2. If the solenoid valve assembly was removed from the lift truck, install it as follows:

1. Loosen bolt for wire clamp on bottom of coil cover. See Figure 7.

a. Install two mount bolts through valve.

2. Remove bolts for coil cover and carefully remove cover from valve.

b. Make sure all four grommets are in the cowl, then install valve on grommets. Tighten nuts.

3. With the red and white wires attached, disconnect diode assembly from terminals on coil.

c. Install supply and return hoses and header hoses on solenoid valve.

4. To remove complete solenoid valve assembly, continue with Step 5. To remove coil from valve, loosen screws for end plate. See Figure 8. Remove screws, end plate, and coil.

2. If a bad coil was removed, install a new coil as shown in Figure 9. Make sure the coil terminals are in the correct position. Tighten screws for end plate to 4.5 to 5.6 Nâ&#x20AC;˘m (40 to 50 lbf in).

NOTE: For assembly, make a note of the position of the coil terminals in relation to the valve ports.

NOTE: Make sure wires and diode are connected as shown in Figure 7. The diode must be installed with color-code band toward positive terminal.

5. Put tags on hoses at solenoid valve. Disconnect hoses at solenoid valve. 6. Remove nuts and washers from mount bolts, and pull solenoid valve from cowl.

3. Connect diode assembly with red and white wires at coil terminals. 4. Put coil cover on valve. Make sure control switch wire is under wire clamp when cover is installed on valve. 5. Install bolts, lockwashers, and nuts for cover. Tighten nuts for cover and wire clamp.

Legend for Figure 7 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

BOLT CLAMP LOCKWASHER NUT COIL COVER BOLT NUT LOCKWASHER END PLATE COIL SOLENOID VALVE NUT WASHER

14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25.

BOLT FITTING O-RING FITTING O-RING CONTROL KNOB STRAP CLAMP WIRE ASSEMBLY DIODE ASSEMBLY WIRING HARNESS GROMMET DIODE COLOR-CODE

2000 SRM 77

Solenoid Valve for Auxiliary Function Repair

Figure 7. Solenoid Valve and Control Circuit

Pressure Relief Valve Check and Adjustment

2000 SRM 77 terminals. Check connections of the red and white wires to diode assembly terminals. Check connection of the black wire. d. Cowl ground stud: Make sure there are no loose ground wires. 3. Remove diode assembly. Test diode with an ohmmeter for high resistance in one direction and no resistance in the other direction. If there is no resistance or infinite resistance in both directions, replace diode.

1. SOLENOID VALVE 2. COIL

3. END PLATE

Figure 8. Solenoid Valve and Coil

TROUBLESHOOTING

NOTE: Make sure the wires and the diode are connected as shown in Figure 7. The diode must be installed with the color-code band toward the positive terminal. 4. Disconnect the red and white wires from the diode assembly terminals. Connect voltmeter across the wire terminals, check for current when control knob button is depressed.

If the solenoid valve does not operate, do the following steps:

a. If there is no current, check wiring for short circuits.

1. Check the 7.5 amp fuse for the solenoid valve on the fuse panel.

b. If there is current, test coil. See Step 5.

2. Check for loose electrical connections: a. Ignition switch: Check the black wire at the accessory terminal of the switch connector body. b. Control knob button: Remove snap ring and knob cover. Check wire connectors and switch connections. c. Solenoid valve coil: Remove coil cover. See Figure 7. Check diode connections to coil

5. Test coil for continuity by connecting an ohmmeter lead to each coil terminal. Put ohmmeter on the R Ă&#x2014; 1 scale. a. If there is no ohmmeter reading, the coil is bad. Replace coil. b. If there is an ohmmeter reading, the coil is good. If the coil is good, but the solenoid valve does not energize when the button is depressed, the solenoid valve is bad. Replace solenoid valve assembly.

Pressure Relief Valve Check and Adjustment NOTE: The control valve can have two relief valves: a primary relief valve and a secondary relief valve. The primary relief valve is always on the inlet section of the control valve. The secondary relief valve is on the section with the lift/lower spool.

PRIMARY RELIEF VALVE 1. Connect a 0 to 25 MPa (0 to 3500 psi) gauge to the test port. E1.25-1.75XL (E25-35XL) and E/J2.003.00XL (E/J40-60XL) lift trucks: Install a

fitting and gauge in the port below the return line at the control valve. S/H1.25-1.75XL (S/H25-35XL) lift trucks: Test port is near the left-hand tilt cylinder. S/H2.00-3.00XL (S/H40-60XL), E3.505.50XL (E70-120XL, E70-120XL 3), and E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) [D098/E098] lift trucks: Test port is near the inlet port of the main control valve. H3.50-5.00XL (H70-110XL) and S3.505.50XL (S70-120XL) lift trucks: Test port is

2000 SRM 77 on the control valve at the fitting for the lift cylinders. 2. If installed, remove acorn nut from relief valve. Loosen jam nut. 3. Start engine and operate hydraulic system to warm oil temperature to 55 to 65 C (130 to 150 F). Run engine at approximately 1000 rpm when making pressure checks. 4. E/S/H1.25-1.75XL (E/S/H25-35XL) lift trucks: Tilt mast backward until it stops. Hold the lever and check the reading of the gauge when the relief valve opens. Turn the adjustment screw as necessary to change the setting. See Specifications for the correct setting. Tighten the jam nut when the adjustment is correct. 5. E/J/S/H2.00-3.00XL (E/J/S/H40-60XL), H3.505.00XL (H70-110XL), and S3.50-5.50XL (S70120XL) lift trucks: Check relief valve by raising mast until it stops. Hold lever and check reading of the gauge when relief valve opens. Turn adjustment as necessary to change setting. See Specifications for correct setting. Tighten jam nut when adjustment is correct. 6. Remove gauge when checks are complete.

SECONDARY RELIEF VALVE 1. Connect a 0 to 20 MPa (0 to 3000 psi) gauge to the test port. S/H1.25-1.75XL (S/H25-35XL) lift trucks: Test port is near the left-hand tilt cylinder. S/H2.00-3.00XL (S/H40-60XL) lift trucks: Test port is near the inlet port of the main control valve. E/J2.00-3.00XL (E/J40-60XL) lift trucks: Install a gauge and fitting at a port for the rod side of the tilt cylinders. H3.50-5.00XL (H70-110XL) lift trucks: Test port is on the control valve at the tee fitting for the tilt cylinders.

Pressure Relief Valve Check and Adjustment S/E3.50-5.50XL (S/E70-120XL, E70-120XL 3), and E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) [D098/E098] lift trucks: Connect a gauge to the forward tilt port on the main control valve. 2. If installed, remove acorn nut from relief valve. Loosen jam nut. 3. Start engine and operate hydraulic system to warm oil temperature to 55 to 65 C (130 to 150 F). Run engine at approximately 1000 rpm when making pressure checks. 4. S/H1.25-1.75XL (S/H25-35XL) lift trucks: Tilt mast backward until it stops. Hold lever and check reading of the gauge when relief valve opens. Turn adjustment screw as necessary to change setting. See Specifications for correct setting. Tighten jam nut when adjustment is correct. 5. E/J/S/H2.00-3.00XL (E/J/S/H40-60XL) lift trucks: Check secondary relief valve by tilting mast backward until it stops. Hold lever and check reading of the gauge when relief valve opens. Turn adjustment screw as necessary to change the setting. See Specifications for correct setting. Tighten jam nut when adjustment is correct. 6. H3.50-5.00XL (H70-110XL) and S3.50-5.50XL (S70-120XL) lift trucks: Tilt mast forward until it stops. Hold lever and check reading of the gauge when relief valve opens. Turn adjustment screw as necessary to change setting. See Specifications for correct setting. Tighten jam nut when adjustment is correct. 7. Remove gauge when checks are complete.

Control Lever Arrangement and Adjustment

2000 SRM 77

Control Lever Arrangement and Adjustment NOTE: For electric lift trucks, see the section Hydraulic System 1900 SRM 286 or Hydraulic System 1900 SRM 559 section for the arrangement and adjustment of the control valve levers. See Figure 9.

Figure 9. Control Lever Arrangement (Sheet 1 of 2)

2000 SRM 77

Control Lever Arrangement and Adjustment

NOTE: AUXILIARY CONTROL LEVER MUST BE PUSHED TO THE RIGHT TO ENGAGE THE THIRD CONTROL VALVE SPOOL. WHEN RELEASED, THE CONTROL LEVER MUST RETURN TO THE LEFT. A. ALL UNITS [EXCEPT EARLIER PRODUCTION H2.00-3.00XL (H40-60XL)] B. ALL UNITS

C. EARLIER PRODUCTION H2.00-3.00XL (H40-60XL) UNITS

1. ADJUST LENGTH OF LINKAGE SO LEVERS ARE 51.5 mm (2.02 in.) FROM COWL IN NEUTRAL POSITION 2. CAPSCREW [TIGHTEN TO 19 N•m (14 lbf ft)] 3. COLLAR, TIGHTEN SETSCREW TO 7 N•m (62 lbf ft) 4. PIVOT SPACER 5. TO THE LIFT CYLINDER 6. TILT BACKWARD

7. TILT FORWARD 8. AUXILIARY FUNCTION [FOR SIDESHIFT CARRIAGE: UPPER PORT IS "Y" = LEFT SIDESHIFT (LEVER FORWARD). LOWER PORT IS "X" = RIGHT SIDESHIFT (LEVER BACKWARD)] 9. AUXILIARY FUNCTION 10. CAPSCREW 11. SPACER

Figure 9. Control Lever Arrangement (Sheet 2 of 2)

Specifications

2000 SRM 77

Specifications Unit

Relief Valve Settings Primary Relief Valve

Secondary Relief Valve

S/H/E1.25-1.75XL (S/H/E25-35XL)

15.15 to 15.85 MPa (2200 to 2300 psi)

Not Used

S/H2.00-3.00XL (S/H40-60XL) (With VISTA upright)

19.25 to 19.95 MPa (2800 to 2900 psi)

15.15 to 15.85 MPa (2200 to 2300 psi)

H2.00-3.00XL (H40-60XL) (Without VISTA upright)

17.55 to 18.25 MPa (2550 to 2650 psi)

15.15 to 15.85 MPa (2200 to 2300 psi)

E/J2.00-3.00XL (E/J40-60XL) 36/48 Volt

18.90 to 19.30 MPa (2750 to 2950 psi)

15.15 to 15.85 MPa (2200 to 2300 psi)

E/J2.00-3.00XL (E/J40-60XL) 72/80 Volt

18.60 to 19.00 MPa (2650 to 2850 psi)

15.15 to 15.85 MPa (2200 to 2300 psi)

H3.50-5.00XL (H70-110XL)

21.4 MPa (3100 psi)

15.15 to 15.85 MPa (2200 to 2300 psi)

E3.50-5.50XL (E70-120XL, E70-120XL 3)

20.7 MPa (3000 psi)

15.15 to 15.85 MPa (2200 to 2300 psi)

E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) [D098/E098]

20.7 MPa (3000 psi)

15.15 to 15.85 MPa (2200 to 2300 psi)

S3.50-5.50XL (S70-120XL)

21.4 MPa (3100 psi)

15.15 to 15.85 MPa (2200 to 2300 psi)

13.1 to 14.5 MPa (2000 to 2100 psi)

Not Used

N30-40CR

2000 SRM 77

Troubleshooting

Troubleshooting PROBLEM Slow or no movement of cylinders.

Oil leaks at the end of a spool.

Spool will not move or is difficult to move.

Spool will not return to NEUTRAL.

POSSIBLE CAUSE

PROCEDURE OR ACTION

Air is in the hydraulic system.

Remove air from hydraulic system.

The hydraulic pump is worn or damaged.

Repair or replace hydraulic pump.

Restriction in the hydraulic lines.

Repair hydraulic lines.

Cylinder seals are damaged.

Repair cylinders.

Load is greater than capacity.

Reduce load.

Linkage is disconnected or damaged.

Repair and adjust linkage for control levers.

Pressure relief valve(s) is not adjusted correctly or is damaged.

Repair or adjust relief valve(s).

Large leaks between spool and bore.

Replace valve section.

Spool is not fully extended or retracted.

Adjust linkage to spool.

Seal for spool is damaged.

Replace seal.

Spool is damaged.

Replace valve section.

Valve body is damaged.

Replace valve section.

Linkage is disconnected or damaged.

Repair and adjust linkage.

Return spring is damaged.

Replace spring.

The spool or bore is damaged.

Replace valve section.

Linkage is disconnected or damaged.

Repair and adjust linkage.

Return spring is damaged.

Replace spring.

Dirt between spool and the bore.

Clean valve.

Spool is bent or damaged.

Replace valve section.

Troubleshooting

PROBLEM Hydraulic pressure is above specifications.

2000 SRM 77

POSSIBLE CAUSE

PROCEDURE OR ACTION

Pressure relief valve(s) is not adjusted correctly or is damaged.

Repair or adjust relief valve(s).

Restriction in return line.

Clean or replace return line or filter.

Cylinder seal have leaks.

Repair tilt cylinders.

Oil leaks between control valve spool and bore.

Replace valve section.

Hydraulic lines have leaks.

Repair or tighten lines or fittings.

Tilt cylinders extend suddenly when the tilt spool is moved to BACK TILT position.

Check valve for tilt spool is damaged.

Replace check valve.

Tilt cylinders extend suddenly when the tilt spool is moved to FORWARD TILT position.

Tilt control spool inside the tilt spool is damaged.

Replace valve section.

Lift cylinders retract when the lift spool is in the NEUTRAL position.

Check valve for the lift spool is damaged.

Replace check valve.

Cylinder seals have leaks.

Repair lift cylinders.

Hydraulic lines have leaks.

Repair or tighten lines or fittings.

Leaks between the lift spool and the bore.

Replace valve section.

Tilt cylinders extend when the tilt spool is in the NEUTRAL position.

VISTA Â® MASTS DESCRIPTION AND REPAIRS FOR LIFT TRUCKS WITH 3,500 TO 6,000 KG (7,000 TO 12,000 LB) CAPACITIES H3.50-5.00XL (H70-110XL) [G005]; S3.50-5.50XL (S70-120XL) [D004]; E3.50-5.50XL (E70-120XL) [C098]

PART NO. 897122

4000 SRM 340

Vista ® Masts

Table of Contents

TABLE OF CONTENTS General ............................................................................................................................................................... Description and Operation ................................................................................................................................ Carriages ........................................................................................................................................................ Two-Stage Mast With Limited Free-Lift ...................................................................................................... Two-Stage Mast With Full Free-Lift Mast ................................................................................................... Three-Stage Mast With Full Free-Lift ......................................................................................................... Safety Procedures When Working Near Mast.................................................................................................. Forks Replacement ............................................................................................................................................ Remove and Install........................................................................................................................................ Hook Fork .................................................................................................................................................. Remove .................................................................................................................................................. Install..................................................................................................................................................... Pin Fork ..................................................................................................................................................... Remove .................................................................................................................................................. Install..................................................................................................................................................... Carriage Repair.................................................................................................................................................. Remove ........................................................................................................................................................... Sideshift Carriage Repair.................................................................................................................................. Sideshift Carriage (Earlier Designs) ............................................................................................................ Disassemble ............................................................................................................................................... Assemble .................................................................................................................................................... Install ......................................................................................................................................................... Sideshift Carriage (1993 and Later Design) ................................................................................................ Remove....................................................................................................................................................... Repairs ....................................................................................................................................................... Install ......................................................................................................................................................... Weight of Mast Parts ......................................................................................................................................... Two-Stage Mast With Limited Free-Lift Repair .............................................................................................. Remove ........................................................................................................................................................... Disassemble ................................................................................................................................................... Clean and Inspect .......................................................................................................................................... Assemble ........................................................................................................................................................ Install ............................................................................................................................................................. Two-Stage Mast With Full Free-Lift Repair..................................................................................................... Remove ........................................................................................................................................................... Disassemble ................................................................................................................................................... Clean and Inspect .......................................................................................................................................... Assemble ........................................................................................................................................................ Install ............................................................................................................................................................. Three-Stage Mast With Full Free-Lift.............................................................................................................. Remove ........................................................................................................................................................... Disassemble ................................................................................................................................................... Clean and Inspect .......................................................................................................................................... Assemble ........................................................................................................................................................ Install ............................................................................................................................................................. Mast Operation Check ....................................................................................................................................... Lift and Tilt System Leak Check ...................................................................................................................... Lift System..................................................................................................................................................... Tilt System ..................................................................................................................................................... Tilt Cylinder Stroke and Backward Tilt Angle Adjustment............................................................................ Lift Chain Adjustments .....................................................................................................................................

1 1 1 1 2 3 5 7 7 7 7 7 8 8 8 8 8 10 10 10 11 14 14 14 14 14 17 17 17 17 19 19 21 21 21 21 23 23 23 24 24 24 24 24 26 28 29 29 29 30 30

Table of Contents

Vista Â® Masts

TABLE OF CONTENTS (Continued) Mast Adjustments.............................................................................................................................................. Carriage Adjustment ......................................................................................................................................... Troubleshooting.................................................................................................................................................. This section is for the following models: H3.50-5.00XL (H70-110XL) [G005]; S3.50-5.50XL (S70-120XL) [D004]; E3.50-5.50XL (E70-120XL) [C098]

31 33 34

4000 SRM 340

Description and Operation

General This section has the description, operation, and repair procedures for the VistaÂŽ masts for the 3,500 to 6,000 kg (7,000 to 12,000 lb) capacity lift trucks. Information on the different types of sideshift carriages is also included. The lift cylinders and the lowering control valves are described in the section Lift Cylinders 4000 SRM 1354000 YRM 135. The tilt cylinders are described in the section Tilt Cylinders 2100 SRM 103 .

Description and Operation The vertical frames of a mast are called weldments. See Figure 1. Channels, load rollers and crossmembers are parts of the weldments. The channels on each side of the weldment are the support members of the mast and the tracks for the load rollers. During lifting and lowering a load, large forces are put on the mast assembly. The load rollers reduce the friction between the channels when the weldments move vertically. Each mast can tilt forward and backward. Tilt cylinders are installed between the frame of the lift truck and the outer weldment of the mast. The pivot mounts at the bottom of the outer weldment connect the mast to the lift truck. During the tilt operation, the mast rotates on the pivot pins in the frame.

1. FORKS 2. CARRIAGE 3. LOAD BACKREST EXTENSION

4. OUTER WELDMENT 5. INNER WELDMENT 6. LIFT CYLINDER

CARRIAGES The carriage is a separate section that moves on load rollers within the vertical channels of the inner weldment. Forks or other types of load handling equipment are attached to the carriage. A load backrest extension is installed on the carriage. A sideshift carriage permits the operator to hydraulically change the lateral position of the load handling device on the carriage.

TWO-STAGE MAST WITH LIMITED FREE-LIFT The Vista Two-Stage mast has two weldments, an outer weldment and an inner weldment. See Figure 2. The outer weldment is connected to the lift truck by the pivot mounts and the tilt cylinders. The top of the outer weldment has one load roller on each side. The base of the inner weldment has one load roller on each side. These load rollers travel along the channels of the weldments. The angle of the load rollers permits them to control the forces from the front, back and sides of the mast. The shims on the load rollers control the lateral clearance between the weldments and the load rollers. Strip bearings are installed at the top of each side of the outer weldment. The strip bearings keep the correct clearance (forward and backward) between the outer weldment and the inner weldment. The two-stage mast has two single stage lift cylinders. The lift cylinders are installed at the back of the outer weldment. The base of each lift cylinder sits in a mount at the bottom of the outer weldment. The hydraulic fitting for each lift cylinder goes through a hole in the mount. The top of each lift cylinder (cylinder rod) fits into a guide at the top of the inner weldment. A bracket on the cylinder shell holds the lift cylinder in position on the outer weldment. Operation of the lift cylinders extends and retracts the inner weldment.

Figure 1. Mast Components

Description and Operation

4000 SRM 340 Two lift chains control the movement of the carriage. The chains are fastened to mounts near the top of the lift cylinder shells. The chains go up and over the chain sheaves on the inner weldment and then connect to the carriage. When the lift cylinders extend, the lift chains transfer the force from the lift cylinders to the carriage. When the lift cylinders retract, the weight of the load, carriage and inner weldment push the oil from the lift cylinders. The oil flows from the lift cylinders, through the lowering control valves, main control valve and then to the hydraulic tank.

TWO-STAGE MAST WITH FULL FREE-LIFT MAST The Vista Free-Lift mast has an inner weldment, an outer weldment and three single stage lift cylinders. See Figure 3. It is called a free-lift mast because the carriage can travel to the top of the inner weldment without increasing mast height. The free-lift mast has load roller and strip bearing arrangements similar to the two-stage mast. The two main lift cylinders are installed at the back of the outer weldment. The base of each lift cylinder sits in a mount at the bottom of the outer weldment. The hydraulic fitting for each lift cylinder goes through a hole in the mount. The top of each lift cylinder (cylinder rod) fits into guides at the top of the inner weldment. The free-lift cylinder is installed in the inner weldment. The main lift cylinder on the right side of the mast and the free-lift cylinder each have an internal lowering control valve. A single external lowering control valve is connected by tubing to all of the lift cylinders. Two chain sheaves are installed on the cylinder rod of the free-lift cylinder. The lift chains are connected to a mount behind the free-lift cylinder. The chains then go over the sheaves and are connected to the carriage. 1. 2. 3. 4. 5. 6. 7. 8. 9.

LIFT CYLINDER (2) LIFT CHAIN OUTER WELDMENT CHAIN SHEAVE INNER WELDMENT CARRIAGE FROM MAIN CONTROL VALVE EXTERNAL LOWERING CONTROL VALVE INTERNAL LOWERING CONTROL VALVE Figure 2. Two-Stage Mast With Limited Free-Lift

The three lift cylinders are connected by hoses and tubing. To extend the mast, oil from the main control valve flows to all of the lift cylinders at the same time. The free-lift cylinder raises first because it lifts the least amount of weight. The free-lift cylinder raises the carriage to the top of the inner weldment. After the free-lift cylinder reaches the end of its stroke, the main lift cylinders begin to extend and raise the inner weldment.

4000 SRM 340

1. 2. 3. 4. 5.

Description and Operation

MAIN LIFT CYLINDER (2) OUTER WELDMENT FREE-LIFT CYLINDER INNER WELDMENT CHAIN SHEAVE

6. 7. 8. 9. 10.

LIFT CHAIN CARRIAGE FROM MAIN CONTROL VALVE EXTERNAL LOWERING CONTROL VALVE INTERNAL LOWERING CONTROL VALVE

Figure 3. Two-Stage Mast With Full Free-Lift During lowering, the main lift cylinders lower first because they have a greater load. After the main lift cylinders have retracted, the free-lift cylinder lowers. All of the oil from the lift cylinders flows through the lowering control valves to the hydraulic tank.

THREE-STAGE MAST WITH FULL FREE-LIFT The Vista Three-Stage mast has an outer, an intermediate and an inner weldment. See Figure 4. Three single stage lift cylinders are used on the mast to raise the carriage and extend the weldments. The weldments are telescopic and have load roller and strip bearing arrangements similar to the two-stage

mast. The two main lift cylinders are installed at the back of the outer weldment. The base of each lift cylinder is held on a mount at the bottom of the outer weldment. The hydraulic fittings for the lift cylinders go through holes in the mounts. The top of each main lift cylinder (cylinder rod) fits into a guide at the top of the intermediate weldment. The free-lift cylinder is installed in the inner weldment. The two main lift chains fasten at one end near the top of the outer weldment. The lift chains then go over sheaves at the top of the intermediate weldment and fasten at the bottom of the inner weldment. The free-lift chains are connected to a mount behind the free-lift cylinder. The chains then go over the sheaves and connect to the carriage.

Description and Operation

4000 SRM 340

A. PHASE 2 1. 2. 3. 4. 5.

MAIN LIFT CYLINDER (2) OUTER LIFT CHAIN FREE-LIFT CYLINDER INNER LIFT CHAIN INNER WELDMENT

6. 7. 8. 9. 10.

INTERMEDIATE WELDMENT OUTER WELDMENT FROM MAIN CONTROL VALVE EXTERNAL LOWERING CONTROL VALVE INTERNAL LOWERING CONTROL VALVE

Figure 4. Three-Stage Mast With Full Free-Lift

4000 SRM 340

Safety Procedures When Working Near Mast

The three lift cylinders are connected by hoses and tubing. To extend the mast, oil from the main control valve flows to all cylinders at the same time. The free-lift cylinder raises first because it lifts the least amount of weight. The free-lift cylinder raises the carriage to the top of the inner weldment. After the free-lift cylinder reaches the end of its stroke, the main lift cylinders begin to extend. As the main lift

cylinders extend the intermediate weldment, the inner weldment is extended by the lift chains. During lowering, the main lift cylinders lower first because they have a greater load. After the main lift cylinders have retracted, the free-lift cylinder lowers. All oil from the lift cylinders flows through the lowering control valves to the hydraulic tank.

Safety Procedures When Working Near Mast The following procedures MUST be used when inspecting or working near the mast. Additional precautions and procedures can be required when repairing or removing the mast. See the correct Service Manual section for the specific mast being repaired.

WARNING Mast parts are heavy and can move. Distances between parts are small. Serious injury or death can result if part of the body is hit by parts of the mast or the carriage. • Never put any part of the body into or under the mast or carriage unless all parts are completely lowered or a safety chain is installed. Also make sure that the power is off and the key is removed. Put a DO NOT OPERATE tag in the operator’s compartment. Disconnect the battery on electric lift trucks and put a tag or lock on the battery connector. • Be careful of the forks. When the mast is raised, the forks can be at a height to cause an injury. • DO NOT climb on the mast or lift truck at any time. Use a ladder or personnel lift to work on the mast. • DO NOT use blocks to support the mast weldments nor to restrain their movement. • Mast repairs require disassembly and removal of parts and can require removal of the mast or carriage. Follow the repair procedures in the correct Service Manual for the mast. WHEN WORKING NEAR THE MAST ALWAYS: • Lower the mast and carriage completely. Push the lift/lower control lever toward and make sure there is no movement in the mast. Make sure that all parts of the mast that move are fully lowered.

• If parts of the mast must be in a raised position, install a safety chain to restrain the moving parts of the mast. Connect moving parts to a part that does not move. Follow these procedures: 1. Put mast in vertical position. 2. Raise mast to align bottom crossmember of weldment that moves in the outer weldment with a crossmember on the outer weldment. On the two-stage and free-lift mast, the moving part is the inner weldment. On the three-stage mast, it is the intermediate weldment. See Figure 5. 3. Use a 3/8 inch minimum safety chain with a hook to fasten the crossmembers together so the movable member cannot lower. Put the hook on the back side of the mast. Make sure the hook is completely engaged with a link in the chain. Make sure the safety chain does not touch lift chains or chain sheaves, tubes, hoses, fittings, or other parts on the mast. 4. Lower mast until there is tension in the safety chain and the free-lift cylinder (free-lift, threestage, and four-stage masts only) is completely retracted. If running, stop the engine. Apply parking brake. Install a DO NOT REMOVE tag on the safety chain(s). 5. Install another safety chain (3/8 inch minimum) between the top or bottom crossmember of the carriage and a crossmember on the outer weldment. NOTE: Apply parking brake. After lowering or restraining the mast, shut off power and remove key. Put a DO NOT OPERATE tag in the operator’s compartment. Disconnect battery on electric lift trucks and put a tag or lock on battery connector.

Safety Procedures When Working Near Mast

4000 SRM 340

A. TWO-STAGE LFL MAST

B. TWO-STAGE FFL MAST

C. THREE-STAGE FFL MAST

1. OUTER WELDMENT 2. INNER WELDMENT 3. INTERMEDIATE WELDMENT

4. HOOK 5. FREE-LIFT CYLINDER 6. CROSSMEMBER

7. CROSSMEMBER

Figure 5. Two-Stage LFL, Two-Stage FFL, and Three-Stage FFL Masts

4000 SRM 340

Forks Replacement

Forks Replacement The identification of a fork describes how the fork is connected to the carriage. The series of lift trucks that use this mast normally have hook forks. See Figure 6. Pin forks are available on the larger capacity lift trucks in this series as an option. Pin forks are fastened to the carriage with large fork pins. See Figure 8.

[66 to 183 kg (145 to 402 lb) for a hook fork] and [128 to 226 kg (281 to 498 lb) for a pin fork]. A fork can be removed from the carriage for replacement of the fork or other maintenance.

Hook Fork

Hook forks are connected to the carriage by hooks and lock pins. These lock pins are installed through the top fork hooks and fit into slots in the top carriage bar. Separate the forks as much as possible for maximum support of the load. Hook forks will slide along the carriage bars to adjust for the load to be lifted. Raise the lock pin in each fork to slide the fork on the carriage bar. Make sure the lock pin is engaged in the carriage bar to lock the fork in position after the width adjustment is made.

Remove

REMOVE AND INSTALL

Move fork and carriage so top hook on fork can engage upper carriage bar. Raise carriage to move lower hook through fork removal notch. Slide fork on carriage so both upper and lower hooks engage carriage. Engage lock pin with a notch in the upper carriage bar.

WARNING Do not try to move a fork without a lifting device. Each fork for these lift trucks can weigh

1. FORK REMOVAL NOTCH 2. FORK 3. HOOK

Slide a hook fork to the fork removal notch on the carriage. See Figure 6. Lower fork on to blocks so bottom hook of fork moves through fork removal notch. See Figure 7. Lower carriage further so top hook of fork is disengaged from top carriage bar. Move carriage away from fork, or use lifting device to move fork away from carriage. Install

4. LOCKING PIN ASSEMBLY 5. CARRIAGE Figure 6. Hook Fork

Carriage Repair

4000 SRM 340

Pin Fork Remove Put blocks under forks and lower carriage. When weight of forks have been removed from fork pin, remove load backrest extension. The load backrest extension holds the fork pin in the carriage. Slide fork pin from its mount in the carriage and through the eye of the fork. See Figure 8. Use lifting device to lift fork away from carriage. Install 1. CARRIAGE BARS 2. HOOK FORK

Install fork pin in carriage. Align eyes of forks so forks will be installed on fork pin. When fork pin is installed in carriage so it holds forks, install load backrest extension. Engage fork with lock pin.

3. BLOCKS

Figure 7. Hook Fork Removal

1. CARRIAGE 2. FORK

3. FORK PIN 4. LOCK PIN

5. LOAD BACKREST EXTENSION

Figure 8. Pin Forks

Carriage Repair REMOVE WARNING Do not work under a raised carriage. Lower the carriage or use a chain or blocks to prevent

the carriage and inner weldment from lowering. NOTE: If the mast is equipped with a sideshift carriage, see the paragraphs under Sideshift Carriage Repair.

4000 SRM 340

Carriage Repair

1. Lower carriage and forks on blocks so lift chains become loose. See Figure 9 and Figure 12.

WARNING When disconnecting the lift chains, keep control of the ends. Use wire to temporarily connect the ends of the lift chains to the mast. This procedure will prevent the lift chains from falling and causing an injury or damage. 2. Remove pin from each chain anchor at the carriage. Disconnect lift chains from carriage. 3. Put weight on forks so carriage has stability and will not fall when it is disconnected from mast.

WARNING Make sure that the carriage has stability and will not fall over when the inner weldment is raised above the load rollers of the carriage. 4. Use lift cylinders to raise inner weldment until it is above load rollers of carriage. If the hydraulic system cannot be used, connect lifting device to top of inner weldment. Carefully raise inner weldment until it is above load rollers of carriage. 5. Move lift truck from carriage. Connect lifting device to carriage. Make sure carriage has stability. Remove load backrest, fork pins, and forks. Put carriage on floor so load rollers are up. 6. If any of the load rollers must be replaced, make a note of the arrangement of the shims.

1. 2. 3. 4.

CARRIAGE LOAD ROLLER SHIMS SNAP RING

5. SIDE ROLLER 6. CHAIN ANCHOR (TWO-STAGE MAST) 7. CHAIN ANCHOR (FREE-LIFT AND THREE-STAGE MAST) Figure 9. Carriage

Sideshift Carriage Repair

4000 SRM 340

Sideshift Carriage Repair SIDESHIFT CARRIAGE (EARLIER DESIGNS) The earlier Hyster Company designs of sideshift carriages for this mast are shown in Figure 12 and Figure 13. These designs are used on lift trucks manufactured through 1993. During the second half of 1993, a second design shown in Figure 14 was installed on lift trucks. The operation of the designs are similar, but the components are different. NOTE: See the section, Main Control Valve 2000 SRM 77 for information about the control valve linkage for the sideshift carriage.

Disassemble WARNING Make sure any lifting devices have the correct capacity for the parts being moved. See Weight of Mast Parts.

1. Disconnect hydraulic lines at sideshift cylinder. Disconnect sideshift cylinder at carriage and at apron. Remove sideshift cylinder. See Figure 10, Figure 11, Figure 12, and Figure 13. 2. Remove keeper plates or carriage hooks at bottom of carriage. Use lifting device and lift apron from carriage. Remove rollers and bearing segments as necessary. 3. Disassemble sideshift cylinder (see Figure 10) and Figure 11 as follows: a. Remove retaining ring, then remove retainer from cylinder shell. Pull rod and piston from shell. b. Remove nut from rod, and remove piston and retainer. c. Remove seals and O-rings.

Figure 10. Sideshift Cylinders for Earlier Design Carriages (Old Style)

4000 SRM 340

Sideshift Carriage Repair Legend for Figure 10

1. 2. 3. 4. 5. 6. 7.

RETAINER COVER WIPER ROD SEAL SNAP RING CAPSCREW RETAINING RING

8. 9. 10. 11. 12. 13. 14.

BACKUP RING O-RING ROD PISTON PISTON SEAL NUT SHELL

1. 2. 3. 4. 5.

CYLINDER SHELL GLAND WIPER O-RING BACKUP RING

6. 7. 8. 9. 10.

ROD SEAL "T" SEAL (INCLUDES BACKUP RING) PISTON NUT ROD

Figure 11. Sideshift Cylinders for Earlier Design Carriages (New Style)

Assemble NOTE: Several different types of carriages are used on these lift trucks. Not all procedures are necessary for some carriages. See Figure 12 and Figure 13 when assembling the carriage. 1. Assemble sideshift cylinder (see Figure 10) and Figure 11 as follows: a. Lubricate seals and O-rings with clean hydraulic oil. Install rod seal and wiper in retainer. Install retainer on rod. Install O-ring and backup ring in groove of retainer. b. Install piston on rod. Tighten nut for rod to 122 to 149 N•m (90 to 110 lbf ft). c. Install piston seal and backup ring on piston. Install rod and piston in shell. Install gland into cylinder tube. Tighten gland to 140 to 160 N•m (103 to 118 lbf ft).

2. Install guide rollers on brackets at carriage. When used, install bearing segments as shown in Figure 12 and Figure 13. Make sure to lubricate bearing segments and sliding surfaces with multipurpose grease. 3. Install load rollers on apron. rollers on carriage.

Install thrust

4. Use a lifting device and install apron on carriage. Install keeper plate or carriage hooks on carriage. Tighten capscrews for keeper plates to 90 N•m (66 lbf ft). Tighten capscrews for carriage hooks to 165 N•m (120 lbf ft). For carriages that have hook-type forks and carriage hooks, adjust carriage hooks during Install, Step 5. 5. When used, install mount bracket for sideshift cylinder. Tighten capscrews that hold bracket to carriage to 320 N•m (235 lbf ft).

Sideshift Carriage Repair

4000 SRM 340

Figure 12. Sideshift Carriages

4000 SRM 340

Sideshift Carriage Repair Legend for Figure 12

A. H3.50-4.00XL-5 (H70-80XL) B. FACE OF CARRIAGE

C. BACK OF CARRIAGE D. H4.00XL-6, H4.50-5.00XL (H90-100XL)

1. 2. 3. 4. 5. 6. 7.

8. SIDE ROLLER 9. CHAIN ANCHOR (FREE-LIFT AND THREE-STAGE MAST) 10. FORK PIN 11. SHIMS 12. SNAP RING 13. BEARING SEGMENT

CARRIAGE APRON SIDESHIFT CYLINDER LOAD ROLLER GUIDE ROLLER THRUST ROLLER KEEPER PLATE

A. S/H3.50-4.50XL (S/H70-110XL) 1. 2. 3. 4. 5. 6.

CARRIAGE APRON SIDESHIFT CYLINDER LOAD ROLLER SHIMS SNAP RING

7. 8. 9. 10. 11.

CARRIAGE HOOK CYLINDER MOUNT SIDE ROLLER BEARING SEGMENT BEARING BLOCK

Figure 13. Sideshift Carriages 6. Install sideshift cylinder in carriage. Install anchor pins or nuts at both ends of the cylinder. After the nut at the apron is just tight, loosen nut 1/4 turn. Connect hydraulic lines to cylinders.

7. Install side rollers and load rollers on carriage. Tighten capscrews for side rollers to 65 Nâ&#x20AC;¢m (50 lbf ft).

Sideshift Carriage Repair

Install 1. Use hydraulic system of lift truck or a lifting device to raise inner weldment. Raise inner weldment until it is above the load rollers of the carriage. Carefully lower inner weldment until it engages all load rollers. 2. Check clearance of load rollers and side rollers. See Mast Adjustments and Carriage Adjustment in this section. When installing the side rollers, make sure grease fittings are toward front of lift truck. Tighten capscrews for side rollers to 65 N•m (50 lbf ft). 3. Connect lift chains. Install pins using new cotter pins.

4000 SRM 340 bracket and cylinder will stay on the standard carriage. Remove bushings. 4. Disconnect hydraulic lines at sideshift cylinder. Put caps on open lines. Remove cylinder mount bracket from carriage. If necessary, remove threaded rods and shims to remove sideshift cylinder.

Repairs 1. Do the following procedure to repair the sideshift cylinder (see Figure 15 and Figure 16): a. Remove retainers from shell. Pull rod from shell.

4. Install forks and fork pins. Install load backrest.

b. Replace seals, O-rings, or backup rings as necessary.

5. Adjust carriage hooks (see Figure 12 and Figure 13) as follows:

c. Lubricate all internal parts with clean hydraulic oil.

a. Check clearance between carriage hook and bottom carriage bar. The maximum clearance is 4 mm (0.16 in.).

d. Install piston and rod in shell. Apply Loctite® 242 to threads of retainers. Install retainers and tighten them to 25 to 30 N•m (223 to 267 lbf in).

b. There are two sets of mount holes for the carriage hooks. Install carriage hooks in mount holes so clearance measured in Step a is 4 mm (0.16 in.) or less. Tighten capscrews for carriage hooks to 165 N•m (120 lbf ft). 6. Connect any hydraulic lines as necessary. Check lift chains as described in Lift Chain Adjustments.

SIDESHIFT CARRIAGE (1993 AND LATER DESIGN) Remove 1. Lower carriage completely and remove forks. See Figure 14. 2. Connect lifting device to lifting eye on sideshift carriage. 3. Remove two upper capscrews from bottom carriage bar. Slowly loosen two bottom capscrews, but do not remove them. The holes have slots that will permit the bottom carriage bar to move down so the sideshift carriage can be removed. Carefully lift sideshift carriage from standard carriage. The sideshift cylinder mounting

2. Use new bushings if the old bushings are worn or damaged.

Install 1. Install sideshift cylinder in bracket. Use an equal number of shims on both sides of the cylinder to limit side-to-side movement within the bracket. Maximum movement is 0.6 mm (0.024 in.). Install threaded rods to hold cylinder in position. 2. Install cylinder mount bracket on standard carriage, and make sure it is engaged in the notch in the top carriage bar. Connect hydraulic lines to sideshift cylinder. Put grease on ends of cylinder rod. 3. Install top bushing on mounting bracket. Lubricate outer surface of bushing with multipurpose grease. 4. Connect top and bottom carriage bars by installing two bottom capscrews. Do not tighten capscrews. Lubricate outer surface of bottom bushing with multipurpose grease. Install bottom bushing in bottom bar of sideshift carriage.

4000 SRM 340

1. 2. 3. 4.

Sideshift Carriage Repair

STANDARD CARRIAGE TOP BAR, SIDESHIFT CARRIAGE TOP BUSHING CYLINDER MOUNT BRACKET

5. BOTTOM BUSHING 6. SIDESHIFT CYLINDER 7. BOTTOM BARS, SIDESHIFT CARRIAGE

Figure 14. Sideshift Carriage (1993 and Later Design) 5. Make sure standard carriage is completely lowered. Connect lifting device to lifting eye. Install sideshift carriage on standard carriage. Put blocks under bottom bar of sideshift carriage so bottom bushing is moved tight against standard carriage. 6. Install two top capscrews. On 2.00 to 2.75 ton (4,000 to 5,000 lb) lift trucks, tighten all capscrews to 435 N•m (320 lbf ft). On 3.00 to 3.20 ton (6,000 to 6,500 lb) lift trucks, tighten all capscrews to 755 N•m (557 lbf ft). Remove lifting device. Lubricate top bushing at grease fittings. 7. Install forks. 1. 2. 3. 4.

SHELL O-RING BACKUP RING ROD SEAL

5. 6. 7. 8.

RETAINER WIPER PISTON AND ROD PISTON SEAL

Figure 15. Sideshift Cylinder

Sideshift Carriage Repair

4000 SRM 340

A. HYDRAULIC CONNECTIONS - TWO-STAGE, LIMITED FREE-LIFT B. HYDRAULIC CONNECTIONS - TWO-STAGE, FULL FREE-LIFT AND THREE-STAGE, FULL FREE-LIFT 1. 2. 3. 4. 5.

TOP BUSHING CYLINDER MOUNTING BRACKET THREADED ROD SHIM SIDESHIFT CYLINDER

6. 7. 8. 9. 10.

GREASE FITTING TOP CARRIAGE BAR BOTTOM BUSHING BOTTOM CARRIAGE BAR LIFTING EYE

Figure 16. Sideshift Carriage

4000 SRM 340

Two-Stage Mast With Limited Free-Lift Repair

Weight of Mast Parts Item

Weight Masts

H3.50-4.00XL (H70-80XL) S/E3.50-4.00XL (S/E70-80XL) 2800 mm 5600 mm 2800 mm 4850 mm 4320 mm 7575 mm

(110 in.) (220 in.) (110 in.) (191 in.) (170 in.) (298 in.)

Two-Stage Two-Stage Free-Lift Free-Lift Three-Stage Three-Stage

618 kg (1362 lb) 1030 kg (2270 lb) 663 kg (1460 lb) 856 kg (1289 lb) 899 kg (1980 lb) 1391 kg (3063 lb)

H4.00-H5.00XL (H90-110XL) S/E4.50-5.50XL (S/E100-120XL) 2800 mm 5600 mm 3815 mm 6365 mm

(110 in.) Two-Stage (220 in.) Two-Stage (150 in.) Three-Stage (250.5 in.) Three-Stage

639 kg (1410 lb) 1044 kg (2300 lb) 860 kg (1899 lb) 1193 kg (2633 lb)

S/E4.50-5.50XL (S/E100-120XL) 2800 mm (110 in.) Free-Lift 5600 mm (220 in.) Free-Lift

681 kg (950 lb) 1098 kg (2419 lb) Carriage

1219 mm (48 in.)

273 kg (600 lb) Sideshift Carriages (Earlier Designs)

1219 mm (48 in.)Integral 1219 mm (48 in.)

432 kg (950 lb) 250 kg (550 lb) Forks

51 × 127 × 1219 mm (2 × 5 × 48 in.) 64 × 152 × 1289 mm (2.5 × 6 × 72 in.)

84 kg (185 lb) each 184 kg (405 lb) each

Two-Stage Mast With Limited Free-Lift Repair REMOVE 1. Fully lower inner weldment. If the mast must be disassembled, remove forks and carriage. See Figure 17. 2. Connect lifting device to all top crossmembers of mast weldments. See Weight of Mast Parts to make sure lifting device will hold mast. Raise lifting device so mast has stability. 3. Remove anchor pins for tilt cylinders at mast. Disconnect hydraulic line for mast at lowering control valve.

4. On H3.50-5.00XL (H70-110XL) units, remove capscrews for pivot pins at frame of lift truck. On S/E3.50-5.50XL (S/E70-120XL) units, remove capscrews from mast hanger caps. Use lifting device to move mast from lift truck. Put mast in a position so crossmembers are on floor.

DISASSEMBLE 1. Clean area around hydraulic fittings for lift cylinders. Disconnect fittings at lift cylinders and put caps on open lines. See Figure 17.

Two-Stage Mast With Limited Free-Lift Repair

1. 2. 3. 4. 5. 6. 7.

OUTER WELDMENT INNER WELDMENT LIFT CYLINDER LIFT CHAIN CHAIN SHEAVE CHAIN ANCHOR LOAD ROLLER

8. 9. 10. 11. 12. 13.

SHIMS SNAP RING PIVOT PIN LIFT TRUCK FRAME SPACER EXTERNAL LOWERING CONTROL VALVE

4000 SRM 340

14. STRIP BEARING 15. MOUNT FOR H3.50-5.00XL (H70-110XL) 16. MOUNT FOR S/E3.50-5.50XL (S/E70-120XL) 17. HANGER CAP 18. BEARING HALF

Figure 17. Two-Stage Mast With Limited Free-Lift

4000 SRM 340 2. Remove pins for lift chains at chain anchors. Remove snap rings and washers from top of each lift cylinder. Remove capscrew, washer, and shims (if installed) at the mount for each lift cylinder. 3. Slide inner weldment from outer weldment approximately 30 cm (12 in.) to disengage lift cylinders from inner weldment. Remove lift cylinders from mounts at bottom of outer weldment. Make a note of the spacers (snap rings) that are installed at the bottom of the lift cylinders. 4. Slide inner weldment from bottom of outer weldment approximately 30 cm (12 in.). Remove strip bearings. Remove load rollers from both weldments. Make a note of shim arrangement. The shim arrangement will be approximately the same during assembly procedures. 5. Slide inner weldment halfway out of the top of the outer weldment. Connect a crane to the center of the inner weldment. See Figure 21. Slide inner weldment out of outer weldment until stub shafts are in notches of outer weldment. Remove inner weldment from outer weldment. 6. Remove and disassemble chain sheaves as necessary for cleaning and repair.

CLEAN AND INSPECT WARNING Commercial cleaning solvents may be flammable and toxic and can cause severe skin irritation. When using commercial cleaning solvents, always comply with solvent manufacturerâ&#x20AC;&#x2122;s recommended safety precautions.

WARNING Never replace just the worn section of a chain. Replace the complete chain. Never replace just one chain of a chain pair. Replace both chains.

CAUTION DO NOT use steam or high-pressure water to clean the load rollers of the lift chains. Steam and high-pressure water can remove the lubrication from the bearings in the load rollers. Water in the bearings of the sheaves and the

Two-Stage Mast With Limited Free-Lift Repair link pins of chains can also shorten the service life of these parts. 1. Inspect sheaves and load rollers for wear or damage. DO NOT use steam to clean lift chains, sheaves, or load rollers. The bearings in the sheaves and load rollers are sealed and lubricated. 2. Clean lift chains with solvent. Inspect lift chains for wear or damage. See Figure 18. A lift chain becomes longer when it is worn. If a section of chain is 3% longer than a similar section of new chain, the chain is worn and must be replaced. If a chain scale is available, check lift chains as shown in Figure 18. If a chain scale is not available, measure 20 links of chain. Measure from center of pin to center of another pin 20 pitches away. Compare length with the chart in Figure 18. Replace chain if length of 20 links of the worn section is more than the maximum wear limit. Lubricate chains with SAE 30 engine oil. The best procedure is to remove lift chains from lift truck and soak them in oil.

Two-Stage Mast With Limited Free-Lift Repair

4000 SRM 340

Pitch

12.7 mm (0.50 in.) 15.9 mm (0.625 in.) 19.1 mm (0.75 in.) 25.4 mm (1.00 in.) 31.8 mm (1.25 in.) 44.5 mm (1.75 in.) 50.8 mm (2.00 in.)

Total length of 20 links (pitch) of new chain

Wear Limit The maximum length of 20 links

254.0 mm (10.0 in.) 317.5 mm (12.5 in.) 381.0 mm (15.0 in.) 508.0 mm (20.0 in.) 635.0 mm (25.0 in.) 889.0 mm (35.0 in.) 1016.0 mm (40.0 in.)

261.6 mm (10.3 in.) 327.0 mm (12.88 in.) 392.4 mm (15.45 in.) 523.25 mm (20.6 in.) 654.1 mm (25.75 in.) 915.7 mm (36.05 in.) 1046.5 mm (41.2 in.)

NOTE: THE INSTRUCTIONS FOR MEASURING CHAIN WEAR ARE SHOWN ON THE CHAIN WEAR SCALE. 1. CHAIN WEAR SCALE 2. WORN PIN

3. CRACKS 4. EDGE WEAR

5. HOLE WEAR 6. LOOSE LEAVES

7. DAMAGED PIN 8. CORROSION

Figure 18. Lift Chains Check 4. Install lift cylinders. Make sure spacers, when installed, are in their original positions at the bottom mounts. Push inner weldment to engage rods of lift cylinders. Install washers and snap rings at top of lift cylinders. Install capscrews, spacers, and washers at lift cylinder mounts. Tighten capscrews at mounts to 53 N•m (40 lbf ft).

5. Install lowering control valve on outer weldment. Tighten capscrews for lowering control valve to 33 N•m (25 lbf ft). Connect hydraulic lines and fittings between lowering control valve and lift cylinders. 6. Install chain sheaves and brackets. Connect lift chains to chain anchors at lift cylinders. Attach wires between ends of lift chains and crossmember to control lift chains during installation.

4000 SRM 340

Two-Stage Mast With Full Free-Lift Repair together. Make sure chains do not damage any of the hydraulic lines or other parts. See Figure 17. 2. Raise mast assembly to vertical position. On S/E3.50-5.50XL (S/E70-120XL) units, lubricate and install bearing halves in mast. Move mast assembly into position on lift truck. 3. On H3.50-5.00XL (H70-110XL) units, make sure pivot pins are in the correct position, then install capscrews. Tighten capscrews to 225 N•m (165 lbf ft). On S/E3.50-5.50XL (S/E70-120XL) units, install hanger caps and bearing halves. Install capscrews for hanger caps. Tighten capscrews to 320 N•m (235 lbf ft). 4. Connect hydraulic line to mast assembly. Install header hoses as shown in Figure 23.

INSTALL

5. Install tilt limit spacers, if necessary. Connect tilt cylinders to outer weldment (see Figure 26). Install bushings, pins, and anchor pins. The capscrew on the rod end of the tilt cylinder must be toward the lift truck. The capscrew for anchor pin retainer must be toward the outside. Tighten both capscrews to 80 N•m (60 lbf ft).

1. Install pivot pins in mounts in outer weldment. Make sure grease fittings are toward center of lift truck. Connect lifting device to top of mast assembly. Make sure all weldments are fastened

6. Adjust lift chains, carriage, and tilt cylinders as described in Lift Chain Adjustments, Carriage Adjustment, and Tilt Cylinder Stroke and Backward Tilt Angle Adjustment.

1. STRIP BEARING 2. SHIMS

3. TOP OF OUTER WELDMENT

Figure 19. Strip Bearings

Two-Stage Mast With Full Free-Lift Repair REMOVE Remove free-lift mast using the same procedures as described for two-stage mast. See Figure 20.

DISASSEMBLE 1. Clean area around hydraulic fittings for lift cylinders. Disconnect fittings at lift cylinders and put caps on open lines. See Figure 20. 2. Remove pins for lift chains at chain anchors and remove lift chains. Disconnect and remove hydraulic line for free-lift cylinder. Remove capscrews that hold free-lift cylinder to inner weldment. Remove free-lift cylinder.

4. Slide inner weldment from outer weldment approximately 30 cm (12 in.) to disengage lift cylinders from inner weldment. See Figure 21. Remove lift cylinders from mounts at bottom of outer weldment. Make a note of the spacers (snap rings) that are installed at the bottom of the lift cylinders. 5. Slide inner weldment from bottom of outer weldment approximately 30 cm (12 in.). Remove strip bearings. Remove load rollers from both weldments. Make a note of shim arrangement. The shim arrangement will be approximately the same during assembly procedures.

3. Remove snap rings and washers from top of each lift cylinder. Remove capscrew, washer, and spacer at mount for each lift cylinder.

Two-Stage Mast With Full Free-Lift Repair

Figure 20. Two-Stage Mast With Full Free-Lift Repair

4000 SRM 340

Two-Stage Mast With Full Free-Lift Repair Legend for Figure 20

1. 2. 3. 4. 5. 6. 7. 8.

OUTER WELDMENT INNER WELDMENT LIFT CYLINDER LIFT CHAIN CHAIN SHEAVE CHAIN ANCHOR LOAD ROLLER SHIMS

9. 10. 11. 12. 13.

SNAP RING PIVOT PIN LIFT TRUCK FRAME SPACER EXTERNAL LOWERING CONTROL VALVE 14. FREE-LIFT CYLINDER 15. STRIP BEARING

6. Slide inner weldment half-way out of top of outer weldment. Connect lifting device to center of inner weldment. See Figure 21. Slide inner weldment out of outer weldment until stub shafts are in notches of outer weldment. Remove inner weldment from outer weldment. 7. Remove and disassemble chain sheaves as necessary for cleaning and repair.

CLEAN AND INSPECT Clean and inspect parts of free-lift mast using the same procedures as described for two-stage mast.

16. MOUNT FOR H3.50-5.00XL (H70-110XL) 17. MOUNT FOR S/E3.50-5.50XL (S70-120XL) 18. HANGER CAP 19. BEARING HALF

1. Connect lifting device to center of inner weldment (see Figure 21). Put stub shafts through notches in outer weldment. Slide inner weldment into outer weldment so stub shafts are seen at top and bottom of weldments. 2. Install strip bearings and shims on outer weldment. Apply grease to bearing surface. See Figure 19. 3. Install load rollers and shims on both weldments. Check clearance of load rollers and strip bearings as described in Mast Adjustments and Carriage Adjustment. 4. Install chain sheave assembly on free-lift cylinder. Install free-lift cylinder on inner weldment. 5. Install lift cylinders. Make sure spacers, when installed, are in their original positions at the bottom mounts. Push inner weldment to engage rods of lift cylinders. Install washers and snap rings at top of lift cylinders. Install capscrews, spacers, and washers at lift cylinder mounts. Tighten capscrews at mounts to 53 Nâ&#x20AC;˘m (40 lbf ft). 6. Install lowering control valve on outer weldment. Connect hydraulic lines and fittings between lowering control valve, lift cylinders, and free-lift cylinder.

Figure 21. Inner Weldment

7. Connect lift chains to chain anchors at mount on inner weldment. Attach wires between ends of lift chains and bottom crossmember to control lift chains during installation.

INSTALL Install free-lift mast using the same procedures described for the two-stage mast. See Figure 20. See header hoses arrangement in Figure 24.

Three-Stage Mast With Full Free-Lift

4000 SRM 340

Three-Stage Mast With Full Free-Lift REMOVE Remove three-stage mast using the same procedures as described for two-stage mast. See Figure 22.

DISASSEMBLE 1. Clean area around hydraulic fittings for lift cylinders. Disconnect fittings at lift cylinders and put caps on open lines. See Figure 22. 2. Remove pins for lift chains at chain anchors on free-lift cylinder. Disconnect hydraulic lines for free-lift cylinder. Remove capscrews that hold free-lift cylinder to inner weldment. Remove free-lift cylinder. 3. Disconnect and remove lift chains between outer weldment and inner weldment. Slide inner weldment from intermediate weldment approximately 30 cm (12 in.). Remove strip bearings. Remove load rollers from inner and intermediate weldments. Make a note of shim arrangement. The shim arrangement will be approximately the same during assembly procedures. 4. Slide inner weldment halfway out of intermediate weldment. Connect lifting device to center of inner weldment. See Figure 21. Slide inner weldment out of intermediate weldment. 5. Disconnect hydraulic lines from lift cylinders. Remove snap rings and washers from top of each lift cylinder. Remove capscrew, washer, and spacer at mount for each lift cylinder. 6. Slide intermediate weldment from outer weldment approximately 30 cm (12 in.) to disengage lift cylinders from intermediate weldment. Remove lift cylinders from mounts at bottom of outer weldment. Make a note of the spacers (snap rings) that are installed at the bottom of the lift cylinders. 7. Slide intermediate weldment from bottom of outer weldment approximately 30 cm (12 in.). Remove strip bearings. Remove load rollers. Make a note of shim arrangement. The shim arrangement will be approximately the same during assembly procedures.

Slide intermediate weldment out of outer weldment until stub shafts are in notches of outer weldment. Remove intermediate weldment from outer weldment. 9. Remove and disassemble sheaves and load rollers as necessary for cleaning and repair.

CLEAN AND INSPECT Clean and inspect parts of three-stage mast using the same procedures as described for two-stage mast.

ASSEMBLE NOTE: The shims for the load rollers keep the weldments parallel and give correct clearance. During assembly, the location of the shims will be approximately the same as they were before disassembly. Check clearance and adjust shims for wear or changes because of repairs. The strip bearings are also adjusted by using shims. See Mast Adjustments in this section for the instructions to make the necessary adjustments. 1. Connect lifting device to center of intermediate weldment (see Figure 21). Put stub shafts through notches in outer weldment. Slide intermediate weldment into outer weldment so stub shafts are seen at top and bottom of weldments. See Figure 22. 2. Install strip bearings and shims on outer weldment. Apply grease to bearing surface. See Figure 19. 3. Install load rollers and shims on both weldments. Check clearance of load rollers and strip bearings as described in Mast Adjustments and Carriage Adjustment. 4. Install main lift cylinders. Make sure spacers, when installed, are in their original positions at bottom mounts. Push inner weldment to engage rods of lift cylinders. Install washers and snap rings at top of lift cylinders. Install capscrews, washers, and spacers at mount for each lift cylinder. Tighten capscrews at mounts to 53 Nâ&#x20AC;˘m (40 lbf ft). 5. Install chain sheaves on intermediate weldment.

8. Slide intermediate weldment halfway out of top of outer weldment. Connect lifting device to center of intermediate weldment. See Figure 21.

4000 SRM 340

1. 2. 3. 4. 5. 6. 7. 8. 9.

Three-Stage Mast With Full Free-Lift

OUTER WELDMENT INTERMEDIATE WELDMENT INNER WELDMENT LIFT CYLINDER LIFT CHAIN CHAIN SHEAVE CHAIN ANCHOR LOAD ROLLER SHIMS

10. 11. 12. 13. 14.

SNAP RING PIVOT PIN LIFT TRUCK FRAME SPACER EXTERNAL LOWERING CONTROL VALVE 15. HOSE SHEAVE 16. FREE-LIFT CYLINDER

17. MOUNT FOR H3.50-5.00XL (H70-110XL) 18. MOUNT FOR S/E3.50-5.50XL (S/E70-120XL) 19. HANGER CAP 20. BEARING HALF 21. BASE RING 22. SELF ADJUSTING NUT

Figure 22. Three-Stage Mast With Full Free-Lift

Three-Stage Mast With Full Free-Lift 6. Connect lift chains to chain anchors at bottom of inner weldment. Use wire to hold the other end of the lift chains to top of inner weldment. 7. Connect lifting device to center of inner weldment (see Figure 21). Put stub shafts through notches in intermediate weldment. Slide inner weldment into intermediate weldment so stub shafts are seen at top and bottom of weldments. 8. Install strip bearings and shims on outer weldment. Apply grease to bearing surface. See Figure 19. 9. Install load rollers and shims on both weldments. Check clearance of load rollers and strip bearings as described in Mast Adjustments and Carriage Adjustment. 10. Connect lift chains to mounts at top of outer weldment.

1. H3.50-5.00XL (H70-110XL) 2. S3.50-5.50XL (S70-120XL)

4000 SRM 340 11. Install chain sheave assembly on free-lift cylinder. Install free-lift cylinder on inner weldment. 12. Connect lift chains to chain anchors at mount on inner weldment. Attach wires between ends of lift chains and bottom crossmember to control lift chains during installation. 13. Install lowering control valve on outer weldment. Tighten capscrews for lowering control valve to 33 Nâ&#x20AC;˘m (25 lbf ft). Connect hydraulic lines and fittings between lowering control valve and lift cylinders.

INSTALL Install three-stage mast using the procedures as described for the two-stage mast. See Figure 22. See arrangement of header hoses in Figure 23, Figure 24, and Figure 25.

3. E3.50-5.50XL (E70-120XL) 4. S3.50-5.50XL (S70-120XL)

Figure 23. Header Hoses Two-Stage Mast With LFL

4000 SRM 340

Three-Stage Mast With Full Free-Lift

1. H3.50-5.00XL (H70-110XL) 2. S3.50-5.50XL (S70-120XL)

3. E3.50-5.50XL (E70-120XL) 4. S3.50-5.50XL (S70-120XL)

Figure 24. Header Hoses Two-Stage Mast With FFL

Mast Operation Check

4000 SRM 340

1. H3.50-5.00XL (H70-110XL) 2. S3.50-5.50XL (S70-120XL)

3. E3.50-5.50XL (E70-120XL) 4. S3.50-5.50XL (S70-120XL)

Figure 25. Header Hoses Three-Stage Mast With FFL

Mast Operation Check WARNING Lower the lift mechanism completely. Never allow anyone under a raised carriage. Do not put any part of your body in or through the lift mechanism unless all parts of the mast are completely lowered and the engine is STOPPED. Before making any repairs, use blocks and chains on the mast weldments and carriage so they cannot move. Make sure the moving parts are attached to a part that does not move. Do not try to locate hydraulic leaks by putting hands on pressurized hydraulic components. Hydraulic oil can be injected into the body by pressure.

1. Check for leaks in hydraulic system. Check condition of hydraulic hoses and tubes. NOTE: Some parts of the mast move at different speeds during raising and lowering. 2. Slowly raise and lower mast several times without a load. Mast components must raise and lower smoothly in the correct sequence. The carriage raises first, then the inner weldment, and the intermediate weldment (three-stage masts only). 3. The inner weldments and the carriage must lower completely.

4000 SRM 340

Lift and Tilt System Leak Check

4. Check that controls for the attachment operate the functions of the attachment. (See symbols by each of the controls.) Make sure all of the

hydraulic lines are connected correctly and do not leak.

Lift and Tilt System Leak Check LIFT SYSTEM WARNING

TILT SYSTEM WARNING

Never allow anyone under a raised carriage. Do not put any part of your body through the lift mechanism unless all parts of the mast are completely lowered and the engine is stopped.

Before making any repairs, use blocks and chains on the mast weldments and carriage so they cannot move. Make sure the moving parts are attached to the parts that cannot move.

Do not try to find hydraulic leaks by putting hydraulic components under pressure. Hydraulic oil can be injected into the body by pressure.

During the test procedures for the hydraulic system, fasten the load to the carriage with chains to prevent it from falling. Keep all personnel away from the lift truck during the tests.

1. Operate hydraulic system. Put a capacity load on the forks and raise and lower load several times. Lower load and tilt mast forward and backward several times. Check for leaks.

1. Put a capacity load on forks. Slowly tilt mast forward. If mast continues to slowly tilt forward when control valve is in a NEUTRAL position, there are leaks inside the hydraulic system. The maximum speed that the mast is allowed to tilt forward when there are internal leaks in the lift system is 13 mm (0.50 in.) per 10 minutes (measured at the tilt cylinder). This maximum speed is measured when the hydraulic oil is 30 C (90 F). If the oil temperature is 70 C (â&#x20AC;&#x2DC;160 F), the maximum speed is 39 mm (1.5 in.) per 10 minutes.

2. Raise carriage and the load 1 m (3 ft). If carriage lowers slowly with control valve in a NEUTRAL position, there are leaks inside the hydraulic system. The maximum speed the carriage is allowed to lower is 50 mm (2 in.) per 10 minutes when the hydraulic oil is 30 C (90 F). If the oil temperature is 70 C (160 F), the maximum speed the carriage can lower is 150 mm (6 in.) per 10 minutes. 3. Check lift cylinder for internal leaks. Remove load from forks. Install gate valve in supply line between main control valve and mast. Put a capacity load on the forks again. Raise carriage 1 m (3 ft). Close gate valve. If the carriage or mast weldments lower slowly, the seals in the lift cylinders have leaks.

2. If the leak rate is greater than the specifications, remove load from mast. Install valve between port at front of tilt cylinder and hydraulic line. Put load on forks again. Close valve. If mast tilts slowly forward, cylinder seals are leaking. 3. If mast does not move, open gate valve and check movement again. If mast moves forward when gate valve is open, check for leaks in hydraulic lines and fittings. If no leaks are found, check main control valve for damage. Remove load from forks.

Lift Chain Adjustments

4000 SRM 340

Tilt Cylinder Stroke and Backward Tilt Angle Adjustment 1. Adjust tilt cylinders without tilt limit spacers as follows (see Figure 26): a. Tilt mast backward slowly until one rod is against its stop. Turn rod on opposite tilt cylinder out until both rods stop at the same time. If necessary, loosen a fitting on the tilt cylinder to release pressure in cylinder. b. Repeat procedure to make sure rods stop at the same time within 1 mm (0.04 in.). Check that tilt angles are correct as specified on nameplate of lift truck. 2. Adjust tilt cylinders with tilt limit spacers as follows: a. Tilt mast forward slowly until one rod is against its stop. Turn rod on opposite tilt cylinder in until both rods stop at the same time. If necessary, loosen a fitting on tilt cylinder to release pressure in cylinder. Repeat procedure to make sure rods stop at the same time within 1 mm (0.04 in.). b. Tilt mast backward until one rod end touches its spacer. Add shims at opposite spacer (if necessary) so both rod ends touch their spacers at the same time within 1 mm (0.04 in.).

1. 2. 3. 4. 5. 6.

TILT CYLINDER MAST SPACER O-RING SHIM ROD END

7. BUSHING (INSTALL AS SHOWN) 8. PIN 9. ANCHOR PIN 10. CAPSCREW

Figure 26. Tilt Cylinder Arrangement

c. Check that tilt angles are correct as specified on nameplate of lift truck.

Lift Chain Adjustments When correctly adjusted: • The tension will be the same on each chain of the chain set. Check tension by pushing on both chains at the same time. • The chain length will be correct. • The chains must travel freely through the complete cycle. 1. Put a load equal to 80 to 90% of the capacity load on forks. Lower forks as much as possible. Tilt mast fully backward.

2. Check the amount the bottom carriage roller extends below the inner channel of the mast. See Figure 27. The carriage roller must not extend more than 34 mm (1.3 in.) of the roller diameter below the inner channel. If the adjustment is not correct, remove load and adjust chain anchors. Make sure each chain anchor is adjusted the same amount. Put mast in a vertical position and adjust chain anchors so lower edge of bottom carriage bar is 82.5 mm (3.25 in.) above floor.

4000 SRM 340

Mast Adjustments 3. Remove load from forks. Check clearance of carriage when mast is fully extended. The carriage stops must not touch the stop on the top crossmember of the inner weldment. The chains are too tight if the carriage touches the crossmember. Put mast in a vertical position. Lower carriage and check clearance between heel of the fork and the surface (floor). Adjust lift chains so that clearance is 0.06 mm (0.25 in.). If the adjustment is not correct, adjust chain anchors. Make sure each anchor is adjusted the same amount.

1. 2. 3. 4.

TILT MAST FULLY BACKWARD CARRIAGE ROLLER FORK CARRIAGE ROLLER MUST NOT EXTEND MORE THAN 34 mm (1.3 in.) BELOW INNER MAST CHANNEL Figure 27. Lift Chains Adjustment

NOTE: When the chain adjustments are complete, make sure the threads on the nuts of the chain anchors are completely engaged. Make sure the nuts on the chain anchors are not tight against the mounts. The chain anchors must be free to move in their sockets. 4. Three-stage mast chain adjustment: Adjust main lift chains so top of inner weldment is even with top of intermediate weldment within 1.5 mm (0.06 in.). Adjust free-lift chain as described in Step 3.

Mast Adjustments NOTE: Shims are installed on both sides of the load roller. Do not add or remove shims from the stub shafts. To change the position of the load roller on the stub shaft, move the shims from one side of the load roller to the other.

shaft on the opposite side of the weldment. The weldments will be approximately in the center. 2. Adjust the mast load rollers as follows:

During assembly, the shim arrangement will be approximately the same as before disassembly. Check clearance and adjust for wear or change because of repairs.

a. Use a crowbar to move the weldments from side to side to measure the amount of movement. Repeat in a minimum of three different positions of the weldments.

1. The load rollers control the alignment of the masts weldments. The alignment conditions are given on a list in Figure 28 with the most important condition first.

b. Separate weldments and change shim arrangements as needed. Assemble weldments. Slide weldment all the way to the top and bottom to find the tightest fit.

a. The weldments must be parallel to each other to decrease wear.

c. The number of shims under a load roller must be approximately the same as the stub shaft on the opposite side of the weldment. The weldments will be approximately in the center.

b. The maximum side clearance between the load roller and the channel at the point of tightest fit is 0.8 mm (0.030 in.). c. The number of shims under a load roller must be approximately the same as the stub

Mast Adjustments

4000 SRM 340

NOTE: USE SHIMS TO KEEP CARRIAGE AND MAST WELDMENTS PARALLEL, TO GIVE APPROXIMATELY EQUAL SPACE BETWEEN BOTH SIDES OF CARRIAGE AND WELDMENTS, AND TO GIVE CORRECT CLEARANCE AT TIGHTEST FIT. A. TOP VIEW B. UPRIGHT FRONT VIEW

C. CARRIAGE FRONT VIEW

1. 2. 3. 4. 5. 6. 7. 8.

9. PARALLEL 10. INSTALL ALL SHIMS ON OUTSIDE OF ROLLER UNDER SNAP RING 11. USE SHIMS TO ADJUST 0.13 to 0.5 mm (0.005 to 0.020 in.) AT POINT OF TIGHTEST FIT* *MOVE SHIMS FROM ONE SIDE OF ROLLER TO OTHER SIDE TO CHANGE POSITION OF ROLLER ON STUB SHAFT.

CHANNEL (WELDMENT) LOAD ROLLER STUB SHAFT SNAP RING SHIMS* PARALLEL 0.1 to 0.8 mm (0.004 to 0.030 in.) EQUAL SPACE WITHIN 1.5 mm (0.060 in.)

Figure 28. Mast and Carriage Adjustments d. Measure the distance between the channels of the weldments on the top and bottom. Change shims to keep the distance equal between the top and bottom of the weldments. Also make sure weldments are parallel within 1.5 mm (0.060 in.).

3. Adjust strip bearings. See Figure 29. Insert shims between strip bearing and channel. Adjust strip bearings so maximum clearance at the point of tightest fit is 0.8 mm (0.030 in.).

4000 SRM 340

Carriage Adjustment

4. SHIMS 5. O-RING

1. STRIP BEARING 2. LOAD ROLLER 3. WELDMENTS

Figure 29. Strip Bearings Adjustment

Carriage Adjustment 1. Install the load rollers and side rollers on the carriage. Install the shims for the load rollers in the same sequence on the stub shaft as before disassembly. Do not put any shims under the top load rollers. See Figure 28. 2. Use a lifting device to raise the carriage up the inner weldment. Find the point of tightest fit between the load rollers and the inner weldment. 3. Remove the carriage from the mast. Adjust the shim arrangement for each load roller for clearance between the roller and the inner weldment. Maximum clearance is 0.8 mm (0.030 in.) at the point of tightest fit. Repeat Step 2 and Step 3 if necessary.

side rollers and the inner weldment. Adjust the shim arrangement under each side roller so that maximum clearance is 0.8 mm (0.030 in.) at the point of tightest fit. 5. Keep the shim arrangement on each side of the carriage approximately equal. The carriage must be parallel with the inner weldment within 1.5 mm (0.060 in.).

CAUTION Too much grease will cause the rollers to slide and wear flat areas on the rollers. 6. After adjustment, lubricate the channels with a thin layer of grease.

4. Install the shims for the side rollers. Use a lifting device to raise the carriage up the inner weldment. Find the point of tightest fit between the

Troubleshooting

4000 SRM 340

Troubleshooting PROBLEM No movement of the lift cylinders.

Slow action of the lift cylinders.

Rough movement of the mast assembly.

POSSIBLE CAUSE

PROCEDURE OR ACTION

Lift control linkage is disconnected.

Connect control linkage.

No hydraulic oil or not enough hydraulic oil to the lift cylinders.

Fill hydraulic oil tank to proper limits.

There are leaks in the hydraulic system.

Repair leaks in hydraulic system.

Hydraulic pump does not operate or is damaged.

Repair or replace hydraulic pump.

The hydraulic pump drive is damaged.

Repair or replace hydraulic pump drive.

Relief valve pressure is set too low.

Adjust relief valve pressure.

The check valve does not close.

Repair check valve.

Not enough hydraulic oil to the lift cylinders.

Fill hydraulic oil tank to proper limits.

Bad seal in the lift cylinders.

Repair cylinder.

Lift cylinders have internal or external leaks.

Repair cylinder.

Relief valve pressure is set too low.

Adjust relief valve pressure.

Air in the hydraulic system.

Bleed air from hydraulic system.

Bent cylinder rod or damaged cylinder shell.

Replace damaged cylinder.

The lowering control valve function does not operate correctly.

Repair lowering control valve.

The mast assembly is damaged or needs alignment.

Replace damaged mast section or align mast assembly.

4000 SRM 340

PROBLEM The movement of the tilt cylinders is slow or not smooth.

The tilt cylinders permit mast movement when the control lever is in the Neutral position.

The tilt cylinders tilt the mast forward and backward too slowly.

No movement of the sideshift cylinder.

Troubleshooting

POSSIBLE CAUSE

PROCEDURE OR ACTION

No hydraulic oil or not enough hydraulic oil to the tilt cylinders.

Fill hydraulic oil tank to proper limits.

Bad seals in the tilt cylinders.

Repair tilt cylinder.

Restriction in the hydraulic lines of the tilt system.

Clear hydraulic lines of all restrictions.

Air in the hydraulic system.

Bleed air from hydraulic system.

The tilt cylinders have internal damage.

Replace damaged cylinder.

The seals in the tilt cylinders are worn or damaged.

Repair tilt cylinder.

The main control valve is damaged or has an internal leak.

Repair or replace main control valve.

There are leaks in the hydraulic system.

Repair leaks in hydraulic system.

The main control valve is worn or damaged.

Repair or replace main control valve.

There is a leak in the hydraulic system.

Repair leak in hydraulic system.

The relief valve for the hydraulic system is not correct.

Adjust relief valve pressure.

Linkage at the control valve is disconnected.

Connect and adjust control valve linkage.

No oil or not enough oil in the hydraulic tank.

Fill hydraulic oil tank to proper limits.

Relief valve is not set correctly.

Adjust relief valve pressure.

Hydraulic pump does not operate or is damaged.

Repair or replace hydraulic pump.

Troubleshooting

4000 SRM 340

PROBLEM Slow movement sideshift cylinder.

Rough movement sideshift carriage.

POSSIBLE CAUSE

the

Sideshift cylinder moves the carriage in the opposite direction as indicated by the control lever.

PROCEDURE OR ACTION

No oil or not enough oil to the sideshift cylinder.

Fill hydraulic oil tank to proper limits.

Cylinder has internal or external leaks.

Repair cylinder.

Relief valve is not set correctly.

Adjust relief valve pressure.

There is a restriction in a hydraulic line.

Clear hydraulic lines of all restrictions.

Load is more than capacity.

Reduce load to be within the capacity given on nameplate.

There is air in the hydraulic system.

Bleed air from hydraulic system.

Lift cylinder(s) is damaged.

Repair cylinder.

Bushing(s) are damaged or not installed correctly.

Replace bushings.

Bushings are not lubricated correctly.

Lubricate bushings.

Hydraulic lines are not correctly connected.

Disconnect hydraulic lines and reconnect correctly.

METRIC AND INCH (SAE) FASTENERS ALL MODELS

PART NO. 910442

8000 SRM 231

Metric and Inch (SAE) Fasteners

Table of Contents

1 1 1 2 2 7 9

This section is for the following models: All Models

8000 SRM 231

General

General THREADED FASTENERS Threaded fasteners, like bolts, nuts, capscrews, and studs, are made to specifications that describe the mechanical strength and hardness of the fastener. A fastener used in a design application is selected according to its specifications. Hyster® Company buys parts from many countries. Parts that are purchased must be to Hyster® Company standards. There are several standards used by these countries in the manufacture of threaded fasteners. Many of these fasteners are similar, but cannot be used as a direct replacement. To make sure that you have the correct fastener, order fasteners and parts through the Hyster® Parts Depot. Service persons must use replacement fasteners that have the same specifications. Fasteners made to each specification have identification marks for that specification. This specification is commonly called "Grade" for SAE standards and "property class" for metric standards. This section describes the identification of some common fasteners. The metric system used by Hyster® Company is described as SI (Le Systeme d’Unites or the International System of units, also called SI in all languages). The SI System of measurement is described in ISO Standard 1000, 1973. A conversion table of common measurements is shown in Table 7.

shown first in the series [M12 = 12 mm, M20 = 20 mm (1/2 = 1/2 in., 3/4 = 3/4 in.)]. The number of threads per inch is normally not shown for inch nomenclature and only the UNC (Unified National Coarse) or UNF (Unified National Fine) is shown. This number of threads per inch is not shown because a UNC or UNF fastener has a standard number of threads per inch for a specific diameter. Metric fasteners show the number of threads per millimeter. The length of the shank is often indicated as part of the description of a fastener. This length is shown in inches for inch fasteners and in millimeters for metric fasteners. A capscrew will have the following description: Metric

Inch

M12 × 1.75 × 50

1/2 × 13 UNC × 1-1/2

ABC

ABCD

A = Thread Size

A = Shank Diameter

B = Pitch

B = Number of Threads Per Unit of Length

C = Length

C = type of Thread D = Shank Length

NOMENCLATURE, THREADS The thread design is specified by a series of numbers and letters for inch and metric fasteners. See Figure 1. The diameter of the shank of the fastener is

Figure 1. Thread Design

General

8000 SRM 231

STRENGTH IDENTIFICATION CAUTION When fasteners must be replaced, the new fasteners must be of the same strength or greater than the original fasteners. The new fasteners must also be the correct size. NOTE: Identification marks are according to bolt strength. The higher the number or the increase in the number of marks indicates increased bolt strength. The most common property classes for metric fasteners are 8.8 and 10.9. The property class is marked with a number on the head of the capscrew or on a nut. Property classes less than 8.8 are often not marked. Grades for inch bolts go from 2 to 8. Grade 2 fasteners normally do not have any marks. The following tables show the marks that identify the grades and property classes for different fasteners.

Figure 2. Minimum Angle Between Cotter Pin Legs Unless otherwise specified, the legs of chain anchor cotter (split) pins are to be bent against the pin. See Figure 3.

COTTER (SPLIT) PINS Cotter (split) pins are used in many applications on your forklift. They are typically used to retain parts such as pins and nuts. Cotter (split) pins are typically not used as load-bearing members. Service personnel must use new cotter (split) pins. Do not reuse a cotter (split) pin. Replacement cotter (split) pin must be of the correct size. See Table 8. The legs of a cotter (split) pin are bent for the following reasons: â&#x20AC;˘ To retain the cotter (split) pin in the part â&#x20AC;˘ To provide clearance between the cotter pin legs and other parts or members. One or both cotter (split) pin legs must be bent to provide a minimum 90 angle between the legs. See Figure 2.

1. COTTER PIN Figure 3. Cotter (Split) Pins Used On Mast Chain Anchors

8000 SRM 231

General Table 1. Bolts and Screws

General

8000 SRM 231 Table 2. Studs and Nuts

8000 SRM 231

General Table 3. Torque Nuts

General

8000 SRM 231 Table 4. Torque Nuts With Nylon Insert

8000 SRM 231

General

FASTENER TORQUE TABLES Table 5. Torque Values for Metric Fasteners*

Size and Pitch

Property Class 5.8 1

Grade 8.8 2

Grade 10.9 3

N•m

lbf ft

N•m

lbf ft

N•m

lbf ft

M3 × 0.5 M3.5 × 0.6 M4 × 0.7 M5 × 0.8 M6 × 1

0.62 0.97 1.44 2.91 4.94

0.5 0.7 1.1 2.1 3.6

0.99 1.55 2.30 4.65 7.90

0.7 1.1 2.1 3.6 6

1.34 2.11 3.13 6.33 10.8

1.0 1.6 2.3 4.7 8

M8 × 1.25 M8 × 1 M10 × 1.5 M10 × 1.25

12.0 12.8 23.8 25.1

9 9 18 19

19.2 20.5 38.0 40.1

14 15 28 30

26.1 27.9 52 55

19 21 38 41

M12 × 1.75 M12 × 1.25 M14 × 2 M14 × 1.5

41.4 45.3 66 72

31 33 49 53

66 72 105 115

49 53 77 85

90 98 145 155

66 72 105 115

M16 × 2 M16 × 1.5 M20 × 2.5 M20 × 1.5

105 110 200 225

77 81 150 165

165 175 320 355

122 130 235 260

225 240 435 485

165 175 320 360

345 375 505 550

255 275 370 405

555 605 810 875

410 445 600 645

755 820 1,100 1,190

560 605 810 880

690 715 765 940 1,030

510 530 565 695 760

1,100 1,140 1,220 1,500 1,640

810 840 900 1,100 1,210

1,500 1,550 1,660 2,040 2,240

1,100 1,140 1,230 1,510 1,660

1,200 1,280 1,560 1,640

885 945 1,150 1,210

1,930 2,040 2,490 2,630

1,430 1,510 1,840 1,940

2,620 2,780 3,390 3,570

1,940 2,050 2,500 2,640

1,930 2,070 2,410 2,580 2,900 3,160

1,430 1,530 1,780 1,910 2,140 2,330

3,080 3,320 3,850 4,120 4,630 5,040

2,280 2,450 2,840 3,040 3,420 3,720

4,200 4,510 5,240 5,610 6,300 6,860

3,100 3,330 3,870 4,140 4,650 5,060

M24 M24 M27 M27

× × × ×

3 2 3 2

M30 × 3.5 M30 × 3 M30 × 2 M33 × 3.5 M33 × 2 M36 M36 M39 M39

× × × ×

4 3 4 3

M42 × 4.5 M42 × 3 M45 × 4.5 M45 × 3 M48 × 5 M48 × 3

* Unless otherwise specified 1 Approximately equal to Grade 2 2 Approximately equal to Grade 5 3 Approximately equal to Grade 8

General

8000 SRM 231 Table 6. Torque Values for Inch Fasteners* Grade 21

Size and Pitch

Grade 52

lbf ft

N•m

lbf ft

N•m

lbf ft

N•m

1/4 1/4

20 UNC 28 UNF

4 5

6 6

6 7

9 10

12 14

5/16 5/16

18 UNC 24 UNF

8 9

11 13

13 14

18 20

25 28

3/8 3/8

16 UNC 24 UNF

15 17

20 23

23 26

31 36

33 37

44 50

7/16 7/16

14 UNC 20 UNF

24 27

33 36

37 41

50 56

52 58

71 79

1/2 1/2

13 UNC 20 UNF

37 41

50 56

57 64

77 86

80 90

110 120

9/16 9/16

12 UNC 18 UNF

53 59

72 80

82 91

110 125

115 130

155 175

5/8 5/8

11 UNC 18 UNF

73 83

99 110

115 130

155 175

160 180

215 245

3/4 3/4

10 UNC 16 UNF

130 145

175 195

200 225

270 300

280 315

380 425

7/8 7/8

9 UNC 14 UNF

125 140

170 185

320 355

435 480

455 500

615 680

1 1

8 UNC 14 UNF

185 210

255 285

485 540

655 735

680 765

925 1,040

1-1/8 1-1/8

7 UNC 12 UNF

265 300

360 405

595 670

805 905

965 1,080

1,310 1,470

1-1/4 1-1/4

7 UNC 12 UNF

375 415

510 565

840 930

1,140 1,260

1,360 1,500

1,850 2,050

1-3/8 1-3/8

6 UNC 12 UNF

490 560

665 760

1,100 1,250

1,490 1,700

1,780 2,040

2,420 2,760

1-1/2 1-1/2

6 UNC 12 UNF

650 735

885 995

1,460 1,650

1,980 2,230

2,370 2,670

3,210 3,620

* Unless otherwise specified 1 Approximately equal to metric Property Class 5.8 2 Approximately equal to metric Property Class 8.8 3 Approximately equal to metric Property Class 10.9

Grade 83

8000 SRM 231

General

CONVERSION TABLE Table 7. Conversion Table for Metric and English Units By

Multiply

To Get

Multiply

To Get

× 0.155

= inches

Area inches feet

(in. )

(ft 2)

× 6.452

= centimeters

× 0.093

= meters

(cm )

centimeters

(m 2)

meters

(cm 2)

(m 2)

× 10.764 = feet

(in. 2)

(ft 2)

Linear inches (in.)

× 25.4

= millimeters (mm)

millimeter (mm)

× 0.039

= inches (in.)

feet (ft)

× 0.305

= meters (m)

meter (m)

× 3.281

= feet (ft)

yards (yd)

× 0.914

= meters (m)

meter (m)

× 1.094

= yards (yd)

miles (mi)

× 1.609

= kilometers (km)

kilometer (km)

× 0.621

= miles (mi)

Mass ounces (oz)

× 28.35

= grams (g)

grams (g)

× 0.035

= ounces (oz)

pounds (lb)

× 0.454

= kilograms (kg)

kilograms (kg)

× 2.205

= pounds (lb)

tons (2,000 lb)

× 907.18

= kilograms (kg)

kilograms (kg)

× 0.001

= tons (2,000 lb)

tons (2,000 lb)

× 0.907

= metric ton (t)

metric ton (t)

× 1.102

= tons (2,000 lb)

× 1.34

= horsepower (hp)

Power horsepower (hp)

× 0.746

= kilowatts (kW)

kilowatts (kW)

Pressure pounds/in.

(psi)

× 6.895

= kilopascal (kPa)

kilopascals (kPa)

× 0.145

= pounds/in.

(psi)

pounds/in.

(psi)

× 0.007

= megapascal (MPa)

megapascals (MPa)

× 145.04 = pounds/in.

(psi)

Temperature ( Fahrenheit 32)

× 0.56

= Celsius (C)

( Celsius × 1.8) +32

= Fahrenheit

Torque pound inches (lbf in.)

× 0.113

= Newton meter (N•m)

Newton meter (N•m)

× 8.851

= pound inches (lb f in.)

pound feet (lbf ft)

× 1.356

= Newton meter (N•m)

Newton meter (N•m)

× 0.738

= pound feet (lb f ft)

× 0.621

= miles/hour (mph)

× 0.061

= inches

(in. 3)

Velocity miles/hour (mph)

× 1.609

= kilometer/hour (km/h) kilometer/hr (km/h)

Volume inches

(in. )

× 16.387

= centimeters

inches

(in. 3)

× 0.016

= liters (l)

liters (l)

× 61.024 = inches

quarts, U.S. (qt)

× 0.946

= liters (l)

liters (l)

× 1.057

= quarts, U.S. (qt)

quarts, U.S. (qt)

× 0.83

= quarts, Imp. (qt)

quarts, Imp. (qt)

× 1.205

= quarts, U.S. (qt)

gallons, U.S. (gal)

× 3.785

= liters (l)

liters (l)

× 0.264

= gallons, U.S. (gal)

gallons, U.S. (gal)

× 0.83

= gallons, Imp. (gal)

gallons, Imp. (gal)

× 1.205

= gallons, U.S. (gal)

ounces (oz)

× 29.57

= milliliters (ml)

milliliters (ml)

× 0.034

= ounces (oz)

(cm )

centimeters

(cm 3)

General

8000 SRM 231 Table 8. Cotter Pin Dimensional Data

Nominal Size A

Shank Diameter A

Head Dia. B

Length of Extended Prong C

Recommended Hole Size

max

min

max

min

max

1.00 mm (0.031 in.)

0.90 mm (0.035 in.)

0.70 mm (0.028 in.)

1.50 mm (0.060 in.)

1.52 mm (0.060 in.)

0.25 mm (0.01 in.)

0.91 mm (0.036 in.)

1.37 mm (0.054 in.)

1.60 mm (0.047 in.)

1.20 mm (0.048 in.)

0.90 mm (0.035 in.)

1.50 mm (0.060 in.)

2.54 mm (0.10 in.)

0.51 mm (0.02 in.)

1.50 mm (0.059 in.)

1.78 mm (0.070 in.)

2.00 mm (0.062 in.)

1.50 mm (0.060 in.)

1.30 mm (0.051 in.)

2.40 mm (0.094 in.)

2.54 mm (0.10 in.)

0.76 mm (0.03 in.)

1.90 mm (0.075 in.)

2.18 mm (0.086 in.)

2.50 mm (0.094 in.)

2.30 mm (0.091 in.)

2.10 mm (0.083 in.)

4.00 mm (0.158 in.)

2.54 mm (0.10 in.)

1.00 mm (0.04 in.)

2.41 mm (0.095 in.)

2.95 mm (0.116 in.)

3.20 mm (0.125 in.)

3.00 mm (0.120 in.)

2.70 mm (0.106 in.)

5.10 mm (0.201 in.)

3.30 mm (0.13 in.)

1.52 mm (0.06 in.)

3.12 mm (0.123 in.)

3.76 mm (0.148 in.)

4.00 mm (0.156 in.)

3.80 mm (0.150 in.)

3.50 mm (0.138 in.)

6.50 mm (0.256 in.)

4.06 mm (0.16 in.)

1.78 mm (0.07 in.)

3.94 mm (0.155 in.)

4.55 mm (0.179 in.)

5.00 mm (0.188 in.)

4.60 mm (0.181 in.)

4.40 mm (0.172 in.)

8.00 mm (0.315 in.)

4.06 mm (0.16 in.)

2.03 mm (0.08 in.)

4.93 mm (0.194 in.)

5.33 mm (0.210 in.)

6.30 mm (0.250 in.)

5.90 mm (0.232 in.)

5.60 mm (0.220 in.)

10.3 mm (0.406 in.)

4.06 mm (0.16 in.)

2.03 mm (0.08 in.)

6.22 mm (0.245 in.)

6.96 mm (0.274 in.)

8.00 mm (0.312 in.)

7.50 mm (0.295 in.)

7.00 mm (0.275 in.)

13.1 mm (0.516 in.)

4.06 mm (0.16 in.)

2.03 mm (0.08 in.)

7.85 mm (0.309 in.)

8.28 mm (0.326 in.)

9.50 mm (0.375 in.)

9.50 mm (0.374 in.)

8.40 mm (0.329 in.)

16.6 mm (0.654 in.)

6.35 mm (0.25 in.)

4.06 mm (0.16 in.)

9.45 mm (0.372 in.)

9.73 mm (0.383 in.)

13.0 mm (0.500 in.)

12.4 mm (0.488 in.)

11.9 mm (0.467 in.)

21.7 mm (0.854 in.)

6.35 mm (0.25 in.)

3.05 mm (0.12 in.)

12.62 mm (0.497 in.)

13.21 mm (0.520 in.)

16.0 mm (0.625 in.)

15.4 mm (0.606 in.)

15.0 mm (0.590 in.)

27.0 mm (1.063 in.)

8.89 mm (0.35 in.)

3.05 mm (0.12 in.)

15.80 mm (0.622 in.)

16.28 mm (0.641 in.)

8000 SRM 231

General Table 9. Cotter Pin Dimensional Data

Nominal Length L

Length Range

Nominal Size - Part Numbers 1.00 mm (0.031 in.)

1.60 mm (0.047 in.)

2.00 mm (0.062 in.)

2.50 mm (0.094 in.)

3.20 mm (0.125 in.)

5.50 mm (0.217 in.)

0221870

0221875

10.5 mm (0.413 in.)

8.80 mm (0.345 in.)

0221871

0221876

12.7 mm (0.500 in.)

13.5 mm (0.530 in.)

11.5 mm (0.453 in.)

0221872

0221877

0015200

0015211

0015221

19.05 mm (0.750 in.)

20.5 mm (0.807 in.)

18.3 mm (0.720 in.)

0221873

0221878

0015201

0015212

0015222

25.4 mm (1.000 in.)

26.9 mm (1.060 in.)

23.9 mm (0.940 in.)

0221874

0221879

0015202

0015213

0015223

31.75 mm (1.250 in.)

33.3 mm (1.310 in.)

29.2 mm (1.150 in.)

0015203

0015216

0015224

38.1 mm (1.500 in.)

40.9 mm (1.610 in.)

36.6 mm (1.440 in.)

0015204

0015217

0015225

44.45 mm (1.750 in.)

46.0 mm (1.810 in.)

42.9 mm (1.690 in.)

0015205

0015218

0015226

50.8 mm (2.000 in.)

52.3 mm (2.060 in.)

49.3 mm (1.940 in.)

0015206

0015219

0015227

57.15 mm (2.250 in.)

58.7 mm (2.310 in.)

55.1 mm (2.170 in.)

0015220

0056997

63.5 mm (2.500 in.)

65.0 mm (2.560 in.)

62.0 mm (2.440 in.)

0221894

0015229

69.85 mm (2.750 in.)

72.1 mm (2.840 in.)

68.3 mm (2.690 in.)

0015230

76.2 mm (3.000 in.)

81.3 mm (3.200 in.)

74.7 mm (2.940 in.)

0015279

88.9 mm (3.500 in.)

91.4 mm (3.600 in.)

87.4 mm (3.440 in.)

101.6 mm (4.000 in.)

113.3 mm (4.460 in.)

98.8 mm (3.890 in.)

max

min

6.35 mm (0.250 in.)

7.10 mm (0.280 in.)

9.525 mm (0.375 in.)

General

8000 SRM 231

Table 9. Cotter Pin Dimensional Data (Continued) Nominal Length L

Length Range max

min

127.0 mm (5.000 in.)

128.5 mm (5.060 in.)

123.7 mm (4.870 in.)

152.4 mm (6.000 in.)

153.9 mm (3.060 in.)

5.460 mm (138.7 in.)

Nominal Size - Part Numbers 1.00 mm (0.031 in.)

1.60 mm (0.047 in.)

2.00 mm (0.062 in.)

2.50 mm (0.094 in.)

3.20 mm (0.125 in.)

Table 10. Cotter Pin Dimensional Data Nominal Length L

Length Range 4.00 mm (0.156 in.)

5.00 mm (0.188 in.)

18.3 mm (0.720 in.)

0015232

0015241

23.9 mm (0.940 in.)

0015233

0015242

max

min

6.35 mm (0.250 in.)

7.10 mm (0.280 in.)

5.50 mm (0.217 in.)

9.525 mm (0.375 in.)

10.5 mm (0.413 in.)

8.80 mm (0.345 in.)

12.7 mm (0.500 in.)

13.5 mm (0.530 in.)

11.5 mm (0.453 in.)

19.05 mm (0.750 in.)

20.5 mm (0.807 in.)

25.4 mm (1.000 in.)

26.9 mm (1.060 in.)

Nominal Size - Part Numbers 6.30 mm (0.250 in.)

8.00 mm (0.312 in.)

0015251

0015261

9.52 mm (0.375 in.)

8000 SRM 231

General

Table 10. Cotter Pin Dimensional Data (Continued) Nominal Length L

Length Range

Nominal Size - Part Numbers 4.00 mm (0.156 in.)

5.00 mm (0.188 in.)

6.30 mm (0.250 in.)

8.00 mm (0.312 in.)

9.52 mm (0.375 in.)

29.2 mm (1.150 in.)

0015234

0015243

0015252

0015262

0221884

40.9 mm (1.610 in.)

36.6 mm (1.440 in.)

0015235

0015244

0015253

0015263

0221885

44.45 mm (1.750 in.)

46.0 mm (1.810 in.)

42.9 mm (1.690 in.)

0015236

0015245

0015254

0015264

0221886

50.8 mm (2.000 in.)

52.3 mm (2.060 in.)

49.3 mm (1.940 in.)

0015237

0015246

0015255

0015265

0015271

57.15 mm (2.250 in.)

58.7 mm (2.310 in.)

55.1 mm (2.170 in.)

0015238

0015247

0015256

0221880

0221887

63.5 mm (2.500 in.)

65.0 mm (2.560 in.)

62.0 mm (2.440 in.)

0015240

0015248

0015257

0221881

0015273

69.85 mm (2.750 in.)

72.1 mm (2.840 in.)

68.3 mm (2.690 in.)

0015280

0015249

0015258

0221882

0015286

76.2 mm (3.000 in.)

81.3 mm (3.200 in.)

74.7 mm (2.940 in.)

0015283

0015250

0015259

0015267

0015272

88.9 mm (3.500 in.)

91.4 mm (3.600 in.)

87.4 mm (3.440 in.)

0015239

0015284

0015266

0015274

101.6 mm (4.000 in.)

113.3 mm (4.460 in.)

98.8 mm (3.890 in.)

0015301

0015260

0128754

0015275

127.0 mm (5.000 in.)

128.5 mm (5.060 in.)

123.7 mm (4.870 in.)

0221883

0015277

152.4 mm (6.000 in.)

153.9 mm (3.060 in.)

5.460 mm (138.7 in.)

max

min

31.75 mm (1.250 in.)

33.3 mm (1.310 in.)

38.1 mm (1.500 in.)

0221888

General

8000 SRM 231 Table 11. Cotter Pin Dimensional Data

Nominal Length L

Length Range

Nominal Size - Part Numbers 13.0 mm (0.500 in.)

16.00 mm (0.625 in.)

max

min

19.05 mm (0.750 in.)

20.5 mm (0.807 in.)

18.3 mm (0.720 in.)

25.4 mm (1.00 in.)

26.9 mm (1.060 in.)

23.9 mm (0.940 in.)

31.75 mm (1.250 in.)

33.3 mm (1.310 in.)

29.2 mm (1.150 in.)

38.1 mm (1.500 in.)

40.9 mm (1.610 in.)

36.6 mm (1.440 in.)

44.45 mm (1.750 in.)

46.0 mm (1.810 in.)

42.9 mm (1.690 in.)

0221889

50.8 mm (2.000 in.)

52.3 mm (2.060 in.)

49.3 mm (1.940 in.)

0221890

57.15 mm (2.250 in.)

58.7 mm (2.310 in.)

55.1 mm (2.170 in.)

0221891

63.5 mm (2.500 in.)

65.0 mm (2.560 in.)

62.0 mm (2.440 in.)

0221892

69.85 mm (2.750 in.)

72.1 mm (2.840 in.)

68.3 mm (2.690 in.)

0221893

0221895

76.2 mm (3.000 in.)

81.3 mm (3.200 in.)

74.7 mm (2.940 in.)

0015291

0221896

88.9 mm (3.500 in.)

91.4 mm (3.600 in.)

87.4 mm (3.440 in.)

0015292

0221897

101.6 mm (4.000 in.)

113.3 mm (4.460 in.)

98.8 mm (3.890 in.)

0015293

0221898

8000 SRM 231

General

Table 11. Cotter Pin Dimensional Data (Continued) Nominal Length L

Length Range

Nominal Size - Part Numbers 13.0 mm (0.500 in.)

16.00 mm (0.625 in.)

123.7 mm (4.870 in.)

0015295

0221899

138.7 mm (5.460 in.)

0015297

0221900

max

min

127.0 mm (5.000 in.)

128.5 mm (5.060 in.)

152.4 mm (6.000 in.)

153.9 mm (3.060 in.)

MICROPROCESSOR SPARK TIMING SYSTEM (MSTS) LATE MODEL GM 3.0L AND 4.3L LPG FUEL ENGINES

PART NO. 1473385

2200 SRM 765

Microprocessor Spark Timing System (MSTS)

Table of Contents

TABLE OF CONTENTS General ............................................................................................................................................................... Description ......................................................................................................................................................... What MSTS Does........................................................................................................................................... How MSTS Begins Operation ....................................................................................................................... Operation............................................................................................................................................................ Distributor ..................................................................................................................................................... Ignition Coil ................................................................................................................................................... Ignition Module.............................................................................................................................................. When Engine Is Being Started ..................................................................................................................... When Engine Is Running .............................................................................................................................. Manifold Absolute Pressure (MAP) Sensor .................................................................................................. Engine Coolant Temperature (ECT) Sensor................................................................................................. MSTS Module Corrections ............................................................................................................................ Troubleshooting.................................................................................................................................................. General ........................................................................................................................................................... Tools and Test Equipment ............................................................................................................................. MSTS .............................................................................................................................................................. Troubleshooting Procedure............................................................................................................................ Where to Start ........................................................................................................................................... Visual/Physical Inspection ........................................................................................................................ Knowledge/Tools Required ........................................................................................................................ Damage from Static Discharge (Static Electricity) ................................................................................. Troubleshooting Information ........................................................................................................................ Malfunction Indicator Lamp (MIL) .......................................................................................................... Connecting CodeMate Tester .................................................................................................................... Reading Diagnostic Trouble Codes (DTC)................................................................................................ Clearing Diagnostic Trouble Codes (DTC’s)............................................................................................. On-Board Diagnostic (OBD) System Check ................................................................................................. Test Description......................................................................................................................................... No Malfunction Indicator Lamp........................................................................................................................ Circuit Description ........................................................................................................................................ Test Description ............................................................................................................................................. No DTC-12, Malfunction Indicator Lamp ON .................................................................................................. Circuit Description ........................................................................................................................................ Test Description ............................................................................................................................................. Starter Rotates Engine, Engine Does Not Run ................................................................................................ Test Description ............................................................................................................................................. DTC-14 Engine Coolant Temperature (ECT) (Low Temperature Indicated).................................................. Circuit Description ........................................................................................................................................ Test Description ............................................................................................................................................. DTC-15 Engine Coolant Temperature Sensor (ECT) (High Temperature Indicated) .................................... Circuit Description ........................................................................................................................................ Test Description ............................................................................................................................................. DTC-34 Manifold Absolute Pressure (MAP) Sensor ........................................................................................ Circuit Description ........................................................................................................................................ Test Description ............................................................................................................................................. DTC-41 Electronic Spark Timing (EST) Open Circuit..................................................................................... Circuit Description ........................................................................................................................................ Test Description ............................................................................................................................................. DTC-42 Electronic Spark Timing (EST) Grounded Circuit ............................................................................. Circuit Description ........................................................................................................................................

1 2 2 2 3 3 3 3 4 5 6 6 7 8 8 10 11 11 11 11 11 11 12 12 12 13 14 14 14 16 16 16 18 18 18 19 19 23 23 23 25 25 25 27 27 27 30 30 30 32 32

Table of Contents

Microprocessor Spark Timing System (MSTS)

TABLE OF CONTENTS (Continued) Test Description ............................................................................................................................................. DTC-51 MSTS Failure ....................................................................................................................................... Circuit Description ........................................................................................................................................ Distributor Repair.............................................................................................................................................. Remove ........................................................................................................................................................... Disassemble ................................................................................................................................................... Inspect ............................................................................................................................................................ Assemble ........................................................................................................................................................ Install ............................................................................................................................................................. Ignition Timing .............................................................................................................................................. Ignition Module Repair...................................................................................................................................... Test For Fault ................................................................................................................................................ Replace ........................................................................................................................................................... Sensing Coil Repair ........................................................................................................................................... Test For Fault ................................................................................................................................................ Replace ........................................................................................................................................................... Ignition Coil Repair ........................................................................................................................................... Test For Fault ................................................................................................................................................ Remove ........................................................................................................................................................... Install ............................................................................................................................................................. MSTS Module Repair......................................................................................................................................... Remove ........................................................................................................................................................... Install ............................................................................................................................................................. ECT Sensor Replacement .................................................................................................................................. MAP Sensor Replacement ................................................................................................................................. This section is for the following models: GM 3.0L and 4.3L LPG Fuel Engines

32 34 34 34 34 35 35 35 36 36 37 37 38 38 38 38 39 39 39 39 40 40 40 40 41

2200 SRM 765

General

General This section describes the operation of the Microprocessor Spark Timing System (MSTS). The MSTS ignition system is used on engines that use an LPG fuel system. The description, operation, troubleshooting, and repair of the MSTS is identical for both the GM

3.0L and 4.3L engines. Illustrations in this manual show the MSTS in the 3.0L engine only. Repairs and Troubleshooting procedures are also in this section. Typical installation of the MSTS is shown in Figure 1.

1. ENGINE COOLANT TEMPERATURE (ECT) SENSOR 2. DISTRIBUTOR 3. MSTS MODULE

4. TACHOMETER CONNECTOR 5. IGNITION COIL 6. MAP SENSOR

Figure 1. MSTS Arrangement in Engine Compartment (Typical)

Description

2200 SRM 765

Description The general operation of the MSTS system is described in the following paragraphs. The description of the components and a circuit analysis is given in the paragraphs under Operation.

WHAT MSTS DOES The MSTS module receives signals from sensors mounted on the engine and electronically processes the information to adjust the ignition timing for the best fuel use and engine performance. See Figure 2.

Figure 2. MSTS Module The MSTS module receives signals from the following sensors:

â&#x20AC;˘ Manifold Absolute Pressure (MAP) sensor. This sensor is a pressure transducer that measures the atmospheric pressure before the engine is started. The MSTS module uses this pressure as a reference. This sensor then measures changes in pressure in the intake manifold during engine operation. â&#x20AC;˘ Engine Coolant Temperature sensor (ECT). This sensor is a thermistor (resistor that is calibrated to change its value as its temperature changes). â&#x20AC;˘ The ignition module is a small electronic module within the distributor. This module is a signal converter that senses the operation of the distributor. A sensing coil in the distributor senses the rotation of the timer core and the ignition module senses the speed of rotation. A square wave generator in the ignition module converts the pulses from the sensing coil to a square wave signal that is sent to the MSTS module. If the signals from the ignition module to the MSTS indicate that the engine is rotating at less than 400 rpm, the MSTS module determines that the engine is being rotated by the starter. The ignition module controls the ignition for an engine being started. The Electronic Spark Timing (EST) function from the MSTS module is deenergized. If the signals from the ignition module to the MSTS module indicate that the engine is rotating at greater than 400 rpm, the MSTS module determines that the engine is running and the Electronic Spark Timing (EST) controls the ignition.

Figure 3. Electronic Engine Control System

HOW MSTS BEGINS OPERATION When the ignition switch is turned to ON, the MSTS module measures the atmospheric pressure (BARO

signal) from the MAP sensor. See Figure 3. The MSTS module also checks the signal from the engine coolant temperature sensor (ECT). When the

2200 SRM 765

Operation

starter is engaged, the ignition module sends electronic pulses to the MSTS module. The frequency of the pulses indicates to the MSTS module that the engine is being started. The ignition module also electronically energizes (ON) and deenergizes (OFF) the primary circuit of the ignition coil to create a spark at the spark plugs. When the engine starts, the frequency of the pulses from the ignition module increases and indicates to the MSTS module that the engine is running. The

MSTS module then sends a bypass signal to the ignition module that removes control of the spark (ignition) timing from the ignition module. The MSTS module takes control of the ignition timing and follows its program to give ignition timing for the best engine operation. When the engine is operating, the MSTS module continuously checks the signals from the MAP, ECT, and distributor speed to make timing adjustments for the engine operating conditions.

Operation DISTRIBUTOR The distributor uses an internal magnetic pickup assembly that consists of a permanent magnet, pole piece with internal teeth and pickup coil. See Figure 4. When the rotating teeth of the timer core (permanent magnet) line up with the teeth of the pole piece, voltage is induced in the pickup coil. This voltage signals the ignition control module to trigger the primary ignition circuit bypass mode. Current flow in the primary circuit is interrupted and a high voltage of up to 35,000 volts is induced in the ignition coil secondary winding. This high voltage is directed through the secondary ignition circuit to fire the spark plugs. The principle of magnetic induction also controls the polarity of the voltage generated in the pickup coil. An increasing magnetic field will generate a voltage in the coil that is the opposite polarity of a magnetic field that is decreasing. This signal pulse causes the integrated circuits in the ignition module to generate a square wave signal. The ignition module and a magnetic pulse generator control the primary circuit to the ignition coil when the engine is started. After the engine is started, the MSTS module receives the square wave signal from the magnetic pulse generator and ignition module as one of the signals to control the EST. The pole piece has the same number of teeth as the engine has cylinders so that a spark voltage is correctly sent to each spark plug as the shaft in the distributor rotates.

IGNITION COIL The ignition coil generates a secondary voltage of up to 35,000 volts. The ignition coil connects to the distributor cap through a high voltage wire. There are two connectors on the coil used for battery voltage input, primary voltage output to the ignition module,

trigger signal from the ignition module and the tach output signal.

1. ROTOR 2. TIMER CORE/SHAFT 3. RETAINER 4. SHIELD

5. 6. 7. 8.

COIL POLE PIECE IGNITION MODULE HOUSING

Figure 4. Distributor

IGNITION MODULE The ignition module is a solid-state electronic device that operates like a fast switch except that it does not have any moving or mechanical parts. See Figure 5. Small electrical pulses from the sensing coil of the pulse generator go to the ignition module.

Operation

2200 SRM 765

The MSTS module must always know the speed at which the engine is operating. The engine speed signal is generated by the ignition module. The signal converter in the ignition module changes the signal voltage from the sensing coil to a square wave reference signal to the MSTS module. This square wave reference signal for engine speed is called REF HI. The MSTS module must also have a reference to compare with REF HI. An additional wire between the MSTS module and the ignition module is called REF LO. The REF HI and REF LO connections give the EEPROM in the MSTS module the necessary information about engine speed. The other two wires between the MSTS module and the distributor control the Electronic Spark Timing and are called EST and BYPASS. NOTE: The ignition module controls spark timing only when the engine is being started. The MSTS module controls the spark timing during engine operation. The ignition module will also control the spark timing if there are some failures in the signals to the MSTS module. This backup mode of operation will often permit operation of the engine so that the lift

truck can be moved to an area for repair. The results of the failures in signals to the MSTS module is described in the paragraphs under MSTS Module Corrections.

WHEN ENGINE IS BEING STARTED When the engine is rotated by the starter, the electronic relay is in the deenergized position. See Figure 5. The sensing coil is connected through the square wave generator to the base of the transistor. When the sensing coil applies a positive voltage (the square wave voltage is increasing) to the transistor, the transistor goes ON. When the voltage from the sensing coil changes to negative (the square wave voltage is decreasing), the transistor goes OFF. When the transistor is ON, current flows through the primary winding of the ignition coil. When the transistor goes OFF, the current flow through the primary winding stops. The changing magnetic field in the primary winding generates a high voltage in the secondary winding of the ignition coil. This high voltage generates a spark at the spark plug.

Figure 5. Ignition Module When Engine is Being Started

2200 SRM 765

Operation Legend for Figure 5

NOTE: THE NUMBER IN FRONT OF THE PIN DENOTES THE CONNECTOR. FOR EXAMPLE, 6E IS PIN E ON THE 6-PIN CONNECTOR WHILE 5E IS PIN E ON THE 5-PIN CONNECTOR. 1. 2. 3. 4.

IGNITION MODULE ELECTRONIC RELAY SQUARE WAVE GENERATOR SENSING COIL

WHEN ENGINE IS RUNNING When the engine speed is approximately 400 rpm, the MSTS module determines that the engine is running and applies 5 volts on the BYPASS wire to the ignition module. See Figure 6. This voltage energizes the electronic relay and makes the following

5. 6. 7. 8.

MSTS MODULE BATTERY VOLTAGE TO IGNITION COIL TRANSISTOR

changes: The EST wire is not grounded and is now connected to the base of the transistor. The sensing coil is disconnected from the base of the transistor. The ignition module and the ignition timing is now controlled by the EST signal from the MSTS module. This mode of operation is called the EST mode.

NOTE: THE NUMBER IN FRONT OF THE PIN DENOTES THE CONNECTOR. FOR EXAMPLE, 6E IS PIN E ON THE 6-PIN CONNECTOR WHILE 5E IS PIN E ON THE 5-PIN CONNECTOR. 1. 2. 3. 4.

IGNITION MODULE ELECTRONIC RELAY SQUARE WAVE GENERATOR SENSING COIL

5. 6. 7. 8.

MSTS MODULE BATTERY VOLTAGE TO IGNITION COIL TRANSISTOR

Figure 6. Ignition Module When Engine is Running

Operation

2200 SRM 765

MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR The Manifold Absolute Pressure (MAP) sensor is a pressure transducer that measures changes in the pressure in the intake manifold. See Figure 7. The pressure changes are a result of engine load and speed changes. The MAP sensor converts these pressure changes to a signal voltage to the MSTS module.

the engine is started. The MSTS module remembers the barometric pressure (BARO signal) after the engine is running. The MSTS module then automatically adjusts the ignition timing for different altitudes and atmospheric conditions.

ENGINE COOLANT TEMPERATURE (ECT) SENSOR The engine coolant temperature (ECT) sensor (Figure 8) is a resistor that changes its resistance value when the temperature changes (thermistor). This sensor is installed in the engine coolant system. A low coolant temperature makes the thermistor have a high resistance [100,700 ohms at 40 C ( 40 F)]. A higher coolant temperature makes the thermistor have a lower resistance [70 ohms at 130 C (266 F)].

1. SENSOR 2. ELECTRICAL CONNECTOR Figure 7. MAP Sensor The MSTS module sends a 5-volt reference signal to the MAP sensor. When the pressure in the intake manifold changes, the electrical resistance in the MAP sensor also changes. The change in the voltage signal from the MAP sensor enables the MSTS module to sense the pressure in the intake manifold. A closed throttle causes a low pressure (high engine vacuum) in the intake manifold. This low pressure causes a low voltage signal from the MAP sensor to the MSTS module. A fully opened throttle causes a higher pressure (low engine vacuum) in the intake manifold. This higher pressure causes a higher voltage signal from the MAP sensor to the MSTS module. These pressure changes indicate the load on the engine to the MSTS module. The MSTS module then calculates the spark timing for the best engine performance. The MAP sensor also measures the barometric pressure when the key switch is turned to ON and before

1. TEMPERATURE SENSOR 2. ELECTRICAL CONNECTOR 3. LOCK TAB Figure 8. Engine Coolant Temperature (ECT) Sensor The engine coolant temperature sensor uses a thermistor to control the signal voltage (see Figure 9) to the MSTS module. The MSTS module applies a 5-volt reference voltage to the ECT. The reference voltage will be high when the engine coolant is cold. The reference voltage will be lower when the engine coolant is at operating temperature. The MSTS module will adjust the ignition timing for more spark advance when the engine coolant is cold and less spark advance when the engine coolant is hot.

2200 SRM 765

1. 2. 3. 4. 5.

Operation

MSTS MODULE MSTS IGNITION FUSE IGNITION COIL SPARK PLUGS TACHOMETER CONNECTOR

6. 7. 8. 9. 10.

DISTRIBUTOR AND IGNITION MODULE MAP SENSOR ENGINE COOLANT TEMPERATURE SENSOR DIAGNOSTIC CONNECTOR MSTS B+ FUSE

Figure 9. MSTS Wiring Diagram

MSTS MODULE CORRECTIONS The operation of the MSTS module was described in earlier paragraphs. (See the description in What MSTS Does.) These paragraphs describe the corrections made by the MSTS module. The MSTS module does a check of the system components. A set of normal operating limits are part of the PROM program. If a sensor sends a signal that is outside of the limits of the PROM program, the MSTS module will not use the information. The

MSTS module will use a standard value from its program and continue to operate the MSTS. The following examples are the action of the MSTS module if it finds a problem: MAP Sensor Signal Voltage Is Too High Or Too Low. The MSTS module will use a MAP value from its PROM program and use this value to calculate the ignition timing ECT Signal Voltage Is Too High Or Too Low. When a coolant sensor error occurs, the MSTS module will use a value that is approximately the normal operating temperature of the coolant.

Troubleshooting

2200 SRM 765

Open Circuit In The EST Circuit From The MSTS Module To The Ignition Module. If the EST circuit is open, it cannot be at ground potential, and the EST signal will rise and fall from the sensing coil. If the EST circuit becomes open when the engine is running, the engine stops but will restart and run in the backup mode from the ignition module. Short Circuit (Grounded Circuit) In The EST Circuit From The MSTS Module To The Ignition Module. When the engine is being rotated by the starter, the MSTS module normally detects 0 volts in the EST circuit because the circuit is at ground potential in the ignition module. The MSTS module would not detect a problem until the engine began to run. The MSTS module could not operate in the EST mode and the engine stops when the module switches to EST mode. If the EST circuit has a short-circuit (grounded circuit) when the engine is running, it will stop.

Open Circuit Or Short Circuit In The BYPASS Circuit. The MSTS module would not detect a problem until the engine began to run. The MSTS module could not operate in the EST mode and the engine would operate in the bypass mode from the ignition module. If this problem occurs when the engine is running, the engine continues to run but switches to the backup mode from the ignition module. Open Circuit Or Short Circuit In The REF HI Circuit. The MSTS module would not detect that the engine was operating. The MSTS module could not operate in the EST mode and the engine would operate with reduced economy. If this problem occurs when the engine is running, the engine continues to run but switches to the backup mode from the ignition module. Open Circuit In The REF-LO Circuit. This circuit provides a ground for the ignition module and the MSTS. If this circuit were open, it may cause poor performance.

Troubleshooting GENERAL WARNING This troubleshooting requires the operation of the engine for some of the tests. Make sure the tests are done carefully to prevent injury: • Put the lift truck on a level surface. Lower the carriage and forks and apply the parking brake. Make sure the lift truck cannot move and cause an injury during the tests. Put blocks in front and back of the drive tires to prevent movement of the lift truck. • The fuel system and the engine must operate correctly. Any problems or leaks in the fuel system or the engine must be repaired before doing troubleshooting on the MSTS. • The fan and the drive belts can remove fingers or cause other injuries. Be careful that your hands and tools do not touch the moving fan or the drive belts. • The engine exhaust and other parts of the engine are hot. Do not touch a hot surface and cause a burn.

CAUTION Electronic equipment can be damaged if troubleshooting and repairs are not done correctly. The following CAUTIONS must be followed

when doing troubleshooting or repairs on an engine with MSTS: • Always disconnect the battery negative cable before disconnecting and removing any parts of ignition system. • Never disconnect the battery from any equipment when the engine is running. • If the battery must be charged with a battery charger, ALWAYS disconnect the battery from the electrical system. • Make sure that all electrical connections are clean and have good electrical contact. • Never connect or disconnect the wiring harness at the MSTS module when the key switch is ON. • Always disconnect the battery and the MSTS module connectors if electric arc welding must be done on the vehicle. • Make sure that any water or steam is not sent toward the MSTS module or its sensors if the engine compartment is cleaned with steam. The heat and steam can damage the electronic components and cause corrosion in the electrical connections. • Use only the tools and test equipment described in Tools and Test Equipment to prevent damage to good components and to obtain correct test results.

2200 SRM 765

Troubleshooting test for a correct test light is shown in Figure 10.

â&#x20AC;˘ All voltage measurements must be done with a digital voltmeter with a minimum rating of 10 megohm input impedance. â&#x20AC;˘ When a test light is used in troubleshooting, the test light must have less than 0.3 amps (300 milliamps) of maximum current flow. A

The following troubleshooting diagrams are designed to give an efficient method of fault analysis on the MSTS. The MSTS connector pin assignments and functions are shown in Table 1.

Table 1. MSTS Module Connections This voltage chart is for use with a digital voltmeter when doing troubleshooting. There can be small variations in the voltage shown in the chart from those voltages measured during troubleshooting. These small variations are because of the battery charge and other resistances in the connections. A variation of more than 0.5 volts can be an indication of a malfunction. When this chart is used for troubleshooting, the engine must be at its operating temperature and the engine must be at idle speed (for ENGINE RUNNING column). MSTS 6-Pin Connector Pin

Function

Sensor Connector Pin C

Ignition Control Module

5.0

Ignition Control

Ignition Control Module

Bypass

Ignition Control Module

5.0

ECT Sensor

MSTS to ECT Sensor

1.5 - 2.0 2

MAP Sensor Signal

Manifold Absolute Pressure

4.75 1

1.0 1

+5 Volt Reference

Manifold Absolute Pressure

5.0

Function

Connector Pin

Function

Normal Voltage Key ON

Engine Running

Alternator EXC Terminal and Coil

B+ (Fuse Connector)

B+

Ignition Feed

Battery Feed

Alternate Fuel

Not Used

Knock Signal

Not Used

MSTS Ground

Engine Ground

MSTS 3-Pin Connector Pin

Engine Running

Distributor Reference

Key ON

MSTS 5-Pin Connector

Function

Normal Voltage

Function

Diagnostic Connector Pin

Data

Malfunction Indicator Lamp (MIL)

Diagnostic Test Terminal

Function

Malfunction Indicator Lamp

Normal Voltage 3 Key ON

Engine Running

Voltage changes with atmospheric pressure. Voltage changes with temperature. Not applicable.

Troubleshooting

2200 SRM 765

TOOLS AND TEST EQUIPMENT The following tools are necessary for troubleshooting the MSTS: • Digital-Volt-Ohmmeter (DVOM). The voltmeter must have a minimum input impedance of 10-megohms. (A digital voltmeter and ohmmeter are normally included in a multimeter test instrument.) • Tachometer with inductive trigger signal sensor. • Test light that has a low current draw as described in Figure 10.

• Vacuum pump with a gauge. This vacuum pump is held and operated with the hand. The gauge must be able to indicate a gauge pressure (vacuum) of 34 kPa (10 inHg)]. See Table 2. • Spark tester. The spark tester (ST125) is used to check the secondary ignition. • Diagnostic Trouble Code tester. Rinda Technologies CodeMate Tester® (Hyster part number 3071579) or equivalent.

Table 2. Pressure Conversion Chart Absolute Pressure Vacuum and pressure readings often cause confusion because everyone does not use the same point of reference. Absolute pressure is gauge pressure plus the atmospheric pressure. Standard atmospheric pressure is also called the standard barometric pressure and is equal to 101.325 kPa (14.695 psi) or [29.92 inches of mercury (Hg)] at sea level. The reference point for these measurements is zero pressure or an absolute vacuum. The conversion formula used in converting inches of mercury to kPa is: Inches of Hg × 3.37685 = kPa Service people normally use gauge pressure as the reference point which does not add the atmospheric pressure. The reference point for gauge pressure is atmospheric pressure. It is important to know when reading a pressure chart whether the units are given in absolute pressure or gauge pressure. The gauges used by most service people indicate gauge pressure. However, most gauges calibrated in a metric scale (kilopascals) and used to measure less than atmospheric pressure normally indicate absolute pressure as shown in the chart. A gauge calibrated in inches of Hg and used to measure a vacuum begins at zero and increases its indication as the vacuum increases as shown in the gauge pressure column of the chart. An additional cause of confusion is that the manifold pressure gauge for an engine with a turbocharger is normally calibrated for absolute pressure for both kilopascals and inches of Hg. The MAP sensor described in this section is also calibrated for absolute pressure, but the service person doing checking or troubleshooting will often be using gauges calibrated for gauge pressure.

Gauge Pressure

kPa

Inches of Hg

121.57

114.81

108.06

101.31

94.55

87.80

81.04

74.29

67.54

60.78

54.03

47.28

40.52

33.77

27.01

20.26

13.51

Pressure ↑ ----↓ Vacuum

2200 SRM 765

Troubleshooting

Where to Start There are three things to do to start troubleshooting. The first item is to become familiar with the electronic engine control system. Secondly, always start your work with a good visual/ physical inspection. See the following paragraph for more explanation. The last item on the Where-To-Start list is the On-Board Diagnostic (OBD) System Check.

Visual/Physical Inspection

CAUTION If the ammeter indicates less than 0.3 amps (300 milliamps), the test light can be used. If the ammeter indicates more than 0.3 amps (300 milliamps), the test light cannot be used because it can cause damage to the electronic components. 1. DC AMPS 2. TEST LIGHT

3. BATTERY

Figure 10. Current Flow Test for Test Light

MSTS The MSTS has the ability to perform some troubleshooting of itself and of other parts of the system. When a problem is found, the MSTS turns the malfunction indicator lamp in the CodeMate Tester to ON. A diagnostic trouble code (DTC) is kept in the memory of the MSTS.

TROUBLESHOOTING PROCEDURE Before using this part of the manual, you need to know the information and the correct troubleshooting procedures. If the correct troubleshooting procedures are not followed, as described in this section, it can result in replacement of good parts.

A careful visual and physical inspection must be done as part of any diagnostic procedure. This can cause the repair of a problem without further steps. Inspect all vacuum hoses for correct routing, restrictions, cuts or faulty connections. Be sure to inspect hoses that are difficult to see beneath the air filter. Inspect all wires in the engine compartment for proper connections, damaged spots, or contact with sharp edges or the exhaust manifolds. This visual/physical inspection is very important. It must be done carefully.

Knowledge/Tools Required To use this manual most effectively, a general understanding of basic electrical circuits and circuit testing tools is required. One should be familiar with wiring diagrams, the meaning of voltage, ohms, amps, the basic theories of electricity, and understand what happens in an open or shorted wire. To perform the troubleshooting procedures, the use of a diagnostic CodeMate Tester is required. A tachometer, test lamp, ohmmeter, digital voltmeter with 10 megohms impedance, vacuum gauge, and jumper wires are also required. Special tools that are required for system service and the ones described above are shown at the end of this section.

Damage from Static Discharge (Static Electricity) CAUTION To prevent damage to the MSTS by static electricity, do not touch MSTS connector pins. Electronic components used in control systems use a very low voltage and can be easily damaged by static discharge or static electricity. Less than 100 volts

Troubleshooting

2200 SRM 765

of static electricity can cause damage to some electronic components. There are several ways for a person to become statically charged. The most common methods of charging are by friction and by induction. An example of charging by friction is a person sliding across a car seat; in which a charge of as much as 2 to 5,000 volts can build up. Charging by induction occurs when a person with well insulated shoes stands near a highly charged object and momentarily touches ground. Charges of the same polarity are drained off, leaving the person highly charged with the opposite polarity. Static charges of either type can cause damage; therefore, it is important to use care when handling and testing electronic components.

TROUBLESHOOTING INFORMATION The troubleshooting diagrams and function checks in this section are designed to find a faulty circuit or component through logic based on the process of elimination. The diagrams are prepared with the requirement that the vehicle functioned correctly at the time of assembly and that there are no multiple failures. The MSTS does constant testing on certain control functions. The MSTS communicates the source of a malfunction with Diagnostic Trouble Codes (DTC). The DTC’s are two digit numbers that can range from 12 to 99. When a malfunction is found by the MSTS, a DTC is set and the CodeMate Tester malfunction indicator lamp is turned ON. DTC codes for this MSTS are shown in Table 3.

Table 3. MSTS Diagnostic Codes Code

Description

Indicates that the fault monitor system is operating.

Engine Coolant Temperature Sensor Circuit - Low Temp Indicated

Yes

Engine Coolant Temperature Sensor Circuit - High Temp Indicated

Yes

MAP Sensor Circuit

Yes

Ignition Control (IC) System. Open EST Circuit

Yes

Ignition Control (IC) System.

Yes

Checksum Error

Malfunction Indicator Lamp (MIL) The malfunction indicator lamp on the CodeMate Tester has three functions: 1. To test that the lamp is functioning 2. To indicate a malfunction has occurred 3. To display the diagnostic trouble codes (DTC) kept by the MSTS which help the technician troubleshoot system problems. Follow the steps described in Connecting CodeMate Tester to install it onto the engine’s Diagnostic Link Connector.

Connecting CodeMate Tester 1. Turn the engine ignition switch to OFF. 2. Locate the engine diagnostic connector.

Indicator Lamp ON

Grounded EST Circuit, Open or Grounded Bypass Circuit.

Yes 3. Place the CodeMate Tester test switch to OFF and plug the CodeMate into the diagnostic connector. NOTE: Make sure to slide the CodeMate Tester completely into the diagnostic connector so that the connector’s locking tab clicks into place. As a bulb and system check, the lamp comes ON with the ignition switch ON and the engine not running. When the engine is started, the lamp turns OFF. If the lamp remains ON, the system has found a problem. This problem is referred to as a current DTC. If the problem goes away, the lamp goes out after ten seconds. In either condition a DTC remains in the MSTS. When the lamp remains ON while the engine is running, or when there is a malfunction, the On-Board Diagnostic (OBD) System Check must be done.

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Troubleshooting

When a problem is not regular or constant, the malfunction indicator lamp will turn ON for approximately ten seconds and then will turn OFF. However, the diagnostic trouble code (DTC) will be kept in the memory of the MSTS until the DTC’s are cleared (see DTC clearing in this section). A DTC that is not constant can reset. If it is a problem that is not constant, a DTC diagram is not used. When troubleshooting is complete, turn the ignition switch to OFF, and disconnect the CodeMate Tester.

Use the following steps to read trouble codes.

Reading Diagnostic Trouble Codes (DTC)

4. Observe the sequence of flashes on the CodeMate malfunction indicator.

CAUTION To prevent MSTS damage, the key must be OFF when disconnecting or reconnecting MSTS power. The diagnostic connector is used to communicate with the MSTS. See Figure 11. The diagnostic connector is installed on the bracket near the MSTS. It is used in the assembly plant to receive information in checking that the engine is operating correctly before it leaves the plant. The DTC(s) kept in the MSTS’s memory can be read with a CodeMate Tester connected to the diagnostic connector.

1. Install the CodeMate Tester into the diagnostic connector. See the preceding section, Connecting CodeMate Tester. 2. Turn the ignition key to ON but do not start the engine. 3. Place the CodeMate Tester test switch to ON. This puts the MSTS in the diagnostic mode.

At this point, the malfunction indicator lamp on the CodeMate Tester flashes DTC 12 three times consecutively (see Figure 12). The following is the flash sequence for DTC 12: long pause, flash, pause, flash-flash, long pause, flash, pause, flash-flash, long pause, flash, pause, flash-flash. DTC 12 (which means no crankshaft rpm signal) indicates that the MSTS’s diagnostic system is operating correctly at this time. If DTC 12 is not indicated, a problem is in the diagnostic system itself. Following the output of DTC 12, if additional codes are stored, the malfunction indicator lamp flashes the DTC three times. If more than one DTC is stored in the MSTS’s memory, the DTC’s are flashed starting with the lowest DTC set and finishing with the highest DTC set. When all DTC’s have been flashed, the sequence starts over again with DTC 12. 5. When testing is complete, place the CodeMate test switch to OFF, turn the ignition key to OFF, and disconnect the CodeMate Tester from the diagnostic connector.

1. DIAGNOSTIC CONNECTOR

6. Secure the diagnostic connector to the MSTS bracket.

Figure 11. Diagnostic Connector

Troubleshooting

1. LONG PAUSE

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2. FLASH

3. PAUSE

4. FLASH-FLASH

Figure 12. Diagnostic Trouble Code-12 Example

Clearing Diagnostic Trouble Codes (DTCâ&#x20AC;&#x2122;s) To clear the stored Diagnostic Trouble Codes from the MSTS, do the following. 1. Install the CodeMate Tester into the diagnostic connector. See the preceding section Connecting CodeMate Tester. 2. Turn the ignition key to ON, but do not start the engine. 3. Place the CodeMate test switch to the ON position. 4. Turn the ignition switch to OFF for five seconds. 5. Turn the ignition switch to ON and verify that DTC-12 is the only code in the MSTS memory.

no trouble codes shown. The data are an average of display values from normally operating vehicles and show a display of a normally operating system. After the visual/physical inspection, the On-Board Diagnostic (OBD) System Check is the starting point for all troubleshooting procedures. The correct procedure to find a problem is to follow two basic steps. 1. Are the On-Board Diagnostics working? This is determined by doing the OBD System Check. Since this is the starting point for the troubleshooting procedures, always begin here. 2. Is there a Diagnostic Trouble Code? If there is a DTC, go directly to the flowchart for that DTC number. This determines if the fault is still there.

6. When testing is complete, place the CodeMate test switch to OFF, turn the ignition key to OFF, and disconnect the CodeMate Tester from the diagnostic connector.

Test Description

7. Secure the diagnostic connector to the MSTS bracket.

1. The MIL should be ON steady with the ignition ON and the engine OFF. To isolate the malfunction if the MIL does not light, refer to Figure 15.

ON-BOARD DIAGNOSTIC (OBD) SYSTEM CHECK The On-Board Diagnostic (OBD) System Check is a troubleshooting method to find a problem caused by a malfunction in the electronic engine control system. It must be the starting point for any troubleshooting. See Figure 13. The data shown in Table 1 can be used for comparison after doing the troubleshooting checks and finding the on-board diagnostics working correctly with

The numbers below are a reference to the numbers in bold in Figure 13.

2. Diagnostic Trouble Code (DTC) 12 means no rpm reference pulses from the ignition module. This is correct when engine is not running. 3. For list of valid DTCâ&#x20AC;&#x2122;s, refer to the MSTS Diagnostic Trouble Codes, Table 3. An invalid DTC may be the result of a faulty MSTS. 4. If the engine does not start, refer to the troubleshooting diagram (Figure 18).

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Troubleshooting

Figure 13. On-Board Diagnostic System Check

No Malfunction Indicator Lamp

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No Malfunction Indicator Lamp CIRCUIT DESCRIPTION When the CodeMate Tester test switch is in the OFF position and the CodeMate is plugged into the diagnostic connector, the malfunction indicator lamp is

ON when the ignition is ON and engine is not running. See Figure 14. The MSTS controls the lamp and turns it ON by connecting it to ground through pin 3B.

NOTE: THE NUMBER IN FRONT OF THE PIN DENOTES THE CONNECTOR. FOR EXAMPLE, 6D IS PIN D ON THE 6-PIN CONNECTOR WHILE 5E IS PIN E ON THE 5-PIN CONNECTOR. Figure 14. No Malfunction Indicator Lamp Circuit

TEST DESCRIPTION The numbers below are a reference to the numbers in bold in Figure 15. 1. This tests the circuits to the MSTS and diagnostic connector for voltage.

2. This tests the electronic driver circuit for the malfunction indicator lamp. 3. Test the CodeMate on another vehicle. 4. Test for an open circuit between wire harness connectors.

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No Malfunction Indicator Lamp

Figure 15. No Malfunction Indicator Lamp

No DTC-12, Malfunction Indicator Lamp ON

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No DTC-12, Malfunction Indicator Lamp ON CIRCUIT DESCRIPTION When the CodeMate Tester switch is in the OFF position and the CodeMate is plugged into the diagnostic connector, the malfunction indicator lamp is ON when the ignition is ON and engine is not running. See Figure 16. The MSTS controls the lamp and turns it ON by connecting it to ground through pin 3B.

With the diagnostic connector pin B connected to ground through pin A, the malfunction indicator flashes a DTC-12, followed by any trouble codes kept in memory. A steady light means a short to ground in the light control circuit between MSTS connector pin 3B and diagnostic connector pin E, or an open circuit between MSTS connector pin 3C and diagnostic connector pin B.

NOTE: THE NUMBER IN FRONT OF THE PIN DENOTES THE CONNECTOR. FOR EXAMPLE, 6D IS PIN D ON THE 6-PIN CONNECTOR WHILE 5E IS PIN E ON THE 5-PIN CONNECTOR. Figure 16. No DTC-12, Malfunction Indicator Lamp ON Circuit

TEST DESCRIPTION The numbers below are a reference to the numbers in bold in Figure 17. 1. If the malfunction indicator lamp is ON with the MSTS 3-pin connector disconnected, there may

be a short in the circuit between MSTS connector pin 3B and diagnostic connector pin E. If the lamp is off, there may be a problem with either the connector or the MSTS.

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Starter Rotates Engine, Engine Does Not Run

2. If the malfunction indicator is OFF, there is a short between MSTS connector pin 3C and diagnostic connector pin B.

3. If the problem is not fixed by Step 2, replace the MSTS.

Figure 17. No DTC-12, Malfunction Indicator Lamp ON

Starter Rotates Engine, Engine Does Not Run TEST DESCRIPTION If a tachometer has been connected to the TACH CONN., disconnect it before doing this test. See Figure 18. The numbers below are a reference to the numbers in bold in Figure 19.

1. Check a minimum of two spark plug wires to make sure that one of the spark plug wire does not have an open circuit (Spark Tester ST-125).

Starter Rotates Engine, Engine Does Not Run

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Figure 18. Starter Rotates Engine, Engine Does Not Run Circuit 2. If a spark occurs when the electronic spark timing (EST) connector is disconnected, the output from the sensing coil is too low for EST operation. 3. A spark indicates that the fault is in the distributor cap or the rotor. 4. The normal voltage at the C and the + terminals is battery voltage. A low voltage can indicate: a. An open circuit or a high resistance circuit from the ignition switch to the distributor to the ignition coil or b. An open circuit in the primary winding of the ignition coil. If the voltage at C is less than battery voltage, and there is 10 volts or more at +, there is an open circuit from C to the ignition coil or an open circuit in the primary winding of the ignition coil. 5. Use the test light to check for a short circuit in the ignition module. Check for approximately 12 volts between the TACH CONN. and ground. If the voltage is low (approximately 1 to 6 volts), there can be a fault in the ignition module. This

condition can cause a failure in the ignition coil from too much heat. If there is an open circuit in the primary winding of the ignition coil, a low voltage can leak through the ignition module from the B+ to the TACH CONN. terminal. 6. The ignition module normally goes ON when 1.5 to 8 volts is applied to terminal P from the sensing coil. When the ignition module is ON, the voltage between the TACH CONN. and ground will normally decrease to 7 to 9 volts. This test checks if the sensing coil or the ignition module has a fault. When 1.5 to 8 volts is momentarily applied to terminal P, this voltage acts as a trigger voltage that replaces the voltage from the sensing coil. The procedure shows a test light, but any low voltage, low current source can be used as a trigger voltage. 7. When the momentary trigger voltage is removed, a spark is normally generated through the ignition coil. If no spark occurs, replace the ignition coil. If a spark occurs, check the sensing coil and the rotating timer core.

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Starter Rotates Engine, Engine Does Not Run

Figure 19. Starter Rotates Engine, Engines Does Not Run (Sheet 1 of 2)

Starter Rotates Engine, Engine Does Not Run

Figure 19. Starter Rotates Engine, Engines Does Not Run (Sheet 2 of 2)

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DTC-14 Engine Coolant Temperature (ECT) (Low Temperature Indicated)

DTC-14 Engine Coolant Temperature (ECT) (Low Temperature Indicated) DTC-14 is set if the signal voltage indicates a coolant temperature below 5 C ( 23 F) after the engine runs for three minutes.

CIRCUIT DESCRIPTION The Engine Coolant Temperature sensor (ECT) uses a thermistor to control the signal voltage to the MSTS module. See Figure 20. The MSTS module

applies a 5-volt reference voltage (terminal 6D) to the ECT. When the engine coolant is cold, the thermistor resistance is higher than when the engine coolant is at operating temperature. As the temperature of the engine coolant increases after the engine is started, the resistance decreases and the signal voltage decreases. When the engine is operating at 82 to 95 C (180 to 203 F), the signal voltage is approximately 1.5 to 2.0 volts.

NOTE: THE NUMBER IN FRONT OF THE PIN DENOTES THE CONNECTOR. FOR EXAMPLE, 6D IS PIN D ON THE 6-PIN CONNECTOR WHILE 5E IS PIN E ON THE 5-PIN CONNECTOR. Figure 20. ECT Sensor Troubleshooting Circuit

TEST DESCRIPTION The numbers below are a reference to the numbers in bold in Figure 21. 1. This step determines if there is a fault in the wiring or the MSTS module or if the fault is in the ECT.

2. Make sure the electrical connections do not have dirt and corrosion. If an ohmmeter is connected across terminals A and B of the ECT, the resistance normally decreases as the temperature of the engine coolant increases. 3. This step checks if there is a fault in the wiring to the ECT or the sensor ground.

DTC-14 Engine Coolant Temperature (ECT) (Low Temperature Indicated)

Figure 21. ECT Sensor Troubleshooting Diagram (Low Temperature)

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DTC-15 Engine Coolant Temperature Sensor (ECT) (High Temperature Indicated)

DTC-15 Engine Coolant Temperature Sensor (ECT) (High Temperature Indicated) DTC-15 is set if the signal voltage indicates a coolant temperature above 135 C (275 F) for three seconds.

CIRCUIT DESCRIPTION The Engine Coolant Temperature sensor (ECT) uses a thermistor to control the signal voltage to the MSTS module. See Figure 22. The MSTS module applies a 5-volt reference voltage (terminal 6D) to

the ECT. When the engine coolant is at operating temperature, the thermistor resistance is lower than when the engine coolant is cold. As the temperature of the engine coolant increases after the engine is started, the resistance decreases and the signal voltage decreases. When the engine is operating at 82 to 95 C (180 to 203 F), the signal voltage is approximately 1.5 to 2.0 volts.

NOTE: THE NUMBER IN FRONT OF THE PIN DENOTES THE CONNECTOR. FOR EXAMPLE, 6D IS PIN D ON THE 6-PIN CONNECTOR WHILE 5E IS PIN E ON THE 5-PIN CONNECTOR. Figure 22. ECT Sensor Troubleshooting Circuit

TEST DESCRIPTION The numbers below are a reference to the numbers in bold in Figure 23. 1. This step determines if there is a fault in the wiring or the MSTS module or if the fault is in the ECT.

2. Make sure the electrical connections do not have dirt and corrosion. If an ohmmeter is connected across the terminals A and B of the ECT, the resistance normally decreases as the temperature of the engine coolant increases.

DTC-15 Engine Coolant Temperature Sensor (ECT) (High Temperature Indicated)

Figure 23. ECT Sensor Troubleshooting Diagram (High Temperature)

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DTC-34 Manifold Absolute Pressure (MAP) Sensor

DTC-34 Manifold Absolute Pressure (MAP) Sensor CIRCUIT DESCRIPTION When the load on the engine changes, the pressure in the intake manifold changes. See Figure 24. This pressure is less than the atmospheric pressure. The Manifold Absolute Pressure (MAP) sensor measures the changes in the intake manifold pressure and converts these changes to a voltage signal. The MSTS module sends a reference signal (5.0 volts) to the MAP sensor. When the manifold pressure changes, the electrical signal of the MAP sensor changes and the signal is received by the MSTS module. When the engine is at idle speed and does not have a load on it, the normal signal voltage from the MAP

sensor is approximately 1.0 volt. When the throttle valve is fully opened, the intake manifold pressure is higher (less vacuum) and the signal voltage from the MAP sensor is approximately 4.5 volts. When the ignition switch is turned to ON, the initial voltage signal from the MAP sensor indicates the barometric pressure (BARO signal) to the MSTS module. The MSTS module remembers the barometric pressure (BARO signal) after the engine is running. The MSTS module then automatically adjusts the ignition timing for different altitudes and atmospheric conditions.

NOTE: THE NUMBER IN FRONT OF THE PIN DENOTES THE CONNECTOR. FOR EXAMPLE, 6C IS PIN C ON THE 6-PIN CONNECTOR WHILE 5E IS PIN E ON THE 5-PIN CONNECTOR. Figure 24. MAP Sensor Troubleshooting Circuit

TEST DESCRIPTION The numbers below are a reference to the numbers in bold in Figure 25. 1. This step determines if there is adequate vacuum supply to the MAP sensor. 2. This step checks for the 5-volt reference signal in the MAP sensor harness connection.

3. This step checks for an open circuit from pin A to ground or an open or shorted wire between pin C and pin 6F. See Figure 24. 4. These steps are checking the MAP signal circuit for faults. 5. Low manifold vacuum may result from a restriction in the MAP sensor hose or from vacuum leaks in the engine air intake system.

DTC-34 Manifold Absolute Pressure (MAP) Sensor

Figure 25. MAP Sensor Troubleshooting Diagram (Sheet 1 of 2)

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DTC-34 Manifold Absolute Pressure (MAP) Sensor

Figure 25. MAP Sensor Troubleshooting Diagram (Sheet 2 of 2)

DTC-41 Electronic Spark Timing (EST) Open Circuit

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DTC-41 Electronic Spark Timing (EST) Open Circuit DTC-41 is set if there is an open circuit in the electronic spark timing circuit.

Code 41 is set and the MSTS does not go into the EST operation mode.

CIRCUIT DESCRIPTION

If the bypass wire is open or grounded, the ignition module does not change to EST mode, and a Code 42 is indicated.

When the system is running on the ignition module, there is no voltage on the bypass wire and the ignition module grounds the EST signal. See Figure 26. If the MSTS senses a voltage on the EST circuit, a

If the EST circuit has a short circuit to ground, there is no EST signal, and a Code 42 is indicated.

Figure 26. EST Troubleshooting, Open Circuit

TEST DESCRIPTION The numbers below are a reference to the numbers in bold in Figure 27. 1. A Code 41 is indicated if there is an open circuit in the EST circuit. This test determines if the Code 41 is a real fault.

2. This test checks that the ground path through the ignition module is correct. A short circuit from MSTS connector pin 6B to ground also indicates less than 500 Ohms.

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DTC-41 Electronic Spark Timing (EST) Open Circuit

Figure 27. DTC-41 Troubleshooting Diagram

DTC-42 Electronic Spark Timing (EST) Grounded Circuit

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DTC-42 Electronic Spark Timing (EST) Grounded Circuit A DTC 42 is set if the EST circuit is grounded or if there is an open circuit or a short circuit in the bypass circuit.

CIRCUIT DESCRIPTION When the system is running on the ignition module, there is no voltage on the bypass wire and the ignition module grounds the EST signal. See Figure 28. If the MSTS senses a voltage on the EST circuit, a Code 41 is set and the MSTS does not go into the EST mode.

When the engine is being started and approximately 400 rpm is sensed, bypass voltage is applied by the MSTS. The EST circuit is no longer grounded in the ignition module and the EST circuit voltage normally has a variation during operation. If the bypass wire is open or grounded, the ignition module will not change to EST mode and a Code 42 is indicated. If the EST circuit has a short circuit to ground, there is no ignition signal and a Code 42 is indicated.

Figure 28. EST Troubleshooting, Grounded Circuit

TEST DESCRIPTION The numbers below are a reference to the numbers in bold in Figure 29. 1. A Code 42 is indicated if there is an open circuit or a short circuit in the bypass circuit or if the EST circuit is grounded. This test determines if the Code 42 is a real fault.

2. This test checks that the ground path through the ignition module is correct. 3. This test checks to see if the IC module makes the switch in resistance. 4. This test checks for short circuits to ground in the EST circuit, opens in the bypass circuit, and faulty connections in the IC module.

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DTC-42 Electronic Spark Timing (EST) Grounded Circuit

Figure 29. DTC-42 Troubleshooting Diagram

Distributor Repair

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DTC-51 MSTS Failure CIRCUIT DESCRIPTION The Electronic Control Module (MSTS) does an internal check. If the internal check fails, the MSTS sets DTC 51.

1. This step checks the MSTS. If a Code-51 is set and all connections are correct, replace the MSTS.

The number below is a reference to the number in bold in Figure 30.

Figure 30. MSTS Failure

Distributor Repair A distributor with a separate ignition coil is used on all MSTS engines. The ignition coil is connected to the rotor in the distributor through a high-voltage wire. The operation of the ignition module and the magnetic pulse generator is described under Operation at the beginning of this section. When the current in the primary circuit of the ignition coil quickly decreases, the induction in the secondary circuit sends a high voltage pulse (35,000 volts) to the rotor in the distributor. The rotor is aligned with one of the leads to a spark plug wire and this high voltage pulse is sent to one of the spark plugs.

REMOVE CAUTION Carefully lift and release lock tabs on connectors to distributor. Lock tabs can be easily broken if too much force is applied with a screwdriver or other tool. Never permit TACH CONN. terminal to touch ground. Ignition module or ignition coil can be damaged. 1. Disconnect battery negative (ground) cable. 2. If removal of the spark plug wires is not required for the repairs, leave them connected to distributor cap. Remove two capscrews that fasten distributor cap to distributor. Move distributor cap away from work area.

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Distributor Repair

3. Disconnect distributor 4-terminal connector. 4. Disconnect ignition coil connector. 5. Remove bolt and clamp that hold distributor in engine. Make a note of the positions of rotor to distributor housing and distributor to engine. Slowly pull distributor from engine until rotor just stops turning counterclockwise and make a note of the position of rotor. This position must be used when distributor is installed again.

5. Remove retainer from housing. driver as a prybar.

Use a screw-

6. Disconnect sensing coil from ignition module.

CAUTION Carefully lift and release lock tab on connector to sensing coil. Lock tab can be easily broken if too much force is applied with a screwdriver or other tool.

DISASSEMBLE

7. Use a screwdriver to lift lock tab. Remove sensing coil.

1. Remove rotor. See Figure 31. Make a match mark on gear and shaft so they can be assembled in the same position.

8. Remove two screws that hold ignition module in housing. Remove ignition module.

INSPECT Inspect shaft for a loose fit between shaft and its bushing in housing. If bushing or shaft is worn so that shaft moves from side to side in bushing, replace shaft or housing. Inspect housing for cracks or damage.

ASSEMBLE 1. Apply silicon grease to bottom of ignition module. See Figure 31. Install ignition module into housing and tighten two screws. NOTE: Hyster Part No. 304408 is a silicon bearing grease used between electronic components and their heat sinks. A small container of silicon grease is enclosed in the package with a new ignition module. 2. Install sensing coil. Tab on bottom of sensing coil fits into anchor hole in housing. 3. Connect sensing coil to ignition module. Make sure that lock tab on connector is fastened. 1. CAP 2. ROTOR 3. SHAFT/TIMER CORE 4. RETAINER 5. SHIELD 6. COIL 7. POLE PIECE

8. 9. 10. 11. 12. 13. 14. 15.

IGNITION MODULE ALIGNMENT PIN HOUSING WASHER SEAL DRIVE GEAR ROLL PIN GASKET

Figure 31. Distributor 2. Use a punch to remove roll pin from shaft. 3. Remove gear. 4. Remove shaft with timer core from housing.

4. Install shield. 5. Install retainer. 6. Install shaft assembly into housing. 7. Install washer and seal on housing. 8. Install gear on end of shaft. 9. Align marks on gear and shaft. Install roll pin. Turn shaft assembly and make sure teeth of timer core on shaft assembly do not touch pole piece.

Distributor Repair 10. Install gasket on gear. 11. Install rotor on shaft.

INSTALL 1. Put rotor and distributor in the same position as it was removed from engine. If engine has been rotated after distributor was removed, the following procedure must be used before distributor is installed again: a. Remove No. 1 spark plug. b. Put a finger over No. 1 spark plug hole and slowly rotate engine until pressure is felt on compression stroke. c. Align timing mark on crankshaft pulley to 0 (TDC) on engine timing indicator. d. Turn distributor rotor to point between positions on distributor cap for No. 1 and No. 4 spark plug leads. e. Install distributor in engine. Rotor and shaft will rotate a few degrees when gear on distributor shaft engages drive gear on engine cam. Timing is correct if rotor points at the position on distributor cap for No. 1 spark plug lead. 2. Install clamp and bolt. Tighten bolt with your hand. 3. Install distributor 4-terminal connector. 4. Install ignition coil connector. 5. Install distributor cap and two capscrews. If spark plug wires were removed, install them in correct sequence. 6. Connect battery negative cable.

2200 SRM 765 7. Start engine and check engine timing. See the following paragraphs about Ignition Timing. 8. Tighten bolt for distributor clamp to 43 Nâ&#x20AC;˘m (31.7 lbf ft).

IGNITION TIMING WARNING Do not touch moving parts (fan, belt, shafts, pulleys). To check the initial ignition timing set point, do the following. 1. Warm engine to normal operating temperature. 2. Turn engineâ&#x20AC;&#x2122;s ignition switch to OFF position. 3. Make sure that CodeMate test switch is in OFF position. 4. Plug CodeMate into diagnostic connector in engine compartment. 5. Place CodeMate test switch in ON position and start engine. 6. Check initial timing set point with a timing light. The correct setting for initial timing set point is 8 BTDC for 3.0L engine and 0 TDC for 4.3L engine. 7. If timing is not correct, loosen clamp that holds distributor housing. Rotate housing right or left to get correct timing. Tighten clamp when timing is correct. 8. Turn ignition key to OFF position. 9. Remove CodeMate Tester from diagnostic connector and place diagnostic connector into protective cover.

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Ignition Module Repair

Ignition Module Repair TEST FOR FAULT NOTE: The ignition module can be checked in the distributor. A test light and three jumper wires are needed to make the tests. The battery in the vehicle must be fully charged so that the starter rotates the engine at the normal speed. 1. Disconnect 4-terminal connector from distributor. See Figure 32. Use two jumper wires between distributor and 4-terminal connector to connect the following circuits:

REFERENCE (pin C) GROUND (pin A) 2. Connect test light to a 12-volt positive source. Start engine. Touch probe of test light to pin B in 4-terminal connector on distributor. When 12 volts are applied through test light to pin B (BYPASS), ignition module changes to EST mode. The EST connection (pin D) is open and engine will normally stop. This step checks the BYPASS operation of the ignition module.

Figure 32. Ignition System Troubleshooting 3. Use a jumper to connect pin D (EST) to pin C (REFERENCE) at distributor. Apply 12 volts through test light to pin B (BYPASS) as described in Step 2. Start engine. If engine starts, this step checks that EST circuit in ignition module is good. 4. Remove test light from pin B (BYPASS) while engine is running. If engine stops, this check shows that ignition module internally changes EST circuit to ground. Since there is a jumper wire between pin D (EST) to pin C (REFERENCE), the

REFERENCE signal is also sent to ground and engine stops. 5. If any tests described in Step 2, Step 3, or Step 4 do not work as indicated, check wiring harness for a short circuit or an open circuit. If wiring harness is good, replace ignition module. 6. When the tests are complete, connect system for normal operation.

Sensing Coil Repair

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REPLACE 1. Remove distributor cap and rotor. 2. Remove two screws that hold ignition module in distributor. 3. Lift ignition module and disconnect connections. Make a note of the connections so that they can be correctly connected again. Remove ignition module from distributor. NOTE: Do not remove silicon grease from ignition module or distributor if the same ignition module will be installed again. If a new ignition module is installed, a small container of silicon grease is in the

package. Clean old silicon grease and apply a new layer of silicon grease to ignition module and distributor housing. This silicon grease is necessary for cooling the ignition module. 4. Connect connectors in distributor to ignition module. Make sure connectors are the same as when they were removed. 5. Install ignition module in distributor. 6. Install two screws that fasten ignition module in distributor. 7. Install distributor cap and rotor.

Sensing Coil Repair TEST FOR FAULT 1. Disconnect battery negative cable. 2. Remove distributor cap. Disconnect connection from sensing coil to ignition module. 3. Check resistance of sensing coil with an ohmmeter. Connect ohmmeter to sensing coil connections as shown in step 1 of Figure 33. Check resistance between both connections and ground. Ohmmeter will indicate infinity for both connections, if sensing coil is good. 4. Connect ohmmeter across both sensing coil connections as shown in step 2 of Figure 33. If ohmmeter does not indicate 500 to 1500 ohms, replace sensing coil. Check wires for a loose connection.

REPLACE Remove and disassemble distributor as described in Distributor Repair. A. STEP 1

B. STEP 2

1. SENSING COIL CONNECTIONS

2. OHMMETER

Figure 33. Test Sensing Coil

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Ignition Coil Repair

Ignition Coil Repair TEST FOR FAULT 1. Disconnect battery negative (ground) cable. 2. Disconnect high voltage wire. 3. Disconnect connectors at ignition coil. 4. Set ohmmeter on one of the higher scales. Connect ohmmeter as shown in step 1 of Figure 34. If ohmmeter indication is less than infinity, install a new ignition coil.

5. Set ohmmeter on one of the low scales. Connect ohmmeter as shown in step 2 of Figure 34. If ohmmeter indication is greater than one ohm, install a new ignition coil. 6. Set ohmmeter on one of the middle scales. Connect ohmmeter as shown in step 3 of Figure 34. If ohmmeter indication is infinity (open circuit), install a new ignition coil.

REMOVE 1. Turn key switch to OFF. Apply parking brake. 2. Disconnect negative battery cable. 3. Put tags for identification on connectors and disconnect them from coil.

CAUTION Do not damage high voltage wires (spark plug wires) during removal. Hold wire by boot near end of wire. Rotate boot before pulling it and connection from terminal. 4. Remove high voltage wires. 5. Remove nuts (or capscrews) that fasten bracket for ignition coil to engine. 6. Remove ignition coil and bracket assembly from engine. 7. Use a drill and punch to remove two rivets that fasten bracket to coil.

INSTALL A. STEP 1 B. STEP 2

C. STEP 3

1. CLEAN METAL FOR GROUND CONNECTION 2. OHMMETER

3. C AND TACH CONNECTOR 4. B AND + TERMINALS

Figure 34. Ignition Coil

1. Install original bracket on replacement coil using screws (supplied with replacement coil). 2. Install ignition coil assembly on engine with nuts (or capscrews). 3. Install control wire connectors and high voltage wire on ignition coil. 4. Connect negative (ground) battery cable.

ECT Sensor Replacement

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MSTS Module Repair NOTE: See the TROUBLESHOOTING descriptions to check the operation of the MSTS module. The following paragraphs describe the removal and installation of the MSTS module.

INSTALL

REMOVE

2. Connect three connectors at MSTS module. Connect battery negative cable.

1. Install MSTS module on its mount surface and install two bolts.

CAUTION Never connect or disconnect wiring harness at MSTS module when key switch is ON. Never connect jumper wires or test instruments to MSTS module when key switch is ON. The best procedure is to disconnect battery negative cable when removing or installing electrical components. Do not touch connector pins. MSTS module can be damaged with an electrostatic discharge. MSTS connector locations and mounting holes are shown in Figure 35. 1. Disconnect battery negative cable. Disconnect three connectors at MSTS module. 2. Remove two bolts that fasten MSTS module to its mount. Remove MSTS module.

Figure 35. MSTS Module

ECT Sensor Replacement WARNING The coolant can be very hot. Use caution to prevent personal injury.

4. Connect connector at ECT. Connect battery negative cable. 5. Fill radiator with coolant as required.

NOTE: See the TROUBLESHOOTING descriptions to check the operation of the ECT sensor. The following paragraphs describe the disconnection or the removal and installation of the ECT sensor. 1. Disconnect battery negative cable. Disconnect connector at ECT sensor. See Figure 36. 2. Use a wrench and carefully loosen ECT from coolant manifold. 3. Use a liquid sealant on threads and install ECT in its hole in coolant manifold and carefully tighten it with a wrench.

1. TEMPERATURE SENSOR 2. ELECTRICAL CONNECTOR 3. LOCK TAB Figure 36. Engine Coolant Temperature Sensor (ECT)

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MAP Sensor Replacement

MAP Sensor Replacement NOTE: The MAP sensor is on the bracket that is on top of the valve cover. 1. Disconnect battery negative cable. Disconnect vacuum hose from MAP sensor. Disconnect electrical connector at MAP sensor. See Figure 37. 2. Remove screws that fasten MAP to its mount. Remove MAP sensor. 3. Install MAP sensor on its mount surface and install screws. 4. Connect electrical connector at MAP sensor. Connect vacuum hose to MAP sensor. Connect battery negative cable.

1. SENSOR 2. ELECTRICAL CONNECTOR Figure 37. Manifold Absolute Pressure (MAP) Sensor

PERIODIC MAINTENANCE S3.50-5.50XL (S70-120XL) [D004]; S6.00-7.00XL (S135-155XL) [B024, C024]

PART NO. 897304

8000 SRM 393

Periodic Maintenance

Table of Contents

TABLE OF CONTENTS General ............................................................................................................................................................... Serial Number Data ...................................................................................................................................... How to Move Disabled Lift Truck ................................................................................................................. How to Tow Lift Truck............................................................................................................................... How to Put Lift Truck on Blocks................................................................................................................... How to Raise Drive Tires .......................................................................................................................... How to Raise Steering Tires ..................................................................................................................... Maintenance Schedule....................................................................................................................................... Safety Procedures When Working Near Mast.................................................................................................. Maintenance Procedures Every 8 Hours or Daily............................................................................................ How to Make Checks With Engine Stopped................................................................................................. Hydraulic System ...................................................................................................................................... Engine Oil .................................................................................................................................................. Drive Belts ................................................................................................................................................. Intake Manifold Rubber Cap .................................................................................................................... Cooling System .......................................................................................................................................... Air Filter .................................................................................................................................................... Fuel System ............................................................................................................................................... Primary Fuel Filter, Diesel Engine .......................................................................................................... Battery ....................................................................................................................................................... Tires and Wheels ....................................................................................................................................... Forks .......................................................................................................................................................... Adjust..................................................................................................................................................... Remove .................................................................................................................................................. Install..................................................................................................................................................... Forks, Mast, and Lift Chains, Inspect ..................................................................................................... Operator Restraint System....................................................................................................................... Automatic Locking Retractor (ALR) .................................................................................................... Emergency Locking Retractor (ELR) ................................................................................................... Safety Labels ............................................................................................................................................. How to Make Checks With Engine Running................................................................................................ Gauges, Lights, Horn, and Fuses ............................................................................................................. Oil Level, Powershift Transmission ......................................................................................................... Oil Level, Oil Clutch System, S6.00-7.00XL (S135-155XL) .................................................................... Control Levers and Pedals........................................................................................................................ Lift System Operation............................................................................................................................... Inching/Brake Pedal.................................................................................................................................. Service Brakes ........................................................................................................................................... Parking Brake ........................................................................................................................................... Steering System ........................................................................................................................................ Maintenance Procedures Every 250 Hours or 6 Weeks ................................................................................... Engine Oil and Filter, GM V-6...................................................................................................................... Mast, Lubrication .......................................................................................................................................... Lift Chains, Lubrication................................................................................................................................ Crankcase Breather, GM V-6 Engine ........................................................................................................... Drive Shafts, S6.00-7.00XL (S135-155XL) ................................................................................................... Air Filter GM V-6 EPA Compliant Engine................................................................................................... Maintenance Procedures Every 350 Hours or 2 Months ................................................................................. Drive Belts ..................................................................................................................................................... Perkins Diesel Engine............................................................................................................................... GM V-6 Engine, Early Models ..................................................................................................................

ÂŠ2007 HYSTER COMPANY

1 1 1 1 2 2 2 3 11 14 14 14 14 14 14 14 15 17 17 17 17 18 18 18 20 20 21 21 21 23 23 23 24 24 24 25 25 26 26 26 27 27 27 27 27 28 28 29 29 29 29

Table of Contents

Periodic Maintenance

TABLE OF CONTENTS (Continued) GM V-6 Engine, Late Models.................................................................................................................... Forks, Wear and Damage Check................................................................................................................... Lift Chains, Wear Check ............................................................................................................................... Hydraulic Tank Breather, Clean and Check ................................................................................................ Brake Fluid .................................................................................................................................................... Fuel System, Checks and Adjustments ........................................................................................................ Diesel Fuel System.................................................................................................................................... LPG Carburetor......................................................................................................................................... Gasoline Carburetor (Early Models) ........................................................................................................ Fuel Injection (Late Model GM V-6)......................................................................................................... Steering Axle, Lubrication ............................................................................................................................ Cooling System, Clean Debris from Radiator Core ..................................................................................... Air Filter ........................................................................................................................................................ Maintenance Procedures Every 500 Hours or 3 Months ................................................................................. Engine Oil and Filter, Perkins Diesel Engine.............................................................................................. Crankcase Breather, Perkins Diesel Engine................................................................................................ PCV Valve, GM V-6 ....................................................................................................................................... Maintenance Procedures Every 1000 Hours or 6 Months ............................................................................... Manifold Heat Valve, GM V-6 ....................................................................................................................... Crankcase Breather, GM V-6 ........................................................................................................................ Ignition System, GM V-6............................................................................................................................... Valve Clearance, Check and Adjust.............................................................................................................. Fuel Filter, Diesel Engine, Replace .............................................................................................................. Fuel System Air Removal, Perkins (1004.42 Diesel Engine) ...................................................................... Fuel Injection Pump With Vent Tube ....................................................................................................... Fuel Injection Pump With Vent Screw ..................................................................................................... Differential and Drive Axle, Oil Level Check .............................................................................................. Differential S3.50-5.50XL (S70-120XL) ................................................................................................... Differential and Drive Axle for Powershift Transmission S6.00-7.00XL (S135-155XL) ....................... Differential, Speed Reducer, and Drive Axle for Manual Transmission S6.00-7.00XL (S135-155XL) ............................................................................................................................................. Control Levers and Pedals, Lubrication....................................................................................................... Cooling System GM V-6 EPA Compliant Engine......................................................................................... LPG Fuel Filter GM V-6 EPA Compliant Engine, Replace ......................................................................... Inspect Engine Electrical System, Connectors, and FCVS Connection ..................................................... Spark Plug Replacement ............................................................................................................................... Remove....................................................................................................................................................... Install ......................................................................................................................................................... Maintenance Procedures Every 2000 Hours or Yearly .................................................................................... Hydraulic System .......................................................................................................................................... Hydraulic Oil and Filter S3.50-5.50XL (S70-120XL), Replace ............................................................... Hydraulic Oil and Filter S6.00-7.00XL (S135-155XL), Replace ............................................................. Powershift Transmission (All Units), Oil Change and Oil Filter, Replace ................................................. Manual Transmission and Differential S6.00-7.00XL (S135-155XL), Oil Change ................................ Oil Clutch System S6.00-7.00XL (S135-155XL), Oil and Filter Change .................................................... Differential and Drive Axle for Powershift Transmission (All Units), Oil Change ................................... Cooling System .............................................................................................................................................. PCV Valve, GM V-6 ....................................................................................................................................... Service Brakes ............................................................................................................................................... LPG Filter, Replace (Pre-2004) ..................................................................................................................... Oxygen Sensor GM V-6 EPA Compliant Engine..........................................................................................

29 31 31 32 32 32 32 33 33 34 34 34 34 35 35 35 35 35 35 35 35 36 36 36 36 37 39 39 39 39 39 39 40 40 41 41 41 42 42 42 42 42 43 43 43 44 44 44 44 45

Periodic Maintenance

Table of Contents

TABLE OF CONTENTS (Continued) Gasoline Fuel Filter, Replace ........................................................................................................................ Air Filter Element, GM V-6 EPA Compliant Engine................................................................................... Test LPG/GAS Regulator Pressure............................................................................................................... Inspect Low Pressure Regulator (LPR) for Oil Buildup and Leaks............................................................ Check Throttle Shaft for Sticking................................................................................................................. Inspect Exhaust Manifold and Piping for Leaks ......................................................................................... Hood Latch Check .............................................................................................................................................. Lift Chain Adjustments ..................................................................................................................................... Fuel Injectors Repair ......................................................................................................................................... Lift and Tilt System Leak Check ...................................................................................................................... Lift Cylinders, Leak Check ........................................................................................................................... Tilt Cylinders, Leak Check ........................................................................................................................... Welding Repairs ................................................................................................................................................. Overhead Guard Changes ................................................................................................................................. Wheel and Tire Replacement ............................................................................................................................ Solid Rubber Tire, Change ............................................................................................................................ Wheels, Install........................................................................................................................................... Adhesives and Sealants ..................................................................................................................................... Hydraulic Oil, Lubricant, and Coolant Specifications .....................................................................................

45 45 45 45 46 46 47 47 49 50 50 50 51 51 52 52 53 53 54

This section is for the following models: S3.50-5.50XL (S70-120XL) [D004]; S6.00-7.00XL (S135-155XL) [B024, C024]

iii

8000 SRM 393

General

General WARNING Do not make repairs or adjustments unless you have both authorization and training. Repairs and adjustments that are not correct can make a dangerous operating condition.

WARNING Do not operate a lift truck that needs repairs. Report the need for repairs immediately. If repair is necessary, put a DO NOT OPERATE tag in the operator’s area. Remove the key from the key switch. This section contains a Maintenance Schedule and the instructions for maintenance and inspection. The Maintenance Schedule has time intervals for inspection, lubrication, and maintenance for your lift truck. The recommendation for the time intervals are for 8 hours of operation per day. The time intervals must be decreased from the recommendations in the Maintenance Schedule for the following conditions: • If the lift truck is used more than 8 hours per day. • If the lift truck must work in dirty operating conditions. Your dealer for Hyster lift trucks has the equipment and trained service personnel to do a complete program of inspection, lubrication, and maintenance. A regular program of inspection, lubrication, and maintenance will help your lift truck give more efficient performance and operate for a longer period of time. Some users have service personnel and equipment to do the inspection, lubrication, and maintenance shown in the Maintenance Schedule. Service Manuals are available from your dealer for Hyster lift trucks to help users who do their own maintenance.

SERIAL NUMBER DATA The serial number for the lift truck is found on the nameplate and also on the right-hand side of the frame near the counterweight.

HOW TO MOVE DISABLED LIFT TRUCK How to Tow Lift Truck WARNING Use extra caution when towing a lift truck if any of the following conditions exist: • Brakes do not operate correctly. • Steering does not operate correctly. • Tires are damaged. • Traction conditions are bad. • The lift truck must be towed on a slope. If the engine cannot run, there is no power available for the hydraulic steering system and the service brakes. This condition can make the lift truck difficult to steer and stop. If the lift truck uses power from the engine to help apply the brakes, the application of the brakes will be more difficult. Poor traction can cause the disabled lift truck or towing vehicle to slide. A slope will also make the lift truck more difficult to stop. Never lift and move a disabled lift truck unless the disabled lift truck MUST be moved and cannot be towed. A lift truck used to move a disabled lift truck MUST have a capacity rating equal to or greater than the weight of the disabled lift truck. The capacity of the lift truck used to move a disabled lift truck must have a load center equal to half the width of the disabled lift truck. See the nameplate of the disabled lift truck for the approximate total weight. The forks must extend the full width of the disabled lift truck. Put the weight center of the disabled lift truck on load center of the forks. Be careful to not damage the under side of the lift truck. 1. The towed lift truck must have an operator. 2. Tow the lift truck slowly. 3. Raise the carriage and forks approximately 30 cm (12 in.) from the surface. Install a chain to prevent the carriage and mast channels from moving. 4. If another lift truck is used to tow the disabled lift truck, that lift truck must have an equal or larger capacity than the disabled lift truck. Install approximately 1/2 of a capacity load on the

General

8000 SRM 393

forks of the lift truck that is being used to tow the disabled lift truck. This 1/2 capacity load will increase the traction of the lift truck. Keep the load as low as possible. 5. Use a towing link made of steel that fastens to the tow pins in the counterweights of both lift trucks.

HOW TO PUT LIFT TRUCK ON BLOCKS

1. Put blocks on each side (front and back) of the steering tires to prevent movement of the lift truck. See Figure 1. 2. Put the mast in a vertical position. Put a block under each outer mast channel. 3. Tilt the mast fully forward until the drive tires are raised from the surface.

How to Raise Drive Tires WARNING The lift truck must be put on blocks for some types of maintenance and repair. The removal of the following assemblies will cause large changes in the center of gravity: mast, drive axle, engine and transmission, and the counterweight. When the lift truck is put on blocks, put additional blocks in the following positions to maintain stability: â&#x20AC;˘ Before removing the mast and drive axle, put blocks under the counterweight so that the lift truck cannot fall backward. â&#x20AC;˘ Before removing the counterweight, put blocks under the mast assembly so that the lift truck cannot fall forward. The surface must be solid, even, and level when the lift truck is put on blocks. Make sure that any blocks used to support the lift truck are solid, one-piece units.

1. DRIVE TIRES

NOTE: Some lift trucks have lifting eyes. These lifting eyes can be used to raise the lift truck so that blocks can be installed.

4. Put additional blocks under the frame behind the drive tires. 5. If the hydraulic system will not operate, use a hydraulic jack under the side of the frame near the front. Make sure that the jack has a capacity equal to at least half the weight of the lift truck. See the nameplate.

How to Raise Steering Tires 1. Apply the parking brake. Put blocks on both sides (front and back) of the drive tires to prevent movement of the lift truck. See Figure 1. 2. Use a hydraulic jack to raise the steering tires. Make sure the jack has a capacity of at least 2/3 of the total weight of the lift truck as shown on the nameplate. 3. Put the jack under the steering axle or frame to raise the lift truck. Put blocks under the frame to support the lift truck.

2. STEERING TIRES Figure 1. How to Put Lift Truck on Blocks

8000 SRM 393

Maintenance Schedule

NOTE: GM V-6 ENGINE SHOWN. *S6.00-7.00XL (S135-155XL) ONLY Figure 2. Maintenance Points Table 1. Maintenance Schedule Item No.

Item

8 hr/ 250 hr/ 350 hr/ 500 hr/ Daily 6 wks 2 mo 3 mo

Tires, Tire Pressure

Steering Axle Spindles

Coolant Hoses

Cooling System

1000 hr/ 6 mo

2000 hr/ Procedure 1 yr or Quantity

X L

Specification

Check Condition

See Nameplate

2 Fittings

Multipurpose Grease See NOTE 1

Check Condition

See Parts Manual

15.1 liter (16.0 qt)

50% Water and 50% Ethylene Glycol Boron-Free Antifreeze

X=Check C=Change L=Lubricate

Maintenance Schedule

8000 SRM 393

Table 1. Maintenance Schedule (Continued) Item No.

Item

Cooling System Clean Debris from Radiator Core

Cooling System GM V6 EPA Compliant Engine

Valve Adjustment GM V-6

Valve Adjustment Diesel, All Units Inlet Valves (Cold)

Adjust as Required

0.20 mm (0.008 in.)

Valve Adjustment Diesel, All Units Exhaust Valves (Cold)

Adjust as Required

0.45 mm (0.018 in.)

Clean or Replace See NOTE 2

See Parts Manual

Clean or Replace See NOTE 2

See Parts Manual

Air Filter

Air Filter GM V6 EPA Compliant Engine

Air Filter Element GM V6 EPA Compliant Engine

Fuel Tank S3.50-5.50XL (S70-120XL)

8 hr/ 250 hr/ 350 hr/ 500 hr/ Daily 6 wks 2 mo 3 mo

2000 hr/ Procedure 1 yr or Quantity

15.1 liter (16.0 qt)

50% Water and 50% Ethylene Glycol Boron-Free Antifreeze Not Adjustable

Specification

Clean as Needed

X=Check C=Change L=Lubricate

1000 hr/ 6 mo

See NOTE 3

66.2 liter (17.5 gal)

Gasoline [86 Octane (minimum)] Diesel No. 2 LPG - HD-5

8000 SRM 393

Maintenance Schedule

Table 1. Maintenance Schedule (Continued) Item No.

Item

Fuel Tank S6.00-7.00XL (S135-155XL, XL 2, and S155XLS)

Engine Oil GM V-6

Engine Oil (Diesel) Perkins 1004-42 Perkins 1104C-44(RE)

Seat Belts and Seat Rails

Check Condition

Hood Latch, Seat

Check Condition

Safety Labels

Replace as Necessary

Check for Leaks Fuel, Oil, Water

Check for Leaks See NOTE 4

Horn, Gauges, Lights, Alarms

Check Operation

Brake Fluid

Timing GM V-6 Timing Diesel, Units

8 hr/ 250 hr/ 350 hr/ 500 hr/ Daily 6 wks 2 mo 3 mo

1000 hr/ 6 mo

All

Engine Idle Speed GM V-6

2000 hr/ Procedure 1 yr or Quantity

Specification

66.2 liter (17.5 gal)

Gasoline [86 Octane (minimum)] Diesel No. 2 LPG - HD-5

See NOTE 5 4.7 liter (5.0 qt)

18 to 40 C (0 to 104 F) SAE 10W-30 API SL ILSAC GF-3 SAE 2362

See NOTE 5 8.0 liter (8.5 qt)

15 to 40 C (5 to 104 F) SAE 10W-30 10 to 50 C (14 to 122 F) SAE 15W-40 API CG4/CH4 ACEA E3/E5 MIL-PRF-2104G

See Parts Manual

0.2 liter (0.4 pt)

SAE J-1703

Adjust as Required

0 BTDC @ 650 rpm

Adjust as Required

16 BTDC Static

Adjust as Required

625 to 675 rpm

X=Check C=Change L=Lubricate

Maintenance Schedule

8000 SRM 393

Table 1. Maintenance Schedule (Continued) Item No.

Item

8 hr/ 250 hr/ 350 hr/ 500 hr/ Daily 6 wks 2 mo 3 mo

2000 hr/ Procedure 1 yr or Quantity

Specification

Engine Governed Speed GM V-6

Adjust as Required

2400 to 2500 rpm

Engine Idle Speed Diesel

Adjust as Required

725 to 775 rpm

Engine Governed Speed Diesel

Adjust as Required

2400 to 2500 rpm

Service Brakes

Parking Brake

Steering and Steering Wheel Position Latch

X L

Check Operation Check Operation Check Condition

Engine Oil

Check Operation

Clutch, Brake, and Inching/ Brake Pedals

Wheel Nuts Drive Wheels

Check Torque 610 to 680 Nâ&#x20AC;¢m (450 to 500 lbf ft)

Mast, Carriage, and Attachments

Check Condition and Operation

Mast, Sideshift Carriage Rollers

Adjust as Required

Hyster Part Number 328388

4 Fittings

Multipurpose Grease See NOTE 1

Mast Sliding Surfaces and Load Roller Surfaces

As Required

Multipurpose Grease See NOTE 1

Mast Fork Guides

As Required

Multipurpose Grease See NOTE 1

X=Check C=Change L=Lubricate

1000 hr/ 6 mo

8000 SRM 393

Maintenance Schedule

Table 1. Maintenance Schedule (Continued) Item No.

Item

8 hr/ 250 hr/ 350 hr/ 500 hr/ Daily 6 wks 2 mo 3 mo

Mast Pivots

Forks

Lift Chains

1000 hr/ 6 mo

2000 hr/ Procedure 1 yr or Quantity

2 Fittings

Specification

Multipurpose Grease See NOTE 1

Check Condition

Check Condition and Lubrication

Engine Oil

As Required

Engine Oil

Pedals, Levers, Linkages, Cables, Hinges, Seat Rails

Speed Reducer and Differential Oil, Single-Speed Powershift S3.50-5.50XL (S70-120XL)

5.7 liter (6.0 qt) See NOTE 6

SAE 80W-90 SAE 85W-140

Speed Reducer and Differential Oil, Two-Speed Powershift S6.00-7.00XL (S135-155XL, XL 2, and S155XLS)

14.2 liter (15.0 qt) See NOTE 6

SAE 80W-90 SAE 85W-140

Manual Transmission, Differential Oil S3.50-5.50XL (S70-120XL) (B024)

14.2 liter (15.0 qt)See NOTE 6

SAE 80W-90 SAE 85W-140

Powershift Transmission Oil (Single-Speed) S3.50-5.50XL (S70-120XL)

15.1 liter Hyster Part (16 qt) Number 336831 See NOTE 5 Change oil filter when transmission oil is changed.

X=Check C=Change L=Lubricate

Maintenance Schedule

8000 SRM 393

Table 1. Maintenance Schedule (Continued) Item No.

Item

Powershift Transmission Oil (Two-Speed) S6.00-7.00XL (S135-155XL, XL 2, and S155XLS)

Oil Clutch System, Oil Level S3.50-5.50XL (S70-120XL) (B024)

Transmission and Clutch

8 hr/ 250 hr/ 350 hr/ 500 hr/ Daily 6 wks 2 mo 3 mo

Oil Filter, Hydraulic System

Hydraulic Tank Breather

Hydraulic System S3.50-5.50XL (S70-120XL)

Hydraulic System S6.00-7.00XL (S135-155XL, XL 2, and S155XLS)

Crankcase Breather GM V-6

Specification

15.1 liter Hyster Part (16 qt) Number 336831 See NOTE 5 Change oil filter when transmission oil is changed. 9.4 liter (10 qt)

Hyster Part Number 336831 Change oil filter when clutch oil is changed.

Check Operation 1 See NOTE 5

See Parts Manual

Clean or Replace

See Parts Manual

37.0 liter (9.7 gal)

18 C (0 F) and above SAE 10W API CC or CC/SE/SF/SG MIL-L-46152

42.0 liter (11.0 gal)

18 C (0 F) and above SAE 10W API CC or CC/SE/SF/SG MIL-L-46152

1 See NOTE 7

See Parts Manual

1 See NOTE 7

See Parts Manual

Drain Water

See Parts Manual

X=Check C=Change L=Lubricate

2000 hr/ Procedure 1 yr or Quantity

Crankcase Breather Perkins 1004-42 and 1104C-44(RE) Diesel Primary Fuel Filter, Diesel

1000 hr/ 6 mo

8000 SRM 393

Maintenance Schedule

Table 1. Maintenance Schedule (Continued) Item No.

Item

8 hr/ 250 hr/ 350 hr/ 500 hr/ Daily 6 wks 2 mo 3 mo

1000 hr/ 6 mo

2000 hr/ Procedure 1 yr or Quantity

Specification

Battery Electrolyte, Battery Case and Cables

Check Level, Clean

See Parts Manual

Drive Belts

Check Condition

See Parts Manual

Wheel Nuts Steer Wheels

Check Torque 610 to 680 Nâ&#x20AC;¢m (450 to 500 lbf ft)

Drive Shaft and Universal Joints S6.00-7.00XL (S135-155XL, XL 2, and S155XLS)

2 Fittings

Multipurpose Grease See NOTE 1

Engine Oil Filter GM V-6

See NOTE 5

See Parts Manual

See NOTE 5

See Parts Manual

Engine Oil Filter Diesel Perkins 1004-42 Perkins 1104C44(RE)

Final Fuel Filter, Diesel

See Parts Manual

Spark Plugs

Check Plug Wires 6 Plugs

See NOTE 8

See Parts Manual

Fuel Filter Gasoline

See Parts Manual

Fuel Filter LPG

See Parts Manual

PCV Valve GM V-6

Fuel Filter, LPG GM V6 EPA Compliant Engine

X=Check C=Change L=Lubricate

Maintenance Schedule

8000 SRM 393

Table 1. Maintenance Schedule (Continued) Item No.

Item

8 hr/ 250 hr/ 350 hr/ 500 hr/ Daily 6 wks 2 mo 3 mo

Inspect Engine Electrical System, Connectors, and FCVS Connection

2000 hr/ Procedure 1 yr or Quantity

Inspect Engine Vacuum, Fuel Lines, and Fittings

Inspect Lock Off for Leaks, and Ensure Lock Off Closing

Test LPG/GAS Regulator Pressure

Inspect Low Pressure Regulator for Oil Build Up and Leaks

Check Air Induction System for Leaks

Check Manifold for Vacuum Leaks

Check Throttle Shaft for Sticking

Check Injectors and Rails for Leaks

Inspect Exhaust Manifold, and Exhaust Piping for Leaks

Inspect Catalyst Inlet and Outlet

X=Check C=Change L=Lubricate

1000 hr/ 6 mo

Drain Oil if Necessary

Specification

8000 SRM 393

Safety Procedures When Working Near Mast

Table 1. Maintenance Schedule (Continued) Item No.

Item

8 hr/ 250 hr/ 350 hr/ 500 hr/ Daily 6 wks 2 mo 3 mo

1000 hr/ 6 mo

2000 hr/ Procedure 1 yr or Quantity

Oxygen Sensor Connector GM V6 EPA Compliant Engine

Specification

Check Indicator Light

NOTE 1: Multipurpose Grease with 2 to 4% Molybdenum Disulfide. NOTE 2: Very dirty conditions require daily clean and check. NOTE 3: In dirty or dusty environments, replace at 1,000 hours. NOTE 4: Check fuel system for leaks prior to any service or maintenance activity. NOTE 5: Change filter on new lift trucks at the first 100 hours on the hourmeter. NOTE 6: Check the thrust screw adjustment on the differential after the first 150 hours of operation. Adjustments after first 150 hours are normally not needed. NOTE 7: Check the crankcase breather after every engine oil change. NOTE 8: See Capacities and Specifications 8000 SRM 454. X=Check C=Change L=Lubricate

• DO NOT use blocks to support the mast weldments nor to restrain their movement. • Mast repairs require disassembly and removal of parts and can require removal of the mast or carriage. Follow the repair procedures in the correct Service Manual section for the mast. WHEN WORKING NEAR THE MAST ALWAYS: 1. Lower the mast and carriage completely. Push the lift/lower control lever forward and make sure there is no movement in the mast. Make sure that all parts of the mast that move are fully lowered. OR 2. If parts of the mast must be in the raised position, install a safety chain to restrain the moving parts of the mast. Connect moving parts to a part that does not move. Follow these procedures: a. Put the mast in a vertical position.

Safety Procedures When Working Near Mast b. Raise the mast to align the bottom crossmember of the weldment that moves in the outer weldment with a crossmember on the outer weldment. On the two-stage and freelift mast, the moving part is the inner weldment. On the three-stage mast, it is the intermediate weldment. See Figure 3. c. Use a 3/8-in. minimum safety chain with a hook to fasten the crossmembers together so that the movable member cannot lower. Put the hook on the back side of the mast. Make sure the hook is completely engaged with a link in the chain. Make sure the safety chain does not touch lift chains or chain sheaves, tubes, hoses, fittings, or other parts on the mast.

8000 SRM 393 d. Lower the mast until there is tension in the safety chain and the free-lift cylinder (freelift and three-stage masts only) is completely retracted. If running, stop the engine. Apply the parking brake. Install a DO NOT REMOVE tag on the safety chain(s). e. Install another safety chain (3/8-in. minimum) between the top or bottom crossmember of the carriage and a crossmember on the outer weldment. 3. Apply the parking brake. After lowering or restraining the mast, shut off the power and remove the key. Put a DO NOT OPERATE tag in the operatorâ&#x20AC;&#x2122;s compartment.

8000 SRM 393

Safety Procedures When Working Near Mast

A. TWO-STAGE LFL MAST

B. TWO-STAGE FFL MAST

C. THREE-STAGE FFL MAST

1. OUTER WELDMENT 2. INNER WELDMENT 3. INTERMEDIATE WELDMENT

4. HOOK 5. FREE-LIFT CYLINDER 6. CROSSMEMBER

7. CROSSMEMBER

Figure 3. Two-Stage LFL, Two-Stage FFL, and Three-Stage FFL Masts

Maintenance Procedures Every 8 Hours or Daily

8000 SRM 393

Maintenance Procedures Every 8 Hours or Daily HOW TO MAKE CHECKS WITH ENGINE STOPPED WARNING Do not operate a lift truck that needs repairs. Report the need for repairs immediately. If repair is necessary, put a DO NOT OPERATE tag in the operatorâ&#x20AC;&#x2122;s area. Remove the key from the key switch. Put the lift truck on a level surface. Lower the carriage and forks, stop the engine, and apply the parking brake. Open the hood and check for leaks and conditions that are not normal. Clean any oil or fuel spills. Make sure that lint, dust, paper, and other materials are removed from the engine compartment.

Hydraulic System WARNING At operating temperature, the hydraulic oil is HOT. Do not permit the hot oil to touch the skin and cause a burn.

CAUTION Do not permit dirt to enter the hydraulic system when the oil level is checked or the filter is changed. Never operate the hydraulic pump without oil in the hydraulic system. The operation of the hydraulic pump without oil will damage the pump. Check the hydraulic oil level when the oil is at operating temperature, the carriage is lowered, and the engine is stopped. See Figure 4. Add hydraulic oil only as needed. If more hydraulic oil is added than the FULL level, the hydraulic oil will leak from the breather during operation. The oil level indicated by the dipstick is most accurate when the oil temperature is 53 to 93 C (127 to 200 F). Check the hydraulic system for leaks and damaged or loose components.

Engine Oil After the engine has stopped, wait 1 minute before checking the oil level. See Figure 5. Keep the oil at the correct level as indicated on the dipstick. Use the correct oil as shown in the Maintenance Schedule.

Drive Belts Check the drive belts for wear and damage.

Intake Manifold Rubber Cap Check for cracks or dry rot.

Cooling System WARNING DO NOT remove the radiator cap from the radiator when the engine is hot. When the radiator cap is removed, the pressure is released from the system. If the system is hot, the steam and boiling coolant can cause burns. DO NOT remove the cover for the radiator when the engine is running. Make sure the coolant level is between the FULL and the ADD mark on the auxiliary coolant reservoir. See Figure 6. The coolant will expand as it is heated and the level in the auxiliary coolant reservoir will increase. Add coolant to the auxiliary reservoir if additional coolant is needed.

8000 SRM 393

Maintenance Procedures Every 8 Hours or Daily

Air Filter

Air pressure must be less than 210 kPa (30 psi). Apply the air from the inside to the outside of the element.

Inspect the filter element. Put a bright light inside and look for holes or other damage. If the element is damaged, replace it with a new element. Use a cloth with solvent to clean the inside of the canister when the filter element is cleaned or replaced.

Clean or replace the air filter as necessary. See Figure 7. Use compressed air to clean the filter element.

NOTE: BREATHER IS ON TOP OF HYDRAULIC TANK AND UNDER TOP OF FRAME. A. S3.50-5.50XL (S70-120XL)

B. S6.60-7.00XL (S135-155XL)

1. 2. 3. 4.

5. ENGINE BREATHER 6. HYDRAULIC OIL FILL CAP 7. FILTER HEAD

BATTERY BRAKE FLUID RESERVOIR HYDRAULIC OIL DIPSTICK HYDRAULIC TANK BREATHER

Figure 4. Maintenance Points

Maintenance Procedures Every 8 Hours or Daily

8000 SRM 393

A. DIESEL

B. GASOLINE/LPG

1. 2. 3. 4.

5. 6. 7. 8.

DIPSTICK FOR ENGINE OIL ENGINE OIL FILL CAP AIR FILTER AUXILIARY COOLANT RESERVOIR

PCV VALVE (GM V-6) BATTERY FILL CAP, FUEL COLD START AID, DIESEL

Figure 5. Engine Maintenance Points

1. CANISTER 2. O-RING 3. FILTER ELEMENT Figure 6. Auxiliary Coolant Reservoir

4. BAFFLE 5. CLAMP 6. END COVER

Figure 7. Air Filter

8000 SRM 393

Fuel System WARNING All fuels are very flammable and can burn or cause an explosion. Do not use an open flame to check the fuel level or to check for leaks in the fuel system. If there is a leak in the fuel system, extra care must be used during the repair. Do not operate the lift truck until a leak is repaired.

Maintenance Procedures Every 8 Hours or Daily flame away from the battery area. Do not make sparks from the battery connections. Disconnect the battery ground cable when doing maintenance. Keep the battery and cable terminals clean. See Figure 2 and Figure 4. Check the electrolyte level (unless a maintenance-free battery). Keep the electrolyte level above the separators and plates. Use distilled water. Do not fill the battery more than to the bottom of the internal filler neck.

Check the fuel system for leaks and the condition of parts. When fuel is added to the lift truck, see the section, How To Add Fuel To The Lift Truck procedures in the Operating Manual.

If the battery becomes discharged and requires a booster battery to start the engine, follow these procedures carefully when connecting the jumper cables:

Primary Fuel Filter, Diesel Engine

1. Always connect the positive jumper cable to the positive terminal of the discharged battery and the negative jumper cable to the negative terminal.

1. Drain the water from the primary fuel filter. See Figure 8. Open the valve on the bottom of the filter canister. Drain some fuel (and any water) into a cup until clean fuel flows from the filter.

2. Always connect the jumper cable that is the ground cable last.

2. Close the valve. 3. Always connect the jumper cables to the discharged battery before connecting them to the booster battery.

Tires and Wheels CAUTION

Figure 8. Primary Fuel Filter

Battery WARNING The acid in the electrolyte can cause injury. If the electrolyte is spilled, use water to flush the area. Use a solution of sodium bicarbonate (soda) to make the acid neutral. Acid in the eyes must be flushed with water immediately. Wear eye protection.

Check all wheel nuts after 2 to 5 hours of operation: when new lift trucks begin operation and on all lift trucks when the drive wheels have been removed and installed. Tighten the nuts in a cross pattern to the correct torque value shown in the Maintenance Schedule. When the nuts stay tight for 8 hours, the interval for checking the torque can be extended to 350 hours. Check the tires for damage. See Figure 9. Check the tread and remove any objects that will cause damage. Check for bent or damaged rims. Check for loose or missing parts. Remove any wire, straps, or other material wrapped around the axle. Make sure the drive wheel nuts are tight. Tighten the wheel nuts in a cross pattern to the correct torque value shown in the Maintenance Schedule.

Batteries generate explosive fumes. Keep the vents in the caps clean. Keep sparks or open

Maintenance Procedures Every 8 Hours or Daily

8000 SRM 393 lock pins are installed through the top fork hooks and fit into slots in the top carriage bar. Adjust the forks as far apart as possible for maximum support of the load. Hook forks will slide along the carriage bars to adjust for the load to be lifted. Raise the lock pin in each fork to slide the fork on the carriage bar. Make sure the lock pin is engaged in the carriage bar to lock the fork in position after the width adjustment is made. Remove

WARNING Do not try to move a fork without a lifting device. Each hook fork for these lift trucks can weigh 45 to 105 kg (99 to 231 lb). 1. CHECK FOR DAMAGE (REMOVE NAILS, GLASS, AND OTHER OBJECTS FROM TREAD) 2. MAKE SMOOTH EDGES Figure 9. Tires Check

Forks The identification of a fork describes how the fork is connected to the carriage. These lift trucks have hook-type forks. See Figure 10. Adjust The forks are connected to the carriage by one of two types of hooks and lock pins. See Figure 10. These

A fork can be removed from the carriage for replacement of the fork or other maintenance. Slide the fork to the fork removal notch on the bottom carriage bar. See Figure 11. Lower the fork onto blocks so that the bottom hook of the fork moves through the fork removal notch. See Figure 11 and Figure 12. Lower the carriage further so that the top hook of the fork is disengaged from the top carriage bar. Move the carriage away from the fork, or use a lifting device to move the fork away from the carriage.

8000 SRM 393

Maintenance Procedures Every 8 Hours or Daily

A. OLD-STYLE LOCK PIN ASSEMBLY

B. NEW-STYLE LOCK PIN ASSEMBLY

1. 2. 3. 4. 5.

6. 7. 8. 9. 10.

FORK LOCK PIN SPRING WASHER WASHER

WEDGE KNOB LEVER COTTER PIN LOCK PIN ASSEMBLY

Figure 10. Fork Lock Pin Assembly

Maintenance Procedures Every 8 Hours or Daily

8000 SRM 393 1. Inspect the welds on the mast and carriage for cracks. Make sure that the capscrews and nuts are tight. 2. Inspect the channels for wear in the areas where the rollers travel. Inspect the rollers for wear or damage. 3. Inspect the load backrest extension for cracks and damage. 4. Inspect the forks for cracks and wear. Check that the fork tips are aligned as shown in Figure 12. Check that the bottom of the fork is not worn.

1. CARRIAGE BARS 2. HOOK FORK

3. BLOCKS

Figure 11. Hook Fork Removal Install

WARNING Do not try to move a fork without a lifting device. Each hook fork for these lift trucks can weigh 45 to 105 kg (99 to 231 lb). Move the fork and carriage so that the top hook on the fork can engage the upper carriage bar. Raise the carriage to move the lower hook through the fork removal notch. Slide the fork on the carriage so that both upper and lower hooks engage the carriage. Engage the lock pin with a notch in the upper carriage bar.

Forks, Mast, and Lift Chains, Inspect WARNING When working on or near the mast, see Safety Procedures When Working Near Mast of this section. Lower the lift mechanism completely. Never allow any person under a raised carriage. Do not put any part of your body in or through the lift mechanism unless all parts of the mast are completely lowered and the engine is STOPPED. Do not try to correct the alignment of the fork tips by bending the forks or adding shims. Replace damaged forks. Never repair damaged forks by heating or welding. Forks are made of special steel using special procedures. Replace damaged forks.

Fork Tip Alignment Length of Forks

3% Dimension

912 mm (36 in.) 1220 mm (48 in.) 1830 mm (72 in.)

27 mm (1.10 in.) 37 mm (1.46 in.) 55 mm (2.17 in.)

1. TIP ALIGNMENT (MUST BE WITHIN 3 PERCENT OF FORK LENGTH) 2. CRACKS 3. LATCH DAMAGE 4. HEEL OF FORK (MUST BE 90% OF DIMENSION X) 5. CARRIAGE 6. LOAD BACKREST EXTENSION 7. MAXIMUM ANGLE 93 DEGREES 8. FORK REMOVAL NOTCH Figure 12. Forks Check

8000 SRM 393

Maintenance Procedures Every 8 Hours or Daily

5. Replace any damaged or broken parts that are used to keep the forks locked in position. 6. If the lift truck is equipped with a sideshift carriage or attachment, inspect the parts for cracks and wear. Make sure the parts that fasten the sideshift carriage or attachment to the carriage are in good condition. 7. Check that the lift chains are correctly lubricated. Use SAE 30 engine oil to lubricate the lift chains. 8. Inspect the lift chains for cracks or broken links and pins. See Figure 13.

Operator Restraint System The seat belt, hip restraint brackets, seat and mount, hood, latches, and floor plates are all part of the operator restraint system. Each item must be checked to make sure it is fastened correctly, functions correctly, and is in good condition. Automatic Locking Retractor (ALR) NOTE: lift trucks produced before November 2005 are equipped with the ALR type seat belts. The seat belt must fasten securely. Make sure the seat belt extends and retracts smoothly and is not frayed or torn. If the seat belt is damaged or does not operate properly, it must be replaced. See Figure 14. Emergency Locking Retractor (ELR) NOTE: Lift trucks produced after November 2005 are equipped with the Emergency Locking Retractor (ELR) style seat belt. When the ELR style seat belt is properly buckled across the operator, the belt will permit slight operator repositioning without activating the locking mechanism. If the truck tips, travels off a dock, or comes to a sudden stop, the locking mechanism will be activated and hold the operator’s lower torso in the seat.

1. 2. 3. 4.

WORN PIN CRACKS EDGE WEAR HOLE WEAR

5. LOOSE LEAVES 6. DAMAGED PIN 7. CORROSION

Figure 13. Lift Chains Check 9. Check that the lift chains are correctly lubricated. Use SAE 30 engine oil to lubricate the lift chains. 10. Inspect the chain anchors and pins for cracks and damage. 11. Make sure the lift chains are adjusted so that they have equal tension. Adjustment or replacement of the lift chains must be done by authorized personnel. See Lift Chain Adjustments described later in this section.

A seat belt that is damaged worn or does not operate properly will not give protection when it is needed. The end of the belt must fasten correctly in the latch. The seat belt must be in good condition. Replace the seat belt if damage or wear is seen. See Figure 14. The following seat belt operation checks must be performed: • With the hood closed and in the locked position, pull the seat belt slowly from the retractor assembly. Make sure the seat belt pulls out and retracts smoothly. if the seat belt cannot be pulled from the retractor assembly or the belt will not retract, replace the seat belt assembly. • With the hood closed and in the locked position, pull the seat belt with a sudden jerk. Make sure the seat belt will not pull from the retractor assembly. If the seat belt can be pulled from the retractor, when it is pulled with a sudden jerk, replace the seat belt assembly. • With the hood in the open position, make sure the seat belt will not pull from the retractor assembly. If the seat belt can be pulled from the retractor,

Maintenance Procedures Every 8 Hours or Daily with the hood in the open position, replace the seat belt assembly. Make sure the seat rails and latch striker are not loose. The seat rails must lock tightly in position, but move freely when unlocked. The seat rails must be correctly fastened to the mount surface. If the mount surface is the hood, the hood must be fastened to the floor plate with the latch. The floor plate must be

8000 SRM 393 fastened to the lift truck frame. Try to lift the hood to make sure it is fastened correctly and will not move. See Figure 14. The seat belt must fasten correctly. Make sure the seat belt can be pulled from the retractor and retracts smoothly. The seat belt must not be damaged or worn. If the seat belt cannot be pulled from the retractor assembly, replace the seat belt assembly.

NOTE: S3.50-5.50XL (S70-120XL)SHOWN. A. GASOLINE AND DIESEL ARRANGEMENT

B. LPG ARRANGEMENT

1. 2. 3. 4. 5. 6.

7. 8. 9. 10. 11.

LATCH STRIKER HOOD LATCH LATCH LEVER SEAT SEAT BELT LATCH HIP RESTRAINT

SEAT RAIL FLOOR PLATE HOOD GAS CYLINDER HINGE

Figure 14. Hood and Seat Latches Check

8000 SRM 393

Safety Labels WARNING Safety labels are installed on the lift truck to give information about operation and possible hazards. It is important that all safety labels are installed on the lift truck and can be read. Check that all safety labels are installed in the correct locations on the lift truck. See the Parts Manual or the Frame section of the Service Manual for the correct location of the safety labels. If new labels must be installed, use the following procedure:

Maintenance Procedures Every 8 Hours or Daily Make sure that the area around the lift truck is clear before starting the engine or making any checks of the operation. Be careful when making the checks. If the lift truck is stationary during a check, apply the parking brake and put the transmission in NEUTRAL. Make the checks carefully.

Gauges, Lights, Horn, and Fuses Start the engine. Check the gauges and lights for correct operation as described in the Operating Manual. Check the operation of the horn. The fuses are under the instrument panel on the left side of the cowl. See Figure 15.

WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the recommendations of the manufacturer. 1. Make sure the surface is dry and has no oil or grease. Do not use solvent on new paint. Clean the surface of old paint with a cleaning solvent. 2. Remove the paper from the back of the label. Do not touch the adhesive surface. 3. Carefully hold the label in the correct position above the surface. The label cannot be moved after it touches the surface. Put the label on the surface. Make sure that all air is removed from under the label and the corners and edges are tight.

HOW TO MAKE CHECKS WITH ENGINE RUNNING WARNING FASTEN YOUR SEAT BELT! The seat belt is installed to help the operator stay on the truck if the lift truck tips over. IT CAN ONLY HELP IF IT IS FASTENED.

1. LH GAUGES & XMSN SHIFT 2. RH GAUGES 3. HORN

4. DSL COLD START 5. LIGHT 6. OTHER OPTIONS

Figure 15. Fuses On S6.00-7.00XL (S135-155XL) (C024) lift trucks only, there are additional fuses and relays located in the engine compartment. See Figure 16 and Figure 17.

Maintenance Procedures Every 8 Hours or Daily

1. FUSE PANEL 2. MOUNTING BRACKET F1 20 AMPS

F2 5 AMPS F3 15 AMPS F4 15 AMPS F5 SPARE

8000 SRM 393

F6 SPARE R1 STARTER RELAY R2 POWER RELAY

R3 FUEL PUMP RELAY R4 SPARE

Figure 16. Engine Compartment Fuses and Relays, GM 4.3L EPA Compliant Engine S6.00-7.00XL (S135-155XL) (C024) Trucks Only

Oil Level, Powershift Transmission Apply the parking brake. Check the oil level in the powershift transmission when the engine is running at idle speed. See Figure 18. If the lift truck has a direction control lever, put the direction control lever in the NEUTRAL (N) position. Use the correct oil shown in the Maintenance Schedule. Keep the oil level at the FULL mark on the dipstick. The most accurate check of the oil level is when the transmission is at operating temperature.

Oil Level, Oil Clutch System, S6.00-7.00XL (S135-155XL)

1. 2. 3. 4. 5. 6.

LIFT PUMP RELAY LIFT PUMP FUSE (10A) ALTERNATOR FUSE (60A) GLOW PLUG FUSE (60A) STARTER RELAY GLOW PLUG RELAY

Figure 17. Engine Compartment Fuses and Relays, Perkins 1104C-44(RE) Diesel Engine S6.00-7.00XL (S135-155XL) (C024) Trucks Only

Put the direction control lever in the NEUTRAL (N) position. Apply the parking brake. Check the oil level in the clutch housing when the engine is running at idle speed. See Figure 18. Make sure the oil is at operating temperature. Use the correct oil as shown in the Maintenance Schedule. Keep the oil at the FULL mark on the dipstick.

Control Levers and Pedals Check that the control levers for the transmission, mast, and attachment operate as described in the Operating Manual. Check that the pedals operate correctly as described in the Operating Manual.

8000 SRM 393

Maintenance Procedures Every 8 Hours or Daily

A. S3.50-5.50XL (S70-120XL)

B. S6.00-7.00XL (S135-155XL)

1. DIPSTICK FOR POWERSHIFT TRANSMISSION OIL OR OIL CLUTCH SYSTEM OIL

2. DIPSTICK FOR POWERSHIFT TRANSMISSION 3. FLOOR PLATE

Figure 18. Powershift Transmission or Oil Clutch System Oil Check

Lift System Operation WARNING Lower the lift mechanism completely. Never allow any person under a raised carriage. Do not put any part of your body in or through the lift mechanism unless all parts of the mast are completely lowered and the engine is STOPPED.

NOTE: Some parts of the mast move at different speeds during raising and lowering. 3. The inner weldments and the carriage must lower completely. 4. Raise the mast 1 m (3 ft) with a capacity load. The inner weldments and the carriage must raise smoothly. Lower the mast. All moving components must lower smoothly.

Before making any repairs, use blocks and chains on the mast weldments and carriage so that they cannot move. Make sure the moving parts are attached to a part that does not move.

5. Lower the load to approximately 0.3 m (1 ft) from the floor. Tilt the mast forward and backward. The mast must tilt smoothly and both tilt cylinders must stop evenly.

Do not try to find hydraulic leaks by putting hands on pressurized hydraulic components. Hydraulic oil can be injected into the body by the pressure.

6. Check that the controls operate the functions of the attachment correctly. (See the symbols next to each of the controls.) Make sure all of the hydraulic lines are connected correctly and do not leak.

Do the following checks and inspections: 1. Check for leaks in the hydraulic system. Check the condition of the hydraulic hoses and tubes. 2. Slowly raise and lower the mast several times without a load. Raise the mast to its full extension height at least once. The mast components must raise and lower smoothly in the correct sequence.

Inching/Brake Pedal Push on the inching/brake pedal. The service brakes must be applied before the inching/brake pedal reaches the floor plate. Full application of the inching/brake pedal applies the service brakes and puts the transmission in NEUTRAL. Lift trucks with a MONOTROL pedal: When the inching/brake pedal is fully applied, a switch in the starting circuit is closed so the engine can be started.

Maintenance Procedures Every 8 Hours or Daily

Service Brakes WARNING Loss of fluid from the brake fluid reservoir indicates a leak. Repair the brake system before using the lift truck. Replace the brake fluid in the system if there is dirt, water, or oil in the system. The lift truck has a brake booster that receives power from the hydraulic system. The brake pedal can be difficult to push when the engine is not running because the hydraulic system is not operating. Check the operation of the service brakes. Push on the brake pedal. The brake pedal must stop firmly and must not move slowly down after the brakes are applied. The service brakes must apply equally to both drive wheels. The service brakes must not pull the lift truck to either side of the direction of travel when they are applied. The service brakes are automatically adjusted when the brakes are applied and the lift truck changes direction.

Parking Brake Check the operation of the parking brake. The operator must adjust the parking brake so that the lift

8000 SRM 393 truck does not move if it is parked on an incline. The parking brake, when in good condition and correctly adjusted, will hold a lift truck with a capacity load on a 15% grade [a slope that increases 1.5 m in 10 m (1.5 ft increase in 10 ft)]. Turn the adjustment knob on the end of the lever to adjust the parking brake. Do not tighten the adjustment so that the brake is applied when the lever is released. The lever for the parking brake has a lock. Use your finger to release the lock on the lever when the parking brake is released. Lift trucks with a MONOTROL pedal: When the parking brake is applied, a switch in the starting circuit is closed so that the engine can be started. The switch also puts the transmission in NEUTRAL.

Steering System WARNING The lift truck has hydraulic power steering. The steering can be difficult if the engine is not running. Make sure the steering system operates smoothly and gives good steering control.

8000 SRM 393

Maintenance Procedures Every 250 Hours or 6 Weeks

Maintenance Procedures Every 250 Hours or 6 Weeks NOTE: Do these procedures in addition to the 8-hour checks.

3. If a sideshift carriage is installed, lubricate the fittings for the rollers or the sliding surfaces with multipurpose grease.

ENGINE OIL AND FILTER, GM V-6 WARNING Long-term exposure to used engine oil may cause skin irritation or cancer. Wash with detergent and water. Disposal of lubricants and fluids must meet local environmental regulations.

CAUTION Never run the engine without oil. NOTE: Change the oil filter for the engine after the first 100 hours of operation on new lift trucks. Change the oil filter at the same time engine oil is changed. Use the correct oil as shown in the Maintenance Schedule. Apply clean oil to the gasket of the new filter and install. Turn the filter until the gasket touches, then tighten 1/2 to 3/4 turn with your hand. Start the engine. Check the area around the oil filter for leaks.

A. UPPER LOAD ROLLERS B. LOWER LOAD ROLLERS

MAST, LUBRICATION

LIFT CHAINS, LUBRICATION

WARNING Do not work under a raised carriage. Lower the carriage or use a safety chain. Use the safety chain to prevent the carriage and the inner or intermediate weldments from lowering when servicing the mast and lift chains. Make sure the moving parts are attached to parts that cannot move. 1. Lubricate the sliding surfaces and the load roller surfaces along the full length of the channels as shown in Figure 19. Apply lubricant only to the indicated surfaces. NOTE: The load rollers and sheaves have sealed bearings and do not need additional lubrication.

1. LUBRICATE STRIP BEARINGS SURFACE 2. LUBRICATE LOAD ROLLER SURFACES 3. LOAD ROLLER Figure 19. Mast Lubrication

WARNING Do not repair a worn or damaged lift chain. Replace a worn or damaged lift chain with a new chain. If a pair of lift chains is used in the mast, both lift chains must be replaced. Lubricate the lift chains with SAE 20 engine oil. The best procedure is to remove the chains from the lift truck and soak them in engine oil.

CRANKCASE BREATHER, GM V-6 ENGINE Check the crankcase breather after every engine oil change. If the crankcase breather is worn or damaged, replace it with a new breather. Tighten the breather with your hand. See Figure 4.

2. Lubricate the pivot pins for the mast at the grease fittings on the pivot pins. Use multipurpose grease.

Maintenance Procedures Every 250 Hours or 6 Weeks

8000 SRM 393

DRIVE SHAFTS, S6.00-7.00XL (S135-155XL)

AIR FILTER GM V-6 EPA COMPLIANT ENGINE

Remove the floor plate for access to the grease fittings. There is a grease fitting at each universal joint. See Figure 20 and Figure 21.

NOTE: Very dirty conditions require daily check and clean.

WARNING Compressed air can move particles so they cause injury to the user or to other personnel. Make sure the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes. Clean or replace the air filter as necessary. See Figure 22. Use compressed air to clean the filter element. Air pressure must be less than 210 kPa (30 psi). Apply the air from the inside to the outside of the element.

1. 2. 3. 4. 5.

GREASE FITTING DIFFERENTIAL THRUST SCREW DIPSTICK OIL CLUTCH HOUSING MANUAL TRANSMISSION HOUSING Figure 20. Drive Shafts (Oil Clutch Arrangement) S6.00-7.00XL (S135-155XL)

1. BODY 2. ELEMENT 3. LABEL

4. COVER 5. VALVE 6. PLUG Figure 22. Air Filter

WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the recommendation of the manufacturer. 1. 2. 3. 4. 5.

GREASE FITTING DIFFERENTIAL THRUST SCREW DIPSTICK TORQUE CONVERTER HOUSING POWERSHIFT TRANSMISSION HOUSING Figure 21. Drive Shafts (Powershift Arrangement) S6.00-7.00XL (S135-155XL)

8000 SRM 393

Maintenance Procedures Every 350 Hours or 2 Months

Maintenance Procedures Every 350 Hours or 2 Months NOTE: Do these procedures in addition to the 250hour checks.

DRIVE BELTS Check the drive belts for wear and damage. When a pair of drive belts are used, they must be replaced as a pair. When a pair of drive belts are used, adjust the tension for the tightest belt. A gauge is available that will indicate the tension of the drive belt. Fit the gauge at the center of the longest length of the drive belt and measure the tension. See Figure 23. The correct tension is approximately 355 N (80 lbf).

1. PIVOT FASTENER

2. ADJUSTMENT LINK

Figure 24. Drive Belt Tension (Perkins Diesel) Check and Adjust

GM V-6 Engine, Early Models Figure 23. Drive Belt Tension Check Gauge Many service people press on the drive belt with their thumb at the center of the longest length of the drive belt and check the deflection. When the thumb pressure is 100 N (20 lbf), the correct deflection is approximately 13 mm (0.5 in.). To check tension on late model GM V-6 engines, see Figure 28.

Perkins Diesel Engine Loosen the bolt on the adjustment link (2) and the pivot fasteners (1) to adjust the tension of the drive belts. See Figure 24. Push the alternator pulley against the drive belts to adjust the tension. Tighten the adjustment link and pivot fasteners.

Drive belt for the coolant pump and alternator. Loosen the alternator support bracket to adjust the tension of the belt. See Figure 25. Drive belt for the fan. Loosen the mount for the idler pulley to adjust the tension of the belt.

GM V-6 Engine, Late Models Check the drive belt for wear and damage. See Figure 26. A few small cracks that run across the belt are acceptable. A belt with cracks that run the length of the belt or a belt with missing pieces is not acceptable.

The drive belts are removed from the engine by loosening the tension and then removing them from the pulleys.

Maintenance Procedures Every 350 Hours or 2 Months

8000 SRM 393 into the lower hole (6) in the bracket (1) for new drive belts. Do not use the upper hole (2) when installing a NEW drive belt. Putting the lug in the upper hole is only necessary to extend the life of a used drive belt.

1. CHECK TENSION HERE 2. ALTERNATOR SUPPORT BRACKET 3. IDLER PULLEY Figure 25. Drive Belts, Early Model GM V-6

1. ACCEPTABLE CRACKS 2. NOT ACCEPTABLE CRACKS AND DAMAGE Figure 26. Drive Belt Inspection 1. Check the alignment of the fan, alternator, and crankshaft pulleys. The pulleys must be aligned correctly to prevent damage to the drive belt. 2. Install the drive belt tensioner on the bracket and tighten the bolts. See Figure 27. Make sure the lug on the back of the drive belt tensioner fits

1. ALTERNATOR PULLEY 2. FAN PULLEY 3. WATER PUMP PULLEY 4. CRANKSHAFT PULLEY 5. DRIVE BELT

6. TENSIONER PULLEY 7. DRIVE BELT TENSIONER 8. ALIGNMENT LUG 9. LOWER HOLE 10. UPPER HOLE 11. BRACKET

Figure 27. Drive Belt Arrangement, Late Model GM V-6

8000 SRM 393

Maintenance Procedures Every 350 Hours or 2 Months

CAUTION Do not use a pry bar to install the drive belt on the pulleys. The pry bar can damage the drive belt and pulleys. 3. Loosen the top capscrew at the alternator mount and move the alternator toward the engine. Install the drive belt over the fan and onto the pulleys. 4. Use a socket with a long handle on the capscrew for the tensioner pulley (6, Figure 27) on the drive belt tensioner. (The capscrew has left-hand threads and will not loosen.) Use the handle to pull the tensioner pulley away from the drive belt. While holding the tensioner pulley away from the belt, pull the alternator away from the engine (as far as it will move) and tighten the capscrew at the mount. Release the tensioner pulley for the drive belt tensioner. 5. After installation is complete, check the position of the indicator on the tensioner. See Figure 28. When the tension is correct, the indicator will be in the area (3) as shown in Figure 28. If the indicator is in the area as shown by (4), change the position of the tensioner to the upper hole (10, Figure 27). Use the procedure described in Step 4. If the tension on the drive belt is still not correct, install a new drive belt. Also check that the brackets and pulleys are installed correctly.

FORKS, WEAR AND DAMAGE CHECK WARNING Never repair damaged forks. Do not heat, weld, or bend the forks. Forks are made of special steel using special methods. Replace damaged forks. 1. Check the heel and attachment points of the forks with a penetrant or magnetic particle inspection. See Figure 12. 2. Measure the thickness of the forks at a vertical section where there is no wear. This thickness is dimension X. Now measure the thickness at the heel (5) of the fork. If the thickness of the heel is not greater than 90% of dimension X, replace the fork.

1. TENSIONER 2. INDICATOR 3. TENSION IS CORRECT

4. ADJUST TENSION OR REPLACE DRIVE BELT

Figure 28. Drive Belt Tension Check, Late Model GM V-6

LIFT CHAINS, WEAR CHECK If a section of chain is 3% longer than a similar section of new chain, the chain is worn and must be replaced. Measure the chain for wear where it moves over the sheaves. If a chain scale is available, check the lift chains as shown in Figure 29. If a chain scale is not available, measure 20 links of chain. Measure from the center of a pin to the center of another pin 20 pitches away. Compare the length with the chart in Figure 29. Replace the chain if the length of 20 links of the worn section is more than the WEAR LIMIT.

Maintenance Procedures Every 350 Hours or 2 Months

8000 SRM 393 cleaning solvents, always follow the solvent manufacturerâ&#x20AC;&#x2122;s recommended safety precautions. Clean the hydraulic tank breather in solvent. Replace the breather element if air will not flow through it easily. (See the location of the hydraulic tank breather in Figure 4.)

BRAKE FLUID WARNING Loss of fluid from the reservoir indicates a leak. Repair the brake system before the lift truck is used. Replace the brake fluid in the brake system if there is oil, water, or dirt in the system.

NOTE: THE INSTRUCTIONS FOR MEASURING CHAIN WEAR ARE SHOWN ON THE CHAIN WEAR SCALE. Pitch

Total Length of 20 Links (Pitch) of New Chain

Wear Limit Maximum Length of 20 Links

31.8 mm (1.25 in.)

635 mm (25.0 in.)

654 mm (25.7 in.)

38.1 mm (1.50 in.)

762 mm (30.0 in.)

785 mm (30.9 in.)

44.5 mm (1.75 in.)

889 mm (35.0 in.)

915 mm (36.0 in.)

1. CHAIN WEAR SCALE Figure 29. Lift Chains Check

HYDRAULIC TANK BREATHER, CLEAN AND CHECK WARNING Cleaning solvents can be flammable and toxic, and can cause skin irritation. When using

Check the fluid level in the reservoir for the master cylinder. See Figure 4. The brake fluid reservoir is in the engine compartment. Add brake fluid as necessary. Use the brake fluid shown in the Maintenance Schedule.

FUEL SYSTEM, CHECKS AND ADJUSTMENTS Diesel Fuel System CAUTION The adjustment of the throttle cable must be correct or it can break during operation. The accelerator pedal or the MONOTROL pedal must reach the pedal stop (floor plate) by the time the throttle lever on the fuel injection pump reaches its stop. The engine must be at the normal operating temperature. Loosen the lock nut and turn the idle speed screw until the idle speed is within the specifications shown in the Maintenance Schedule. See Figure 30. Adjust the idle speed within the specifications for the least vibrations. Tighten the lock nut.

8000 SRM 393

Maintenance Procedures Every 350 Hours or 2 Months Legend for Figure 31 1. IDLE SPEED SCREW 2. IDLE MIXTURE ADJUSTMENT 3. FUEL INLET

Gasoline Carburetor (Early Models) 1. The engine must be at the normal operating temperature. Start the engine. The idle solenoid must be energized (stem extended). Adjust the stem (2) of the solenoid for an idle speed of 650 rpm. See Figure 32.

1. IDLE SPEED SCREW Figure 30. Fuel Injection Pump

LPG Carburetor 1. The engine must be at the normal operating temperature. Turn the idle speed screw until the idle speed is within the specifications shown in the Maintenance Schedule. See Figure 31.

2. Disconnect the wire at the solenoid. Make sure the choke plate is fully open and the fast idle cam is rotated fully clockwise. Turn the idle speed screw to adjust the idle speed to 400 rpm. Connect the wire to the idle solenoid and check that the idle speed returns to 650 rpm. 3. Check that the engine runs at the governed speed when the accelerator or MONOTROL pedal reaches the floor plate. If necessary, adjust the throttle cable at the bracket on the engine. Loosen the lock nuts and move the cable as necessary. Check that the maximum engine speed is within the specifications shown in the Maintenance Schedule.

2. Check that the engine runs at governed speed when the accelerator pedal or the MONOTROL pedal reaches the floor plate. If necessary, adjust the throttle cable at the bracket on the engine. Loosen the lock nuts and move the cable as necessary. Check the maximum engine speed within the specifications shown in the Maintenance Schedule.

1. IDLE SOLENOID 2. SOLENOID STEM 3. SOLENOID WIRE

4. IDLE SPEED SCREW 5. FAST IDLE CAM 6. CHOKE ROD

Figure 32. Gasoline Carburetor (Early Models) Figure 31. LPG Carburetor

Maintenance Procedures Every 350 Hours or 2 Months

8000 SRM 393

Fuel Injection (Late Model GM V-6)

AIR FILTER

Engine speeds are not adjustable. See the section Electronic Engine Control, Troubleshooting and Repair GM 4.3 Liter V-6 (Gasoline Fuel Injection) 2200 SRM 468 for repairs and adjustments to the fuel injection system.

NOTE: Very dirty conditions require daily check and clean.

STEERING AXLE, LUBRICATION Lubricate the spindles on the steering axle at the grease fittings on the bearing caps. Use multipurpose grease. See Figure 33.

WARNING Compressed air can move particles so that they cause injury to the user or to other personnel. Make sure that the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes. Clean or replace the air filter as necessary. See Figure 34. Use compressed air to clean the filter element. Air pressure must be less than 210 kPa (30 psi). Apply the air from the inside to the outside of the element.

1. GREASE FITTING Figure 33. Steering Axle

COOLING SYSTEM, CLEAN DEBRIS FROM RADIATOR CORE Check radiator core for restrictions and remove material causing radiator core to be plugged or restricted.

4. COVER 5. VALVE 6. PLUG

1. BODY 2. ELEMENT 3. LABEL

Figure 34. Air Filter

WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the recommendations of the manufacturer. Inspect the filter element Put a bright light inside and look for holes or other damage. If the element is damaged, replace it with a new element. Use a cloth with solvent to clean the inside of the canister when the filter element is cleaned or replaced.

8000 SRM 393

Maintenance Procedures Every 1000 Hours or 6 Months

Maintenance Procedures Every 500 Hours or 3 Months NOTE: Do these procedures in addition to the 350hour checks.

ENGINE OIL AND FILTER, PERKINS DIESEL ENGINE WARNING Long term exposure to used engine oil may cause skin irritation or cancer. Wash with detergent and water. Disposal of lubricants and fluids must meet local environmental regulations.

Change the oil filter at the same time the engine oil is changed. Use the correct oil according to the specifications shown in the Maintenance Schedule. Apply clean oil to the gasket of the new filter and install. Turn the filter until the gasket touches, then tighten 1/2 to 3/4 turn with your hand. Start the engine. Check the area around the oil filter for leaks.

CRANKCASE BREATHER, PERKINS DIESEL ENGINE Check the crankcase breather after every engine oil change. If the crankcase breather is worn or damaged, replace with a new breather. Tighten the breather with your hand. See Figure 4.

CAUTION Never run the engine without oil.

PCV VALVE, GM V-6

NOTE: Change the oil filter for the engine after the first 100 hours on new lift trucks.

Check the operation of the PCV valve by shaking it and feeling for movement of the ball. If there is no movement of the ball from inside the PCV valve, replace with new PCV valve. The check valve inside the PCV valve must permit airflow only in one direction: from the valve cover. The PCV valve on the GM V-6 engine is on the right-hand valve cover.

Maintenance Procedures Every 1000 Hours or 6 Months

MANIFOLD HEAT VALVE, GM V-6

adjustable. See the section Electronic Engine Control, Troubleshooting and Repair GM 4.3 Liter V-6 (Gasoline Fuel Injection) 2200 SRM 468 for additional information.

The manifold heat valve is installed between the exhaust manifold and the exhaust pipe. Check that the shaft for the heat valve moves freely. Lubricate the shaft with a high-temperature lubricant.

Check the spark plugs and ignition timing. Replace the spark plugs as needed and adjust the timing as needed. The correct timing is shown in the Maintenance Schedule.

CRANKCASE BREATHER, GM V-6

If fuel detonation occurs in the engine cylinders when the ignition timing is set to the specifications, do the following procedures:

NOTE: Do these procedures in addition to the 500hour checks.

Remove and replace the crankcase breather. Tighten the breather with your hand. See Figure 4.

IGNITION SYSTEM, GM V-6 NOTE: The following instructions are for earlier production lift trucks that have a High Energy Ignition (HEI) System. See the section High Energy Ignition (HEI) System, GM Engines 2200 SRM 107 for additional information. Later-production lift trucks have an Electronic Engine Control and the ignition timing is not

1. Use a gasoline fuel with higher octane number if it is available. 2. If gasoline with a higher octane number is not available or the fuel still detonates in the cylinders, decrease the ignition timing. Decrease the timing by small amounts (1 to 2 degrees), to a maximum of 6 ATDC. When the ignition timing is decreased 6 ATDC, engine power will be reduced by approximately 15%.

Maintenance Procedures Every 1000 Hours or 6 Months

8000 SRM 393

VALVE CLEARANCE, CHECK AND ADJUST

FUEL SYSTEM AIR REMOVAL, PERKINS (1004.42 DIESEL ENGINE)

The GM V-6 engines have hydraulic valve lifters and do not require valve clearance adjustments during normal service. Check the valve clearance on the Perkins diesel engines and make adjustments as needed. NOTE: Additional information on the Perkins diesel engines can be found in the section Perkins Diesel Engines, 1004-4, 1004-4T, 1006-6, 1006-6T 600 SRM 412.

The engine cannot be started if there is air in the fuel system. The air must be removed from the fuel system if any part of the fuel system has been disconnected or if there is a leak in the low pressure part of the fuel system during operation of the engine. The following procedures are for removal of air from the fuel system. For Perkins 1104C-44 (RE) Fuel System Air Removal, see the section Perkins Diesel Engines, 1104 (RE) 600 SRM 1070 for more information.

FUEL FILTER, DIESEL ENGINE, REPLACE

Fuel Injection Pump With Vent Tube

1. Clean the outside of the fuel filter assembly. If there is a drain on the filter bowl, drain the fuel from the fuel filter. See Figure 35.

Some engines have a fuel injection pump with a tube installed in place of the vent screw. See Figure 36. Air can move through the tube from the pump to the fuel return line. It is not necessary to loosen plugs or connections to remove air from this type of injection pump. Use the procedure in Step 1 or Step 2 to remove air from a fuel system with an injection pump that has a vent tube.

2. Hold the bowl and connector and loosen the through bolt from the top of the filter head. 3. Lower the bowl and filter element and discard the filter element. 4. Clean inside of the bowl and the filter head. 5. Install new seal rings. Put the bowl on the new filter element, and hold the bowl and filter element in position against the filter head. Install and tighten the through bolt. 6. Remove the air from the fuel system. See Fuel System Air Removal, Perkins (1004.42 Diesel Engine).

1. If the fuel system or a component in the fuel system has been drained: a. Turn the key switch to the ON position. b. Slowly operate the priming lever of the fuel pump for approximately 2 minutes. c. Operate the engine with the starter motor until the engine starts. 2. If air in the fuel system causes the engine to stop: a. Make sure that there is enough fuel in the tank. Check the system for leaks and make the necessary repairs. See the procedures How to Add Fuel to Lift Truck in the Operating Manual. b. Operate the engine with the starter motor until the engine starts.

1. PRIMARY FUEL FILTER

2. FINAL FUEL FILTER

Figure 35. Diesel Fuel Filters

8000 SRM 393

Maintenance Procedures Every 1000 Hours or 6 Months 1. Make sure there is fuel in the fuel tank. Refer to the How to Add Fuel to Lift Truck procedures in the Operating Manual. 2. Loosen the fitting at the top of the final fuel filter. Remove air from system by following steps 1 through 5 in Figure 37. Operate the lever under the fuel pump until fuel, without air bubbles, comes out of the fitting. Tighten the fitting. 3. Turn the key to the ON position to activate the shutoff solenoid. 4. Loosen the vent screw at the top of the injection pump. Operate the lever under the fuel pump until fuel, without air bubbles, comes out of the threads. Tighten the vent screw. 5. Loosen the fitting for the fuel line at the cold start aid. Operate the lever under the fuel pump until fuel, without air bubbles, comes out of the threads. Tighten the fitting.

1. VENT TUBE Figure 36. Fuel Injection Pump With Vent Tube

Fuel Injection Pump With Vent Screw Some engines have a vent screw that must be loosened to remove air from the fuel system. The engine cannot be started if there is air in the fuel system. The air must be removed from the fuel system if any part of the fuel system has been disconnected. Also remove the air if there was a leak in the low pressure part of the fuel system while the engine was running.

6. Loosen the fittings at two of the fuel injectors. Disconnect the wire at the shutoff solenoid so the engine will not start. Use the starter to rotate the engine until fuel, without air bubbles, comes out of the threads. Tighten the fittings. Make sure all other fuel line fittings are tight. The engine is now ready to start. If the engine runs correctly for a short time and then stops, or runs rough, check for air in the fuel system. Make sure you check for leaks in the low pressure (suction) part of the fuel system.

Maintenance Procedures Every 1000 Hours or 6 Months

1. FUEL FILTER FITTING 2. FUEL PUMP LEVER 3. VENT SCREW (FUEL INJECTION PUMP)

8000 SRM 393

4. FITTING (COLD START AID) 5. FITTING (FUEL INJECTOR) 6. SHUTOFF SOLENOID

Figure 37. Diesel Fuel System Air Removal (Perkins 1004.42)

8000 SRM 393

DIFFERENTIAL AND DRIVE AXLE, OIL LEVEL CHECK Differential S3.50-5.50XL (S70-120XL) WARNING Do not work under a raised carriage. Lower the carriage or use a safety chain. Use the safety chain to prevent the carriage and the inner or intermediate weldments from lowering when servicing the differential. Make sure the moving parts of the mast are attached to parts that cannot move. The differential and drive axle use a common oil supply. See Figure 38. Check the oil level at the plug on the right side of the speed reducer housing. The oil level must be even with the bottom of the hole for the plug.

Maintenance Procedures Every 1000 Hours or 6 Months

Differential, Speed Reducer, and Drive Axle for Manual Transmission S6.00-7.00XL (S135-155XL) The manual transmission, differential, speed reducer, and drive axle use the same oil supply. The oil level must be even with the bottom of the fill hole in the cover of the speed reducer. (Do not use the plug on the front of the differential housing to check the oil level.) Add the oil shown in the Maintenance Schedule. Install the plug and check for leaks.

CONTROL LEVERS AND PEDALS, LUBRICATION Lubricate the following items with engine oil: • Linkages • Pedal shafts and control cables (throttle, hood, parking brake) • Seat rails • Bushing for the transmission • Mast control levers

COOLING SYSTEM GM V-6 EPA COMPLIANT ENGINE The LPG vaporizer is connected into the cooling system, low coolant levels and restricted or plugged radiator cores can impact the performance of the fuel system.

WARNING

1. CHECK AND FILL PLUG, DIFFERENTIAL Figure 38. Differential and Drive Axle S3.50-5.50XL (S70-120XL)

DO NOT remove the radiator cap from the radiator when the engine is hot. When the radiator cap is removed, the pressure is released from the system. If the system is hot, the steam and boiling coolant can cause burns. DO NOT remove the cover for the radiator when the engine is running.

Differential and Drive Axle for Powershift Transmission S6.00-7.00XL (S135-155XL)

1. Change coolant in cooling system. Put lift truck on level surface and stop engine.

The fill and check plug is under the floor plate on the left side of the differential housing. Make sure the oil level is even with the bottom of the fill hole. (Do not use the plug on the front of the differential housing to check the oil level.) Add the oil shown in the Maintenance Schedule.

2. Remove drain plugs or open drain valves. Remove radiator cap and flush cooling system. Check hoses and fittings for damage. Replace with new hoses and fittings as needed. 3. Install drain plugs or close drain valves. Fill cooling system with correct coolant (50% water and 50% ethylene glycol boron-free antifreeze) shown in the Maintenance Schedule.

Maintenance Procedures Every 1000 Hours or 6 Months

8000 SRM 393

4. Install radiator cap, start engine, and check for leaks. Add coolant to auxiliary coolant reservoir as needed.

LPG FUEL FILTER GM V-6 EPA COMPLIANT ENGINE, REPLACE WARNING LPG is flammable. Make sure there are no sparks or open flames in the area when the fuel line is drained. The LPG fuel system on the GM V6 EPA Compliant Engine uses an in-line replaceable fuel filter element. Check the following: 1. LPG FILTER ELEMENT • Leaks at the inlet and outlet fittings. Use a soapy solution or electronic leak detector to detect leaks and repair. • Filter is securely mounted. • Filter housing for external damage, if damaged replace. To replace the fuel filter preform the following steps: 1. Move all equipment to a well-ventilated area with no ignition sources.

Figure 39. LPG Fuel Filter, GM-V6 EPA Compliant Engine 8. Check for contamination. 9. Tap the filter opening on a clean cloth, and check for debris. 10. Check canister for proper mounting direction. 11. Reinstall filter housing.

2. Start engine.

12. Tighten inlet and outlet fittings.

3. Close manual value with the engine still running.

NOTE: The fuel cylinder manual valve contains an Excess Flow Check Valve. Open the manual valve slowly, to prevent activating the Excess Flow Check Valve.

4. When the engine runs out of fuel and stops, turn the key to OFF. 5. Disconnect battery negative cable.

WARNING A small amount of fuel may still be present in the fuel line, use gloves to prevent burns, wear protective eye protection. If liquid fuel continues to flow from the connections when loosened check to make sure the manual valve is fully closed. 6. Slowly loosen and disconnect inlet and outlet fittings. 7. Remove filter housing. See Figure 39.

13. Slowly open manual valve. 14. Check for leaks at the inlet and outlet fittings, and filter house end connection by using soapy solution or electron leak detector. If leaks are detected, make proper repairs.

INSPECT ENGINE ELECTRICAL SYSTEM, CONNECTORS, AND FCVS CONNECTION When inspecting the electrical system, check the following: • Check and clean battery connection. Ensure that connections are tight. • Check battery for damage or cracks to the case. Replace if necessary.

8000 SRM 393

Maintenance Procedures Every 1000 Hours or 6 Months

• Check positive and negative cables for corrosion, rubbing, and chaffing. Tighten connections at both ends. • Check engine wire harness for rubbing, chaffing, pinching, and cracks or breaks in the wiring. • Check engine harness connectors. Check to ensure connectors are fitted and locked by pushing the connectors together. Pull on the connector halves to make sure they are locked. • Check ignition coil wire and spark plug wires for hardening, cracking, arching, chaffing, separation, split boot covers, and proper fit. Replace spark plugs at the recommended interval as shown in the Maintenance Schedule. • Check that all electrical components are securely mounted and retained to the engine or chassis. • Check the MIL, charging, and oil pressure lights for operation by starting the engine and checking that the light illuminates before turning out.

5. Do not damage the spark plug wires during removal. Hold the wire by the boot near the end of the wire. Rotate the boot a half-turn before pulling it and the connection from the spark plug. Do not use pliers or other tools that can damage the boot. Do not pull the wires to disconnect the spark plug wires. Pull the boot, or use a tool designed for this purpose.

SPARK PLUG REPLACEMENT

2. Install air cleaner and ECU bracket.

Remove

3. Install drip shield.

1. Park the truck in a safe work area.

4. Make sure the spark plug wires are installed in the same locations using the clips. The spark plug wires can be damaged or cause poor engine operation if they are not correctly installed.

2. Disconnect and remove the battery. 3. Remove the drip shield for access to the #3 and #5 plugs. 4. Remove the air cleaner and unbolt the ECU bracket and set it to the side to gain access to the #4 and #6 plugs.

CAUTION Do NOT put a hole in the boot or the insulation of the spark plug wire. Do NOT try to insert a wire between the boot and the connector of the spark plug wire. NOTE: The condition of the spark plugs removed from the engine can show engine operating problems.

General Electric®

GE627

Packard®

PM776

Wacker® Silicones

G47

6. Remove spark plugs.

Install 1. Install spark plugs.

5. Special care must be used when spark plug boots are installed. Make sure that the metal terminal within the boot is fully connected to the spark plug terminal by pulling lightly on the spark plug wire. If there is boot to wire movement, the boot has not been fully installed. NOTE: Shields and insulators are not installed on all engines. 6. Make sure to align all boots perpendicular to the center line of the engine. 7. Make sure to install the insulator in the shield at the boot of all spark plug wires. 8. Install and connect the battery.

NOTE: Use a silicon grease on the inside of the spark plug boots to make a better weather seal and make the spark plug boot easier to remove. The following silicon greases are approved for use:

Maintenance Procedures Every 2000 Hours or Yearly

8000 SRM 393

Maintenance Procedures Every 2000 Hours or Yearly NOTE: Do these procedures in addition to the 1000hour checks.

HYDRAULIC SYSTEM Hydraulic Oil and Filter S3.50-5.50XL (S70-120XL), Replace WARNING At operating temperature, the hydraulic oil is HOT. Do not permit the oil to touch the skin and cause a burn.

CAUTION Do not permit dirt to enter the hydraulic system when the oil level is checked or the filter is changed. Dirt can cause damage to components of the hydraulic system. NOTE: Change the oil filter for the hydraulic system after the first 100 hours on new lift trucks. 1. Put the lift truck on a level surface and lower the carriage. Put a container under the hydraulic tank. Disconnect the supply line for the pump at the tank to drain the oil. 2. Remove the capscrews that hold the filter to the frame. See Figure 40. Disconnect the hydraulic lines from the filter and discard the filter. Install a new filter. Install the capscrews and connect the hydraulic lines.

Legend for Figure 40 NOTE: S3.50-5.50XL (S70-120XL) SHOWN. 1. HYDRAULIC FILTER 2. POWERSHIFT TRANSMISSION FILTER 3. When the hydraulic oil has drained, connect the supply line to the tank. Fill the hydraulic tank with the correct oil. Operate the system and check for leaks.

Hydraulic Oil and Filter S6.00-7.00XL (S135-155XL), Replace 1. Put the lift truck on a level surface and lower the carriage. Put a container under the drain plug in the hydraulic tank. Drain the hydraulic oil. 2. Use a spanner to remove the filter head and filter element. Replace the filter element. Make sure the relief valve is in the correct position. Use a new O-ring and install the filter head. 3. When the hydraulic oil has drained, install the drain plug. Fill the hydraulic tank with the correct oil. Operate the system and check for leaks.

POWERSHIFT TRANSMISSION (ALL UNITS), OIL CHANGE AND OIL FILTER, REPLACE WARNING At operating temperature, the transmission oil can be hot. Do not permit the oil to touch the skin and cause a burn.

CAUTION Do not permit dirt to enter the powershift transmission when the oil level is checked or the filter is changed. Dirt can cause damage to components. NOTE: Change the oil filter for the transmission after the first 100 hours on new lift trucks. NOTE: Additional information on the powershift transmission can be found in the following: Figure 40. Hydraulic Filters

8000 SRM 393 • Single-Speed Powershift Transmission, Description and Operation 1300 SRM 399 [S3.50-5.50XL (S70-120XL)] • Single-Speed Powershift Transmission, Troubleshooting and Repair 1300 SRM 397 [S3.505.50XL (S70-120XL)] • Two-Speed Powershift Transmission, Description and Operation 1300 SRM 324 [ S6.00-7.00XL (S135-155XL)] • Two-Speed Powershift Transmission, Troubleshooting and Repairs 1300 SRM 325 [ S6.00-7.00XL (S135-155XL)]

Maintenance Procedures Every 2000 Hours or Yearly 1. Remove the floor plate for access to the oil clutch system. The drain plug for the clutch housing is at the bottom of the housing. Disconnect the oil line for the pump at the fitting on the housing. Remove the fitting and screen. Clean the screen. When the oil has drained, install the fitting and drain plug. Connect the oil line to the fitting. 2. Remove and discard the old filter. See Figure 41. Apply clean oil to the gasket of the new filter. Install the new filter and tighten it with your hand. Check for leaks during operation.

1. The drain plug for the transmission is on the left side of the transmission. Remove the drain plug, spring, and screen. See Figure 40. 2. Clean the screen. When the oil has drained, install the screen, spring, and drain plug. 3. Replace the oil filter when the oil in the transmission is changed. Remove and discard the old oil filter. Apply clean oil to the gasket of the new filter. Install the new filter and tighten it with your hand. Check for leaks during operation.

Manual Transmission and Differential S6.00-7.00XL (S135-155XL), Oil Change WARNING Do not work under a raised carriage. Lower the carriage or use a safety chain. Use the safety chain to prevent the carriage and the inner or intermediate weldments from lowering when servicing the differential. Make sure the moving parts of the mast are attached to parts that cannot move. NOTE: Additional information can be found in the section Three-Speed Manual Transmission 1300 SRM 335. The drain plug is near the bottom of the differential in the axle housing. The fill and check plug is also on the differential housing. See Figure 38. Fill the transmission with oil so that the oil level is even with the bottom of the fill hole. Use the oil shown in the Maintenance Schedule.

OIL CLUTCH SYSTEM S6.00-7.00XL (S135-155XL), OIL AND FILTER CHANGE

1. FILTER, OIL CLUTCH SYSTEM 2. FILTER, HYDRAULIC Figure 41. Oil Clutch System Filter

DIFFERENTIAL AND DRIVE AXLE FOR POWERSHIFT TRANSMISSION (ALL UNITS), OIL CHANGE WARNING Do not work under a raised carriage. Lower the carriage or use a safety chain. Use the safety chain to prevent the carriage and the inner or intermediate weldments from lowering when servicing the differential. Make sure the moving parts of the mast are attached to parts that cannot move. Change the oil for the differential and drive axle. The oil level must be even with the bottom of the fill hole. The fill hole for checking the oil level is on the cover of the differential housing. See Figure 38. Add the oil shown in the Maintenance Schedule. Install the plug and check for leaks.

NOTE: Additional information can be found in the section Oil Clutch Assembly 1200 SRM 334.

Maintenance Procedures Every 2000 Hours or Yearly

COOLING SYSTEM WARNING DO NOT remove the radiator cap from the radiator when the engine is hot. When the radiator cap is removed, the pressure is released from the system. If the system is hot, the steam and boiling coolant can cause burns. DO NOT remove the cover for the radiator when the engine is running. 1. Change the coolant in the cooling system. Put the lift truck on a level surface. Stop the engine. 2. Remove the drain plugs or open the drain valves. Remove the radiator cap. Flush the cooling system. Check the hoses and fittings for damage. Replace with new hoses and fittings as needed. 3. Install the drain plugs or close the drain valves. Fill the cooling system with the correct coolant (50% water and 50% ethylene glycol boron-free antifreeze). 4. Install the radiator cap. Start the engine. Check for leaks. Add coolant to the auxiliary coolant reservoir as needed.

PCV VALVE, GM V-6 Replace the PCV valve on the GM V-6 engine.

SERVICE BRAKES WARNING Brake linings can contain dangerous fibers. Inhaling the dust from these brake linings is a cancer or lung disease hazard. Do not make dust! Do not clean brake parts with compressed air or by brushing. Use vacuum equipment approved for brake dust or follow the cleaning procedure in this section. When the brake drums are removed, do not create dust. Do not sand, grind, chisel, hammer, or change brake linings in any way that will create dust. Any changes to brake linings must be done in a restricted area with special ventilation. Protective clothing and a respirator must be used.

8000 SRM 393 Cleaning Procedures: 1. Do not release brake lining dust from the brake linings into the air when the brake drum is removed. 2. Use a solvent approved for cleaning of brake parts to wet the brake lining dust. Follow the instructions and cautions of the manufacturer for the use of the solvent. If a solvent spray is used, do not permit brake lining dust to be spread by the spray. 3. When the brake lining dust is wet, clean the parts. Put any rags or towels in a plastic bag or an airtight container while they are still wet. Put a DANGEROUS FIBERS warning label on the plastic bag or airtight container. 4. Any cleaning rags that will be washed must be cleaned so that fibers are not released into the air.

CAUTION Do not use an oil solvent to clean the wheel cylinder. Use a solvent approved for cleaning of brake parts. Do not permit oil or grease in the brake fluid or on the brake linings. Check the brake lining and brake assembly parts for wear or damage. See the section Brake System 1800 SRM 452 for the removal and installation procedures of the drive wheels and hubs. If the linings or shoes are worn or damaged, replace the brake shoes. Brake shoes must be replaced in complete sets. Inspect the brake drums for cracks or damage. Replace any damaged parts.

LPG FILTER, REPLACE (PRE-2004) WARNING LPG is flammable. Make sure there are no sparks or open flames in the area when the fuel line is drained. 1. Close the fuel valve on the tank. Run the engine until all of the fuel is used from the fuel system and the engine stops. Slowly loosen the hose fitting to the filter. Let any fuel drain from the fitting before disassembling the filter unit.

8000 SRM 393

Maintenance Procedures Every 2000 Hours or Yearly

2. Remove the screws and the filter cover. Replace the filter element. See Figure 42. 3. Install the cover and the gasket. Tighten the screws for the cover. Tighten the hose fitting.

1. GASOLINE FUEL FILTER 1. FILTER ELEMENT Figure 42. LPG Fuel Filter

OXYGEN SENSOR GM V-6 EPA COMPLIANT ENGINE NOTE: Make sure connections are air tight. If these connections are not air tight, the incorrect oxygen readings could be entered into the fuel air ratio.

CAUTION Do not use silicone spray or silicone based products on the oxygen sensor. Use of silicone products can cause severe damage to the oxygen sensor. Check that the oxygen sensor electrical connector is seated and locked. Check wires for cracks, splits, chaffing, or burn through. If necessary, repair.

GASOLINE FUEL FILTER, REPLACE Replace the gasoline filter. Make sure the fuel lines do not leak when they are connected again. See Figure 43.

AIR FILTER ELEMENT, GM V-6 EPA COMPLIANT ENGINE NOTE: In dirty or dusty environments, change at 1,000 hours. Check the air filter element after 2,000 hours and replace.

Figure 43. Gasoline Fuel Filter

TEST LPG/GAS REGULATOR PRESSURE For more information regarding the Test LPG/GAS Regulator Pressure, see the section Electronic Controlled LPG/Gasoline Fuel System, GM 3.0L and 4.3L EPA Compliant Engines 900 SRM 1088.

INSPECT LOW PRESSURE REGULATOR (LPR) FOR OIL BUILDUP AND LEAKS CAUTION The Low Pressure Regulator (LPR) has been designed for the GM V6 EPA Compliant Engine. The regulator should not be disassembled or rebuilt. If the LPR fails to operate or has a leak, the LPR should be replaced with ONLY recommended HYSTER replacement parts. To check the LPR, perform the following checks: • Check for fuel leaks at the inlet fitting, outlet fitting, and regulator body. • Check the inlet and outlet fittings of the coolant supply for water leaks. • Check the coolant lines for hardening, cracking, chaffing or splits. Replace if needed. • Check coolant supply hose clamp connections, make sure they are tight. • Check the Pressure Trim Valve (PTV) electrical connection. Make sure the connector is seated and locked, check mounting bolts, and check for external damage. • Check regulator is securely mounted.

Maintenance Procedures Every 2000 Hours or Yearly NOTE: During normal operation, oil may buildup inside the secondary chamber of the LPR. This may be a result of poor fuel quality, contamination of fuel supply chain, or regional variation of the fuel makeup. To correct these problems, drain oil periodically.

CAUTION Disposal of lubricants and fluids must meet local environmental regulations. To drain the oil from the LPR follow these steps: NOTE: Drain oil from the LPR when the engine is warm. This will help the oil flow freely from the LPR. 1. Move the equipment to a well-ventilated area with no ignition sources. 2. Start engine. 3. Close manual value with engine still running. 4. When the engine runs out of fuel and stops, turn the key to OFF. 5. Disconnect negative battery cable.

WARNING A small amount of fuel may still be in the fuel line. Use gloves and eye protection to prevent injury. If fuel continues to flow from the connections when loosened, make sure the manual valve is completely closed.

8000 SRM 393 14. Remove drain pan and reinstall LPR with the two retaining bolts. 15. Reinstall outlet fitting and secure with locking pin. 16. Reconnect PTV electrical connection, push connector until it locks ("clicks") into place. Pull connector to check it is locked. Connect vacuum line. 17. Reconnect the outlet hose and hose clamp. 18. Reinstall fuel inlet line and tighten connection. NOTE: Open manual valve slowly to prevent activating the Excess Flow Check Valve. 19. Slowly open manual service valve. 20. Check for leaks at inlet and outlet fittings and coolant line connections. 21. Use soapy solution or electron leak detector. If leaks are found, make proper repairs. 22. Start the engine and recheck for leaks at regulator. 23. Dispose of any drained material in a safe and proper manner.

CHECK THROTTLE SHAFT FOR STICKING Check Throttle body return action to ensure throttle shaft is not sticking. Repair if necessary.

6. Slowly loosen and disconnect inlet fitting.

INSPECT EXHAUST MANIFOLD AND PIPING FOR LEAKS

7. At the outlet hose fitting, loosen clamp and remove hose.

To check the exhaust manifold and piping for leaks, perform the following:

8. Remove and retain locking pin in the outlet fitting and remove outlet fitting from the LPR.

• Check the exhaust manifold at the cylinder head for leaks. Ensure that all bolts and shields are in place. • Check exhaust pipe fasteners to manifold for leaks to ensure they are tight. Repair if necessary. • Check all exhaust pipe extension connectors for leaks and tighten, if necessary. • Visually inspect converter for correct muffler mounting and tail pipe mounting. • Check for any leaks at the inlet and outlet of the converter.

9. Disconnect PTV connection, and vacuum hose. 10. Remove two LPR mounting bolts. 11. Put a drain pan in engine compartment. 12. Rotate LPR to 90 degrees, so the outlet fitting is pointing down into the drain pan. Drain LPR. 13. Inspect secondary chamber for dried particles and remove.

8000 SRM 393

Lift Chain Adjustments

Hood Latch Check WARNING The hood, hood latch, and hood striker must be correctly adjusted for the correct operation of the operator restraint system. 1. Install the floor plate and tighten the capscrews. See Figure 14. 2. Install the latch striker in the highest slot position on the floor plate. Check that the latch striker is in the center of the jaws of the hood latch.

4. Loosen the capscrews for the latch striker just enough to let the striker move. Push the hood down until the hood just touches the rubber bumpers on the frame. Make sure the latch striker is still in the center of the hood latch. Tighten the capscrews for the striker. 5. Check the operation of the hood latch. Have an operator sit in the seat. Make sure that the hood is fully closed (two clicks). Also check that the hood touches the rubber bumpers. If necessary, repeat Step 4.

3. Close the hood to the fully closed position. The hood latch has two positions. The hood is fully closed after two clicks of the latch.

Lift Chain Adjustments WARNING When working on or near the mast, see Safety Procedures When Working Near Mast in this section. Never allow anyone under a raised carriage. Do not put any part of your body in or through the lift mechanism unless all parts of the mast are completely lowered and the engine is STOPPED. Do not try to find hydraulic leaks by putting your hand on hydraulic components under pressure. Hydraulic oil can be injected into the body by the pressure. During test procedures for the hydraulic system, fasten the load to the carriage with chains to prevent it from falling. Keep all personnel away from the lift truck during the tests. When the lift chains are correctly adjusted: • The tension will be the same on each chain of the chain set. Check tension by pushing on both chains at the same time. • The chain length will be correct. • The chains must travel freely through the complete cycle.

NOTE: When the chain adjustments are complete, make sure that the threads on the nuts of the chain anchors are completely engaged. Make sure that all of the adjustment is not removed from the chain anchors. The chain anchors must be able to move on their mounting. 1. When adjusting the lift chains on forklift trucks equipped with either pin- or hook-type forks installed, start with Step 2. If the forklift truck is normally equipped with a hook-type carriage and has an attachment without forks, go to Step 3. If the forklift truck is normally equipped with a pin-type carriage and has an attachment without forks, go to Step 4. NOTE: Prior to performing adjustment procedures, make sure that the forklift truck is parked on a level surface and that the mast is in the vertical position. 2. Adjust the chain anchors which support the carriage until the bottom of the fork heel is 6 ±3 mm (0.25 ±0.12 in.) above the floor level. See Figure 44.

Lift Chain Adjustments

1. 2. 3. 4.

MAST CARRIAGE FORK HEEL OF FORK IS 6 ±3 mm (0.25 ±0.12 in.) ABOVE THE FLOOR LEVEL.

8000 SRM 393

1. MAST 2. CARRIAGE 3. DISTANCE FROM FLOOR TO LOWER CARRIAGE BAR

Figure 44. Lift Chain Adjustment, Hook- or Pin-Type Forks

Figure 45. Lift Chain Adjustment, Hook-Type Carriage

3. Adjust chain anchors which support the carriage until the bottom of the lower carriage bar is above the floor level as shown in Table 2. See Figure 45.

4. Adjust chain anchors which support the carriage until the center line of the fork pin is above the floor level as shown in Table 3. See Figure 46.

Table 2. Hook-Type Carriage Chain Adjustment

Table 3. Pin-Type Carriage Chain Adjustment

Class II and III

82.5 ±3 mm (3.25 ±0.12 in.)

H70/80, 90XLS

545 ±3 mm (21.5 ±0.12 in.)

Class IV

133.5 ±3 mm (5.25 ±0.12 in.)

H90-110XL

708 ±3 mm (27.88 ±0.12 in.)

H135-155XL

907 ±3 mm (35.71 ±0.12 in.)

8000 SRM 393

Fuel Injectors Repair Legend for Figure 46 1. LOAD BACKREST 2. FORK PIN 3. DISTANCE FROM FORK PIN TO FLOOR

Figure 46. Lift Chain Adjustment, Pin-Type Carriage

Fuel Injectors Repair WARNING Do not put your hands on fuel lines under pressure. Fuel oil can be injected into your body by the hydraulic pressure and cause injury. NOTE: The inspection and repair of fuel injectors require special tools and training. Many users have a special repair service to make repairs on injectors. Fuel injector nozzles that have a defect will cause black smoke in the exhaust, a decrease in engine power, and an increase in engine noise.

NOTE: Additional information on the Perkins diesel engines can be found in the section Perkins Diesel Engines, 1004-4, 1004-4T, 1006-6, 1006-6T 600 SRM 412. The engine will run roughly if a fuel injector has a defect. To find which fuel injector has a defect, operate the engine at approximately 1000 rpm. Loosen and tighten the connection to the inlet of each fuel injector in a sequence. When the connection to the defective fuel injector is loosened, there will not be a change in the engine speed.

Lift and Tilt System Leak Check

8000 SRM 393

Lift and Tilt System Leak Check LIFT CYLINDERS, LEAK CHECK WARNING Never allow anyone under a raised carriage. Do not put any part of your body in or through the lift mechanism unless all parts of the mast are completely lowered and the engine is stopped. Before making any repairs, use blocks and chains on the mast weldments and carriage so they cannot move. Make sure the moving parts are fastened to the parts that cannot move. Do not try to find hydraulic leaks by putting your hand on hydraulic components under pressure. Hydraulic oil can be injected into the body by the pressure. During test procedures for the hydraulic system, fasten the load to the carriage with chains to prevent it from falling. Keep all personnel away from the lift truck during the tests. 1. Operate the hydraulic system. Put a capacity load on the forks, and raise and lower the load several times. Lower the load and tilt the mast forward and backward several times. Check for leaks. 2. Raise the carriage and load 1 m (3 ft). If the carriage slowly lowers when the control valve is in the NEUTRAL position, there are leaks inside the hydraulic system. The maximum speed that the carriage is allowed to lower is 33 mm (1.3 in.) per 10 minutes when the hydraulic oil is 30 C (90 F). If the oil temperature is 60 C (140 F), the maximum speed that the carriage can lower is 146 mm (5.8 in.) per 10 minutes. 3. Check the lift cylinder for internal leaks. Remove the load from the forks. Install a gate valve in the supply line between the main control valve

and the mast. Put a capacity load on the forks again. Raise the carriage approximately 1 m (3 ft). Close the gate valve. If the carriage or mast weldments lower slowly, the seals in the lift cylinders have leaks. 4. If the carriage does not move, open the gate valve and check the movement again. If the carriage lowers when the gate valve is open, check for leaks in the hydraulic lines and fittings. If no leaks are found, the main control valve can have a defect. Remove the load from the forks.

TILT CYLINDERS, LEAK CHECK 1. Put a capacity load on the forks. Raise the carriage and load 1 m (3 ft). Slowly tilt the mast forward. If the mast continues to slowly tilt forward when the control valve is in the NEUTRAL position, there are leaks inside the hydraulic system. The maximum speed that the mast is allowed to tilt forward when there are internal leaks in the lift system is 11 mm (0.4 in.) per 10 minutes (measured at the tilt cylinder). The maximum speed is measured when the hydraulic oil is 30 C (90 F). If the oil temperature is 60 C (140 F), the maximum speed is 50 mm (2.0 in.) per 10 minutes. 2. If the leak rate is greater than the specifications, remove the load from the mast. Install a valve between the port at the front of the tilt cylinder and the hydraulic line. Put the load on the forks again. Close the valve. If the mast tilts slowly forward, the cylinder seals are leaking. 3. If the mast does not move, open the gate valve and check the movement again. If the mast moves forward when the gate valve is open, check for leaks in the hydraulic lines and fittings. If no leaks are found, the main control valve can have a defect. Remove the load from the forks when the checks are complete.

8000 SRM 393

Overhead Guard Changes

Welding Repairs WARNING

CAUTION

Welding can cause a fire or an explosion. Always follow the instructions in the Frame section of the Service Manual if a fuel or hydraulic tank must be welded. Make sure there is no fuel, oil, or grease near the weld area. Make sure there is good ventilation in the area where the welding must be done. Do not heat, weld, or bend forks. Forks are made of special steel using special methods. The strength of the overhead guard can be reduced by welding or heating. Get information from your dealer for Hyster lift trucks before welding on a mast.

When an arc welder is used, always disconnect the ground cable from the battery in the lift truck. This action will prevent damage to the alternator or the battery. Connect the ground clamp for the arc welder as close as possible to the weld area. This action will prevent damage to a bearing from the large current from the welder. Some repairs require welding. If an acetylene or arc welder is used, make sure the procedures in the previous WARNING and CAUTION are done.

Overhead Guard Changes WARNING Do not weld mounts for lights or accessories to the overhead guard except to the front and rear cross bars shown in Figure 47. The strength of the overhead guard can be reduced by welding or heating. Install lights and accessories or their mounts with clamps or nuts and bolts. Make sure the mount holes are the correct size and are in the correct location. The strength of the overhead guard can be reduced if the holes are in the wrong location or are larger than the specifications shown in Figure 47. The numbers on Figure 47 correspond to the following steps.

on the centerline of the inside or outside surface of the leg. The maximum hole diameter allowed is 13 mm (0.50 in.). The minimum dimension allowed between holes is 50 mm (2.00 in.). 2. (VIEW A-A). Drill holes only on the centerline of the 50 mm (2.00 in.) surface of the 12 Ă&#x2014; 50 mm (0.50 Ă&#x2014; 2.00 in.) cross bars. The maximum hole diameter allowed is 10 mm (0.375 in.). The minimum dimension allowed between holes is 50 mm (2.00 in.). 3. (VIEW B-B). One 22.3 mm (0.88 in.) hole is permitted on the centerline of the inside surface of the right rear leg in the location shown for the electric wires to the lights or accessories. 4. Mounts for lights and accessories can be welded to the front and rear cross bars.

1. DO NOT drill holes on the front or rear surfaces of the legs of the overhead guard. Drill holes only

Wheel and Tire Replacement

8000 SRM 393

A. SIDE VIEW OF OVERHEAD GUARD Figure 47. Overhead Guard Changes

Wheel and Tire Replacement SOLID RUBBER TIRE, CHANGE When new solid rubber tires (press-on) must be installed, put the lift truck on blocks as described in at the beginning of this section. Remove the wheel. The correct tools, equipment, and a press ring must be used for each size wheel. A press that has a capacity of approximately 36,000 kg (80,000 lb) for wheels on the S70-120XL lift trucks or 180,000 kg (400,000 lb) for wheels on the S135-155XL lift trucks is also required to press the wheel from the rim. Do not try to change the solid rubber tires on the wheels unless you have the correct tools, equipment, and experience. Make sure the tires are installed on the wheels according to the dimensions shown in Figure 48. Install the tires on both drive wheels at the same dimensions. Install the tires on both steering wheels at the same dimensions. Check the nameplate on the lift truck for the correct tread width. The tread width is measured from the outside of one wheel to the inside of the other wheel.

Unit

S70-80XL, S135-155XL

25.4 mm (1.0 in.)

S100-120XL A. STEER TIRE AND WHEEL

B. DRIVE TIRE AND WHEEL

1. OUTSIDE EDGE

2. INSIDE EDGE

Figure 48. Wheels and Tires

8000 SRM 393

Adhesives and Sealants

Wheels, Install CAUTION Check all wheel nuts after 2 to 5 hours of operation: when new lift trucks begin operation and on all lift trucks when the drive wheels have been removed and installed. Tighten the nuts in a cross pattern to the correct torque value shown in the Maintenance Schedule. When the nuts stay tight for 8 hours, the interval for checking the torque can be extended to 350 hours.

Steering Wheels. Lubricate the bearings with multipurpose grease, and install the wheel and bearings on the spindle. Install the washer and nut on the spindle. Tighten the nut to 200 N•m (150 lbf ft) while rotating the wheel. Loosen the nut until the wheel rotates freely and the bearings are not loose. Tighten the nut to 35 N•m (25 lbf ft) and install the cotter pin at the closest slot in the nut. Install the cap for the bearings. Drive Wheels. Install the wheel on the hub. Tighten the nuts in a cross pattern to the torque value in the Maintenance Schedule table.

Adhesives and Sealants Hyster Part No.

Loctite® Part No.

Description

Size

360387

222

Small Screw Threadlock (Purple)

50 ml

318702*

242

Removable Threadlock (Blue)

10 ml

226414*

271

High Strength Threadlock (Red)

10 ml

318996

277

High Viscosity Threadlock (Red)

50 ml

318650

290

Low Viscosity Threadlock (Green)

0.02 oz

251099

290

Low Viscosity Threadlock (Green)

50 ml

355844*

422

SuperBonder® Adhesive

3 ml

350830

515

Gasket Eliminator (Purple)

6 ml

313022*

515

Gasket Eliminator (Purple)

50 ml

273338*

567

Pipe Sealant with Teflon®

50 ml

318705

595

Super Flex® Silicone

100 ml

318701*

609

Retaining Compound

10 ml

341959

680

Retaining Compound

50 ml

226415

Primer T - Aerosol

6 oz

316865

Antiseize Compound

1 lb

360053-10

Chisel Gasket Remover (10 Aerosol cans per case)

318700

Adhesive & Sealant Kit (Contains one each of * items)

18 oz

* Items marked with an asterisk are included in the Adhesive and Sealant Kit PN 318700. Loctite®, Super Flex®, and Super Bonder® are registered trademarks of the Loctite Corporation. Teflon® is a registered trademark of Du Pont de Nemours Co., Inc.

Hydraulic Oil, Lubricant, and Coolant Specifications

8000 SRM 393

Hydraulic Oil, Lubricant, and Coolant Specifications Hyster Part No.

Description

Size

336830

Hydraulic and Transmission Oil (J20A Specifications)

1 qt

336831

Hydraulic and Transmission Oil (J20A Specifications)

2 gal

336832

Hydraulic and Transmission Oil (J20A Specifications)

5 gal

336833

Hydraulic and Transmission Oil (J20A Specifications)

55 gal

3002338

Antifreeze (Ethylene Glycol)

1 gal

326457

Multipurpose Grease

5 lb

328388

Silicone Spray Lubricant

8 and 16 oz

PERKINS DIESEL ENGINES 1004-42 (AR), 1006-60 (YG), 1006-60T (YH) H3.50-5.00XL (H70-110XL) [G005]; S3.50-5.50XL (S70-120XL) [D004]; H6.00-7.00XL (H135-155XL, H135-155XL 2) [F006]; S6.00-7.00XL (S135-155XL, S135-155XL 2) [B024]; H13.00-16.00XL (H300-360XL) [D019]; H8.00-12.00XL (H165-280XL) [E007]; H3.50-5.50XM (H70-120XM) [K005]; H8.00-12.00XM (H170-280HD) [F007]; H13.00-16.00XM (H300-360HD) [E019]; H10.00-12.00XM-12EC (H360HD-EC) [E019]; H3.50-5.50XM (H70-120XM) [E004, F004]

PART NO. 1455747

600 SRM 705

Perkins Diesel Engines

Table of Contents

TABLE OF CONTENTS General ................................................................................................................................................................. General Safety Rules ....................................................................................................................................... Description ........................................................................................................................................................... Engine Serial Number Codes.......................................................................................................................... Engine Data ..................................................................................................................................................... Engine Removal and Installation ....................................................................................................................... Lift Engine ....................................................................................................................................................... Cylinder Head Assembly Repair ......................................................................................................................... Valve Cover ...................................................................................................................................................... Remove......................................................................................................................................................... Install ........................................................................................................................................................... Rocker Arm Assembly ..................................................................................................................................... Remove......................................................................................................................................................... Install ........................................................................................................................................................... Disassemble ................................................................................................................................................. Inspect.......................................................................................................................................................... Assemble ...................................................................................................................................................... Valve Clearance Adjustments ......................................................................................................................... Four-Cylinder Engines.............................................................................................................................. Six-Cylinder Engines ................................................................................................................................ Valve Springs ................................................................................................................................................. Cylinder Head Assembly ............................................................................................................................... Remove....................................................................................................................................................... Install ......................................................................................................................................................... Valves and Valve Springs .............................................................................................................................. Remove....................................................................................................................................................... Inspect........................................................................................................................................................ Install ......................................................................................................................................................... Valve Guides .................................................................................................................................................. Inspect........................................................................................................................................................ Remove....................................................................................................................................................... Install ......................................................................................................................................................... Cylinder Head and Valve Seats .................................................................................................................... Inspect........................................................................................................................................................ Repair......................................................................................................................................................... New Valve Seats, Install ........................................................................................................................... Piston and Connecting Rod Assemblies Repair ............................................................................................... Rod Bearings.................................................................................................................................................. Remove....................................................................................................................................................... Install ......................................................................................................................................................... Piston and Connecting Rod Assembly .......................................................................................................... Service Note............................................................................................................................................... Remove....................................................................................................................................................... Install ......................................................................................................................................................... Piston Rings ................................................................................................................................................... Remove....................................................................................................................................................... Inspect........................................................................................................................................................ Install ......................................................................................................................................................... Piston and Connecting Rod ........................................................................................................................... Disassemble ............................................................................................................................................... Inspect........................................................................................................................................................

ÂŠ2006 HYSTER COMPANY

1 1 2 5 5 7 7 7 7 7 8 8 8 8 8 9 9 9 10 10 10 12 12 14 18 18 18 19 19 19 20 20 20 20 20 20 22 22 23 23 24 24 24 25 26 26 26 26 27 27 28

Table of Contents

Perkins Diesel Engines

TABLE OF CONTENTS (Continued) How to Select Correct Replacements ....................................................................................................... Install ......................................................................................................................................................... Piston Cooling Jets ........................................................................................................................................ Remove....................................................................................................................................................... Install ......................................................................................................................................................... Crankshaft Assembly Repair ............................................................................................................................ General ........................................................................................................................................................... Crankshaft Pulley.......................................................................................................................................... Engine AR, Remove................................................................................................................................... Engines YG and YH, Remove ................................................................................................................... Inspect........................................................................................................................................................ Engine AR, Install..................................................................................................................................... Engines YG and YH, Install ..................................................................................................................... Rear Oil Seal .................................................................................................................................................. Replace ....................................................................................................................................................... Main Bearings................................................................................................................................................ Remove....................................................................................................................................................... Inspect........................................................................................................................................................ Install ......................................................................................................................................................... Thrust Washers.............................................................................................................................................. Crankshaft Axial Movement, Check ........................................................................................................ Remove....................................................................................................................................................... Install ......................................................................................................................................................... Crankshaft ..................................................................................................................................................... Remove....................................................................................................................................................... Inspect........................................................................................................................................................ Install ......................................................................................................................................................... Flywheel ......................................................................................................................................................... Remove....................................................................................................................................................... Ring Gear, Replace .................................................................................................................................... Install ......................................................................................................................................................... Flywheel Housing .......................................................................................................................................... Remove....................................................................................................................................................... Install ......................................................................................................................................................... Timing Case and Timing Gears Repair ............................................................................................................ General ........................................................................................................................................................... Timing Case Cover ........................................................................................................................................ Remove....................................................................................................................................................... Install ......................................................................................................................................................... Front Oil Seal................................................................................................................................................. Remove....................................................................................................................................................... Install ......................................................................................................................................................... Crankshaft Pulley Wear Sleeve .................................................................................................................... Install ......................................................................................................................................................... Idler Gear and Hub ....................................................................................................................................... Remove....................................................................................................................................................... Install ......................................................................................................................................................... Air Compressor Drive, Bendix ...................................................................................................................... Disassemble ............................................................................................................................................... Assemble .................................................................................................................................................... Fuel Injection Pump Gear .............................................................................................................................

28 29 29 29 30 30 30 31 31 31 32 32 32 33 33 34 34 35 35 35 35 36 36 37 37 37 37 39 39 39 39 40 40 40 41 41 41 41 42 42 42 42 43 43 43 43 44 45 45 46 46

Perkins Diesel Engines

Table of Contents

TABLE OF CONTENTS (Continued) Remove....................................................................................................................................................... Install ......................................................................................................................................................... Camshaft Gear............................................................................................................................................... Remove....................................................................................................................................................... Install ......................................................................................................................................................... Crankshaft Gear ............................................................................................................................................ Remove....................................................................................................................................................... Install ......................................................................................................................................................... Timing Case ................................................................................................................................................... Remove....................................................................................................................................................... Install ......................................................................................................................................................... Camshaft and Tappets .................................................................................................................................. Remove....................................................................................................................................................... Install ......................................................................................................................................................... Cylinder Block Assembly Repair....................................................................................................................... Description ..................................................................................................................................................... Cylinder Block ............................................................................................................................................... Disassemble ............................................................................................................................................... Inspect........................................................................................................................................................ Assemble .................................................................................................................................................... Cylinder Bore (Four-Cylinder Engines) ....................................................................................................... Cylinder Liner (Six-Cylinder Engines)......................................................................................................... Inspect........................................................................................................................................................ Cylinder Liner Condition, Check.............................................................................................................. Remove....................................................................................................................................................... Service Liner, Install ................................................................................................................................. Partially Finished Liner, Install............................................................................................................... Engine Timing.................................................................................................................................................... Description ..................................................................................................................................................... How to Set Number One Piston to TDC on Compression Stroke ........................................................... How to Set Number One Piston to TDC on Compression Stroke (Alternate Procedure)...................... Valve Timing, Check.................................................................................................................................. Fuel Injection Pump Timing, Check......................................................................................................... Turbocharger - Engine YH Repair .................................................................................................................... General ........................................................................................................................................................... Remove....................................................................................................................................................... Install ......................................................................................................................................................... Impeller and Compressor Housing, Clean ............................................................................................... Lubrication System Repair................................................................................................................................ General ........................................................................................................................................................... Oil Filter, Replace .......................................................................................................................................... Filter Head ..................................................................................................................................................... Remove and Install ................................................................................................................................... Oil Sump ........................................................................................................................................................ Remove....................................................................................................................................................... Install ......................................................................................................................................................... Oil Pump ........................................................................................................................................................ Remove....................................................................................................................................................... Inspect........................................................................................................................................................ Install ......................................................................................................................................................... Relief Valve ....................................................................................................................................................

47 47 48 48 48 49 49 49 49 49 50 51 51 51 52 52 52 52 53 53 54 54 54 54 55 56 57 58 58 59 60 60 61 62 62 62 62 63 64 64 64 65 65 65 65 66 66 66 66 67 67

iii

Table of Contents

Perkins Diesel Engines

TABLE OF CONTENTS (Continued) Remove....................................................................................................................................................... Disassemble ............................................................................................................................................... Inspect........................................................................................................................................................ Assemble .................................................................................................................................................... Install ......................................................................................................................................................... Idler Gear Shaft, Replace .............................................................................................................................. Remove....................................................................................................................................................... Remove (Alternative) ................................................................................................................................ Install ......................................................................................................................................................... Install (Alternative) .................................................................................................................................. Install (Alternative for Four-Cylinder Engines Only)............................................................................. Fuel System Repair............................................................................................................................................ Description ..................................................................................................................................................... Fuel Injection Pump ...................................................................................................................................... Remove....................................................................................................................................................... Install ......................................................................................................................................................... Check and Adjust ...................................................................................................................................... Fuel System Air Removal.............................................................................................................................. Fuel Filter, Replace ....................................................................................................................................... Canister Type ............................................................................................................................................ Quick Release Canister Type.................................................................................................................... Fuel Injectors ................................................................................................................................................. Remove....................................................................................................................................................... Inspect........................................................................................................................................................ Install ......................................................................................................................................................... Fuel Pump...................................................................................................................................................... Remove....................................................................................................................................................... Disassemble ............................................................................................................................................... Assemble .................................................................................................................................................... Install ......................................................................................................................................................... Test ............................................................................................................................................................. Cooling System Repair ...................................................................................................................................... General ........................................................................................................................................................... Thermostat..................................................................................................................................................... Remove....................................................................................................................................................... Install ......................................................................................................................................................... Test ............................................................................................................................................................. Coolant Pump ................................................................................................................................................ Remove....................................................................................................................................................... Disassemble ............................................................................................................................................... Assemble .................................................................................................................................................... Install ......................................................................................................................................................... Fan and Fan Drive ........................................................................................................................................ Remove....................................................................................................................................................... Install ......................................................................................................................................................... Oil Cooler (Six-Cylinder Engines) ................................................................................................................ Remove....................................................................................................................................................... Disassemble and Assemble ....................................................................................................................... Install ......................................................................................................................................................... Oil Cooler Bypass Valve ............................................................................................................................ Electrical Equipment Repair.............................................................................................................................

67 68 68 68 69 69 69 69 70 70 71 71 71 72 72 73 74 74 75 76 76 77 77 78 78 79 79 79 79 80 80 81 81 81 81 81 82 82 82 82 84 86 87 87 87 88 88 88 88 88 89

Perkins Diesel Engines

Table of Contents

TABLE OF CONTENTS (Continued) Drive Belts ..................................................................................................................................................... Adjustment ................................................................................................................................................ Remove....................................................................................................................................................... Install ......................................................................................................................................................... Alternator....................................................................................................................................................... Remove....................................................................................................................................................... Install ......................................................................................................................................................... Starter Motor ................................................................................................................................................. Remove....................................................................................................................................................... Install ......................................................................................................................................................... Cold Start Aid ................................................................................................................................................ Air Compressor - Engines YG and YH.............................................................................................................. General ........................................................................................................................................................... Repair ............................................................................................................................................................. Remove....................................................................................................................................................... Install ......................................................................................................................................................... Rotary Exhauster Replacement ........................................................................................................................ Remove ........................................................................................................................................................... Clean .............................................................................................................................................................. Install ............................................................................................................................................................. Engine Specifications......................................................................................................................................... Cylinder Head Assembly ............................................................................................................................... Piston and Connecting Rods ......................................................................................................................... Crankshaft Assembly .................................................................................................................................. Crankshaft Overhaul .............................................................................................................................. Timing Case and Drive Assembly............................................................................................................... Engine Block Assembly ............................................................................................................................... Turbocharger................................................................................................................................................ Lubrication System ..................................................................................................................................... Fuel System ................................................................................................................................................. Cooling System ............................................................................................................................................. Flywheel and Housing.................................................................................................................................. Electrical Equipment................................................................................................................................... Torque Specifications ....................................................................................................................................... Cylinder Head Assembly ............................................................................................................................. Piston and Connecting Rod Assemblies ..................................................................................................... Crankshaft Assembly .................................................................................................................................. Timing Case and Drive Assembly............................................................................................................... Turbocharger................................................................................................................................................ Lubrication System ..................................................................................................................................... Fuel System ................................................................................................................................................. Cooling System ............................................................................................................................................ Flywheel ....................................................................................................................................................... Auxiliary Equipment ................................................................................................................................... Special Torque Specifications .......................................................................................................................... Flywheel and Housing................................................................................................................................. Turbocharger................................................................................................................................................ Electrical Equipment................................................................................................................................... Auxiliary Equipment ................................................................................................................................... Special Tools* ................................................................................................................................................... Troubleshooting................................................................................................................................................

89 89 90 90 90 90 90 90 90 90 90 91 91 91 91 91 93 93 93 93 94 94 97 100 102 104 105 108 108 109 111 111 112 112 112 112 112 113 113 113 113 113 113 113 114 114 114 114 114 115 120

Table of Contents

Perkins Diesel Engines

TABLE OF CONTENTS (Continued) This section is for the following models: H3.50-5.00XL (H70-110XL) [G005]; S3.50-5.50XL (S70-120XL) [D004]; H6.00-7.00XL (H135-155XL, H135-155XL 2) [F006]; S6.00-7.00XL (S135-155XL, S135-155XL 2) [B024]; H13.00-16.00XL (H300-360XL) [D019]; H8.00-12.00XL (H165-280XL) [E007]; H3.50-5.50XM (H70-120XM) [K005]; H8.00-12.00XM (H170-280HD) [F007]; H13.00-16.00XM (H300-360HD) [E019]; H10.00-12.00XM-12EC (H360HD-EC) [E019]; H3.50-5.50XM (H70-120XM) [E004, F004]

600 SRM 705

General

General This section has the description and repair instructions for three models of the Series 1000 Perkins diesel engine. The three diesel engines described in this section: 1004-42 (AR)..................... Four cylinder, normally aspirated 1006-60 (YG)..................... Six cylinder, normally aspirated 1006-60T (YH) .................. Six cylinder, turbocharged

GENERAL SAFETY RULES WARNING Some seals used in this engine are made of synthetic materials called fluoroelastomers (a commercial name is Viton). These fluoroelastomers can decompose at temperatures greater than 316 C (600 F) or by burning and cause hydrofluoric acid to form on the surface of the seal or nearby equipment. Do not touch gaskets, seals or O-rings which appear charred or black and sticky after exposure to temperatures greater than 316 C (600 F) or burning. Contact with this acid can cause severe burns of the skin and eyes. Burns can be delayed several hours after contact.

the electrical system. Put a DO NOT OPERATE tag in the operator’s area and on the battery connectors. Long-term exposure to used engine oil can cause skin irritation or cancer. Wash with detergent and water. Exhaust from internal combustion engines contains carbon monoxide and other harmful chemicals. Carbon monoxide is a colorless, odorless poison and can cause unconsciousness or death without warning. Long term exposure to exhaust or chemicals in the exhaust can cause cancer, birth defects, and other reproductive harm. Avoid exposure to engine exhaust. Do not use diesel engines indoors where soot can accumulate. If engines are operated in confined spaces, maintain adequate ventilation or vent exhaust to the outside. Do not exceed applicable air contaminant limits. Follow the inspection and maintenance schedule and procedures in this manual. Do not alter exhaust, ignition, or fuel systems.

CAUTION Do the following procedures to prevent exposure to hydrofluoric acid: • Wear disposable neoprene or PVC gloves and discard the gloves after use. • Wash the area with 10% calcium hydroxide solution to neutralize any acid and then clean with water. If burned seal by-product touches the skin or eyes: • Immediately flush with water for a minimum of 15 minutes. • Apply 2.5% calcium gluconate gel to affected area of skin. • Get medical help immediately for suspected hydrogen fluoride or hydrofluoric acid burn.

WARNING Disconnect the battery cables before doing any disassembly and repair of the engine or parts of

Disposal of lubricants and fluids must meet local environmental regulations. Disposal of batteries must meet local environmental regulations. The diodes and resistors in the electrical system can be damaged if the following cautions are not followed: • Do not disconnect the battery when the engine is running. The voltage surge can damage the diodes and resistors. • Do not disconnect an electric wire before the engine is stopped and the switches are OFF. • Do not cause a short circuit by connection of the electric wires to the wrong terminals. Make sure a correct identification is made of the wire before it is connected. • Make sure a battery is the correct voltage and polarity before it is connected.

Description

600 SRM 705

â&#x20AC;˘ Do not check for current flow by making a spark because the electronic components can be damaged.

CAUTION When setscrews or studs are fitted into holes which are tapped through the cylinder block, a suitable sealant must be used to prevent leakage. Micro encapsulated anaerobic sealant (M.E.A.S.) fasteners have been introduced instead of jointing compounds or other sealants when the fasteners are fitted in through holes into oil or coolant passages. The

identification of these fasteners, as supplied, is by a red, blue, or other color sealant around the fastener threads. With M.E.A.S. sealed studs, the sealed end must be fitted into the cylinder head/cylinder block, etc. Ensure that the threaded holes have a 1.59 mm (0.0625 in.) 45 chamfer, to ensure that when the new fasteners are fitted, the M.E.A.S. sealant is not removed. If the fasteners have to be removed and fitted again, the threads must be cleaned and a suitable sealant used. Observe the previous WARNINGS and CAUTION before repairing any equipment.

Description The cylinder head is cast iron and has one inlet valve and one exhaust valve for each cylinder. The valve seats and the valve guides are replaceable. The fuel injectors are in the cylinder head. The overhead valve assembly is actuated by a camshaft inside of the engine block. A gear train, turned by the crankshaft, turns the camshaft, coolant pump, injection pump, and a power-takeoff (PTO) is available for additional equipment. The hydraulic pump for the steering function or a compressor is normally turned by the PTO. The fuel pump is actuated by the camshaft. See Figure 1 and Figure 2. The crankshaft in the six-cylinder models have seven main bearings. The crankshaft in the four-cylinder models have five main bearings. The main bearing in the center of the crankshaft is the thrust bearing and has thrust washers on both sides of the bearing.

piston has three piston rings (two compression rings, and an oil control ring). The top compression ring has a special insert for the groove to reduce wear. Axial location of the fully floating piston pin is by circlips. The piston pin is off-center to reduce the noise level. A jet for cooling oil to the bottom of the piston is installed. The four-cylinder AR engines have only one cooling jet installed in the number one cylinder. The cooling fan and the alternator are turned by a drive belt. The cooling fan is not connected to the coolant pump. The coolant pump is turned by the gear for the fuel injection pump in the timing gear case.

The cylinder block is cast iron. The six-cylinder engines have cylinder liners that can be replaced during overhaul. The cylinders for the four-cylinder engine are bored directly into the cylinder block.

The timing and quantity of fuel sent to the fuel injectors is controlled by a throttle and governor in the fuel injection pump. The static timing is set by the position of the fuel injection pump when it is installed. The throttle linkage must be correctly adjusted to control the quantity of fuel sent to the injectors. A mechanical governor is used to control the engine speed.

A Fastramâ&#x201E;˘ combustion chamber in the top of each piston is a design to give an efficient mix of fuel and air. The pistons for the four-cylinder AR engines have two recesses in the top face for the valves. Each

A Lucas DP200 series fuel injection pump is used on all engines. Special tools are needed to repair an injection pump and they are normally sent to an authorized repair station if repairs are necessary.

600 SRM 705

1. 2. 3. 4. 5.

FILL CAP FOR ENGINE OIL FUEL FILTER FUEL INJECTION PUMP COOLANT PUMP OIL SUMP

Description

6. OIL FILTER (CAN BE INSTALLED ON EITHER SIDE OF ENGINE) 7. FAN DRIVE 8. ALTERNATOR

9. DIPSTICK, ENGINE OIL (CAN BE INSTALLED ON EITHER SIDE OF ENGINE) 10. CRANKSHAFT PULLEY 11. TIMING CASE

Figure 1. Engine 1004-42 AR

Description

600 SRM 705

NOTE: ENGINE 1006-60 YG IS SIMILAR BUT WITHOUT TURBOCHARGER. 1. 2. 3. 4. 5. 6. 7.

FILL CAP FOR ENGINE OIL FUEL FILTER (2) FUEL INJECTION PUMP COOLANT PUMP AIR COMPRESSOR VIBRATION DAMPER OIL FILTER (2)

8. 9. 10. 11. 12. 13. 14.

OIL SUMP ALTERNATOR TURBOCHARGER DIPSTICK, ENGINE OIL FAN DRIVE OIL COOLER TIMING CASE

Figure 2. Engine 1006-60T YH

600 SRM 705

Description

ENGINE SERIAL NUMBER CODES The engine number is on a label on the side or the rear of the engine block. See Figure 3.

Bore and stroke ............... 103 × 127 mm (4.055 × 5.000 in.) Displacement................... 4.23 liter (258 in. 3 ) Compression Ratio .......... 18.5:1 Minimum oil pressure..... 207 kPa (30 psi) (at 2400 rpm and normal operating temperature) Governor speed (no load) See the Periodic Maintenance section for your model of lift truck. Idle Speed ........................ 725 to 775 rpm Thermostat

1. PART NUMBERS FOR FUEL INJECTION PUMP

2. ENGINE SERIAL NUMBER 3. EMISSIONS LABEL

Figure 3. Serial Number Locations A typical serial number has the following code: AR

30126

510256

where: 1 = Type of engine; AR = 1004-42, (-42 4 liter engine) YG = 1006-60, YH = 1006-60T (-60 6 liter engine) 2 = Parts list number 3 = Country of manufacture (U = manufactured in the United Kingdom) 4 = Serial number 5 = Year of manufacturer. The letter indicates the year of manufacture. The letters I, O, Q, R, and Z are not used. If parts or service are required for your engine, the complete engine number must be given to your dealer.

ENGINE DATA The specifications and tolerance details for engine repair are in a chart at the end of this section. 1004-42 (AR) ENGINE (Low Governed Speed) Power Rating at 2100 rpm................................... 60.0 kW (80.5 bhp) Number of cylinders........ 4

Begin to open .............. 77 to 85 C (170 to 185 F) Fully open.................... 92 to 98 C (198 to 208 F) Valve clearance (cold) Inlet ............................. 0.20 mm (0.008 in.) Exhaust ....................... 0.45 mm (0.018 in.)

1004-42 (AR) ENGINE (High Governed Speed) Power Rating at 2400 rpm.................................... 61.5 kW (82.4 bhp) Number of cylinders......... 4 Firing order ...................... 1 3 4 2 Bore and stroke ................ 103 × 127 mm (4.055 × 5.000 in.) Displacement.................... 4.23 liter (258 in. 3 ) Compression Ratio ........... 18.5:1 Minimum oil pressure...... 207 kPa (30 psi) (at 2400 rpm and normal operating temperature) Governor speed (no load) See the Periodic Maintenance section for your model of lift truck. Idle Speed ......................... 725 to 775 rpm Thermostat Begin to open ............... 77 to 85 C (170 to 185 F) Fully open..................... 92 to 98 C (198 to 208 F) Valve clearance (cold) Inlet .............................. 0.20 mm (0.008 in.) Exhaust ........................ 0.45 mm (0.018 in.)

Firing order ..................... 1 3 4 2

Description

600 SRM 705

1006-60 (YG) ENGINE

1006-60T (YH) ENGINE

Power Rating at 2200 rpm................................... 79 kW (106 bhp)

Power Rating at 2300 rpm................................... 106 kW (142 bhp)

Number of cylinders........ 6

Firing order ..................... 1 5 3 6 2 4

Bore and stroke ............... 100 × 127 mm (3.937 × 5.000 in.)

Displacement................... 6 liter (365 in. 3 )

Compression Ratio .......... 17.25:1

Minimum oil pressure..... 280 kPa (40 psi)

(at 2200 rpm and normal operating temperature) Governor speed (no load)

(at 2300 rpm and normal operating temperature) Governor speed (no load)

See the Periodic Maintenance section for your model of lift truck.

Idle Speed ........................ 700 to 775 rpm

Thermostat

600 SRM 705

Cylinder Head Assembly Repair

Engine Removal and Installation See the Frame section for the procedure for removing the engine and transmission. See the Transmission section for the procedure to separate the transmission from the engine.

LIFT ENGINE There can be a variation in the maximum weight of the engine depending upon the components that are attached to it. The following minimum lifting capacity is needed for an engine without coolant, lubricants, or transmission: four-cylinder engines

500 kg (1102 lb)

six-cylinder engines

600 kg (1322 lb)

Always use a lifting device that provides a vertical lift above the engine lift brackets as shown in Figure 4. Never use a single bracket to lift an engine. Make sure the engine brackets are correctly fastened to the engine. Make sure that the valve cover and other components are not damaged by the lifting device. Use a lifting device to lift and move the heavy components of the engine: cylinder block, cylinder head, flywheel housing, flywheel, and crankshaft. 1. ENGINE LIFT BRACKETS Figure 4. Lifting an Engine

Cylinder Head Assembly Repair VALVE COVER Remove 1. Disconnect the breather pipe. 2. Remove the cap nuts and the sealing washers from the top of the valve cover. See Figure 5. 3. Lift the valve cover, gasket, and seal from the cylinder head. The valve cover seal fits between the valve cover and the induction manifold. 4. When the valve cover is installed, the cap nuts are tightened onto the nuts of the rocker brackets. When the cap nuts are removed, the nuts for the rocker brackets can be loosened. Check that the nuts for the rocker brackets are tight each time that the valve cover is removed.

1. CAP NUT AND RUBBER SEAL Figure 5. Valve Cover

Cylinder Head Assembly Repair

600 SRM 705

Install 1. Check the condition of the valve cover gasket and the seal washers used under the cap nuts. Make sure that the surfaces are clean. 2. Install the valve cover, gasket, and seal on the cylinder head. See Figure 6. Install the seal washers under the cap nuts. Tighten the cap nuts to 30 N•m (22 lbf ft). Do not tighten the cap nuts so that they are fastened to the nuts for the rocker brackets.

Figure 7. Rubber Seal Location

Install 1. Install a new rubber seal in the hole for the oil supply in the cylinder head. See Figure 7. 2. Check that the push rods fit correctly in the sockets for the tappets. Install the rocker arm assembly. Make sure that the oil supply connection fits correctly into the rubber seal. 1. SEAL, OIL FILLER CAP 2. CAP NUT

3. RUBBER SEAL 4. GASKET 5. VALVE COVER

Figure 6. Valve Cover 3. Connect the breather pipe.

ROCKER ARM ASSEMBLY Remove 1. Remove the valve cover. 2. Loosen the nuts evenly that fasten the brackets for the rocker arm shafts to the cylinder head. Loosen the brackets at each end of the cylinder head first and loosen the brackets in sequence toward the center. Remove the nuts and washers when the pressure is removed from the rocker arms. Lift the rocker arm assembly from the cylinder head. 3. Remove the rubber seal from the oil supply connection or the hole for the oil supply in the cylinder head. See Figure 7.

3. Make sure that the alignment of the rocker arms and the push rods are correct. Install the nuts and washers on the studs that hold the brackets for the rocker arm shafts to the cylinder head. Tighten the nuts evenly. Begin tightening the nuts at the center of the rocker arm shaft and tighten in sequence toward the ends of the shaft. The final torque on the nuts: aluminum brackets = 40 N•m (30 lbf ft) iron brackets = 75 N•m (55 lbf ft). 4. Check and adjust valve tip clearances. See Valve Clearance Adjustments.

Disassemble 1. Remove the clips from both ends of the rocker arm shaft. Make sure that the ends of the rocker arm shaft are not damaged. Loosen the location screw for the oil supply connection. 2. Make a note of the position of each component on the rocker arm shaft so that they can be assembled correctly. Remove the components from the rocker arm shaft.

600 SRM 705

Cylinder Head Assembly Repair

Inspect 1. Clean and inspect all the components for wear and damage. Check the clearance of the rocker arms on the rocker arm shaft. If the clearance is greater than 0.13 mm (0.005 in.), install a new bushing in the rocker arm or install a new rocker arm shaft if it is worn. 2. If the bushing in the rocker arm is worn, use a press to remove the bushing. 3. Use a press to install a new bushing in the rocker arm. Make sure that the lubrication hole in the bushing is aligned with the hole in the rocker arm.

4. Use a reamer in the bushing as necessary to give a clearance on the rocker arm shaft of 0.03 to 0.09 mm (0.001 to 0.004 in.).

Assemble 1. Make sure that the lubrication holes in the rocker arms and the rocker arm shaft are open and clean. 2. Lubricate the components with clean engine oil as they are assembled on the rocker arm shaft. Make sure the components are assembled in the correct order. See Figure 8. Make sure that the location screw for the oil supply connection is fitted correctly in the rocker arm shaft. Install the clips at the ends of the rocker arm shaft.

Figure 8. Rocker Arm Assembly

VALVE CLEARANCE ADJUSTMENTS The valve clearance is measured between the top of the valve stem and the rocker arm as shown in Figure 9. Valve clearance (cold) Inlet Exhaust

0.20 mm (0.008 in.) 0.45 mm (0.018 in.)

Number one cylinder is at the end of the engine with the fan. The inlet valve is the first valve in the sequence. See Figure 10. Figure 9. Valve Clearance Adjustment

Cylinder Head Assembly Repair

600 SRM 705 3. Turn the crankshaft in the normal direction of rotation until the inlet valve of number four cylinder has just opened and the exhaust valve of the same cylinder has not fully closed. Check the valve clearances on number three cylinder and adjust them as necessary.

Figure 10. Valve Positions

Four-Cylinder Engines 1. Turn the crankshaft in the normal direction of rotation until the inlet valve of number four cylinder has just opened and the exhaust valve of the same cylinder has not fully closed. Check the clearance of the valves of number one cylinder and adjust them as necessary. 2. Turn the crankshaft in the normal direction of rotation until the inlet valve of number two cylinder has just opened and the exhaust valve of the same cylinder has not fully closed. Check the valve clearances on number three cylinder and adjust them as necessary. 3. Turn the crankshaft in the normal direction of rotation until the inlet valve of number one cylinder has just opened and the exhaust valve of the same cylinder has not fully closed. Check the valve clearances on number four cylinder and adjust them as necessary. 4. Turn the crankshaft in the normal direction of rotation until the inlet valve of number three cylinder has just opened and the exhaust valve of the same cylinder has not fully closed. Check the valve clearances on number two cylinder and adjust them as necessary.

4. Turn the crankshaft in the normal direction of rotation until the inlet valve of number one cylinder has just opened and the exhaust valve of the same cylinder has not fully closed. Check the valve clearances on number six cylinder and adjust them as necessary. 5. Turn the crankshaft in the normal direction of rotation until the inlet valve of number five cylinder has just opened and the exhaust valve of the same cylinder has not fully closed. Check the valve clearances on number two cylinder and adjust them as necessary. 6. Turn the crankshaft in the normal direction of rotation until the inlet valve of number three cylinder has just opened and the exhaust valve of the same cylinder has not fully closed. Check the valve clearances on number four cylinder and adjust them as necessary.

VALVE SPRINGS NOTE: This procedure is normally for changing the valve springs of a single cylinder while the cylinder head is still installed on the engine. If the valves and springs must be removed from the cylinder head for repairs, see the procedures under Valves and Valve Springs later in this section. Special Tools:

Valve spring compressor Stud adapter Setscrew adapter

Six-Cylinder Engines 1. Remove the valve cover. 1. Turn the crankshaft in the normal direction of rotation until the inlet valve of number six cylinder has just opened and the exhaust valve of the same cylinder has not fully closed. Check the clearance of the valves of number one cylinder and adjust them as necessary. 2. Turn the crankshaft in the normal direction of rotation until the inlet valve of number two cylinder has just opened and the exhaust valve of the same cylinder has not fully closed. Check the valve clearances on number five cylinder and adjust them as necessary.

2. Turn the crankshaft in the normal direction of rotation until the piston for the cylinder is at top dead center (TDC). The inlet valve will just open and the exhaust valve will not be fully closed when the cylinder is at TDC. 3. Remove the rocker arm assembly. 4. Install the spring compressor and the adapter. See Figure 11.

600 SRM 705

Cylinder Head Assembly Repair NOTE: Valve springs can be changed in two cylinders at a time. ENGINE AR. When the piston in cylinder one is at TDC, the piston in cylinder four is also at TDC. When the piston in cylinder two is at TDC, the piston in cylinder three is also at TDC. ENGINES YG and YH. When the piston in cylinder one is at TDC, the piston in cylinder six is also at TDC. When the piston in cylinder two is at TDC, the piston in cylinder five is also at TDC. When the piston in cylinder three is at TDC, the piston in cylinder four is also at TDC.

1. VALVE SPRING COMPRESSOR 2. STUD ADAPTER

3. SETSCREW ADAPTER

Figure 11. Valve Spring Compressor 5. Compress the valve springs and remove the retainers. Make sure the valve springs are compressed parallel to the valve stems or the valve stems can be damaged.

If the rocker arm assembly was removed before TDC was found, install the valve spring compressor and compress the valve springs to open the valve. Turn the crankshaft by hand in the normal direction until the piston touches the valve. Continue to turn the crankshaft, and at the same time, release the pressure on the valve spring compressor until the piston is at TDC. See Figure 12.

6. Release the valve spring compressor and remove the retainer cap and valve springs. NOTE: Do not turn the crankshaft while the valve springs are removed. NOTE: The outer diameter of the exhaust valve guide is 1 mm larger than the inlet valve guide. To prevent leakage past the inlet valve stem it is important that the larger exhaust valve seal is not fitted into the inlet guide. The seals are color coded. 7. Install new valve stem seals on the valve guides. Make sure that the brown seal is installed on the exhaust valve and the green seal on the inlet valves. 8. Install the new valve springs. Make sure the closed damper coils of the valve springs are toward the cylinder head. 9. Install the retainer cap. 10. Use the valve spring compressor to compress the valve springs and install the retainers. Remove the valve spring compressor. 11. Install the rocker arm assembly. 12. Check the valve clearances. See Valve Clearance Adjustments. 13. Install the valve cover.

Figure 12. Find TDC With Valve Spring Compressor

Cylinder Head Assembly Repair

600 SRM 705

CYLINDER HEAD ASSEMBLY Remove 1. If the engine is still in the lift truck, do the following procedures: a. Disconnect the battery terminals. b. Drain the cooling system. c. Disconnect the sender unit for the coolant temperature gauge. 2. ENGINES AR and YG. Remove the hose from the air filter at the induction manifold. ENGINE YH. Remove air filter connection at the compressor inlet of the turbocharger. 3. Remove the fuel line between the cold start aid in the induction manifold and the fuel filter. Disconnect the electrical connection.

1. TOP HALF - INDUCTION MANIFOLD 2. BOTTOM HALF - INDUCTION MANIFOLD 3. CAPSCREWS Figure 13. Induction Manifold

4. ENGINE YH. Remove the boost control line between the front of the induction manifold and the fuel injection pump. 5. Remove the induction manifold. See Figure 13. For induction manifolds fitted to engine types AR: The top half of the induction manifold is sealed to the bottom half with a liquid joint and fastened together by six capscrews. The top half of the manifold must be removed to obtain access to four of the manifold capscrews, fitted inside the manifold. These capscrews retain the bottom half of the manifold to the cylinder head. 6. ENGINE YH. Disconnect all connections to the turbocharger and remove the turbocharger. See Turbocharger - Engine YH Repair, Remove. 7. Remove the exhaust manifold. Loosen the manifold fasteners in the reverse order shown in Figure 14. 8. Remove the low pressure fuel lines between the fuel injection pump and the fuel filter. Remove the fuel filter bracket and the fuel filters. 9. Remove the high pressure fuel lines. Use a separate wrench to prevent movement of the outlets of the fuel injection pump when the fuel lines are disconnected. Put plugs in the open ports of the fuel injection pump.

Figure 14. Exhaust Manifold Tightening Sequence 10. Remove the return fuel line from the fuel injectors.

600 SRM 705

Cylinder Head Assembly Repair

11. Remove the fuel injectors from the cylinder head. Keep the fuel injectors clean and prevent damage to the nozzles. 12. ENGINES YG and YH. If an air compressor is installed, remove the coolant pipe between the cylinder head and the compressor. Remove the coolant pipe between the bypass connection and the compressor. 13. Loosen the hose clamp and remove the coolant bypass hose from the cylinder head. Remove the capscrews and remove the coolant bypass connection and the hose.

20. Lift the cylinder head from the engine block. Do not use a pry bar between the cylinder head and the engine block that can cause damage to the gasket surfaces. See Figure 17. 21. Inspect the capscrews for the cylinder head with a straightedge. See Figure 18. Check that the capscrews are straight and do not have distortion. If there is a reduction in the diameter of the thread that has not been in engagement with the cylinder block, the capscrew must be discarded.

14. Disconnect the coolant temperature sender. 15. ENGINE AR. Remove the oil cooler if it is integral with the cylinder block. 16. Remove the valve cover. See Valve Cover, Remove. 17. Remove the rocker arm assembly. See Rocker Arm Assembly, Remove.

Figure 15. Cylinder Head Tightening Sequence, Four-Cylinder Engines

18. Remove the push rods. 19. Loosen the capscrews for the cylinder head evenly in a reverse sequence from the sequence shown in Figure 15 or Figure 16.

Figure 16. Cylinder Head Tightening Sequence, Six-Cylinder Engines

Cylinder Head Assembly Repair

600 SRM 705

Install Special Tools:

Angle gauge to tighten the capscrews for the cylinder head

1. Make sure the surfaces of the cylinder head and the top of the engine block are clean. Make sure that there is no dirt or objects in the cylinders. 2. Install the gasket for the cylinder head as shown in Figure 19. Make sure the "TOP FRONT" is in the correct position. Do not use any gasket sealant on any of the surfaces.

Figure 17. Cylinder Head Removal

Figure 19. Head Gasket Position

1. STRAIGHTEDGE 2. CAPSCREW MUST BE STRAIGHT AND WITHOUT DISTORTION 3. THREADS MUST BE IN GOOD CONDITION AND NOT HAVE A REDUCED DIAMETER

3. Use two 1/2 UNF studs in positions 16 and 21 on four-cycle engines and positions 25 and 30 on six-cycle engines. See Figure 20 and Figure 21 to hold the gasket in position. Lower the cylinder head into position on the engine block. See Figure 22.

Figure 18. Capscrews Inspection

Figure 20. Cylinder Head Tightening Sequence, Six-Cylinder Engines

600 SRM 705

Cylinder Head Assembly Repair shown in Figure 20 or Figure 21 according to the following procedure: Six-Cylinder Engines a. The short capscrews (S) must be tightened an additional 150 (2.5 flats). b. The medium capscrews (M) must be tightened an additional 180 (3.0 flats). c. The long capscrews (L) must be tightened an additional 210 (3.5 flats).

Figure 21. Cylinder Head Tightening Sequence, Four-Cylinder Engines

Figure 22. Cylinder Head Installation

CAUTION There are three lengths of capscrews. S = short, M = medium, L = long. Figure 20 and Figure 21 show their positions in the engine. Make sure that the capscrews are installed in the correct positions. 4. Lubricate the capscrews with a thin coat of oil and install them into their holes in the cylinder head. When the cylinder head and gasket are held in position, remove the two studs and install the two capscrews in those positions. The four 1/2 UNF capscrews on the four-cylinder (AR) engines are in positions 2, 8, 13, and 18. See Figure 21. 5. Evenly tighten the capscrews in the sequence shown in Figure 20 or Figure 21. The final torque on the capscrews is 110 N•m (81 lbf ft) for the six-cylinder engines and 45 N•m (33 lbf ft) for the four-cylinder engines.

Four-Cylinder Engines a. The short capscrews (S) must be tightened an additional 120 (2 flats). b. The medium capscrews (M) must be tightened an additional 120 (2 flats). c. The long capscrews (L) must be tightened an additional 150 (2.5 flats). d. The four 1/2 UNF capscrews in position 2, 8, 13, and 18 must be tightened an additional 180 (3 flats). NOTE: A special tool shown in Figure 23 can be used for this procedure to measure the tightening angles. If an angle gauge is not available, make a mark in a line with one of the corners of the capscrew. See Figure 24 and Figure 25. Make another mark at the correct angle (counterclockwise) on the edge of the flange of the cylinder head for each capscrew and according to the length of each capscrew. Tighten each capscrew in the correct sequence until the two marks are aligned. 7. Install the push rods in the engine. Make sure that the end of each push rod fits correctly in the tappet socket. 8. Install the rocker arm assembly per Rocker Arm Assembly, Install. 9. Adjust the valve clearances per Valve Clearance Adjustments. 10. Install the fuel injectors per Fuel Injectors, Install. 11. Install the high pressure fuel lines between the fuel injection pump and the fuel injectors. Use a separate wrench to prevent movement of the outlets of the fuel injection pump when the fuel lines are connected. Tighten the connection nuts to 22 N•m (16 lbf ft).

6. Make sure all of the capscrews are tightened to the correct torque described in Step 5. The capscrews must be further tightened in the sequence

Cylinder Head Assembly Repair

600 SRM 705 13. Install the coolant bypass connection. Tighten the capscrews and the hose clamp. 14. ENGINES YG and YH. If an air compressor is installed on the engine, install the coolant pipe between the cylinder head and the compressor. Install the pipe between the coolant bypass and the compressor. 15. Prepare to install the induction and exhaust manifolds. Do not use sealant on the joints of the manifolds. 16. ENGINE AR. Install the oil cooler if it is integral with the cylinder block.

Figure 23. Angle Gauge

17. ENGINE AR. The front and rear gaskets have tabs. Make sure that the gaskets are installed with the tabs installed toward the oil sump. See Figure 26.

Figure 24. Tighten Cylinder Head Capscrews, Engine AR

1. GASKET 2. GASKET

3. LOCATION TABS

Figure 26. Induction and Exhaust Manifold Gaskets, Engine AR Figure 25. Tighten Cylinder Head Capscrews, Engine YG and YH 12. Install the fuel filter and bracket. Install the lowpressure fuel lines between the fuel filter and the fuel injection pump.

NOTE: Some gaskets are now made as a single piece. 18. ENGINES YG and YH. The two end gaskets are the same. The center gasket has tabs. Make sure that the gaskets are installed with the tabs installed toward the oil sump. See Figure 27.

600 SRM 705

Cylinder Head Assembly Repair 20. Install the induction manifold. Tighten the capscrews evenly and gradually to 44 Nâ&#x20AC;˘m (32 lbf ft). 21. For induction manifolds on engines AR (see Figure 29), the top half of the induction manifold is sealed to the bottom half with a gasket and fastened together by six capscrews.

1. GASKET 2. GASKET

3. LOCATION TABS

Figure 27. Manifold Gasket Installation, Engines YG and YH NOTE: Some replacement exhaust manifolds have large clearance holes for the fasteners. Two alignment bushings are supplied with a replacement manifold (Figure 28). These bushings must be installed for the replacement manifold. New alignment bushings are not necessary when the original manifold is installed. 19. Install the exhaust manifold. Tighten the capscrews 44 Nâ&#x20AC;˘m (32 lbf ft) in the sequence shown in Figure 28.

1. 2. 3. 4. 5.

TOP HALF OF MANIFOLD BOTTOM HALF OF MANIFOLD CAPSCREWS (INSIDE OF MANIFOLD) CAPSCREWS (OUTSIDE OF MANIFOLD) GASKET

Figure 29. Induction Manifold Installation, Engine AR 22. The top half of the manifold must be removed to obtain access to four of the manifold capscrews inside the manifold. These capscrews and the four capscrews on the outside of the manifold retain the bottom half of the manifold cylinder to the cylinder head.

CAUTION Before the inlet manifold capscrews are installed again, any loose M.E.A.S. in the cylinder head holes must be removed to allow the manifold to be fully tightened. Do not scratch or damage the flange faces of the inlet manifold. A. FAN END 1. BUSHING (SEE NOTE) Figure 28. Induction Manifold Installation, Engines YG and YH

NOTE: The capscrews which retain the manifold to the cylinder head have M.E.A.S. applied to the threads. If the capscrews are removed and installed again, the threads must be cleaned and POWERPART threadlock sealant used.

Cylinder Head Assembly Repair 23. ENGINE YH. Install the turbocharger per Turbocharger - Engine YH Repair, Install. 24. Install the fuel line between the fuel pump and the fuel filter. 25. Install the fuel line between the fuel filter and the cold start aid. If the engine is in the lift truck, install the electrical connection to the cold start aid. 26. ENGINE YH. Install the boost control line between the induction manifold and the top of the fuel injection pump. 27. If the engine is still in the lift truck, do the following procedures: a. Connect the sender unit for the coolant temperature gauge. b. ENGINE YH. Install air filter connection at the compressor inlet of the turbocharger. ENGINES AR and YG. Install the hose from the air filter at the induction manifold. c. Connect the hoses for the coolant system. Fill the cooling system. d. Connect the battery terminals. e. If the engine is ready to operate, remove the air from the fuel system. See the procedure described in Fuel System Air Removal. 28. When the engine can be started, run it at low speed. Check that oil flows from the holes in the rocker arms. If the oil flow is correct, install the valve cover. See Valve Cover, Install.

600 SRM 705 2. Clean the bottom face of the cylinder head and check the depth of the heads of the valves below the face of the cylinder head. See Figure 30. 3. Check the depth of the valves below the face of the cylinder head before the valve springs are removed. Put the dial indicator and fixture or other measuring tool on the face of the cylinder head and set the gauge to zero. Carefully put the dial indicator over the head of each valve and make a note of the measurement. The maximum service depth is shown in the Engine Specifications. If a valve is below the depth limit, remove the valve and install a new valve in that position. If the valve depth is still below the limit, the valve seat must be replaced. See New Valve Seats, Install. 4. If the valves will be used again, make a mark on each valve head so that they can be installed again in the same positions. 5. Use the valve spring compressor and the correct adapter to compress the valve springs and remove the retainers. Make sure the valve springs are compressed parallel to the valve stems or the valve stems can be damaged. See Figure 31. 6. Release the valve stem compressor. Remove the valve spring cap, valve springs, seal, and seat washer. 7. Repeat Step 5 and Step 6 to remove the other valves.

Inspect 1. Check the valves for cracks. Check the stems of the valves for wear and the correct clearance in their valve guides. See Valve Guides.

NOTE: It is not necessary to tighten the cylinder head capscrews again with the engine hot or after a limited period of service.

VALVES AND VALVE SPRINGS Special Tools:

Valve spring compressor Stud adapter Setscrew adapter

Remove 1. Remove the cylinder head. See Cylinder Head Assembly, Remove. Figure 30. Valves Depth Check

600 SRM 705

Cylinder Head Assembly Repair leakage past the inlet valve stem it is important that the larger valve seal is not installed into the inlet guide. The seals are color coded. 2. Install the seat washer. Install new seals on the valve guides. Make sure that the brown seal is installed on the exhaust valves and the green seal is installed on the inlet valves. 3. Install the inner and outer valve springs on the seat washer. Make sure that the damper coils of the valve springs are toward the cylinder head. 4. Use the valve spring compressor and the correct adapter to compress the valve springs. Install the retainers. Make sure the valve springs are compressed parallel to the valve stems or the valve stems can be damaged. 5. Repeat the installation procedure for each valve.

VALVE GUIDES Inspect

1. CAP 2. COLLET (2) 3. SPRING

4. VALVE STEM SEAL 5. VALVE

Figure 31. Valve Components 2. Check that the seat faces of the valves are not badly burned. Seat faces of valves that are damaged, but can be repaired, must be checked for valve depth when they are installed. See Figure 30. When new valves are installed, the valve depth must be checked. 3. Check that the load on the valve springs is correct at their installed length. See Engine Specifications. 4. Install new valve springs during a complete overhaul of the engine.

Install 1. Lubricate the valve stems with engine oil when they are installed in their valve guides.

1. Check the valve guides for wear. The maximum clearance between the valve stem and the bore of the guide is 0.100 mm (0.0039 in.) for inlet valves and 0.121 mm (0.0048 in.) for exhaust valves. If the clearance is greater than the limit when a new valve is installed, the valve guide must be replaced. 2. The following procedure is for checking the valve guides (see Figure 32): a. Put a new valve into the valve guide. b. Install a dial indicator on the cylinder head. c. Lift the head of the valve approximately 15 mm (0.6 in.) above its seat. Move the valve head away from the plunger of the dial indicator and set the dial indicator to zero. d. Move the valve toward the dial indicator and make a note of the movement. If the reading is equal to or greater than the maximum clearance, a new valve guide must be installed.

CAUTION The outer diameter of the exhaust valve guide is 1 mm larger than the valve guide. To prevent

Cylinder Head Assembly Repair

600 SRM 705 1. Check the cylinder head for cracks. Carefully check the areas around the valve seats and around the holes for the fuel injectors. 2. Use a straightedge and spacer gauges to check the cylinder head for distortion across and along its face that joins the engine block. See the Engine Specifications. If the distortion is more than the specifications, the face can be machined. Remove only the minimum metal so that the thickness of the cylinder head will not be less than 102.48 mm (4.035 in.) after the cylinder head has been machined.

1. MAGNETIC BASE 2. DIAL INDICATOR 3. VALVE HEAD

4. VALVE GUIDE 5. MAXIMUM CLEARANCE

Figure 32. Valve Guides Check NOTE: The partially finished valve guides are reamed and the valve seats are cut in one operation with a special tool. This is done to ensure the concentricity of the valve seat to the valve guide and provide a good seal between the guide and its seat. New valves and valve seat inserts must be installed each time a new valve guide is used.

Remove Install the tool for removal and replacement and the adapter on the valve guide. Pull the valve guide from the cylinder head. See Figure 33.

Install 1. Make sure the bore in the cylinder head is clean. 2. Lubricate the outer surface of the new valve guide with engine oil. 3. Install the valve guide on the special tool. See Figure 34. Use the special tool to pull the valve guide into the cylinder head. When the valve guide is correctly installed, the valve guide will extend 14.85 to 15.15 mm (0.585 to 0.596 in.) above the seat of the valve spring.

CYLINDER HEAD AND VALVE SEATS Inspect The valves must be removed from the cylinder head before the valve seats can be inspected and repaired. Carefully clean the cylinder head.

NOTE: After the cylinder head has been machined, the valve seats must be checked for the correct depth. See Valves and Valve Springs, Inspect. If the depth of the valve seats must be increased, use the minimum limit to allow for later wear. 3. Check the valve seats for wear and damage. Before any work is done on the valve seats, make sure the valve guides are good. See Valve Guides, Inspect for inspection and replacement. 4. Damaged valve seats can be repaired with a cutter tool. See Figure 35. If the valve seat cannot be repaired so that the valve depth is within the specifications, the valve seat must be replaced.

Repair Special Tools:

Cutter for inlet valve seats Cutter for exhaust valve seats Valve guides reamer

1. Install the correct cutter into the valve seat that is to be repaired. Carefully turn the cutter in a clockwise direction. Remove only the minimum metal to repair the valve seat. Keep the valve seat as narrow as possible. 2. When the valve seat has been cut, remove the cutter and pilot. Clean the port area and remove any particles. 3. Check the valve depth. See Valves and Valve Springs, Inspect. If the valve seat is badly damaged or worn, replace the valve seat as described in the following paragraphs.

New Valve Seats, Install 1. Remove the valve guide. Clean the bore and install a new valve guide. See Valve Guides for inspection and replacement.

600 SRM 705

Cylinder Head Assembly Repair

Figure 33. Valve Guide Removal 2. Use the bore of the new valve guide as a pilot and use a milling machine to remove the old valve seat. See the Engine Specifications. Clean the particles from the port and the area where the new valve seat will be installed.

1. 14.85 to 15.15 mm (0.585 to 0.596 in.) ABOVE SEAT OF VALVE SPRING Figure 34. Valve Guide Installation

3. If the bottom face of the cylinder head has been machined, the back face of the new valve seat must be machined so that it will not extend above the surface of the cylinder head. If the back face of the valve seat is machined, make sure that the outer edge of the back face dimensions are within the Engine Specifications. 4. Use the bore of the valve guide as a pilot. Use a press to install the valve seat into the cylinder head. Make sure the valve seat is fully inserted into the cylinder head. 5. Use a cutter to cut the valve seat at the correct angle. Check the valve depth as shown in Figure 30. Make sure that the dimensions are within the Engine Specifications.

Figure 35. Valve Seats Cutter

Piston and Connecting Rod Assemblies Repair

600 SRM 705

Piston and Connecting Rod Assemblies Repair The connecting rods are forged from steel. The piston height is controlled by the length of the connecting rod. Each piston and connecting rod is matched to a cylinder during assembly to make sure the piston height is correct for combustion efficiency to meet emission standards. The manufacturer uses six length grades of connecting rods during assembly to give the correct piston height. These six height grades are made by machining the small-end bushing a small amount off-center. Connecting rods for service replacement are available in two height grades. The combustion chamber is machined into the top of the piston. See Figure 36 and Figure 37. The pistons have two compression rings and an oil control ring. The groove for the top compression ring has a hard metal insert to reduce wear in the groove. The piston skirt has a layer of graphite to reduce wear.

Figure 37. Piston, Engines YG and YH

1. LOCATION DOWELS Figure 38. Connecting Rod Assembly with Location Dowels Figure 36. Piston, Engine AR

ROD BEARINGS Some engines have two steel dowels that are installed into the bearing cap to keep the alignment with the connecting rod. Two capscrews fasten the bearing cap to the connecting rod. See Figure 38. Some engines have grooves (serrations) that are machined in the joint faces of the connecting rod and bearing cap to keep alignment between the two parts. The bearing cap is fastened to the connecting rod with two nuts and special bolts. See Figure 39.

1. SERRATIONS Figure 39. Connecting Rod Assembly with Serrations

600 SRM 705

Remove 1. Drain the engine oil from the sump. Remove the oil sump. See Oil Sump, Remove. 2. Remove the suction pipe and oil strainer. See Figure 40. Remove the capscrew that holds the bracket to the main bearing cap. Remove the two capscrews from the flange of the suction pipe and remove the suction pipe and screen. Clean the faces of both flanges.

Piston and Connecting Rod Assemblies Repair 5. Remove the lower bearing half from the bearing cap. Keep the bearing half with its cap. 6. Carefully push the connecting rod up the cylinder bore just enough to permit access to the upper bearing half. Remove the upper bearing half from the connecting rod. Keep the bearing halves together.

Install 1. Clean the bearing surfaces of the connecting rod and the crankshaft. Make sure that the protrusion for the location dowels is 3.0 to 4.5 mm (0.12 to 0.18 in.) above the cap faces. Clean the bearing halves and lubricate them with clean engine oil. 2. Install the upper bearing half into the connecting rod. Make sure that the location tab is installed correctly into its position in the connecting rod. See Figure 41.

1. SUPPORT BRACKET, MAIN BEARING CAP 2. CAPSCREWS, FLANGE, SUCTION PIPE Figure 40. Sump Screen Removal 3. Turn the crankshaft until the connecting rod to be removed is at the lowest position on the crankshaft.

CAUTION Do not permit the connecting rods to hit the cooling jets for the pistons. If a cooling jet is hit, the alignment must be checked and the cooling jet replaced if necessary. 4. Connecting rods with capscrews. Loosen the capscrews for the bearing cap approximately four turns. Lightly hit the heads of the capscrews with a soft hammer to separate the connecting rod from the bearing cap. Remove the capscrews and the bearing cap.

1. POSITION OF LOCATION TAB IN BEARING HALF AND CONNECTING ROD Figure 41. Rod Bearings Position 3. Install the bearing cap on the connecting rod. Make sure that the assembly number on the bearing cap is the same as the number on the connecting rod. Make sure that the two assembly numbers are on the same side of the connecting rod as shown in Figure 42.

Connecting rods with nuts. Remove the nuts and remove the bearing cap.

Piston and Connecting Rod Assemblies Repair

Figure 42. Bearing Cap Position, Connecting Rod

600 SRM 705

Figure 43. Piston Grade Mark

Remove

4. Connecting rods with nuts. Install and tighten the nuts evenly to a torque of 125 Nâ&#x20AC;˘m (92 lbf ft). Make sure that the crankshaft turns freely.

1. If the engine is still in the lift truck, drain the engine oil and the coolant.

Connecting rods with capscrews. Install and tighten the capscrews evenly to a torque of 155 Nâ&#x20AC;˘m (114 lbf ft). Make sure that the crankshaft turns freely.

2. Remove the cylinder head assembly as described in Cylinder Head Assembly, Remove. Remove the carbon from the tops of the bores of the cylinder liners.

5. Loosely assemble the bracket of the suction pipe to the main bearing cap. Install a new gasket and fasten the flanges of the suction line to the oil pump. Make sure that the suction pipe is aligned correctly and then tighten the capscrew that holds the bracket to the main bearing cap. 6. Install the oil sump. See Oil Sump, Install.

PISTON AND CONNECTING ROD ASSEMBLY Service Note If a piston must be replaced, make sure that the piston has the same height grade. An H or an L is stamped into the top of the piston. See Figure 43. A production piston does not have an H or an L mark. The piston height must be checked after installation. See the procedure described in Installation.

3. Remove the oil sump. See Oil Sump, Remove. 4. Remove the suction line and oil strainer. See Figure 40. Remove the capscrew that holds the bracket to the main bearing cap. Remove the two capscrews from the flange of the suction line and remove the suction line and screen. Clean the faces of both flanges. 5. Remove the bearing cap and rod bearings as described under Rod Bearings, Remove. Mark the bearing caps and rod bearings so that they can be installed again in their original positions.

CAUTION Do not permit the connecting rods to hit the cooling jets for the pistons. If a cooling jet is hit, the alignment must be checked and the cooling jet replaced if necessary. 6. Push the piston and connecting rod out of the top of the cylinder liner. 7. Inspect the bearing surfaces on the crankshaft for damage.

600 SRM 705

Piston and Connecting Rod Assemblies Repair

Install

mark on the piston must be turned toward the end of the engine with the cooling fan. See Figure 45.

Special Tools:

Piston installation tool (piston ring compressor) Piston height tool Dial indicator gauge

1. Make sure all of the parts are clean. Lubricate the parts with engine oil as they are installed. 2. Turn the crankshaft until the position for the connecting rod to be installed is at the lowest position on the crankshaft. 3. Install the upper bearing half into the connecting rod. Make sure that the location tab is installed correctly into its position in the connecting rod. See Figure 41. 4. Put the piston installation tool at the top of the cylinder. See Figure 44. The tool has a bore with a taper to compress the piston rings when the piston and connecting rod assembly is installed. Make sure the smaller end of the taper is toward the cylinder block. 5. Put the spaces in the three piston rings so that they are 120 apart. Put the connecting rod through the piston installation tool and permit the piston to enter the tool. The piston and connecting rod must be turned so that the connecting rod does not hit the cooling jet for the piston.

Figure 45. Piston in Bore Position 7. Lubricate the lower half of the rod bearing and install it into the bearing cap. 8. Install the bearing cap on the connecting rod. Make sure that the assembly number on the bearing cap is the same as the number on the connecting rod. Make sure that the two assembly numbers are on the same side of the connecting rod as shown in Figure 42. 9. Connecting rods with nuts. Install and tighten the nuts evenly to a torque of 125 Nâ&#x20AC;˘m (92 lbf ft). Make sure that the crankshaft turns freely. Connecting rods with capscrews. Install and tighten the capscrews evenly to a torque of 155 Nâ&#x20AC;˘m (114 lbf ft). Make sure that the crankshaft turns freely. 10. Measure the height of the piston above the top of the engine block with a dial indicator gauge. The crankshaft must be turned so that the piston is at TDC in the engine block. Put the dial indicator on the top of the engine block and measure the height of the piston above the face of the engine block. See Figure 46.

Figure 44. Piston Installation Tool 6. When the connecting rod has passed the cooling jet during installation, the arrow or "FRONT"

The correct height of the piston above the engine block is 0.36 to 0.50 mm (0.014 to 0.020 in.). The tops of the pistons must not be changed or machined.

Piston and Connecting Rod Assemblies Repair

Figure 46. Piston Height Above Engine Block Measurement 11. Loosely assemble the bracket of the suction pipe to the main bearing cap. Install a new gasket and fasten the flanges of the suction pipe to the oil pump. Make sure that the suction pipe is aligned correctly and tighten the capscrew that holds the bracket to the main bearing cap. 12. Install the oil sump. See Oil Sump, Install.

600 SRM 705

Figure 47. Piston Ring End Clearance Check 3. Install new piston rings on the piston and check the clearance in the grooves with a spacer gauge. See Figure 48. If the clearance between the piston rings and the piston are greater than the specifications, the piston must be replaced. See the Engine Specifications. The clearance in the top groove of the pistons for these engines cannot be checked because it has a taper.

13. Install the cylinder head. See Cylinder Head Assembly, Install.

PISTON RINGS Remove 1. Check that the piston rings can move freely in their grooves and are not broken. 2. Remove the piston rings with a ring expander. Increase the diameter of the piston rings only enough to remove them without damaging the piston.

Inspect

Figure 48. Piston Ring Clearance Check

1. Check the piston for wear and damage.

Install

2. Clean the carbon from the top of the cylinder liners. Fit the piston rings in the top part of the cylinder liner and measure the clearance at the ends of the ring. See Figure 47. The spring must be installed in the oil control ring when its end clearance is measured. The clearance measurements for the piston rings are shown in the Engine Specifications.

Install the piston rings with a ring expander. Increase the diameter of the piston rings only enough to remove them without damaging the piston.

1. Install the spring for the oil control ring in the bottom groove of the piston. See Figure 49. Install the latch pin inside both ends of the spring. See Figure 50 and Figure 51. Install the oil control ring over the spring so that the end space in the oil control ring is 180 to the latch pin.

600 SRM 705

Piston and Connecting Rod Assemblies Repair mark which must be on the left of the clearance space at the ends of the ring when the ring is installed on the piston and the piston is upright. 3. Engines YG and YH. Install the barrel face ring with the molybdenum insert into the top groove of the piston. Engines AR. Install the parallel face ring with the molybdenum insert into the top groove of the piston.

Figure 49. Spring Installation for Oil Control Ring

1. TOP RING 2. SECOND RING

3. OIL CONTROL RING AND SPRING

Figure 51. Piston Rings Installation, Engine AR

1. TOP RING 2. SECOND RING

3. OIL CONTROL RING AND SPRING

Figure 50. Piston Rings Installation, Engines YG and YH 2. Install the cast iron ring with the taper into the second groove of the piston. Make sure that the word "TOP" or the manufacturerâ&#x20AC;&#x2122;s symbol is toward the top of the piston. New piston rings have a green identification mark which must be on the left of the clearance at the ends of the ring when the ring is installed on the piston and the piston is upright.

CAUTION Make sure that the word "TOP" or the manufacturerâ&#x20AC;&#x2122;s symbol is toward the top of the piston. New piston rings have a red identification

4. Check that the open gap of the piston rings are spaced 120 apart before installing the piston.

PISTON AND CONNECTING ROD Disassemble 1. Remove the piston rings as described in Piston Rings, Remove. 2. Make a mark on the piston to indicate the cylinder number as shown on the connecting rod. Make the mark on the same side of the piston as the number on the connecting rod. See Figure 52. 3. Remove the snap rings that hold the piston pin in the piston. Push the piston pin from the piston with your thumb. If the piston pin is tight, heat the piston and connecting rod to 40 to 50 C (104 to 122 F) to make removal of the piston pin easier.

Piston and Connecting Rod Assemblies Repair

600 SRM 705 A partially finished small-end bushing, which can be installed in the original connecting rod and machined to obtain correct length grade is also available. 3. If the bushing in the connecting rod is worn, use a press to remove the bushing. 4. Clean the parent bore of the connecting rod and remove any sharp edges.

CAUTION Figure 52. Marking Piston

Do not use a reamer to machine the partially finished bushing. Special equipment and trained personnel are needed.

1. Clean and inspect all the components for wear and damage. Check the alignment of the connecting rod with a test mandrel. See Figure 53.

5. Use a press to install a partially machined bushing in the connecting rod. Make sure that the lubrication hole in the bushing is aligned with the lubrication hole in the connecting rod.

Inspect

NOTE: The small end is wedge shaped. After the small end bushing has been installed, machine the bushing to the shape of the small end and remove any sharp edges. 6. Machine the partially finished bushing to obtain the correct connecting rod grade.

CAUTION Do not use a letter stamp to mark the connecting rod. NOTE: THE LARGE AND SMALL BORES IN THE CONNECTING ROD MUST BE SQUARE AND PARALLEL WITH EACH OTHER WITHIN THE LIMITS OF Âą0.25 mm (0.010 in.). THE MEASUREMENT IS MADE AT 127 mm (5.0 in.) ON EACH SIDE OF THE AXIS OF THE CONNECTING ROD. IF THE BUSHING IS INSTALLED IN THE SMALL END OF THE CONNECTING ROD, THE LIMITS ARE REDUCED TO Âą0.06 mm (0.0025 in.). Figure 53. Connecting Rod Alignment Check 2. Check the clearance of the bushing in the connecting rod with the piston pin. If the clearance is greater than 0.043 mm (0.0017 in.) or is damaged, install a new bushing. NOTE: Connecting rod kits are available with a new small-end bushing installed and finished to the correct grade. Refer to How to Select Correct Replacements to identify the correct rod grade.

7. Check that the grade letter on the connecting rod is correct. If necessary, delete the letter and etch a new letter on the side of the rod.

How to Select Correct Replacements CAUTION It is important that the piston does not contact the cylinder head. Ensure that the piston height above the cylinder block is correct. Check that the connecting rods are fitted in the correct cylinder. Record the position of the connecting rod and its relevant cylinder when it is removed from the engine. To check that the piston height above the cylinder block is correct, the engine may have up to six length grades (F to L) of connecting rods fitted.

600 SRM 705

Piston and Connecting Rod Assemblies Repair

Identification of the length grade is by a letter or color which is marked on the side of each connecting rod. See Figure 54. The letter F is the longest grade of connecting rod and letter L is the shortest grade. The difference between grades is 0.046 mm (0.0018 in.).

3. Turn the piston for access to install the connecting rod. Install the connecting rod in position in the piston. If the original piston is to be installed again, make sure that the mark on the piston is aligned with the mark on the connecting rod as shown in Figure 52. Make sure that the piston and connecting rod are installed in the same cylinder again. 4. If a new piston or connecting rod is being installed, make sure that index slot in the connecting rod for the rod bearing is on the same side of the piston as the boss for the piston pin. See Figure 55.

1. CONNECTING ROD Figure 54. Rod Bearings Position If the grade letter or color on the side of the connecting rod cannot be seen, the length can be checked by the measurement of the dimension (x) shown in Figure 54. Before the length of the connecting rod is measured, check that the bores of the big end and the small end are square and parallel, see Figure 53. The length is checked with the big end bearing removed and the original small end bush fitted. The dimensions for each grade are listed in the table below. Length Letter

Color Code

Length

Red

165.728 to 165.761 mm

Orange

165.682 to 165.715 mm

White

165.637 to 165.670 mm

Green

165.591 to 165.624 mm

Purple

165.545 to 165.578 mm

Blue

165.499 to 165.532 mm

1. INDEX SLOT FOR BEARING

2. IBOSS FOR PISTON PIN

Figure 55. Piston and Connecting Rod Orientation 5. Install the piston pin to fasten the connecting rod to the piston. If the piston pin is tight, heat the piston to 40 to 50 C (104 to 122 F) to make installation of the piston pin easier. 6. Install the other snap ring to hold the piston pin in the piston. 7. Install the piston rings as described under Piston Rings, Install.

PISTON COOLING JETS Install 1. Make sure that the parts are clean. Lubricate the parts with engine oil as they are assembled. 2. Install a new snap ring into one of the grooves to hold the piston pin.

Remove Release the valve assembly and remove the piston cooling jet. The crankshaft has been removed in Figure 56 to show the piston cooling jet. The AR engines have only one cooling jet and it is installed in the number one cylinder.

Crankshaft Assembly Repair

600 SRM 705 fit into the nozzle of the cooling jet. See Figure 57 and Figure 58 for checking the alignment of the cooling jet.

1. ALIGNMENT DOWEL Figure 56. Piston Cooling Jet Figure 57. Piston Cooling Jet Alignment, Engines YG and YH

Install 1. Check that the ball assembly moves freely against the spring pressure in the valve assembly and that the jet tube is not damaged. Replace any damaged or worn parts. 2. Install the cooling jet. Make sure that the assembly is installed correctly on the alignment dowel in the cylinder block. Tighten the valve assembly to 20 Nâ&#x20AC;˘m (15 lbf ft). 3. Check the alignment of the cooling jet. Insert a 1.70 mm (0.067 in.) rod into the nozzle of the cooling jet. The length of the rod must extend out of the top of the cylinder. If a rod of the correct diameter is not available, grind one end of a thicker rod to the 1.70 mm (0.067 in.) diameter for a length of 16.00 mm (0.630 in.) so that it will

Figure 58. Piston Cooling Jet Alignment, Engine AR

Crankshaft Assembly Repair GENERAL The crankshaft is forged from chrome-molybdenum steel. The four-cylinder engines have five main journals and the six-cylinder engines have seven main journals. The center main bearing is the thrust bearing that controls the axial movement of the crankshaft. The thrust bearing has thrust washers on both sides of the bearing. The main bearings are an alloy of tin and aluminum. The center main bearing in the six-cylinder engines is a lead and bronze alloy. The

main bearing caps are made of cast iron or spheroidal graphite (SG) iron. The front and rear oils seals are lip seals with an additional dust seal outside of the main lip and oil return grooves on the face of the main lip. ENGINE AR. The crankshaft pulley, usually fitted without a damper is held in position by a plain thrust block and three setscrews. The nose of the crankshaft is serrated for location. See Figure 59.

600 SRM 705

Crankshaft Assembly Repair of the chassis or frame. The purpose of the balancer unit is to reduce the effect of the out-of-balance forces.

CRANKSHAFT PULLEY Engine AR, Remove 1. Remove the drive belts. 2. Remove the three capscrews which hold the pulley to the crankshaft. See Figure 59. Remove the thrust block and pulley.

1. THRUST BLOCK 2. CAPSCREWS

3. CRANKSHAFT PULLEY

3. Clean the parts and check for damage. Replace any damaged parts.

Engines YG and YH, Remove Figure 59. Crankshaft Pulley Arrangement, Engine AR ENGINES YG and YH. The location of the front pulley is by a key in the crankshaft nose and the pulley is held in position by a tapered rings arrangement. See Figure 60.

1. CRANKSHAFT PULLEY

1. Remove the drive belts. 2. Remove the three capscrews which hold the pulley to the crankshaft. See Figure 61. Remove the thrust block. If the crankshaft pulley will not slide from the crankshaft, DO NOT use a puller to remove the pulley. Hold a wood block against the inner hub of the pulley and lightly hit the wood block with a hammer. See Figure 62. This action will loosen the inner ring and outer ring so that the pulley can be removed from the crankshaft as shown in Figure 61.

2. VISCOUS DAMPER 3. TAPERED RING

Figure 60. Crankshaft Pulley Arrangement, Engines YG and YH An integral damper, with a rubber insert is built into the pulley of six-cylinder engines and some four-cylinder engines. Six-cylinder engines have a viscous damper which is fastened to the front or rear face of the pulley. See Figure 60. All dampers are designed for the suppression of torsional vibrations in the engine crankshaft.

1. SPACER RING 2. INNER RING 3. OUTER RING

4. THRUST BLOCK 5. O-RING

Figure 61. Crankshaft Pulley Arrangement, Engines YG and YH

A balancer unit is fitted to certain four-cylinder engines which have rigid mountings or which are part

Crankshaft Assembly Repair

600 SRM 705

CAUTION Do not use excessive force to lever the damper away from the engine. 3. Remove any paint or dirt in four positions 90 apart on the face of the damper, above the rubber insert. See Figure 63. Use a lever to move the damper forward and eliminate the crankshaft end-float. Fit a dial test indicator on the front cover of the timing case. Measure the alignment of the damper face at four locations, 90 apart. The maximum permissible difference between the maximum and minimum figures obtained is 0.18 mm (0.007 in.). Figure 62. Crankshaft Pulley Installation, Engines YG and YH 3. If a separate damper is connected to the crankshaft pulley, remove the capscrews and remove the damper.

Inspect 1. When an integral pulley and damper is fitted, the assembly should be replaced if (see Figure 63): • The rubber insert between the hub and the outer ring is split. • The rubber insert is damaged by oil or solvents. • There is movement of the pulley or outer ring on the hub.

4. Remove any paint or dirt from the circumference of the damper. Fit a dial test indicator on the front cover of the timing case. 5. Rotate the crankshaft slowly one complete revolution and measure for run-out on the circumference of the damper with the dial test indicator. The maximum permissible difference between the maximum and minimum figures obtained in 0.12 mm (0.005 in.). 6. If the alignment or the run-out is in excess of the permissible limit, renew the pulley. 7. A viscous damper must be renewed if there is impact damage to the outer casing or if there is leakage of the viscous fluid from the cover plate. See Figure 60. Check the area around the holes for the damper fasteners for damage.

Engine AR, Install 1. Put the pulley into position on the crankshaft. See Figure 59. Lubricate lightly the threads of the three capscrews. Install the thrust block and the three capscrews. Tighten the three capscrews evenly to 115 N•m (85 lbf ft). Check each capscrew again for the correct torque. 2. Install the drive belts. See Drive Belts. 1. RUBBER INSERT

2. PULLEY

Figure 63. Crankshaft Pulley 2. Check the area around the holes for the damper fasteners for cracks or wear.

Engines YG and YH, Install 1. If your engine has a separate damper that is connected to the crankshaft pulley and it was removed, install it on the crankshaft pulley. If a viscous damper is used, install the damper in position on the face of the pulley. Install the clamp ring or the washers and tighten the capscrews gradually and evenly to 35 N•m (26 lbf ft). If

600 SRM 705 M12 capscrews are used, tighten them to 75 N•m (55 lbf ft). 2. Clean the end of the crankshaft and the parts of the crankshaft pulley. Do not use a degreasing solution. See Figure 61. Do not make any changes to the inner ring or the outer ring. 3. Put the crankshaft pulley on the crankshaft so that the key is engaged. Push the pulley onto the crankshaft. NOTE: If the rings are not installed correctly, the crankshaft pulley will be very difficult to remove again. 4. Install the spacer ring, inner ring, and the outer ring in the correct order. 5. Lightly lubricate the O-ring and the thrust faces of the capscrews with engine oil. Put the thrust block and the capscrews in position.

Crankshaft Assembly Repair the housing. The spring in the seal goes toward the housing. The installation tool has two sides and will install the oil seal in the housing in either position 1 or position 2. 8. There are three positions in which the oil seal can be installed in the seal housing. See Figure 64. • Position "1" is used when a new seal is first fitted in service. • Position "2" is used when a new seal is fitted in service and the crankshaft flange is worn in position "1". • Position "3" can be used with a new seal in service, if a wet clutch is not used and the crankshaft is new or the crankshaft palm area has been corrected. Check that the seal is fitted square in the housing. If all positions have been used, the crankshaft must have a new surface ground on the crankshaft flange. See the Engine Specifications for the size limits.

6. Gradually and evenly tighten the capscrews to push the crankshaft pulley on the crankshaft. Tighten the capscrews to 115 N•m (85 lbf ft). 7. Install the drive belts. See Drive Belts.

REAR OIL SEAL Replace Special Tools: Replacement tool for oil seal. 1. Remove the drive components from the rear of the engine. Figure 64. Oil Seal Positions 2. Remove the flywheel and housing. See Flywheel, Remove. 3. Remove the capscrews and remove the seal housing and seal assembly. Clean the parts. 4. Inspect the oil seal for wear and damage. If there is any question about the condition of the oil seal, replace the oil seal. 5. Check that the oil seal area and outer circumference of the crankshaft flange are not worn or damaged. 6. Press the oil seal from the housing. 7. Lubricate the oil seal with engine oil and carefully press the oil seal into one of the positions in

9. Make sure that the two position dowels are installed in the engine block. Use a new gasket. Do not use gasket compound on any of the surfaces. 10. Make sure the lip of the seal is lubricated with engine oil where it touches the crankshaft flange. This lubrication of the oil seal is necessary to prevent damage to the oil seal when the engine is first started. 11. Install a new gasket on the seal housing. Put the oil seal and housing on the seal guide. Carefully push the oil seal assembly into position on the crankshaft flange and onto the dowels. See Figure 65.

Crankshaft Assembly Repair

600 SRM 705 The front main bearing can be difficult to replace when the timing case is on the engine. The oil pump is installed on the front bearing cap. A special wrench can be required to apply the correct torque to the capscrews for removal and installation. If a wrench is not available to install the capscrews on the main bearing cap, the timing case must be removed. The oil pump will be removed with the cap for the front main bearing. The suction pipe, oil strainer, delivery pipe, and relief valve must be removed.

Remove 1. Drain the engine oil and remove the oil sump. 1. SEAL GUIDE 2. OIL SEAL AND HOUSING

3. GASKET 4. DOWEL (2)

Figure 65. Oil Seal Installation 12. Remove the seal guide. Install the capscrews. See Figure 66. Tighten the capscrews and the two special capscrews to 22 Nâ&#x20AC;˘m (16 lbf ft).

2. Remove the necessary components for access to the bearing cap for the bearing that must be replaced. 3. Remove the capscrews and remove the bearing cap. Remove the lower half of the bearing from the bearing cap. 4. Use a thin flexible tool to push on the side of the upper bearing half that is opposite from the location tab. Push on the bearing half so that it begins to rotate out of the engine block. Carefully rotate crankshaft so that bearing will rotate out of the engine block. 5. Check that the bearing journal on the crankshaft is clean and in good condition. See Figure 67.

1. SPECIAL CAPSCREWS Figure 66. Oil Seal Installation

MAIN BEARINGS NOTE: The following procedure is for replacement of the main bearings without removing the crankshaft from the engine. If the rear main bearing must be replaced, the flywheel, flywheel housing, rear oil seal housing, and bridge piece must be removed.

1. BEARING REMOVAL TOOL

2. LOCATION SLOTS 3. BEARING GROOVE

Figure 67. Main Bearing Removal

600 SRM 705

Crankshaft Assembly Repair

Inspect Inspect the bearings for wear and other damage. If a bearing is worn or damaged, replace both halves of the shell bearings and check the condition of the other bearings.

Install NOTE: Only the upper half of the bearing has lubrication holes and it must be installed into the engine block. 1. Lubricate the upper bearing half with engine oil. Install the plain end of the bearing between the crankshaft journal and the side of the bearing housing that has the location slot. Carefully slide the bearing half into the bearing housing until the location tab fits into the location slot. 2. Lubricate the lower bearing half with engine oil and install it into the bearing cap. Make sure the location tab is installed correctly into the location slot. 3. Make sure that the location thimbles are installed in either the bearing cap or the bearing housing of the engine block. Make sure that the orientation of the location slots for the bearing halves are correct as shown in Figure 68. Install the bearing cap. 4. Make sure the capscrews are in good condition. Install the capscrews into the bearing cap. Tighten the capscrews gradually and evenly. Tighten the capscrews to a final torque of 265 Nâ&#x20AC;˘m (195 lbf ft).

1. LOCATION SLOTS FOR MAIN BEARING HALVES Figure 68. Main Bearing Cap Orientation

THRUST WASHERS Crankshaft Axial Movement, Check The axial movement of the crankshaft is controlled by two half thrust washers installed on each side of the center main bearing. See Figure 69. The axial clearance can be checked with a spacer gauge inserted between the crankshaft and the thrust washer. See Figure 70. A dial indicator can be used to check the axial movement from the end of the crankshaft as shown in Figure 71. The normal axial movement is 0.05 to 0.38 mm (0.002 to 0.015 in.). The maximum axial movement permitted is 0.51 mm (0.020 in.).

5. Make sure that the crankshaft rotates freely. If the thrust washers have been removed and installed again, the axial movement of the crankshaft must be checked. See Thrust Washers in the following paragraphs. 6. Install the components that were removed for access to the main bearing. 7. Install the oil sump.

Figure 69. Thrust Washers

Crankshaft Assembly Repair

600 SRM 705 3. Remove the capscrews for the center main bearing cap. Remove the bearing cap, lower bearing half, and the lower halves of the thrust washers. 4. Use a thin flexible tool to push the upper halves of the thrust washers from their positions next to the main bearing housing. See Figure 72. Use a small pry bar as necessary to move the crankshaft to loosen a tight thrust washer.

Figure 70. Axial Clearance Measurement With Spacer Gauge

Figure 72. Thrust Washer Upper Half Removal

Install 1. Lubricate the thrust washers with engine oil. Slide the upper halves of the thrust washers into their positions in the engine block. Make sure that the sides of the thrust washers with the grooves are against the crankshaft. Figure 71. Axial Movement Measurement With Dial Indicator If the axial movement is greater than the specifications, oversize thrust washers can be installed on one side or both sides of the main bearing. The oversize thrust washers are 0.019 mm (0.00075 in.) larger than the standard thrust washers.

2. Install the lower halves of the thrust washers into the main bearing cap. Make sure that the location tabs are in their correct positions. 3. Make sure that the location thimbles are installed in either the bearing cap or the bearing housing of the engine block. Make sure that the orientation of the location slots for the bearing halves are correct as shown in Figure 68. Lubricate the bearing and thrust washers with engine oil. Install the bearing cap. 4. Inspect the capscrews, reuse if in good condition. Install the capscrews into the bearing cap. Tighten the capscrews gradually and evenly. Tighten the capscrews to a final torque of 265 Nâ&#x20AC;˘m (195 lbf ft). 5. Make sure that the crankshaft rotates freely. Check the axial movement of the crankshaft to make sure that it is within the specifications.

600 SRM 705 6. Loosely assemble the bracket of the suction line to the main bearing cap. Install a new gasket and fasten the flanges of the suction line to the oil pump. Make sure that the suction line is aligned correctly and tighten the capscrew that holds the bracket to the main bearing cap. 7. Install the oil sump. See Oil Sump, Install.

CRANKSHAFT Remove 1. Remove the engine from the lift truck. See the Frame section. See the Transmission section for separating the engine from the transmission. 2. Remove the oil sump. See Oil Sump, Remove. 3. Remove the fan, drive belts, fan drive pulley and housing, and the coolant pump. 4. Remove the crankshaft pulley. See Crankshaft Pulley. 5. Remove the alternator and its mount bracket. 6. Remove the timing case cover. See Timing Case Cover, Remove.

Crankshaft Assembly Repair crankcase. Some engines have rubber seals and other engines have sealant. 13. Remove the bearing caps and lower bearing halves from the connecting rods. Make an arrangement so that the parts for each connecting rod will be assembled again in their original positions. Carefully push the pistons into their bores a small amount so that the connecting rods are separated from the crankshaft.

CAUTION Make sure the cooling jets for the pistons are not damaged or moved out of alignment. If a cooling jet is hit, the alignment must be checked and the cooling jet replaced if necessary. 14. Make sure that the main bearing caps are marked with their position number. Remove the main bearing caps, lower bearing halves, and the upper and lower thrust washers. Keep all the parts in an arrangement so that the parts can be installed in their original positions. 15. Lift the crankshaft from the cylinder block. Remove the upper bearing halves and put each of them with their lower bearing half.

7. Remove the fuel injection pump. See Fuel Injection Pump, Remove.

Inspect

8. Remove the timing gears and the timing case. See the section Timing Case and Timing Gears Repair.

Check the crankshaft for wear and other damage. The maximum wear and out-of-round on the bearing journals is 0.04 mm (0.0016 in.).

9. Remove the flywheel and the flywheel housing. See Flywheel, Remove.

The bearing journals on standard crankshafts can be ground to the following diameters smaller than the original size: 0.25 mm (0.010 in.) 0.50 mm (0.020 in.) 0.75 mm (0.030 in.)

10. Remove the rear oil seal housing. See Rear Oil Seal, Replace. 11. If the engine is not already in a position with the crankshaft facing up, turn the engine to that position. Remove the suction pipe and oil strainer. See Figure 40. Remove the capscrew that holds the bracket to the main bearing cap. Remove the two capscrews from the flange of the suction pipe and remove the suction pipe and screen. Clean the faces of both flanges. Remove the oil pump, delivery tube, and relief valve. See Oil Pump and Relief Valve. 12. Remove the bridge piece over the rear main bearing. Make a note if there is a round rubber seal at each end of the bridge piece where it joins the

Special bearings are available for these sizes. The crankshaft must be replaced if the surface must be ground more than 0.75 mm (0.030 in.). The area on the crankshaft flange for the rear oil seal can be machined to remove wear marks if the oil seal has been used in all three positions. See the Engine Specifications. The minimum diameter of this area is 133.27 mm (5.247 in.).

Install 1. Make sure that all of the oil passages are clean.

Crankshaft Assembly Repair

600 SRM 705

2. Make sure all of the bearings and bearing caps are clean. Install the upper bearing halves into their positions in the connecting rods and the housings for the main bearings. Make sure that the position tags of the bearings fit into their position slots. Lubricate the bearings with engine oil. 3. Install the crankshaft in position on the main bearings. 4. Lubricate the thrust washers with engine oil. Slide the upper halves of the thrust washers into their positions in the engine block. Make sure that the sides of the thrust washers with the grooves are against the crankshaft. 5. Install the lower halves of the thrust washers into the main bearing cap. Make sure that the location tags are in their correct positions. 6. Make sure that the location thimbles are installed in either the bearing cap or the bearing housing of the engine block. Make sure that the orientation of the location slots for the bearing halves are correct as shown in Figure 68. Lubricate the bearing and thrust washers with engine oil. Install the bearing cap. 7. Make sure the main bearing caps are installed according to their position numbers shown on the cap. The serial numbers on the main bearing caps will also be in alignment. The serial number on the main bearing caps must be the same as the number on the bottom face of the engine block. (The third and fifth bearing caps on six-cylinder engines are not marked with a serial number.)

1. LOWER GROOVE

2. UPPER GROOVE

Figure 73. Bridge Piece and Sealant NOTE: Many engines have capscrews instead of the two studs shown in the bridge piece in Figure 74. These capscrews fasten the oil sump to the bridge piece. Use sealant on the threads of either the studs or the capscrews. 10. Use a straightedge to make sure the bridge piece is aligned with the rear face of the engine block. See Figure 74. Tighten the capscrews to 16 N•m (12 lbf ft).

8. Inspect the capscrews, reuse if in good condition. Install the capscrews into the main bearing cap. Tighten the capscrews gradually and evenly. Tighten the capscrews to a final torque of 265 N•m (195 lbf ft). Repeat this step for all five main bearings. 9. When the bridge piece is put into position, inject liquid gasket sealant (Loctite® 5900) into the upper groove at each end of the bridge piece. See Figure 73. Inject the sealant until the upper groove is full and the sealant leaves the lower groove at the front and rear of the bridge piece. Make sure all of the grooves are completely full of sealant.

Figure 74. Bridge Piece Alignment 11. Install the connecting rods to the crankshaft. See Rod Bearings, Install. Install the upper bearing half into the connecting rod. Make sure that the location tab is installed correctly into its position in the connecting rod. See Figure 41. Make sure that the assembly number on the bearing cap is the same as the number on the connecting rod. Make sure that the two assembly numbers are

600 SRM 705

Crankshaft Assembly Repair

on the same side of the connecting rod as shown in Figure 42.

control the flywheel when the other capscrews are removed.

12. Connecting rods with nuts. Install and tighten the nuts evenly to a torque of 125 N•m (92 lbf ft). Make sure that the crankshaft turns freely. Connecting rods with capscrews. Install and tighten the capscrews evenly to a torque of 155 N•m (114 lbf ft). Make sure that the crankshaft turns freely.

2. Remove the other capscrews that fasten the flywheel to the crankshaft. Remove the flywheel.

13. Install the oil pump, delivery pipe, and relief valve. Loosely assemble the bracket of the suction pipe to the main bearing cap. Install a new gasket and fasten the flanges of the suction line to the oil pump. Make sure that the suction pipe is aligned correctly and tighten the capscrew that holds the bracket to the main bearing cap.

3. Check the flywheel and ring gear for damage.

Ring Gear, Replace WARNING Wear eye protection for this operation to prevent eye injury from metal chips. You will be using a hammer and chisel to break the ring gear. 1. Before the ring gear is removed, check the position of the chamfer on the teeth.

14. Install the rear oil seal housing. See Rear Oil Seal, Replace.

2. Use a hammer and chisel to break the ring gear. Make sure that you do not damage the flywheel.

15. Install the flywheel and the flywheel housing. See Flywheel, Install.

3. The ring gear must be heated before it can be installed on the flywheel. Use an oven that has a temperature control. Make sure that the ring gear is not heated to more than 250 C (482 F).

16. Install the timing gears and the timing case. See Timing Case and Timing Gears Repair. 17. Install the fuel injection pump. See Fuel Injection Pump, Install.

4. Make sure that the chamfer on the ring gear teeth is in the correct direction. Install the ring gear on the flywheel.

18. Install the timing case cover. See Timing Case Cover, Install.

Install

19. Install the alternator and its mount bracket. 20. Install the crankshaft pulley. See Crankshaft Pulley. 21. Install the coolant pump, fan drive pulley and fan housing, drive belts, and the fan. 22. Install the oil sump. See Oil Sump, Install. 23. Install the engine into the lift truck. See the Frame section and the Transmission section for the lift truck.

FLYWHEEL The steel flywheel has a hardened steel starter ring. The starter ring has 126 teeth.

Remove 1. Remove two opposite capscrews from the flywheel and temporarily install two studs to help

1. Make sure the surfaces of the crankshaft and flywheel are clean so that the two parts will fit together correctly. 2. Install the flywheel over the guide studs. Install four capscrews. Remove the two studs and install the remainder of the capscrews. Tighten the capscrews in a cross pattern to 105 N•m (77 lbf ft). 3. Check the flywheel run-out with a dial test indicator. See Figure 75. This must be less than 0.30 mm (0.012 in.) total indicator reading. 4. Check the alignment of the flywheel face. See Figure 76. The error in alignment must not be more than 0.003 mm (0.0001 in.) total indicator reading for every 25 mm (1.0 in.) of the flywheel radius from the crankshaft axis to the indicator plunger. During this check, keep the crankshaft pressed toward the front to remove the effect of crankshaft end-float.

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600 SRM 705

Install 1. Ensure that the rear face of the cylinder block and the faces of the housing are clean and free from damage. Ensure that the location dowels are fitted correctly. If a felt seal is installed to the rear flange of the sump, replace the seal. 2. Fit the housing onto the dowels and tighten lightly the setscrews.

Figure 75. Flywheel Run-Out Check

Figure 76. Flywheel Face Alignment

FLYWHEEL HOUSING Remove WARNING The flywheel housing is heavy, use lift equipment or get help to assist with the lift operation before removal of the flywheel housing fasteners. 1. Remove the starter. 2. Release the housing setscrews and with a soft face hammer, hit carefully the housing to remove it from the dowels.

3. Check the housing concentricity with a dial test indicator. See Figure 77. The run-out limit is given in the data and dimensions. If any adjustment is necessary, it must be made on the housing and the concentricity checked again.

Figure 77. Flywheel Housing Concentricity Check 4. Tighten the setscrews to the torque recommended in the Special Torque Specifications. 5. Check the housing alignment. See Figure 78. The maximum tolerance is given in the data and dimensions. Any necessary adjustment must be made on the housing and not on the cylinder block. 6. Install the flywheel and the starter motor.

600 SRM 705

Timing Case and Timing Gears Repair

Figure 78. Flywheel Housing Alignment Check

Timing Case and Timing Gears Repair GENERAL The timing case can be either cast aluminum or cast iron. The timing gears are steel. The gear train includes the crankshaft gear, idler gear, gear for the fuel injection pump, camshaft gear, and PTO gear. The timing case cover is aluminum and has the front oil seal for the crankshaft. The timing case cover has a noise shield on its front surface. See Description for additional information on timing gears and engine timing. The camshaft is made from cast iron. The lobes on the camshaft for the fuel pump are hardened.

TIMING CASE COVER Remove 1. Drain the coolant. Remove the fan. See Figure 79. 2. Remove the drive belts and alternator. 3. Remove the crankshaft pulley. See Crankshaft Pulley. 4. Remove the fan drive pulley if additional clearance is needed. 5. Remove the coolant pump. See Coolant Pump, Remove.

1. CAPSCREW 2. CYLINDER BLOCK 3. STUD

4. GASKET 5. TIMING CASE COVER

Figure 79. Timing Case Cover

Timing Case and Timing Gears Repair 6. Remove the capscrews and nuts that hold the timing case cover to the timing case. Remove the timing case cover and the sound shield.

Install Special Tools:

600 SRM 705 5. Install the fan drive pulley if it was removed. 6. Install the alternator and drive belts and adjust the tension. See Drive Belts. 7. Install the fan. Fill the cooling system.

Alignment tool, front oil seal

1. Use a new gasket and install the timing case cover on the timing case. See Figure 79. Use two capscrews to hold the timing case cover in position. Install the special tool on the crankshaft. Use the special washer and the capscrews for the crankshaft pulley to hold the alignment tool in position. The purpose of the special tool is to make sure that the front oil seal evenly fits the circumference of the seal surface of the crankshaft pulley. See Figure 80.

FRONT OIL SEAL Remove 1. Remove the fan and drive belts. 2. Remove the crankshaft pulley. 3. Use a pry bar to remove the front oil seal from the timing gear cover. Put the pry bar behind the main lip of the front oil seal. Make sure that the edge of the housing for the oil seal is not damaged during removal.

Install Special Tools:

Installation tool for front oil seal Pressure plate Fastener plate Sleeve Seal adapter

NOTE: The front oil seal is normally installed to a depth of 9.3 mm (0.366 in.) from the front face of the oil seal housing to the flat front face of the oil seal. If the crankshaft pulley is worn at this location, a wear sleeve can be installed. See Figure 82. Figure 80. Front Oil Seal Alignment Tool

CAUTION The correct alignment of the timing case cover is important and must be done carefully. The front oil seal can leak and the gears for the coolant pump can fail if the alignment is not correct. 2. When the timing case cover is aligned with the crankshaft, install the capscrews and nuts in the timing case cover. Tighten the capscrews and nuts to 22 Nâ&#x20AC;˘m (16 lbf ft). Remove the alignment tool. 3. Install the coolant pump. See Coolant Pump, Install. 4. Install crankshaft pulley. See Crankshaft Pulley.

1. Clean the oil seal housing. Inspect the oil seal for damage. Do not install a front oil seal that has a scratch or any damage on the lip of the seal. 2. Lubricate the outer circumference of the oil seal with engine oil and install the front oil seal into the oil seal housing. Make sure that the lip of the seal is toward the inside of the cover for the timing gear case and the front oil seal is parallel to the bore of the oil seal housing. 3. Put the replacement tool for the front oil seal on the crankshaft as shown in Figure 81. Use the fastener plate to fasten the installation tool to the crankshaft. Install the seal adapter so that the 10.5 mm mark is toward the front oil seal. Put the sleeve and the pressure plate into position and fasten it to the stud of the fastener plate as shown in Figure 81.

600 SRM 705

Timing Case and Timing Gears Repair A new front oil seal must be used when a wear sleeve is fitted. The dimension, to press the new oil seal into the timing case, with or without a wear sleeve fitted, is 9.3 mm (0.366 in.), from the front face of the timing case. 3. Install the crankshaft pulley. See Crankshaft Pulley, Installation.

1. REPLACEMENT TOOL FOR FRONT OIL SEAL 2. PRESSURE PLATE

3. FASTENER PLATE 4. SLEEVE 5. SEAL ADAPTER

Figure 81. Front Oil Seal Installation 4. Install a rod through the hole in the end of the tool so that the tool will not turn. Turn the nut on the pressure plate with a wrench and the front oil seal will be pushed into the housing. Push the seal into the correct depth. Remove the installation tool.

1. SPIGOT 2. WEAR SLEEVE

3. FLANGE 4. OIL SEAL

Figure 82. Crankshaft Pulley Wear Sleeve

5. Lubricate the seal area of the crankshaft pulley with engine oil. Install the crankshaft pulley. See Crankshaft Pulley.

IDLER GEAR AND HUB

6. Install the drive belts and adjust the belt tension.

Remove

7. Install the fan.

1. Remove the timing case cover. See Timing Case Cover, Remove.

CRANKSHAFT PULLEY WEAR SLEEVE Install To renew a worn crankshaft pulley, a wear sleeve is fitted over the spigot. See Figure 82. 1. Remove the crankshaft pulley. See Crankshaft Pulley, Removal. NOTE: Full instructions and a special tool to install the wear sleeve are in each service kit. 2. Install the wear sleeve, in accordance with the manufacturerâ&#x20AC;&#x2122;s instructions. It is not necessary to remove the flange of the wear sleeve after it has been fitted.

2. Turn the crankshaft until the marked teeth of the crankshaft gear, the camshaft gear, and the gear for the fuel injection pump are aligned as shown in Figure 83. The marked teeth on the idler gear will not necessarily be aligned with the marked teeth of the other three gears because of the different speed of rotation of the idler gear.

CAUTION Make sure that the crankshaft is not turned while the idler gear is removed. A piston can hit and damage a valve. The valve timing and the fuel injection pump timing will be lost if the crankshaft is turned. 3. Remove the three capscrews, remove the plate of the idler gear, and remove the idler gear. See

Timing Case and Timing Gears Repair

600 SRM 705

Figure 84. Make a note of the position of the oil hole. The gear for the fuel injection pump will turn a small amount in the counterclockwise direction as the teeth become disengaged from the idler gear.

available, grind one of the faces from the bushings and use a press to remove them from the idler gear. Use a press to install new bushings. The bores and faces of the bushings will need machining to correctly fit the hub. See the Engine Specifications, Idler Gear and Hub for the measurements. 6. For engines that use the idler gear assembly with needle roller bearings - remove the three capscrews, remove the plate of the idler gear. Remove the front thrust washer, the front spacer, and the gear. Remove the two needle roller bearings. If these are to be used again, they should be fitted in their original positions. Remove the rear thrust washer and the rear spacer. Remove the hub. See Figure 85.

1. CAMSHAFT GEAR 2. CRANKSHAFT GEAR 3. IDLER GEAR

4. GEAR FOR FUEL INJECTION PUMP 5. PTO GEAR

Figure 83. Timing Marks Alignment

1. 2. 3. 4. 5.

PLATE THRUST WASHER FRONT SPACER IDLER GEAR NEEDLE BEARINGS

6. REAR THRUST WASHER 7. REAR SPACER 8. HUB

Figure 85. Idler Gear with Needle Bearings Components

Install

1. 2. 3. 4. 5.

PLATE THRUST WASHER IDLER GEAR TIMING MARKS HUB

6. OIL HOLE 7. REAR THRUST WASHER 8. CAPSCREW

Figure 84. Idler Gear Components 4. Inspect the idler gear and bushings for wear and damage. The idler gear and bushings are available as an assembly or as separate parts. 5. If the bushings must be replaced, use a puller to remove them from the idler gear. If a puller is not

1. Use the three capscrews for the idler gear to make sure that the hub for the idler gear is in the correct position with the lubrication hole at the top. 2. Lubricate the bushings in the idler gear with engine oil. Align the timing marks on the idler gear with the marks on the crankshaft gear and the camshaft gear. Turn the gear for the fuel injection pump clockwise as necessary to align the timing marks when the teeth of the idler gear engage the other gears. Make sure all of the alignment marks are aligned as shown in Figure 83.

600 SRM 705

Timing Case and Timing Gears Repair

3. Install the plate for the idler gear and the three capscrews. Tighten the capscrews to 44 Nâ&#x20AC;˘m (32 lbf ft).

7. Install the timing case cover, coolant pump, crankshaft pulley, fan drive pulley, drive belts, and fan. See Timing Case Cover, Install.

4. Check the clearance between the bushings of the idler gear and the plate of the idler gear. The correct clearance is 0.10 to 0.20 mm (0.004 to 0.008 in.). A maximum service limit is 0.38 mm (0.015 in.). See Figure 86.

AIR COMPRESSOR DRIVE, BENDIX Disassemble CAUTION Do not turn the engine crankshaft nor the crankshaft for the air compressor. If either crankshafts are moved, the air compressor must be timed to the engine. 1. Set the number one piston to TDC as described in the Engine Timing section. 2. Remove the timing case cover as described in Timing Case Cover, Remove. 3. Remove the three capscrews shown. See Figure 87. Remove the cover plate. Remove the idler gear and the needle bearings from the idler hub.

Figure 86. Idler Gear Hub Clearance Check 5. For engines that use the idler gear assembly with needle roller bearings - inspect the components for wear and other damage and replace them as necessary. Lightly lubricate the components with clean lubricating oil before assembly onto the hub. See Figure 84. Position the idler gear hub with the lubrication hole to the top. See Figure 85. Put the rear spacer in position on the hub. Put the rear thrust washer in position on the rear spacer. Put bearings in position on the hub in the same position as they were removed. Lightly lubricate the bore and thrust washer faces of the gear with clean lubricating oil and put the gear in position on the bearings. Put the front spacer in position on the hub then put the front thrust washer in position on the spacer. Put the plate in position. The plate has TOP stamped on the front face as the holes in the plate are not equally spaced. Fit the setscrews and tighten them to 44 Nâ&#x20AC;˘m (33 lbf ft). 6. Check the timing gear clearances as shown in Figure 89. The minimum clearances for all gears is 0.08 mm (0.003 in.).

1. 2. 3. 4.

O-RING CAPSCREW BRACKET DRIVE GEAR, AIR COMPRESSOR 5. TIMING CASE 6. COVER, TIMING CASE

7. 8. 9. 10. 11. 12.

NEEDLE BEARING CAPSCREW (3) IDLER HUB COVER PLATE IDLER GEAR ENGINE IDLER GEAR

Figure 87. Bendix Compressor Drive 4. Remove the three capscrews which fasten the idler hub to the bracket. Remove the idler gear hub. See Figure 88.

Timing Case and Timing Gears Repair

1. TIMING CASE 2. BRACKET, IDLER HUB

3. CAPSCREWS (3) 4. CAPSCREWS (4) 5. IDLER GEAR

Figure 88. Bendix Compressor Drive 5. Remove and discard the O-ring. See Figure 87. 6. Inspect the parts for wear or damage.

Assemble 1. Install the O-ring. See Figure 87. 2. Check that the four capscrews which fasten the idler hub bracket (4) to the timing case are tightened to 35 N•m (26 lbf ft). See Figure 88.

600 SRM 705

Figure 89. Timing Gear Clearances Check 7. Install the timing case cover as described in Timing Case Cover, Install.

FUEL INJECTION PUMP GEAR The fuel injection pump has a timing plate fastened to the front face of the gear for the fuel injection pump. See Figure 90. This timing plate is installed by the manufacturer after the fuel injection timing has been accurately set to TDC, number one cylinder on the compression stroke. The timing plate is fastened by two M5 special capscrews.

3. Install the hub into the timing case. See Figure 87 and Figure 88. Install the three capscrews and tighten them to 60 N•m (44 lbf ft). Install the needle bearing assembly on the hub. 4. Lubricate the bore of the idler gear with clean engine oil and install the idler gear on the needle bearings. See Figure 87. Install the cover plate and tighten three capscrews to 22 N•m (16 lbf ft). 5. Check the clearance between the bushings of the idler gear and the plate of the idler gear. The correct clearance is 0.10 to 0.20 mm (0.004 to 0.008 in.). A maximum service limit is 0.38 mm (0.015 in.). See Figure 86. 6. Check the timing gear clearances as shown in Figure 89. The minimum clearance is 0.08 mm (0.003 in.).

1. M5 SPECIAL CAPSCREWS

2. TIMING PLATE 3. CAPSCREWS (4)

Figure 90. Fuel Injection Pump Gear Removal

600 SRM 705

Timing Case and Timing Gears Repair

Remove CAUTION Do not loosen the two M5 special capscrews. If this timing plate is moved, the fuel injection pump must be timed again. Do not loosen nor remove the large nut from the shaft of the fuel injection pump. The hub is permanently fastened to the shaft. If the hub is removed, special equipment and special training is required to correctly install the hub again. Special Tools:

Lucas fuel injection pump timing pin

1. Remove the timing case cover. See Timing Case Cover, Remove.

CAUTION Make sure the shaft of the fuel injection pump is not locked. 2. Set the number one piston to TDC on the comTurn the crankshaft until pression stroke. the marked teeth of the crankshaft gear, the camshaft gear, and the gear for the fuel injection pump are aligned as shown in Figure 90. The marked teeth on the idler gear will not necessarily be aligned with the marked teeth of the other three gears because of the different speed of rotation of the idler gear.

1. TIMING PIN Figure 91. Fuel Injection Pump Gear Removal

Install CAUTION Make sure the shaft of the fuel injection pump is not locked. 1. The gear for the fuel injection pump can only be installed in one position. The letters C and M are toward the front of the engine. Make sure the number one piston is set to TDC on the compression stroke. 2. If the timing pin was removed during service, install it in the hole in the body of the fuel injection pump. See Figure 92. Leave the timing pin in position so that the gear for the fuel injection pump can be installed.

CAUTION DO NOT turn the crankshaft while removing the camshaft gear. A piston can hit and damage a valve. 3. Install the timing pin until the small end of the pin is pushed fully into the hole in the body of the fuel injection pump. See Figure 91. 4. Remove the four capscrews from the fuel pump gear and remove the gear from the hub. 5. Inspect the gear for wear and damage, replace if necessary.

1. GEAR FOR FUEL INJECTION PUMP

2. IDLER GEAR 3. TIMING PIN

Figure 92. Fuel Injection Pump Gear Installation 3. Install the gear for the fuel injection pump over the timing pin so that it engages correctly with the idler gear.

Timing Case and Timing Gears Repair

600 SRM 705

NOTE: If a new gear is installed, install the original timing plate onto the front face of the new gear. Install the two M5 special capscrews loosely and install the gear on the hub. If the gear and timing plate are installed correctly, the four threaded holes in the hub can be seen through the slots in the gear. 4. Install the four capscrews loosely in the centers of the slots of the gear. NOTE: If a new gear is installed, carefully rotate the gear counterclockwise to remove any clearance between the gear and the idler gear. See Figure 91. Do not rotate the crankshaft or it will be necessary to set TDC again. 5. Tighten the four capscrews to 28 Nâ&#x20AC;˘m (21 lbf ft). Remove the timing pin from the fuel injection pump. 6. If a new gear has been installed, check the clearance as shown in Figure 89.

1. CAMSHAFT GEAR 2. CRANKSHAFT GEAR 3. IDLER GEAR

4. GEAR FOR FUEL INJECTION PUMP 5. PTO GEAR

Figure 93. Timing Marks Alignment

7. Install the timing case cover, coolant pump, crankshaft pulley, fan drive pulley, drive belts, and fan. See Timing Case Cover, Install.

CAMSHAFT GEAR Remove Special Tools:

Gear puller with adapters

1. Remove the timing case cover. See Timing Case Cover, Remove. 2. Turn the crankshaft until the marked teeth of the crankshaft gear, the camshaft gear, and the gear for the fuel injection pump are aligned as shown in Figure 93. The marked teeth on the idler gear will not necessarily be aligned with the marked teeth of the other three gears because of the different speed of rotation of the idler gear.

CAUTION Make sure that the crankshaft is not turned while the camshaft gear is removed. A piston can hit and damage a valve. 3. Remove the capscrew and washer. Use a puller and adapter to pull the gear from the camshaft. Make sure that the Woodruff key in the camshaft is not lost. Inspect the camshaft gear for wear and damage. See Figure 94.

Figure 94. Camshaft Gear Removal

Install CAUTION If the crankshaft or the camshaft must be turned to permit the alignment of the marks on the timing gears, a piston can hit and damage a valve. The rocker arm assembly must be loosened so that the valves are closed when the crankshaft or the camshaft is turned. 1. Make sure that the Woodruff key is installed correctly in the end of the camshaft. 2. Remove the idler gear. See Idler Gear and Hub, Remove.

600 SRM 705 3. Install the camshaft gear on the shaft with the marked teeth toward the front and the keyway correctly aligned. Use a soft hammer to push the gear onto the camshaft. Make sure that the timing marks are aligned correctly as the gear teeth are engaged. See Figure 93. 4. Install the idler gear with the marked teeth correctly aligned. See Idler Gear and Hub, Install. If the camshaft has to be turned and a valve hits a piston, disengage the rocker assembly. 5. Install the capscrew and washer and tighten the capscrew to press the gear into position. Tighten the capscrew to 78 Nâ&#x20AC;˘m (58 lbf ft). 6. If new gears have been installed, check the timing gear clearances as shown in Figure 89. The minimum clearances for all gears is 0.08 mm (0.003 in.). 7. Install the timing case cover, coolant pump, crankshaft pulley, fan drive pulley, drive belts, and fan. See Timing Case Cover, Install.

CRANKSHAFT GEAR Remove 1. Remove the timing case cover. See Timing Case Cover, Remove. 2. Turn the crankshaft until the marked teeth of the crankshaft gear, the camshaft gear, and the gear for the fuel injection pump are aligned as shown in Figure 93. The marked teeth on the idler gear will not necessarily be aligned with the marked teeth of the other three gears because of the different speed of rotation of the idler gear.

CAUTION Make sure that the crankshaft is not turned while the idler gear or the crankshaft gear is removed. A piston can hit and damage a valve. 3. Remove the idler gear See Idler Gear and Hub, Remove. 4. The crankcase gear is pressed onto the crankshaft. Sometimes a puller will remove the crankcase gear. Sometimes the gear fits so tightly on the crankshaft that the crankshaft must be removed from the engine so that the gear can be removed.

Timing Case and Timing Gears Repair

Install 1. Put the crankshaft gear in a pan of hot oil. Make sure that the temperature can be controlled. DO NOT heat the crankshaft gear more than 180 C (356 F). Use boiling water if a container of hot oil and a temperature control is not available. DO NOT use an open flame to heat the gear. 2. Align the gear with the key on the crankshaft and with the timing marks on the gear away from the engine. Push the gear onto the crankshaft. 3. Install the idler gear. See Idler Gear and Hub, Install. 4. Check the timing gear clearances as shown in Figure 89. The minimum clearances for all gears is 0.08 mm (0.003 in.). 5. Install the timing case cover, coolant pump, crankshaft pulley, fan drive pulley, drive belts, and fan. See Timing Case Cover, Install.

TIMING CASE Remove 1. Remove the fan. 2. Remove the drive belts. 3. Remove the crankshaft pulley. See Crankshaft Pulley. 4. Remove the fan drive assembly. See Fan and Fan Drive, Remove. 5. Drain the coolant and remove the coolant pump. See Coolant Pump, Remove. 6. Remove the alternator and its mount bracket, and the front support plate. 7. Remove the air compressor. See Air Compressor - Engines YG and YH, Remove. Remove the compressor drive. See Air Compressor Drive, Bendix, Disassemble. 8. Remove the timing case cover. See Timing Case Cover, Remove. 9. Turn the crankshaft until the marked teeth of the crankshaft gear, the camshaft gear, and the gear for the fuel injection pump are aligned as shown in Figure 93. The marked teeth on the idler gear will not necessarily be aligned with the

Timing Case and Timing Gears Repair marked teeth of the other three gears because of the different speed of rotation of the idler gear. 10. Remove the fuel injection pump. See Fuel Injection Pump, Remove.

600 SRM 705 with the machined face of the engine block where the alternator bracket is installed. Tighten the M8 capscrews to 22 N•m (16 lbf ft). Tighten the M10 capscrews to 44 N•m (32 lbf ft).

11. Remove the idler gear and the camshaft gear. See Idler Gear and Hub, Remove and Camshaft Gear, Remove. 12. Remove the capscrews that hold the timing case to the engine block. Remove the capscrews that hold the oil sump to the timing gear case. 13. Remove the timing gear case, gasket, and hub for the idler gear. Do not permit the hub to fall and become damaged.

Install 1. Inspect the oil sump gasket for damage. If the gasket is damaged, remove the oil sump and install after the timing case has been installed. A damaged section of the gasket can be cut and a new section can be installed in its place, but the work must be carefully done to prevent oil leaks. 2. If the oil sump has been removed, install the hub for the idler gear on the front of the engine block. Use the three capscrews for the idler gear to hold the hub in position. Make sure that the oil hole in the hub is toward the top of the engine. 3. Make sure that the thrust washer for the camshaft is in the correct position. 4. Install a new gasket for the timing case to the engine block. Cut the bottom ends of the gasket to correctly fit the space. Use gasket compound at the bottom ends of the gasket. 5. Put the timing case into position on the engine block. If the oil sump was not removed, install the hub for the idler gear. Use the four capscrews for the idler gear to hold the hub in position. Make sure that the oil hole in the hub is toward the top of the engine. Install the four capscrews that hold the hub of the idler gear to the engine block. See Figure 95. 6. Install the alternator and its front support plate in position and install the remainder of the capscrews into the timing case. If the front support plate has been separated from the alternator bracket, make sure that the support plate is even

1. CAPSCREWS FOR HUB

2. HUB FOR IDLER GEAR

Figure 95. Idler Gear Hub Installation NOTE: If a new timing case is being installed, remove the two studs from the timing case and clean the threads that fit into the timing case. Apply liquid sealant to the threads of the studs and install them into the new timing case. 7. Install the camshaft gear. Install the capscrew and washer and tighten the capscrew to press the gear into position. Tighten the capscrew to 95 N•m (70 lbf ft). 8. Lubricate the bushings in the idler gear with engine oil. Align the timing marks on the idler gear with the marks on the crankshaft gear and the cam shaft gear. Remove the three capscrews from the hub for the idler gear and install the idler gear. Make sure that the timing marks are aligned as shown in Figure 93. 9. Install the fuel injection pump. See Fuel Injection Pump, Install. 10. If new gears have been installed, check the timing gear clearances as shown in Figure 89. The minimum clearances for all gears is 0.08 mm (0.003 in.). 11. If the oil sump was removed, install it. Make sure that any joints in the gaskets are fitted to prevent oil leaks.

600 SRM 705

Timing Case and Timing Gears Repair

12. Install the timing case cover, coolant pump, crankshaft pulley, fan drive, alternator, drive belts, and fan. See Timing Case Cover, Install.

CAMSHAFT AND TAPPETS Remove NOTE: The removal and installation of the camshaft and tappets require disassembly of many components of the engine. The engine is normally removed from the lift truck for this operation. See the Frame section for procedures to remove the engine. See the Transmission section for procedures to separate the engine from the transmission. 1. Drain the engine oil and coolant. 2. Remove the timing case. See Timing Case, Remove. 3. Remove the valve cover, rocker arm assembly, and push rods. See Rocker Arm Assembly, Remove.

Figure 97. Camshaft Removal and Installation 8. Remove the tappets. 9. Inspect the camshaft and the tappets for wear and damage. See the Engine Specifications for the measurements. Replace any worn or damaged parts.

Install

4. Remove the fuel pump. 5. Turn the engine so that the oil sump is up and remove the oil sump. 6. Remove the thrust washer for the camshaft. See Figure 96.

1. Make sure all of the parts are clean. Lubricate the parts with engine oil as they are assembled. 2. Install the tappets in their positions. 3. Carefully install the camshaft. See Figure 97. 4. Install the thrust washer for the camshaft. Make sure the thrust washer fits correctly on the dowel. See Figure 96. 5. Use a new gasket and install the timing case. See Timing Case, Install. 6. Check the axial clearance of the camshaft. A dial indicator can be used to check the axial movement from the end of the camshaft. The normal axial movement is 0.10 to 0.41 mm (0.004 to 0.016 in.). The maximum axial movement permitted is 0.53 mm (0.021 in.).

1. THRUST WASHER, CAMSHAFT

2. POSITION DOWEL

Figure 96. Camshaft Thrust Washer 7. Carefully remove the camshaft. See Figure 97.

7. Turn the camshaft until the cam for the fuel pump is at the minimum lift position. Install the fuel pump. 8. Turn the engine to the upright position. Turn the crankshaft until the key slot in the crankshaft is toward the top. Install the timing gears. See Crankshaft Gear, Install. 9. Install the fuel injection pump.

Cylinder Block Assembly Repair

600 SRM 705

10. Install the push rods and the rocker arm assembly. See Rocker Arm Assembly, Install.

13. Install the timing case cover. See Timing Case Cover, Install. Install the oil sump.

11. Adjust the valve clearances. See Valve Clearance Adjustments.

14. Install the engine. When the engine can be operated, remove the air from the fuel system before operation.

12. Install the oil pump.

Cylinder Block Assembly Repair DESCRIPTION The cylinder block is made of cast iron. The fourcylinder engines have the cylinders bored directly into the cylinder block. The six-cylinder engines have removable cylinder liners pressed into the cylinder block. A bushing is installed in the front of the cylinder block for the front journal of the camshaft. The other camshaft journals do not have bushings and run directly in the cylinder block.

CYLINDER BLOCK Disassemble 1. Remove the engine from the lift truck. See the Frame section for procedures to remove the engine. See the Transmission section for procedures to separate the engine from the transmission. 2. Remove the fan, drive belts, fan drive, and the coolant pump.

9. ENGINES YG and YH. Remove the oil cooler. See Oil Cooler (Six-Cylinder Engines). 10. ENGINE YH. Remove the turbocharger. See Turbocharger - Engine YH Repair, Remove. 11. Remove the starter motor. See Starter Motor, Remove. 12. Remove the timing gears and the timing case. See Timing Case and Timing Gears Repair. 13. Remove the oil filter and the oil sump. See Oil Sump, Remove. 14. Remove the cylinder head assembly. See Cylinder Head Assembly, Remove. 15. Remove the flywheel and the flywheel housing. See Flywheel. 16. Remove the rear oil seal housing. See Rear Oil Seal, Replace.

6. Remove the timing case cover. See Timing Case Cover, Remove.

17. If the engine is not already in a position with the crankshaft facing up, turn the engine to that position. Remove the suction line and oil strainer. See Figure 115. Remove the capscrew that holds the bracket to the main bearing cap. Remove the two capscrews from the flange of the suction line and remove the suction line and screen. Clean the faces of both flanges. Remove the oil pump, delivery pipe and relief valve. See the sections Oil Pump, Remove and Relief Valve, Remove.

7. Remove the fuel injection pump. See Fuel Injection Pump, Remove.

18. Remove the bridge piece over the rear main bearing.

3. ENGINES YG and YH. If the engine has an air compressor, remove it. 4. Remove the crankshaft pulley. See Crankshaft Pulley. 5. Remove the alternator and its mount bracket.

8. Remove the fuel injectors, fuel lines, fuel filter, and fuel pump. See the Fuel System Repair section.

600 SRM 705

CAUTION Make sure the cooling jets for the pistons are not damaged or moved out of alignment. If a cooling jet is hit, the alignment must be checked and the cooling jet replaced if necessary. 19. Remove the bearing caps and lower bearing halves from the connecting rods. Make an arrangement so that the parts for each connecting rod will be assembled again in their original positions. Carefully push the pistons into their bores a small amount so that the connecting rods are separated from the crankshaft. 20. Make sure that the main bearing caps are marked with their position number. Remove the main bearing caps, lower bearing halves, and the upper and lower thrust washers. Keep all the parts in an arrangement so that the parts can be installed in their original positions. 21. Lift the crankshaft from the cylinder block. Remove the upper bearing halves and put each of them with their lower bearing half.

Cylinder Block Assembly Repair a new bushing and align it in position in the cylinder block.

Assemble 1. Make sure all the parts are clean. 2. Remove the screw plugs from the cylinder block and clean the threads. Apply a sealant to the threads of the plugs and install them in the cylinder block. 3. Install the cooling jets for the pistons. See Piston Cooling Jets, Install. 4. Install the crankshaft and the rear oil seal assembly. See Crankshaft Assembly Repair section. 5. Install the flywheel housing and flywheel. See Flywheel section. 6. Install the tappets and the camshaft. Camshaft and Tappets, Install.

See

7. Install the relief valve, oil pump, suction line, and oil strainer.

22. Carefully remove the pistons and connecting rod assemblies from the engine.

8. Install the timing case and the timing gears. See Timing Case and Timing Gears Repair.

23. Remove the camshaft and tappets. See Camshaft and Tappets, Remove.

9. Install the cylinder head assembly. See Cylinder Head Assembly, Install.

24. Remove the cooling jets for the pistons.

10. Install the starter motor.

Inspect

11. Install the fuel pump.

1. Make sure all of the oil and coolant passages in the engine block are clean.

12. ENGINE YH. Install the turbocharger. See Turbocharger - Engine YH Repair, Install.

2. Check the engine block for cracks and damage.

13. Install the oil filter assembly and the oil sump. See Oil Sump, Install.

NOTE: The top face of the cylinder block for the six-cylinder engines cannot be machined because the cylinder liners and pistons will not fit. The top face of the cylinder block for the four-cylinder engines cannot be machined because the pistons and connecting rods are matched for each cylinder. 3. Check the front bushing for the camshaft for wear. If a new bushing must be installed, use a puller to remove the old bushing. Make sure the oil hole for the new bushing is away from the engine when it is installed. Make sure the oil hole is aligned with the passage in the cylinder block when it is installed. Use a press to install

14. Install the oil cooler. See Oil Cooler (Six-Cylinder Engines). 15. Install the fuel injectors, fuel lines, fuel filter, and fuel injection pump. See Fuel System Repair section. 16. Install the coolant pump, fan drive pulley, and fan. See Cooling System Repair section. 17. Install the alternator and mount brackets. 18. Install the drive belts and adjust the tension. See Drive Belts.

Cylinder Block Assembly Repair 19. Install the engine into the lift truck. 20. Remove the air from the fuel system before operating the engine. See Fuel System Air Removal.

CYLINDER BORE (FOUR-CYLINDER ENGINES) To ensure the best performance during the life of the engine, it is important that worn or damaged cylinder bores are corrected. The condition of a cylinder bore is decided by: • The amount and location of any polished areas. • Wear. • Damage to the cylinder wall.

600 SRM 705

CYLINDER LINER (SIX-CYLINDER ENGINES) Inspect For the best performance during the life of the engine, it is important that worn or damaged cylinder liners are replaced. If a change of liner becomes necessary, transition fit liners and partially finished liners are available. The condition of a cylinder liner is decided by: • The amount and location of any polished areas. • Wear. • Damage to the liner wall.

NOTE: It will not be necessary to correct the bore if: • The honed finish can still be clearly seen. • The engine performance and oil consumption is acceptable.

NOTE: It will not be necessary to replace the liners if: • The honed finish can still be clearly seen. • The engine performance and oil consumption is acceptable.

1. Inspect the surface of the cylinder bore for cracks and deep scratches.

Cylinder Liner Condition, Check

2. Check the bore wall for areas where the honed finish has been polished away. Check especially the area around the top of the liner bore just below the carbon ring. In this area, thrust from the top piston ring is at its maximum.

CAUTION Do not use "Flex-hone" to repair cylinder bores.

1. Inspect the liner surface for cracks and deep scratches. 2. Check the liner wall for areas where the honed finish has been polished away. See Figure 98 and Figure 99. Check especially the area around the top of the liner bore just below the carbon ring. In this area, thrust from the top piston ring is at its maximum.

An engine can have high oil consumption with very little wear of the cylinder bores, if the surfaces of the bores are glazed. Specialist training and equipment is needed to machine the finish of a cylinder bore. 3. If necessary, the cylinder bores can be bored and honed 0.50 mm (0.0195 in.) 1.00 mm (0.039 in.) oversize in diameter and oversize pistons installed. 4. To obtain oversize cylinder bores they must be bored and then diamond honed, silicon carbide base honed and silicon carbide plateau honed to the finished size to conform to the dimensions in the Engine Data section. Specialist training and equipment is needed to machine bore a cylinder bore. For further information contact your nearest Perkins distributor.

Figure 98. Cylinder Liner Wear Check

600 SRM 705

Cylinder Block Assembly Repair removed from the engine for each cylinder liner that must be removed. 2. Turn the crankshaft to give access to the cylinder liner and protect the bearing journal. 3. Install the removal and installation tool over the center of the cylinder liner as shown in Figure 100. Make sure that the base of the tool is not on top of the flange of the next cylinder liner.

Figure 99. Where to Measure Cylinder Liner for Wear Check

CAUTION Do not use "Flex-hone" to repair cylinder liners. Damaged or worn liners must be replaced. New piston rings must be fitted when the cylinder liner is replaced. An engine can have high oil consumption with very little wear of the liner bores, if the surfaces of the liners are glazed. Specialist training and equipment is needed to machine the finish of a partially finished liner. 3. Partially finished cylinder liners must be bored and then diamond honed, silicon carbide base honed and silicon carbide plateau honed to the finished size to conform to the dimensions in the Engine Data section. Specialist training and equipment is needed to machine a partially finished liner. For further information contact your nearest Perkins Distributor.

Remove Special Tools:

Removal and installation tool and adapters for cylinder liners Piston height tool Dial indicator gage

NOTE: If several cylinder liners must be removed, or a cylinder liner is very tight, a recommendation is to remove the crankshaft and use a press to remove the cylinder liners. The removal and installation tool can also be used to remove and install a cylinder liner if a press is not available or the crankshaft must stay in the engine. This procedure can be difficult. 1. Disassemble the engine as necessary. The piston, connecting rod, and piston cooling jet must be

1. 2. 3. 4.

THREADED ROD HANDLE BEARING SHELL REMOVAL ADAPTER

5. CYLINDER LINER 6. REMOVAL ADAPTER

Figure 100. Cylinder Liner Removal 4. Make sure that the lugs on the top of the removal adapter engage flats on the threaded rod. Install the nut and washer on the threaded rod and tighten the nut against the removal adapter. Turn the handle to remove the cylinder liner from the cylinder block. Use lubricating oil on the moving parts to reduce the friction.

Cylinder Block Assembly Repair

Service Liner, Install A service liner is a transition fit of ±0.03 mm (±0.001 in.) of the parent bore. Some replacement cylinder liners are easier to install than others because of the manufacturing tolerances. A cylinder liner installation tool can be used to install a tight cylinder liner. See Figure 101. A press can also be used to install a tight cylinder liner. DO NOT use a hammer to install a cylinder liner.

600 SRM 705 2. Install the cylinder liner in the bore in the cylinder block. Make sure the cylinder liner is vertical and aligned with the bore in the cylinder block. Use the cylinder installation tool as shown in Figure 101 to press the cylinder liner into the cylinder block to within 50 mm (2 in.) of the final position. 3. Apply Loctite 602® to the upper 25 mm (1 in.) of the outer surface of the cylinder liner. Apply Loctite 602® to the flange and the cylinder block where the flange of the cylinder liner will fit into the cylinder block. 4. Press the cylinder liner into its final position in the cylinder block. Remove the tool and clean the Loctite from the cylinder block. 5. Wait 15 minutes before the dimensions in the bore of the cylinder liner are checked. The Loctite will reach full strength after six hours. The inside diameter of a service liner, when fitted, should be 100.00 to 100.06 mm (3.937 to 3.939 in.). 6. Use the piston height tool and dial indicator gauge to check that the cylinder liner is in the correct position. See Figure 102. The flange of the cylinder liner must be between 0.10 mm (0.004 in.) above to 0.10 mm (0.004 in.) below the top surface of the cylinder block.

1. 2. 3. 4.

THREADED ROD HANDLE BEARING INSTALLATION ADAPTER

5. CYLINDER LINER 6. BASE, INSTALLATION ADAPTER

Figure 101. Cylinder Liner Installation 1. Make sure the parts are clean. Lubricate the bore in the cylinder block with engine oil. DO NOT lubricate the upper 50 mm (2 in.) of the bore in the cylinder block. Sealant will be applied to this area.

1. FLAME RING

2. FLANGE

Figure 102. Cylinder Liner Check 7. Install new piston rings on the piston. See Piston Rings, Install.

600 SRM 705 8. Install the piston and connecting rod assembly. See Piston and Connecting Rod Assembly, Install. 9. Install the cooling jets for the pistons. See Piston Cooling Jets, Install. 10. Install the cylinder head assembly. See Cylinder Head Assembly, Install. 11. Install the oil sump. See Oil Sump, Install. NOTE: Special training and equipment are often needed to correctly machine the finish on the inner surface of a cylinder liner. Contact a Perkins distributor for additional information. NOTE: If a new cylinder liner has been installed, the following recommendations are for the next five hours of engine operation: • Do not operate the engine at full load. • Do not operate the engine at high speed. • Do not permit the engine to operate at idle speed for long periods.

Partially Finished Liner, Install The partially finished liner is an interference fit in the parent bore. A special tool will be necessary to fit the liners, see Figure 101. If a liner is a very tight fit it may be necessary to use a hydraulic press.

CAUTION Do not hit a liner with a hammer. 1. Clean thoroughly the parent bore of the cylinder block. 2. Inspect the parent bore for damage and corrosion. Damaged cylinder blocks should be discarded. 3. Clean thoroughly the outer surface of the liner with an approved degreasing fluid.

Cylinder Block Assembly Repair 5. Install the cylinder liner into the parent bore; make sure that the liner is vertical. Use the cylinder installation tool as shown in Figure 101 to press the cylinder liner into the fully fitted position in the cylinder block. 6. Use the piston height tool and dial indicator gauge to check that the cylinder liner is in the correct position. See Figure 102. The flange of the cylinder liner must be between 0.10 mm (0.004 in.) above to 0.10 mm (0.004 in.) below the top surface of the cylinder block.

CAUTION Specialist training and equipment is needed to machine the finish of a partially finished liner. 7. Install new piston rings on the piston. See Piston Rings, Install. 8. Install the piston and connecting rod assembly. See Piston and Connecting Rod Assembly. 9. Install the cooling jets for the pistons. See Piston Cooling Jets, Install. 10. Install the cylinder head assembly. See Cylinder Head Assembly, Install. 11. Install the oil sump. See Oil Sump, Install. NOTE: Special training and equipment are often need to correctly machine the finish on the inner surface of a cylinder liner. Contact a Perkins Distributor for additional information. NOTE: If a new cylinder liner has been installed, the following recommendations are for the next five hours of engine operation: • Do not operate the engine at full load. • Do not operate the engine at high speed. • Do not permit the engine to operate at idle speed for long periods.

4. Apply a small amount of engine oil around the top of the parent bore to assist the entry of the liner.

Engine Timing

600 SRM 705

Engine Timing DESCRIPTION The correct timing is important for this engine to meet current emission standards. The correct timing of the fuel injection pump operates at a static timing very close to top dead center (TDC) on the compression stroke.

not be turned unless the spacer is in position under the lock screw. The latest fuel injection pumps have a hub which is mounted permanently onto the drive shaft. See Figure 105.

The timing gears are stamped with timing marks to make sure they are installed correctly. See Figure 103. The marked teeth of the crankshaft, the camshaft, and the fuel pump gears will each be engaged with the idler gear as shown in Figure 103 when the number one piston is at TDC on the compression stroke. The marks on the idler gear will not necessarily be aligned in this position because of the different speeds at which the gears rotate. The marks on the idler gear can be used to make sure the marked teeth of the other three gears are correctly aligned when the components of the timing system are being assembled. 1. SPACER

2. LOCK SCREW Figure 104. Lock Screw

NOTE: If a timing pin is not available, a 8 mm drill bit can be used. The manufacturer fits the hub to the pump to ensure very accurate timing. Engines that have this arrangement have the drive gear fastened to the hub instead of to the shaft of the pump. A pin is used to accurately time the pumps. See Figure 105.

1. CAMSHAFT GEAR 2. CRANKSHAFT GEAR 3. IDLER GEAR

4. GEAR FOR FUEL INJECTION PUMP 5. PTO GEAR

Figure 103. Timing Marks Alignment The fuel injection pump is timed at TDC on the compression stroke of number one cylinder. There is no timing mark on the rear of the timing case.

CAUTION A replacement fuel injection pump can have the pump shaft locked in position. See Figure 104. The drive shaft of the pump must

1. TIMING PIN 2. HUB

3. NUT

Figure 105. Injection Pump Timing Pin

600 SRM 705

Engine Timing

CAUTION Do not release the nut (Figure 105) from the fuel injection pump. See Figure 106. The nut is shown in position when the fuel pump is installed on the engine. The fuel pump hub is installed to the shaft in the factory to make sure that the fuel pump is in the correct position for timing. If the nut is removed and the hub moves, the hub will need to be accurately installed to the pump by use of specialist equipment before the pump can be installed on the engine.

1. Fasten a temporary pointer to the timing case cover with its tip near to the outer edge of the crankshaft pulley or damper. See Figure 107.

The fuel pump gear is fastened to the hub of the fuel pump by four setscrews. The setscrews pass through slots in the gear which allows for adjustment of the backlash. NOTE: On the latest engines with belt driven coolant pumps, four tamper proof fasteners retain the fuel pump gear. Special tools are needed to remove these fasteners; refer to your Perkins distributor. To remove the fuel injection pump from the engine it is only necessary to remove the four capscrews which secure the fuel pump gear to the hub. See Figure 106.

1. TEMPORARY POINTER

2. DIAL TEST INDICATOR

Figure 107. Procedure to Find TDC 2. Loosen the gland nuts that retain the fuel injectors. 3. Remove the rocker cover. 4. Rotate the crankshaft, clockwise from the front, until the push rod for the inlet valve of the rear cylinder just begins to push on the rocker arm. 5. Remove the spring clip and the spacer from the front of the rocker shaft. Release the capscrews of the front two pedestals of the rocker shaft and remove the front rocker lever; tighten the capscrews of the rocker shaft pedestals. 6. Remove the valve springs from the front valve with the valve spring compressor and the adapter, for pedestal studs, or the adapter for pedestal capscrews.

1. CAPSCREWS (4)

2. NUT

Figure 106. Injection Pump Hub

How to Set Number One Piston to TDC on Compression Stroke Special tools:

Valve spring compressor Stud adapter Setscrew adapter

CAUTION Fit a suitable collar near the top of the valve to hold the valve if the crankshaft is rotated too far. 7. Allow the valve to be held by the top of the piston. 8. Fasten a dial test indicator with its plunger in contact with the top of the valve stem and with a reading shown on the gage. See Figure 107. Rotate slowly the crankshaft, clockwise from the front, until the clockwise movement of the

Engine Timing dial gage pointer just stops. Make a mark on the crankshaft pulley or damper to align with the temporary pointer. Continue to rotate the crankshaft in the same direction until the gauge pointer just begins to move in a counterclockwise direction. Make another mark on the pulley or damper to align with the pointer. Mark the center point between the two marks on the pulley or damper and remove the other two marks. 9. Rotate the crankshaft approximately 45 counterclockwise from the front and then clockwise until the mark on the pulley or damper is aligned with the pointer. Number one piston is now at TDC on the compression stroke.

How to Set Number One Piston to TDC on Compression Stroke (Alternate Procedure) This alternative procedure can be used if the above procedure cannot be used. 1. Fasten a temporary pointer to the timing case cover so that its tip is near the outer edge of the crankshaft pulley as shown. See Figure 108.

600 SRM 705 Open the inlet valve enough to install a 5.0 mm (0.2 in.) spacer between the end of the valve stem and the rocker arm. 6. Slowly rotate the crankshaft counterclockwise until the piston touches the open valve. Carefully make a mark on the pulley that is aligned with the tip of the temporary pointer. 7. Rotate the crankshaft clockwise one or two degrees and remove the spacer between the valve stem and the rocker arm. Rotate the crankshaft 1/4 turn counterclockwise. Install the spacer again between the valve stem and the rocker arm. 8. Slowly rotate the crankshaft clockwise until the piston touches the open valve. Make a second mark on the pulley that is aligned with the temporary pointer. 9. Mark the center point between the two marks on the crankshaft pulley and remove the other two marks. Rotate the crankshaft 1/8 turn counterclockwise and remove the spacer between the valve stem and the rocker arm. 10. Rotate the crankshaft clockwise until the mark on the crankshaft pulley is aligned with the temporary pointer. Number one piston is now at TDC on the compression stroke.

Valve Timing, Check 1. Remove the valve cover. 2. Set the piston of number one cylinder to TDC on the compression stroke.

1. TEMPORARY POINTER Figure 108. Alternate Procedure to Find TDC 2. Loosen the gland nuts on the fuel injectors. 3. Remove the valve cover. 4. Rotate the crankshaft in a clockwise direction from the front until the push rod for the inlet valve in the rear cylinder just begins to push on the rocker arm. 5. Rotate the crankshaft a further 1/8 turn clockwise. Use a small lever between the rocker arm and the spring cap of number one inlet valve.

3. Fasten a temporary pointer to the timing case so that its tip is near the outer edge of the crankshaft pulley. See Figure 108. 4. Rotate the crankshaft, clockwise from the front, until the inlet valve of the rear cylinder is fully open. 5. Set the valve tip clearance of number one cylinder inlet valve to 1.5 mm (0.059 in.). 6. Rotate the crankshaft, clockwise from the front, until the push rod of number one cylinder inlet valve just tightens. In this position, check if the mark on the crankshaft pulley or damper is within Âą2.5 of the temporary pointer. Use the formula below to find the measurement which is equal to 2.5 on the pulley or damper.

600 SRM 705

Engine Timing 2. Remove the gear cover from the cover of the timing case. For gear driven coolant pumps: Remove the coolant pump.

CĂ&#x2014;P 360 C = circumference of pulley or damper P = 2.5 degrees 7. If the timing is more than 2.5 out of position, the timing gears are probably not in correct mesh. NOTE: One tooth on the camshaft gear is equivalent to 23 mm (0.9 in.) at the circumference of a pulley of 203 mm (8 in.) diameter. If a large damper is fitted, one tooth on the camshaft gear is equivalent to 35 mm (1.4 in.) at the circumference of a damper of 310 mm (12.2 in.) diameter, or 37 mm (1.5 in.) at the circumference of a damper of 327 mm (12.9 in.) diameter.

NOTE: On the latest engines with belt driven coolant pumps, four tamper proof fasteners retain the fuel pump gear. Special tools and personnel with the correct training are necessary to remove these fasteners, refer to your nearest Perkins distributor. 3. Insert the timing pin through the hole in the fuel pump gear and the slot of the hub. See Figure 109. Push the pin fully into the hole in the body of the fuel pump. If the pin can be fully inserted then the pump timing is correct. There should be no resistance when the pin is inserted.

8. Rotate the crankshaft, clockwise from the front, until the inlet valve of the rear cylinder is fully open. Set the valve tip clearance of the inlet valve of number one cylinder to 0.20 mm (0.008 in.). 9. Install the rocker cover. 10. Remove the temporary pointer from the timing case and the timing mark from the pulley or damper.

Fuel Injection Pump Timing, Check Special tools:

Timing pin, Bosch fuel injection pumps Timing pin, Lucas and Stanadyne fuel injection pumps

CAUTION Do not remove the nut which retains the hub to the shaft of the fuel injection pump. See Figure 109. The hub is fitted permanently to the shaft. If the hub is moved, it will be necessary for a fuel injection pump specialist to correctly position the hub on the shaft with special test equipment available to Perkins distributors. 1. Set the piston of number one cylinder to TDC on the compression stroke operation. See How to Set Number One Piston to TDC on Compression Stroke or How to Set Number One Piston to TDC on Compression Stroke (Alternate Procedure).

1. TIMING PIN 2. NUT 3. TIMING HOLE IN BODY OF FUEL INJECTION PUMP

4. TIMING SLOT IN HUB 5. TIMING HOLE IN FUEL PUMP GEAR

Figure 109. Timing Gear for Fuel Injection Pump NOTE: The position for the timing pin for Lucas and Stanadyne fuel injection pumps is shown in Figure 109. The position for the timing pin for Bosch fuel injection pumps is shown in Figure 110. 4. Remove the timing pin. 5. If the timing pin cannot be pushed into the pump body, check that the engine is correctly set at TDC on the number one cylinder compression stroke. If the engine is set correctly at TDC on the number one cylinder compression stroke, but the pin does not fit in the hole, the fuel pump must be removed and set by a specialist.

Turbocharger - Engine YH Repair

600 SRM 705

6. Fit the gear cover to the cover of the timing case. For gear driven coolant pumps: Fit the coolant pump.

1. TIMING PIN Figure 110. Timing Gear for Bosch Fuel Injection Pump

Turbocharger - Engine YH Repair GENERAL The turbocharger is installed between the induction and exhaust manifolds. Exhaust gases turn the turbocharger and cause it to supply air to the induction manifold at greater than atmospheric pressure. The bearings in the turbocharger are lubricated with engine oil from the main oil passage in the engine block. The oil passes through the bearing housing of the turbocharger and returns to the oil sump.

6. Disconnect the oil drain line at the flange at the bottom of the bearing housing of the turbocharger. Remove the oil drain line and gasket. If necessary, release the hose clamps from the oil drain line and push the hose down.

Remove

7. Remove the nuts at the flange that holds the turbocharger to the exhaust manifold. Remove the turbocharger from the exhaust manifold. Remove the gasket. Cover the open ports in the manifolds, the turbocharger, and the pipes to be sure that dirt, etc., will not enter.

1. Clean the turbocharger. Remove the air cleaner hose at the compressor inlet.

8. Check the hoses, lines, and duct for cracks, wear, or damage.

2. Remove or disconnect the support bracket for the turbocharger. Remove the heat shield for the fuel pump if additional clearance is necessary.

Install

3. Remove the nuts and remove the exhaust elbow and its gasket from the turbocharger. 4. Release the hose clamps and push the hose from the compressor outlet up the elbow of the induction manifold. 5. Disconnect the oil supply line at the flange at the top of the bearing housing of the turbocharger. Remove the oil supply line and gasket.

1. Remove the covers from the pipes, manifolds, and turbocharger. 2. Check that the openings of the turbocharger and the manifolds are clean. Make sure that the compressor shaft in the turbocharger rotates freely. 3. Install a new gasket where the turbocharger connects to the exhaust manifold. See Figure 111. If the original nuts are to be used, make sure they are in good condition. Use a compound on the threads to prevent seizure of the nuts to the studs.

600 SRM 705

Turbocharger - Engine YH Repair from the oil drain line from the turbocharger. Connect the hose to the oil drain line. Connect the electric stop control.

Impeller and Compressor Housing, Clean NOTE: The compressor housing can sometimes be removed for cleaning without removing the turbocharger first. The compressor housing is held by a circlip and access to the circlip (large snap ring) is not always possible. 1. Clean the turbocharger. Remove the duct from the air filter where it connects to the inlet of the turbocharger. 1. GASKET Figure 111. Turbocharger Installation 4. Install the turbocharger. 44 Nâ&#x20AC;˘m (32 lbf ft).

2. Release the hose clamps and push the hose from the compressor outlet up the elbow of the induction manifold.

Tighten the nuts to

5. Lubricate the bearing housing of the turbocharger with clean engine oil. Use a new gasket and install the oil supply line.

3. Make a reference mark on the compressor housing and the bearing housing as shown in Figure 112.

6. Use a new gasket and install the oil drain line. Tighten the capscrews, but do not connect the hose. 7. Install the exhaust elbow on the turbocharger. If the original nuts are to be used, make sure they are in good condition. Use a compound on the threads to prevent seizure of the nuts to the studs. New nuts have a coating on them to prevent seizure. Install a new gasket on the studs. Tighten the nuts to 22 Nâ&#x20AC;˘m (16 lbf ft) (plated) or 25 Nâ&#x20AC;˘m (18 lbf ft) (non-plated). 8. Install the support bracket for the turbocharger. Install the heat shield for the fuel pump if it was removed.

1. REFERENCE MARK

9. Slide the hose on the elbow for the induction manifold onto the outlet of the turbocharger. Install the hose clamps.

4. Remove the capscrews and remove the lock plates. If the compressor casting is fastened with a circlip, remove the circlip that holds the compressor housing. Carefully remove the compressor housing from the turbocharger as shown in Figure 112. If the compressor housing is a tight fit, use a soft hammer. If the circlip is not accessible, the turbocharger must be removed for this process.

10. Make sure that there is no restriction in the duct from the air filter to the turbocharger. Install the duct on the turbocharger and tighten the fastener. 11. Check that the bearings in the turbocharger have an oil flow. Disconnect the electric stop control so that the engine cannot start. Use the starter motor to operate the engine until engine oil flows

Figure 112. Compressor Housing Removal

Lubrication System Repair

600 SRM 705

Be careful that the blades of the impeller are not damaged. If the impeller is damaged, the turbocharger must be replaced or repaired by a special repair service.

7. Carefully push the impeller toward the bearing housing and turn the impeller with your hand. Check that the impeller turns freely and there is no noise that can indicate wear or damage. If there is a fault, the turbocharger must be replaced or repaired by a special repair service.

5. Put the compressor housing in a container with a solvent that is not caustic. When the dirt has loosened, use a hard brush or a soft scraper to clean the compressor housing. Use compressed air at low pressure to dry the compressor housing.

8. Install the compressor housing on the turbocharger. Make sure the reference marks are aligned. Install the circlip loosely on the bearing housing. Make sure that the face of the circlip with the bevel is toward the exhaust end of the turbocharger. Install the circlip in the groove.

6. Clean the impeller with a soft brush.

9. Install the ducts on the inlet and outlet of the compressor housing and tighten the clamps.

CAUTION

Lubrication System Repair GENERAL The oil pump is turned by a gear on the crankshaft through an idler gear. Engine oil from the sump passes through a strainer and pipe to the suction side of the pump. A relief valve on the outlet of the oil pump controls the maximum oil pressure in the lubrication system. The engine oil flows from the oil pump through an oil cooler fastened on the side of the cylinder block (four-cylinder engines), then to the oil filter. The engine oil flows from the oil pump through the oil filter to the oil cooler (six-cylinder engines). The oil cooler has a bypass valve that controls the oil pressure in the oil cooler and permits some cold oil to flow directly to the oil filter. The normal oil flow is through the oil filter to the main oil passage in the cylinder block.

through the bearings of the turbocharger and returns to the oil sump. Turbocharged engines have a cooling jet connected to the main oil passage for each cylinder. The cooling jets spray engine oil on the bottoms of the pistons for additional cooling. Engine type AR has only one cooling jet installed to the number one cylinder position.

OIL FILTER, REPLACE 1. Change the oil filter when the engine oil is changed. Put a drain pan under the filter. Remove the filter cartridge. Make sure the adapter stays in the filter head as shown in Figure 113. Discard the filter cartridge.

Engine oil from the main oil passage flows to the main bearings of the crankshaft and through the passages in the crankshaft to the rod bearings. The pistons and cylinder bores are lubricated by splash and oil mist. Engine oil also flows from the main bearings to the journals of the camshaft. Some engine oil goes through the center camshaft bearing to the rocker arm assembly. The hub of the idler gear has an oil passage to the main oil passage and the timing gears are splash lubricated. An outlet from the main oil passage supplies oil to the bearings of the turbocharger. The engine flows

1. ADAPTER Figure 113. Oil Filter

600 SRM 705 2. Clean the filter head. 3. Add some clean engine oil to the new filter cartridge. Apply clean engine oil to the gasket. 4. Install the new filter cartridge and tighten by hand only. 5. When new oil has been added and the engine can be operated, start the engine. Check the area around the filter for leaks.

Lubrication System Repair 7. Fit the new gasket to the filter head, the gasket is installed dry. 8. Apply Loctite to the first three threads of the capscrews and tighten the capscrews. 9. Install the oil cooler to the filter head, if used. 10. Install the flexible pipes to the filter head, if used.

Remove and Install

11. If the oil cooler is integral with the cylinder block, fit a new gasket to the flange of the oil cooler pipes. Fit the flange to the filter head and tighten the capscrews.

1. Put a drain pan under the filter head.

12. Install a new filter cartridge.

2. Remove the filter cartridge.

OIL SUMP

3. Remove the canister type oil cooler from the filter head, if one is used.

Remove

4. Remove the flexible pipes from the filter head, if they are used.

1. Drain the engine oil. Remove the capscrews and the two nuts that fasten the oil sump to the engine block. Lower the oil sump. Remove the gasket.

FILTER HEAD

5. Remove the capscrews and remove the filter head from the cylinder block. See Figure 114. Discard the gasket.

2. Clean the oil sump with mineral oil solvent. 3. If the suction line and oil strainer must be removed, see Figure 115. Remove the capscrew that holds the bracket to the main bearing cap. Remove the two capscrews from the flange of the suction line and remove the suction line and screen. Clean the faces of both flanges.

1. ADAPTER 2. GASKET 3. FILTER HEAD Figure 114. Filter Head Replacement 6. Clean the gasket face of the filter head and the cylinder block. NOTE: Some engines have an adapter between the cylinder block and the filter head. If an adapter is used, two gaskets are used.

1. SUPPORT BRACKET, MAIN BEARING CAP 2. CAPSCREWS, FLANGE, SUCTION PIPE Figure 115. Oil Sump Screen Removal

Lubrication System Repair

Install 1. If the oil strainer and suction line was removed, loosely assemble the bracket of the suction line to the main bearing cap. Install a new gasket and fasten the flanges of the suction line to the oil pump. Make sure that the suction line is aligned correctly and tighten the capscrew that holds the bracket to the main bearing cap.

600 SRM 705 2. Remove the outer rotor and clean all of the parts. Check for damage and wear.

2. Use a new gasket and install the oil sump. Use capscrews on each side of the oil sump to align and hold the gasket in position during assembly. Install the remainder of the capscrews and the two nuts. Tighten all of the fasteners to 22 Nâ&#x20AC;˘m (16 lbf ft). 3. Install the drain plug in the oil sump. Use a new O-ring and tighten to 34 Nâ&#x20AC;˘m (25 lbf ft).

OIL PUMP

1. WASHER 2. IDLER GEAR

3. BUSHING

Figure 116. Idler Gear, Oil Pump Removal

Remove 1. Drain the engine oil and remove the oil sump. Remove the oil strainer and suction line. See Oil Sump, Remove. 2. Remove the relief valve and connection line. 3. The oil pump is fastened to the number one main bearing cap. Access to the capscrews on the main bearing can be difficult when the timing case is on the engine. A special wrench can be required to apply the correct torque to the capscrews for removal and installation. If a wrench is not available to install the capscrews on the main bearing cap, the timing case must be removed. See Timing Case, Remove. 4. Remove the snap ring that holds the idler gear to the oil pump. Remove the washer and the idler gear. See Figure 116. 5. Remove the capscrews and remove the oil pump. See Figure 117.

Inspect If the oil pump is worn so that the performance is decreased, the oil pump must be replaced. 1. Remove the capscrews and remove the cover of the oil pump.

Figure 117. Oil Pump Removal 3. Install the outer rotor and check the clearances. See Figure 118. See the Engine Specifications for the wear tolerances. 4. Check the clearances of the inner rotor. See Figure 119. See the Engine Specifications for the wear tolerances. 5. Check end clearance and axial movement of the rotor. Use a spacer gauge and a straightedge. See Figure 120. See the Engine Specifications for the wear tolerances.

600 SRM 705

Lubrication System Repair

Install 1. Lubricate the internal parts of the oil pump with engine oil before installation. Install the oil pump on the main bearing cap and tighten the capscrews to 22 N•m (16 lbf ft). 2. Make sure the idler gear and bushing are in good condition. The bushing is available as a separate part. Install the idler gear, washer, and snap ring. See Figure 116. Check the gear clearance. See Figure 121. The minimum clearance is 0.0076 mm (0.003 in.) between the oil pump gear and the idler gear. Figure 118. Outer Rotor Clearance Check

Figure 121. Clearances Check Between Oil Pump Gear and Idler Gear Figure 119. Inner Rotor Clearances Check

3. If the main bearing cap was removed, lubricate the bearing with engine oil and install the bearing cap. Tighten the capscrews to 265 N•m (195 lbf ft). Check the gear clearance. See Figure 121. The minimum clearance is 0.0076 mm (0.0003 in.) between the crankshaft gear and the idler gear. 4. If the timing case was removed, install the timing case. See Timing Case and Timing Gears Repair. 5. Install the relief valve and the connection line. See Relief Valve, Install. 6. Install the oil sump. See Oil Sump, Install.

RELIEF VALVE Figure 120. Rotor End Clearances Check 6. When the parts are clean and inspected, install the cover to the oil pump. Tighten the capscrews to 28 N•m (21 lbf ft).

Remove 1. Drain the engine oil. Remove the oil sump. See Oil Sump, Remove.

Lubrication System Repair

600 SRM 705

2. ENGINE AR. Remove the capscrew and carefully pull the relief valve from the engine block. See Figure 122. Pull the relief valve from the connection line. Pull the connection line from the oil pump.

Disassemble CAUTION The relief valve has a compressed spring. Do not permit the spring to be released so that it causes an injury. NOTE: The relief valve can be disassembled without removing it from the engine. 1. Apply pressure against the end plate of the spring assembly. See Figure 124. Remove the snap ring. Carefully release the end plate and release the pressure on the compressed spring. Remove the end plate, spring, and the plunger.

1. THIMBLE, RELIEF VALVE 2. CONNECTION PIPE WITH O-RING Figure 122. Engine AR Relief Valve Removal ENGINES YG and YH. See Figure 123. Remove the capscrews that fasten the cross flow pipe to the relief valve. Remove the flange. Remove the two capscrews that fasten the relief valve to the cylinder block and remove the relief valve. 1. BODY, RELIEF VALVE 2. PLUNGER

3. SPRING 4. END PLATE 5. SNAP RING

Figure 124. Relief Valve Assembly

Inspect 1. Clean the parts. Check the parts for wear and damage. Check the load necessary to compress the spring to its fitted length, see Engine Specifications. 1. CAPSCREW (2)

2. CAPSCREW (2)

Figure 123. Engines YG and YH Relief Valve Removal

2. Check that the seat of the plunger is not damaged and that the plunger moves easily in its bore.

Assemble 1. Lubricate the parts with engine oil during assembly. Install the plunger in the bore as shown in Figure 124. Install the spring and end cap. Compress the spring and end cap into the bore so that the snap ring can be installed. Install the snap ring.

600 SRM 705

Lubrication System Repair

Install 1. Engine AR. Install new O-rings on the connection line. Lubricate the O-rings with engine oil and push the connection line into position in the oil pump.

roll pin is hardened metal. If the following procedure does not remove the roll pin, see Remove (Alternative).

2. Push the relief valve onto the connection line and install the relief valve into position on the engine block. Install and tighten the capscrew. 3. Engines YG and YH. Be sure the faces of the cross flow pipe and the relief valve are clean. Install the relief valve and new gasket to the cylinder block. Install the four capscrews and tighten the flange capscrews and then the valve capscrews. 4. Install the oil sump. See Oil Sump, Install.

IDLER GEAR SHAFT, REPLACE The shaft for the idler gear in the oil pump is installed in the front main bearing cap. See Figure 125. If this idler gear shaft must be replaced, use the procedures in the following paragraphs. The idler gear shaft has an oil passage for lubrication of the bushing for the idler gear. Engine oil from the front main bearing passes through a channel in the body of the oil pump and then through the oil passage to the idler gear.

1. ROLL PIN Figure 126. Idler Gear Shaft Roll Pin 1. Carefully use an M5 × 0.8 mm taper tap to put a chamfer in the end of the roll pin. 2. Carefully use an M5 × 0.8 mm plug tap to cut a minimum three threads in the end of the roll pin. If the tap breaks, see Remove (Alternative). 3. Obtain the following parts to make a puller: • M5 × 0.8 mm capscrew that has a minimum thread length of 15 mm. • M5 × 0.8 mm nut. • Spacer with a 15.88 mm or 19.05 mm outside diameter and a minimum internal diameter of 8.73 mm. The length of the spacer must be 9.5 mm. 4. Install the nut fully on the capscrew. Hold the spacer on the capscrew and engage the threads of the roll pin with the capscrew. 5. Center the spacer over the roll pin and tighten the nut against the spacer. Continue to tighten the nut to pull the roll pin from the front main bearing cap. 6. Press the idler gear shaft from the front main bearing cap.

1. OIL PASSAGE 2. IDLER GEAR SHAFT

3. CHANNEL IN OIL PUMP

Figure 125. Idler Gear Shaft

Remove (Alternative) 1. Make a drill guide to the dimensions shown in Figure 127.

Remove The idler gear shaft is fastened in the front main bearing cap with a roll pin. See Figure 126. This

Lubrication System Repair

600 SRM 705 5. Press the idler gear shaft from the front main bearing cap.

Install 1. Make sure the hole in the main bearing cap for the idler gear shaft is clean and any rough edges are removed.

1. 2. 3. 4. 5. 6. 7. 8. 9.

8.3 mm (0.327 in.) 20.0 mm (0.787 in.) 1.0 mm (0.039 in.) 16.1 to 16.4 mm (0.634 to 0.646 in.) 6.9 × 22 mm (0.272 × 0.866 in.) DIAMETER HOLE FOR 5/16-24 UNF × 18 MM THREAD 36.0 mm (1.42 in.) 6.5 to 6.6 mm (0.256 to 0.260 in.) DIAMETER HOLE, COUNTERSUNK 9.0 MM × 900 INCLUDED 31.75 mm (1.250 in.) 15.9 mm (0.626 in.)

Figure 127. Drill Guide Dimensions 2. Install the drill guide on the front main bearing cap as shown in Figure 128. Make sure that the countersink in the guide faces away from the roll pin. Make sure the edge of the drill guide is aligned with the front edge of the bearing cap.

1. CHAMFER 2. OIL PASSAGE

3. IDLER GEAR SHAFT

Figure 129. Idler Gear Shaft Installation 3. Make sure the idler gear shaft is pressed fully into the main bearing cap. Use the original hole for the roll pin as a drill guide. Drill a 6.35 mm (0.25 in.) diameter hole into the idler gear shaft 9.5 mm (0.37 in.) deep. 4. Install a new roll pin into the main bearing cap and the idler gear shaft. 1. DRILL GUIDE 2. ROLL PIN

3. 5/16 UNF CAPSCREW 4. FLAT WASHER

Figure 128. Drill Guide Installation 3. Drill a 6.35 mm (0.25 in.) diameter hole in the bearing cap. Drill the hole 47.0 mm (1.85 in.) into the bearing cap. 4. Use a punch to drive the roll pin from its position.

Install (Alternative) Some engines do not have a roll pin installed to fasten the idler gear shaft in position. If the idler gear shaft must be replaced, a roll pin must be installed to hold the new idler gear shaft in position. This procedure describes how to install a new roll pin. 1. Make sure the hole in the main bearing cap for the idler gear shaft is clean and any rough edges are removed.

600 SRM 705

Fuel System Repair

2. Use a press to install the idler gear shaft into the main bearing cap. Make sure that the oil passage in the idler gear shaft is correctly oriented. See Figure 129. Apply Loctite 603 to the chamfer of the idler gear shaft where it joins the main bearing cap. 3. Make a drill guide as described in Remove (Alternative). 4. Install the drill guide on the front bearing cap as shown in Figure 130.

5. Use the drill guide and drill a 6.35 mm (0.25 in.) diameter hole into the idler gear shaft 25.4 mm (1.00 in.) deep. Remove the drill and the drill guide. 6. Install a roll pin into the bearing cap and the idler gear shaft.

Install (Alternative for Four-Cylinder Engines Only) Some four-cylinder engines do not have a roll pin installed to fasten the idler gear shaft in position. This procedure describes how to install a new idler gear shaft. 1. Make sure the hole in the main bearing cap for the idler gear shaft is clean and any rough edges are removed.

1. DRILL GUIDE 2. FLAT WASHER

3. 5/16 UNF CAPSCREW

2. Use a press to install the idler gear shaft into the main bearing cap. Make sure that the oil passage in the idler gear shaft is correctly oriented. See Figure 129. Apply Loctite 603 to the chamfer of the idler gear shaft where it joins the main bearing cap. Remove any excess Loctite and make sure the oil passage is clean.

Figure 130. Idler Gear Shaft Roll Pin

Fuel System Repair DESCRIPTION NOTE: Special tools and training are needed to repair the Lucas fuel injection pumps. They are normally sent to an authorized repair station if repairs are necessary. Fuel injectors also require special equipment and training for repair. Most users have a special repair service do this work. A Lucas DP200 series fuel injection pump is used on these engines. The pump timing and the speed adjustment cannot be changed. A mechanical governor controls the maximum engine speed. A lock screw holds the shaft of the pump from turning when it is not installed on the engine. See Figure 131. This lock screw must be released when the fuel injection pump is installed on the engine.

1. LOCK SCREW 2. BOOST CONTROL (TURBOCHARGED ENGINES ONLY)

3. STOP SOLENOID 4. COLD START DEVICE

Figure 131. Lucas Fuel Injection Pump

Fuel System Repair An electrically operated cold start device retards the timing for normal operation. A stop solenoid stops the operation of the engine. A vent in the pump permits an engine to start if there is a small amount of air in the fuel system. If the fuel system has a large amount of air, the air must be removed as described in Fuel System Air Removal. A boost control is added to the fuel injection pump for turbocharged engines. See Figure 131. The boost control is a device that is affected by the pressure from the turbocharger and reduces the maximum fuel flow at lower engine speeds. When the engine speed is lower, there is a reduced air supply to the cylinders. The fuel injectors receive fuel under high pressure from the fuel injection pump. The fuel injectors are set by the manufacturer, but must be checked according to the maintenance schedules. See Periodic Maintenance. The operation pressure of a fuel injector can be changed by adding or removing shims above the spring in the fuel injector.

600 SRM 705 Figure 133. The drive shaft of the pump must not be turned unless the spacer is in position under the lock screw. Before the crankshaft is turned or the pump is installed, put the spacer into position under the locking screw to make sure that the pump drive shaft is released. 1. Disconnect the battery. Remove the coolant pump as described in Coolant Pump, Remove. 2. Set the number one piston to TDC on the compression stroke. See How to Set Number One Piston to TDC on Compression Stroke. 3. Insert the timing pin through the hole in the fuel pump gear and the slot of the hub. See Figure 132. Push the pin fully into the hole in the body of the fuel pump. If the pin can be fully inserted, then the pump timing is correct. There should be no resistance when the pin is inserted.

The fuel pump has a diaphragm that is actuated by a lever. The lever is actuated by a lobe on the camshaft. The fuel pump has a small lever that can be operated with your hand to "prime" the fuel pump. NOTE: Good operation of the fuel injection system requires clean fuel and no dirt can be permitted in the system. Always clean carefully around a connection before it is disconnected. Install covers on open ports during maintenance. When the fuel system is opened for maintenance, the air must be removed from the fuel system before the engine is operated.

FUEL INJECTION PUMP Remove Special tools:

Timing pin PD.246 for Lucas fuel injection pumps

CAUTION Do not release the nut on the shaft of the fuel injection pump. See Figure 132. If this nut is removed, the fuel injection pump must be returned to an authorized service center. Setting the correct timing requires special equipment. A replacement fuel injection pump can have the pump shaft locked in position. See

1. TIMING PIN 2. NUT 3. TIMING HOLE IN BODY OF FUEL INJECTION PUMP

4. TIMING SLOT IN HUB 5. GEAR FOR FUEL INJECTION PUMP 6. CAPSCREW

Figure 132. Timing Components 4. Disconnect all of the fuel lines from the fuel injection pump. Use a second wrench to prevent movement of the union nuts when the fuel lines are disconnected. Disconnect the engine stop control. Disconnect the throttle cable. Disconnect the cold start device. 5. Remove the gear for the fuel injection pump as described in Fuel Injection Pump Gear.

600 SRM 705

Fuel System Repair 3. Install the fuel injection pump on the three studs and install the nuts. Tighten the nuts to 28 Nâ&#x20AC;˘m (21 lbf ft). NOTE: The fuel pump gear will only fit in one position. The gear is fitted with the letters C and M at the front. 4. Install the fuel pump gear onto the hub of the fuel pump. See Figure 132. The fasteners for the fuel pump gear should be in the center of the slots to allow for the removal of the backlash. Tighten the capscrews finger tight.

1. SPACER

2. LOCK SCREW Figure 133. Lock Screw

6. Remove the nuts that fasten the flange of the fuel injection pump to the timing case. See Figure 134.

1. GASKET

5. Insert the timing pin through the hole of the fuel pump gear and the slot of the hub until it can be pushed fully into the hole in the body of the fuel pump. See Figure 132. If the timing pin cannot be pushed into the pump body, check that the engine is correctly set at TDC on the number one cylinder. 6. Carefully turn the gear for the injection pump with your hand to remove the clearance between the gear and the idler gear. See Figure 135. Do not rotate the crankshaft or the shaft of the fuel injection pump. Tighten the capscrews for the gear for the fuel injection pump to 28 Nâ&#x20AC;˘m (21 lbf ft).

2. O-RING

Figure 134. Fuel Injection Pump Mount

Install 1. The engine must be set for the number one piston to TDC on the compression stroke. If the crankshaft needs to be rotated, the pump must be installed temporarily, or the loose gear could damage the timing case.

1. REMOVE GEAR CLEARANCE WITH YOUR HAND

2. Install a new gasket and new O-ring as shown in Figure 134. Lubricate the O-ring with a thin coat of engine oil.

7. Remove the timing pin.

Figure 135. Gear for Fuel Injection Pump Installation

8. Install the coolant pump. See Coolant Pump, Install.

Fuel System Repair 9. Connect the fuel lines. Use a second wrench to prevent movement of the union nuts when the fuel lines are connected. Do not tighten the union nuts greater than 22 Nâ&#x20AC;˘m (16 lbf ft). If there is a leak, make sure the fuel line is correctly aligned. A union nut that is too tight can cause a restriction in the fuel line. 10. Connect the engine stop control and the control rod for the fuel injection pump. 11. Remove the air from the fuel system. See Fuel System Air Removal. 12. When the engine can be operated, do Check and Adjust.

Check and Adjust 1. Operate the engine until it reaches normal operating temperature and check the idle speed. The idle speed can be adjusted with the idle adjustment screw shown in Figure 136.

600 SRM 705 code for the fuel injection pump is also found on a data plate fastened to the side of the pump. A typical setting code can be 2643M000AK/1/2750 where 2750 is the correct governed speed. The governed speed on an original fuel injection pump is set and sealed by the manufacturer. A replacement fuel injection pump must have the governed speed correctly set and the adjustment screw sealed. A setting that has been changed from the correct setting can affect the engine warranty.

FUEL SYSTEM AIR REMOVAL Small amounts of air will be removed from the fuel injection pump automatically when the engine is in operation. If the fuel lines have been disconnected, the fuel filter has been replaced, or the engine has run out of fuel, air must be removed from the fuel system.

CAUTION Damage to the fuel injection pump, starter motor, and battery can occur if the starter motor is used to remove air from an empty fuel system. 1. If the fuel system or a component in the fuel system has been drained, use the following steps to remove air from the fuel system. a. Loosen the vent plug on top of the filter. See Figure 137.

1. GOVERNOR ADJUSTMENT SCREW 2. IDLE ADJUSTMENT SCREW Figure 136. Adjustment Screws NOTE: The idle speed and the governed speed can be different than the Engine Data when these engines are installed in some models of lift trucks. See the Periodic Maintenance for the specifications that apply to a lift truck model. 2. Check the governed speed. The maximum engine speed can be adjusted with governor adjustment screw shown in Figure 136. See the Engine Data for the correct governed speed. The setting

1. VENT PLUG Figure 137. Loosen Vent Plug

600 SRM 705 b. Operate the priming lever on the fuel pump until fuel, without air bubbles, comes from the loosened connection bolt. If the lobe on the camshaft has moved the internal lever of the fuel pump to the highest point of its lift, the priming lever will not operate. The crankshaft must be rotated one revolution to move the lobe on the camshaft. See Figure 138.

Fuel System Repair d. Loosen the connections at two of the inlets to the fuel injectors. Operate the engine with the starter motor until fuel, without air bubbles, comes from the loosened connections. Then tighten the connection to 22 Nâ&#x20AC;˘m (16 lbf ft). See Figure 140.

1. CONNECTION Figure 140. Loosen Another Connection on Inlet to Cold Start Aid Figure 138. Rotate Crankshaft c. Loosen the connection on the inlet to the cold start aid. Operate the priming lever on the fuel pump until fuel, without air bubbles, comes from the loosened connection. Then tighten the connection. See Figure 139.

2. The engine is now ready to start. If there is still a small amount of air in the fuel system, the engine sometimes runs correctly for a short time and then stops. If a second attempt to start the engine causes the engine to run correctly for a short time and then stop, or runs roughly, check for air in the fuel system. Make sure you check for leaks in the low pressure (suction) part of the fuel system. 3. After the engine starts, operate the engine at idle speed for five minutes to make sure all of the air is removed from the fuel system.

FUEL FILTER, REPLACE NOTE: Four-cylinder engines normally have a water separator and a fuel filter. Six-cylinder engines normally have two fuel filters.

1. CONNECTION Figure 139. Loosen One Connection on Inlet to Cold Start Aid

Fuel System Repair

600 SRM 705

Canister Type CAUTION Disposal of diesel fuel and filter must meet local environmental regulations.

CAUTION It is important that only the genuine Perkins parts are used. The use of a wrong canister or element can damage the fuel injection pump. Do not allow dirt to enter the fuel system. Before a connection is disconnected, clean thoroughly the area around the connection. After a component has been disconnected, fit a suitable cover to all open connections. 1. Thoroughly clean the outside surfaces of the fuel filter assembly. 2. Loosen the drain device at the bottom of the filter and allow the water/fuel to drain into a suitable container. See Figure 141.

1. ADAPTER

2. TOP SEALS

Figure 142. Canister Type Fuel Filter 5. Lubricate lightly the top seals of the new canister with clean fuel. See Figure 142. Fit the new canister to the filter head and tighten, by hand only. 6. Remove the air from the fuel filter system. See Fuel System Air Removal.

Quick Release Canister Type CAUTION Disposal of diesel fuel and filter must meet local environmental regulations.

CAUTION It is important that only the genuine Perkins parts are used. The use of a wrong canister or element can damage the fuel injection pump. 1. DRAIN DEVICE Figure 141. Water/Fuel Drain 3. Use a strap wrench or similar tool to loosen the filter canister and remove the canister. 4. Make sure that the threaded adapter is secure in the filter head and that the inside of the head is clean. See Figure 142.

Do not allow dirt to enter the fuel system. Before a connection is disconnected, clean thoroughly the area around the connection. After a component has been disconnected, fit a suitable cover to all open connections. 1. Thoroughly clean the outside surfaces of the filter assembly. NOTE: If the filter does not have a drain device, release the cap on top of the filter head. See Figure 143. Remove the nylon insert to lower the level of the fuel in the filter canister. This will prevent fuel spill when the gland ring is released.

600 SRM 705

Fuel System Repair

2. Loosen the drain devices if a prefilter is fitted, at the bottom of the canister or sediment bowl and allow the water or fuel to drain into a suitable container. See Figure 143.

9. Support the canister(s), fit the gland ring, and rotate it to the right to fasten the canister to the filter head. 10. If it was removed, fit the nylon insert used to lower the level of the fuel in the filter canister and fasten the cap. 11. Remove the air from the fuel system. See Fuel System Air Removal.

FUEL INJECTORS The engine will run roughly if a fuel injector has a defect. To find which fuel injector has a defect, operate the engine at approximately 1000 rpm. Loosen and tighten the connection to the inlet of each fuel injector in a sequence. When the connection to the fuel injector with the malfunction is loosened, there will not be a change in the engine speed. 1. CANISTER REMOVAL 2. CAP 3. CANISTER INSTALLATION 4. FUEL FILTER

5. 6. 7. 8. 9.

SEDIMENT BOWL DRAIN DEVICE GLAND RING DRAIN DEVICE FUEL FILTER

Figure 143. Quick Release Canister Type Fuel Filter 3. Support the filter canister(s) and rotate the gland ring to the left and remove the gland ring.

Remove WARNING Do not put your hands on fuel lines under pressure. Diesel fuel can be injected into your body by the hydraulic pressure.

CAUTION

4. Remove the canister(s) from the filter head by a direct pull downwards, and discard the old canister.

Do not allow dirt to enter the fuel system. Before a connection is disconnected, clean thoroughly the area around the connection. After a component has been disconnected, cover all open connections.

5. If a sediment bowl is installed, remove the bowl and thoroughly clean the cover of the bowl.

1. Disconnect the fuel return line from the fuel injector.

6. Check the two O-ring seals of the sediment bowl and fit the bowl for damage and replace them if necessary.

2. Disconnect the high pressure line at the inlet to the fuel injector. Disconnect the other end of the high pressure line from the fuel injection pump. Hold the outlet fitting from the fuel injection pump with a wrench so that it does not turn while the connection is loosened for the fuel line. Do not bend the fuel line. See Figure 144. Install a plastic cap to cover the inlet connection and the injector.

7. Clean the threads of the sediment bowl and fit the bowl to the canister and tighten by hand only.

CAUTION It is important to ensure that the main and prefilters are fitted in the correct positions. 8. Ensure the filter head is clean. Push the new canister(s) fully into the filter head.

3. Loosen the nut and remove the fuel injector. See Figure 144. Remove the seat washer from the cylinder head.

Fuel System Repair

600 SRM 705 2. Make sure the wire clip is correctly installed. Put a 2 mm (0.08 in.) bead of thread sealant onto the first two threads of the nut. The thread sealant is either Perkins POWERPART Atomizer Thread Sealant or Hylomar Advance Formulation, Part No. 21825474. The bead should extend approximately 6 mm (0.24 in.) around each of the threads. Make sure there is no thread sealant on the body of the fuel injector. 3. Use a new seat washer. Make sure the original seat washer was removed from the cylinder head or the fuel injector will not fit correctly. 4. Install the fuel injector into the cylinder head. Make sure the location ball fits into the groove.

CAUTION Do not move the nut after it has been tightened. The seal will be broken and there can be leaks past the seat of the fuel injector. 5. Tighten the nut smoothly to 40 N•m (30 lbf ft). As the nut is tightened, the fuel injector will rotate a small amount clockwise as the location ball moves in its slot. Remove any excess thread sealant.

CAUTION 1. PLASTIC CAP 2. FUEL RETURN CONNECTION 3. NUT

4. 5. 6. 7.

WIRE CLIP GROOVE SEAT WASHER LOCATION BALL

Figure 144. Fuel Injector

Inspect The inspection and repair of fuel injectors require special tools and training. A special repair service normally makes repairs on injectors. Fuel injectors that have a malfunction will cause black smoke in the exhaust, a decrease in engine power, and an increase in engine noise.

Install 1. Make sure the threads of the nut and the threads in the cylinder head are clean. See Figure 144.

CAUTION Do not allow any thread sealant below the threads of the nut.

Do not tighten the union nuts of the high pressure pipes more than the recommended torque tension. If there is a leakage from the union nut, make sure that the pipe is correctly aligned with the fuel injector inlet. Do not tighten the fuel injector union nut more, as this can cause a restriction at the end of the pipe. This can affect the fuel delivery. 6. Remove the plastic cap and install the high pressure fuel line. Tighten the union nuts to 22 N•m (16 lbf ft). 7. Use new seal washers and install the fuel return line to the connection. Tighten the bolt on the banjo fitting to 9.5 N•m (84 lbf in). 8. If the fuel system is empty, remove the air from the fuel system. See Fuel System Air Removal. 9. When the engine can be operated, check for fuel leaks.

600 SRM 705

FUEL PUMP Remove 1. If a heat shield has been installed, remove the heat shield for the fuel pump. Disconnect the fuel lines to the fuel pump. 2. Remove the capscrews. Remove the fuel pump. If the lobe on the camshaft has moved the internal lever of the fuel pump to the highest point of its lift, the fuel pump can be difficult to remove. The crankshaft must be rotated one revolution to move the lobe on the camshaft.

Disassemble 1. Clean the outside surfaces of the fuel pump. Make a mark across the flanges of the two halves of the fuel pump to make sure that it is assembled again in the same positions. 2. Remove the cover and the screen. See Figure 145. Remove the screws and separate the two halves of the fuel pump.

Fuel System Repair 6. Remove the link arm. Hold the rocker lever in a vise and hit the body of the fuel pump with a soft hammer to release the two retainers. Be careful that the joint face of the fuel pump body is not damaged. Remove the rocker lever, pin, link arm, and the return spring. Check the components for wear or damage.

Assemble 1. Thoroughly clean the valve housings. Install new seat washers. See Figure 146. Push new valves into position. The valves are the same, but they are installed in the opposite direction from each other. Make sure that the valves are installed in the correct position. When the valves are correctly installed, use a punch on the edge of the valve housings to hold the valves in position. Use the punch in six places around each valve to hold the valve in position. 2. Install the rocker lever, pin, and the link arm assembly into position in the body of the fuel pump. Install the return spring. Make sure that the ends of the return spring are in their correct positions. 3. Use a small hammer and a drift or a punch to install the retainers in their grooves in the body of the fuel pump until they fasten the pin. Use a punch to close the ends of the grooves to fasten the retainers in position. 4. Install the diaphragm spring into its position under the diaphragm. Put the spring seat washer and the new stem seal into position on the pull rod. Make sure that the small diameter at the top of the stem seal is on the round part of the pull rod.

Figure 145. Fuel Pump Removal and Installation 3. Turn the diaphragm assembly 90 to release the pull rod from the link arm and remove the diaphragm assembly. 4. Remove the stem seal, the spring seat washer, and the spring from the pull rod. The diaphragm and pull rod assembly must be replaced as a unit.

5. Put the diaphragm assembly into position over the lower half of the body of the fuel pump. Align the blade of the pull rod with the slot in the link arm. Press down lightly on the diaphragm until the notch in the pull rod is in the slot in the link arm. Then turn the diaphragm 90 in either direction. This action will engage and retain the pull rod in the slot of the link arm.

5. The valves are held in their seats by punch marks in the metal. The metal must be made smooth so that valves can be removed.

Fuel System Repair

600 SRM 705

Install 1. The lobe on the camshaft must be in the minimum lift position before the fuel pump is installed. See Figure 145. Use a new gasket and install the fuel pump on the engine block. Apply Loctite to the first three threads of the capscrews. Install the capscrews. Tighten the capscrews to 22 Nâ&#x20AC;˘m (16 lbf ft). 2. Connect the fuel lines to the fuel pump. Install the heat shield. 3. Loosen the connection bolt on top of the filter as shown in Figure 137. 4. Operate the priming lever on the fuel pump until fuel, without air bubbles, comes from the loosened connection bolt. See Figure 138. 5. When the engine can be operated again, check for leaks.

Test

1. 2. 3. 4. 5.

COVER SCREEN SEAT WASHER (2) VALVE (2) DIAPHRAGM ASSEMBLY 6. STEM SEAL 7. SPRING SEAT WASHER

8. 9. 10. 11. 12.

LINK ARM PIN RETAINER (2) ROCKER LEVER DIAPHRAGM SPRING 13. SEAL

Figure 146. Fuel Pump Disassembly 6. Push the rocker arm toward the body of the fuel pump until the diaphragm is level with the flange half. Install the top half of the body in position. Align the reference marks. Keep the pressure on the rocker arm and install the lockwashers and screws. Tighten the screws evenly around the circumference of the fuel pump. 7. Install the screen and the cover. Make sure that the rubber seal is fitted correctly and tighten the screw that holds the cover.

1. Disconnect the fuel line from the outlet of the fuel pump. Install a 0 to 70 kPa (0 to 10 psi) pressure gauge to the outlet of the fuel pump. Loosen the connection at the gauge and operate the priming lever on the fuel pump to remove air from the fuel pump and the connection to the pressure gauge. Then tighten the connection. 2. Use the starter motor to operate the engine for 10 seconds. See the maximum pressure indicated on the pressure gauge. If the pressure is less than 42 to 70 kPa (6 to 10 psi), repair or replace the fuel pump. Also check the rate at which the pressure reduces to half of the maximum pressure. If the rate is less than 30 seconds to reduce to half of the maximum pressure, repair or replace the fuel pump. 3. Remove the pressure gauge from the fuel pump. Connect the fuel line to the outlet of the fuel pump again. 4. Loosen the connection bolt on top of the filter as shown in Figure 137. Operate the priming lever on the fuel pump until fuel, without air bubbles, comes from the loosened connection bolt. 5. When the engine can be operated again, check for leaks.

600 SRM 705

Cooling System Repair

Cooling System Repair GENERAL Coolant from the bottom of the radiator flows through the centrifugal coolant pump which is installed on the front of the timing case. The coolant pump is gear driven from the gear for the fuel injection pump. The coolant goes from the coolant pump through a passage in the timing case to the front of the engine block.

THERMOSTAT Most engines are fitted with a single thermostat (see Figure 147), some engines have twin thermostats. See Figure 148. 1. THERMOSTAT Figure 148. Engines YG and YH Thermostats Identification of the thermostat is by the nominal temperature which is stamped on the bypass valve of the thermostat. See Figure 147.

Remove 1. Drain the coolant level in the cooling system to below the thermostat position and disconnect the top hose from the coolant outlet connection. 2. Release the four capscrews and remove the thermostat housing from the lower body. See Figure 147. Discard the gasket. 3. Press the retainer clips inward, and lift the plastic collar from the thermostat housing. 4. Remove the thermostat and O-ring assembly from the thermostat housing. Discard the O-ring. NOTE: Engines YG and YH have two parallel thermostats. See Figure 148.

Install 1. Clean the thermostat housing, make sure that the groove for the clip retainers and the seat for the O-ring are free of debris. 1. THERMOSTAT HOUSING 2. GROOVE FOR RETAINER CLIPS

3. 4. 5. 6.

O-RING RETAINER CLIPS GASKET THERMOSTAT

Figure 147. Engine AR Thermostat

2. Make sure that the gasket faces of the thermostat housing and the lower body are clean and that the jiggle pin in the thermostat is free to move.

Cooling System Repair

600 SRM 705

3. Replace the O-ring and put the new thermostat in position in the housing. 4. Press the retainer clips inward, and push the plastic collar into the thermostat housing until the clip retainers engage the groove. 5. Install a new gasket; the gasket is installed dry. Fit and tighten the capscrews. 6. Connect the top hose and fill the cooling system.

Test 1. Hang the thermostat in a suitable container filled with coolant.

CAUTION If the thermostat does not operate correctly, it must be replaced. Do not try to adjust the settings. 2. Heat the coolant gradually. Use a thermometer to check the temperature at which the valve starts to open and at which it is fully open. The correct temperatures are given in the data and dimensions.

COOLANT PUMP Remove 1. Drain the cooling system and disconnect the hose at the inlet to the coolant pump.

1. NUTS ON REAR FACE OF TIMING CASE 2. COOLANT PUMP COVER 3. INLET CONNECTION Figure 149. Coolant Pump Removal

2. Remove the two capscrews from the rear face of the timing case. See Figure 149. 3. Remove the eight capscrews which hold the coolant pump to the front cover of the timing case. Remove the coolant pump. 4. Remove and discard the gasket.

Disassemble The coolant pump must be repaired if coolant or engine oil leaks from the hole in the pump body. See Figure 150. This leak indicates that the coolant seal or the oil seal is worn or damaged. Special tool:

Seal replacement tool

1. Remove the two studs from the pump body.

2. Remove the cover. See Figure 151. There are three access spaces on the edge of the cover so that a pry bar can be used to remove the cover from the pump body. Work carefully so that the cover does not have distortion. 3. Remove the impeller from the shaft. Drill four 6.35 mm (0.25 in.) holes at equal distance round the end of the pump shaft. These holes will break the press fit between the impeller and the pump shaft so that the impeller can be removed.

CAUTION Do not damage the seal face in the pump body for the coolant seal during removal of the seal. 4. Remove the coolant seal. The carbon seal must be broken and then use an extractor to remove the center sleeve of the seal from the pump shaft.

600 SRM 705

1. COOLANT PUMP COVER 2. OIL SEAL

Cooling System Repair

3. DRAIN HOLE 4. COOLANT SEAL 5. IMPELLER

1. ACCESS SPACE FOR PRY BAR Figure 151. Coolant Pump Cover Removal

Figure 150. Coolant Pump Seals 5. Remove the body of the seal. Drill three 3.175 mm (0.125 in.) holes through the top of the coolant seal 120 degrees apart. Install three 25.4 mm (1.00 in.) self-tapping screws in the holes. Insert a pry bar through the cooling inlet of the pump body and gradually and carefully apply the lever under the head of each self tapping screw. Carefully remove the coolant seal from the shaft. Discard the coolant seal. 6. Drill a 3.175 mm (0.125 in.) hole through the top of the oil seal. Install a 25.4 mm (1.00 in.) self-tapping screw in the hole. Insert a pry bar through the cooling inlet of the pump body and carefully apply the lever under the head of the self tapping screw. See Figure 152. Carefully slide the oil seal from the shaft. Discard the oil seal.

CAUTION Do not damage the seal face in the pump body for the oil seal during removal of the seal. 7. Remove and discard the snap ring. 8. Put a support under the pump body so that it is not damaged. Use a press to push the shaft through the pump gear and the pump body until the shaft and the ball bearing assembly are released from the pump. Discard the ball bearing assembly, pump shaft, and the two snap rings. Remove the pump gear. 9. Inspect the pump gear for wear and damage. Replace a worn or damaged pump gear. 10. Use a press to push the needle roller bearing from the pump body. Discard the bearing.

Cooling System Repair

600 SRM 705 Loctite does not get into the bearing. Use a press to install the needle roller bearing into the pump body until the end of the bearing is even with the body or not more than 0.5 mm (0.020 in.) below the surface of the body.

1. COOLANT PUMP BODY 2. OIL SEAL 3. BALL BEARING 4. PUMP GEAR

5. NEEDLE ROLLER BEARING 6. SNAP RING (2) 7. SNAP RING

Figure 152. Coolant Pump Seals Removal

Assemble 1. Clean the pump body. Give special attention to the bore for the bearing and the bore for the water seal. Both of these bores and their chamfers must be clean and free of corrosion. 2. Install a new snap ring onto the shaft. See Figure 153. 3. Put the pump gear into position in the pump body and use a press to push the shaft into the pump gear. If the original pump gear is used, use Loctite 638 between the pump gear and the shaft. Make sure the pump gear is against the shoulder of the shaft. 4. Apply a thin layer of Loctite 638 to the outer surface of the needle roller bearing. Make sure the

1. COOLANT PUMP BODY 2. BALL BEARING 3. HOUSING SURFACE 4. PUMP GEAR

5. NEEDLE ROLLER BEARING 6. SHAFT 7. SNAP RING 8. SNAP RING 9. SNAP RING

Figure 153. Coolant Pump Assembly 5. Apply a thin layer of Loctite 638 to the outer surface of the ball bearing. Make sure the Loctite does not get into the bearing. Use a spacer as a support for the pump gear. Make sure the pump gear is against the housing surface. Use an adapter and a press to push the new ball bearing onto the shaft. Make sure the adapter presses on both the inner and outer races of the ball bearing so it is not damaged as it is pressed into the housing. Make sure the inner race touches the snap ring.

600 SRM 705 6. Remove the spacer that is a support for the shaft at the end with the pump gear. Continue to press the ball bearing into the housing. Then install the snap ring. 7. Install the new snap ring. Make sure the bevel edge of the snap ring is toward the oil seal. This snap ring holds the shaft and bearing assembly in the pump body.

Cooling System Repair 9. Press the oil seal into the oil seal space in the pump body. The tool shown in Figure 155 can be made to press the oil seal into position. The tool will also prevent axial distortion of the oil seal when it is pressed onto the shaft.

8. Lightly lubricate the oil seal with clean engine oil. See Figure 154. Install the tapered tool PD.247 onto the shaft with the tapered end toward the bearing. The purpose of the tapered tool is to make sure the lip of the oil seal is correctly fitted when the oil seal is pressed into position. Push the oil seal over the tapered tool and into position in the pump body. The flat face of the oil seal is toward the impeller.

A. B. C. D.

40.0 mm (1.57 in.) 80.0 mm (3.15 in.) 60.0 mm (2.36 in.) 42.0 mm (1.65 in.)

E. 29.0 mm (1.14 in.) F. 14.5 mm (0.57 in.) G. 12.0 mm (0.47 in.)

Figure 155. Installation Tool for Oil Seal 10. Use the tool to press the oil seal into the pump body until the seal is 14.5 mm (0.57 in.) from the end of the flange for the coolant seal. When the seal is in position, continue to apply force for approximately 10 seconds to make sure the oil seal remains in position when the force is released.

CAUTION Do not lubricate the coolant seal. It is important that the coolant seal is not contaminated with oil or grease. If the seal is held in the hand, only touch the edge of the outside flange. Make sure the green sealant that is applied to the coolant seal just behind the flange is not damaged.

1. 14.5 mm (0.57 in.) DISTANCE BETWEEN OIL SEAL AND FLANGE FOR COOLANT SEAL 2. OIL SEAL Figure 154. Coolant Pump Seals Oil Seal Installation

11. Push the coolant seal onto the shaft until it touches the counterbore for the coolant seal. See Figure 156. The widest part of the coolant seal is toward the oil seal. Make sure the coolant seal is aligned with the counterbore and use a press and adapter to push the coolant seal into the counterbore. Make sure the adapter only pushes on the outer flange of the coolant seal. Continue to apply force for approximately ten seconds to

Cooling System Repair

600 SRM 705 pump body. See Figure 156. Rotate the impeller after installation to make sure it rotates freely.

be sure the seal remains in position when the force is released.

A. B. C. D. E.

44.0 mm (1.73 in.) 40.0 mm (1.57 in.) 12.2 mm (0.48 in.) 35.8 mm (1.41 in.) 16.1 mm (0.63 in.)

1.00 mm (0.04 in.) AT 45 DEGREES G. 2.00 mm (0.08 in.) AT 45 DEGREES

Figure 157. Installation Tool for Coolant Seal 14. Put a bead of Loctite 290 on the contact surface of the pump cover (2). Make sure the cover is aligned with the pump body and use a press to install the cover. Make sure the pump cover is pressed evenly and fully onto the pump body. 15. Install the two studs into the pump body. See Figure 158. 1. IMPELLER CLEARANCE = 0.44 to 1.06 mm (0.017 to 0.042 in.) 2. COOLANT PUMP COVER 3. IMPELLER 4. COOLANT SEAL 5. RECESS DISTANCE FROM FRONT OF PUMP BODY TO IMPELLER Figure 156. Coolant Pump Assembly 12. A tool can be made to press the coolant seal into position. See Figure 157. The dimensions of this tool will make sure the coolant seal is the correct length after installation. The tool will prevent axial distortion of the coolant seal when it is pressed onto the shaft. 13. Make sure the end of the shaft with the drive gear has a support. Use a press and an adapter to press the impeller onto the shaft. The face of the impeller must be 10.35 to 10.48 mm (0.407 to 0.413 in.) recess distance from the front of the

Install 1. Make sure the gasket surfaces of the coolant pump and the timing case cover are clean. See Figure 158. Make sure the surface at coolant pump is clean. 2. Make sure the gear for the coolant pump is not worn or damaged. A worn or damaged gear must be replaced. 3. Install a new gasket on the pump body. Do not use sealant. 4. Make sure the studs are correctly installed and tightened. 5. Install the coolant pump on the timing case cover. Make sure the pump gear engages correctly the gear for the fuel injection pump.

600 SRM 705

1. TIMING CASE COVER 2. STUDS

Cooling System Repair

3. GASKET 4. COOLANT PUMP

Figure 158. Coolant Pump Connections

1. NUTS ON REAR FACE OF TIMING CASE 2. INLET CONNECTION 3. ADD SEALANT TO THREAD OF CAPSCREWS Figure 159. Coolant Pump Installation

6. Three of the capscrews have sealant applied when they are new. See Figure 159. If these capscrews are installed again, the old sealant must be cleaned and apply Loctite 542 to the first three threads.

2. Loosen the pivot fasteners for the alternator and the fastener for the adjustment bracket. Remove the drive belts.

7. Install and tighten the two nuts on the studs at the back of the timing case.

3. Check the axial movement of the fan shaft. If the axial movement is greater than 0.25 mm (0.010 in.), the fan bearing assembly must be replaced.

8. Install the eight capscrews that fasten the coolant pump to the cover of the timing case. 9. Connect the coolant hose at inlet connection and fill the cooling system. When the engine can be operated, check for leaks.

4. Remove capscrews and remove the fan drive from the timing case cover.

Install

FAN AND FAN DRIVE

1. Install the fan drive on the timing case cover and tighten the capscrews to 44 Nâ&#x20AC;˘m (32 lbf ft).

Remove

2. Install the fan. Tighten the capscrews.

1. Remove the capscrews and remove the fan.

3. Install the drive belts and adjust the tension.

Cooling System Repair

OIL COOLER (SIX-CYLINDER ENGINES)

600 SRM 705 4. Use new O-rings on the flanges and studs as shown in Figure 161.

Remove 1. Drain the cooling system. 2. Disconnect the oil lines at the flange on the cover of the oil cooler. 3. Remove the capscrews and nuts from the cover of the oil cooler and remove the cover and element. See Figure 160.

1. O-RINGS Figure 161. Cooler Element Joints 5. Install the cooler element on the cover and tighten the nuts to 22 Nâ&#x20AC;˘m (16 lbf ft).

Install 1. STUDS Figure 160. Oil Cooler and Element

Disassemble and Assemble 1. Remove the capscrews and remove the cover. 2. Remove the nuts on the front of the cover and remove the cooler element from the cover. 3. Clean the cooler element and check for cracks. If a cleaning solution is used to clean the outside of the element, make sure that the cleaning solution does not enter the element. Check that there are no restrictions for the oil flow through the element. If the internal part of the element must be cleaned, use a cleaning solution that will not damage copper. Flush the element to remove the cleaning solution and dry the element with compressed air at low pressure. Then flush the internal part of the element with clean engine oil.

1. If the studs have been removed and will be used again, clean the threads on the studs and on the engine block. Use liquid sealant on the threads before they are installed in the engine block. 2. Use a new gasket and install the oil cooler assembly to the engine block. Tighten the capscrews and nuts to 22 Nâ&#x20AC;˘m (16 lbf ft). 3. Use a new gasket and connect the oil lines to the flange on the cover and tighten the screws. 4. Fill the coolant system. 5. When the engine can be operated again, check for leaks.

Oil Cooler Bypass Valve 1. Remove the cap and remove the bypass valve. See Figure 162.

600 SRM 705

Electrical Equipment Repair 2. Check the spring and the valve seat for damage. Replace the parts if they are damaged. 3. Use a new aluminum washer. Install the bypass valve into the oil cooler and tighten the cap to 50 Nâ&#x20AC;˘m (37 lbf ft).

1. O-RING Figure 162. Oil Cooler Bypass Valve

Electrical Equipment Repair DRIVE BELTS

the thumb pressure is 45 N (10 lbf), the correct deflection is approximately 10 mm (0.394 in.).

Adjustment Check the drive belts for wear and damage. When a pair of drive belts are used, they must be replaced as a pair. When a pair of drive belts are used, adjust the tension for the tightest belt. A gauge is available that will indicate the tension in the drive belt. Fit the gauge at the center of the longest length of the drive belt and measure the tension. See Figure 163. The correct tension is approximately 355 N (80 lbf).

1. PIVOT FASTENER

2. ADJUSTMENT LINK

Figure 163. Gauge to Check Drive Belt Tension

Figure 164. Drive Belt Tension Check and Adjust

Many service people press on the drive belt with their thumb at the center of the longest length of the drive belt and check the deflection. See Figure 164. When

Loosen the bolt on the adjustment link and the pivot fasteners to adjust the tension of the drive belts. Move the alternator pulley against the drive belts to

Electrical Equipment Repair adjust the tension. Tighten the adjustment link and pivot fasteners. The drive belts are removed from the engine by loosening the tension and then removing them from the pulleys.

Remove 1. Release the belt tension on the drive belt with the correct size socket and a breaker bar. 2. Remove the drive belt from the engine.

Install WARNING Do not use a prybar to install the drive belt on the pulleys. The prybar can damage the drive belt and pulleys. 1. Loosen the top capscrew at the alternator mount and move the alternator toward the fan. Install the Drive belt over the fan and onto the pulleys. 2. Use a socket with a breaker bar to loosen the belt tensioner. Use the handle to pull the pulley away from the drive belt. See Figure 164. While holding the pulley away from the belt, pull the alternator away from the fan (as far as it will move) and tighten the capscrew at the top mount. Release the pulley for the belt tensioner. 3. After installation is complete, check the position of the indicator on the tensioner. When the tension is correct, the indicator will be in the area shown in Figure 163. If the tension is not correct check for the correct installation of the brackets and pulleys.

ALTERNATOR NOTE: The alternator normally used with this engine is made by Delco Remy or Motorola. See the section Alternator With Regulator 2200 SRM 2 for troubleshooting and repairs.

Remove 1. Disconnect electrical connection. 2. Loosen the pivot and adjustment link capscrews. 3. Release belt tension and remove the belts.

600 SRM 705 4. Remove the adjustment link from the alternator and remove the pivot capscrews. Note the position of the washers and spacers. Remove the alternator.

Install 1. Position the alternator in place and loosely install the pivot and adjustment link capscrews. Be sure the washers and spacers are installed in their correct positions. Be sure the alternator is aligned to the crankshaft pulley within Âą2.4 mm (Âą0.09449 in.). 2. Install the drive belts and adjust tension. See Drive Belts for tension adjustment. 3. Tighten all capscrews and check belt tension again. Connect the electrical connection. 4. Connect the electrical connection.

STARTER MOTOR See the section Starter, Delco 2200 SRM 106 for troubleshooting and repairs for the starter motor.

Remove 1. Disconnect the battery. 2. Disconnect the cables to the starter motor. 3. Remove the capscrews and remove the starter motor.

Install 1. Install the starter motor in position on the flywheel housing. Install and tighten the capscrews. 2. Connect the cables to the starter motor. 3. Connect the battery.

COLD START AID The cold start aid is an electrical device. A controlled amount of diesel fuel is inserted into the induction manifold where it is ignited by the cold start aid to heat the induction air. A heater coil in the body of the cold start aid expands a valve holder so that fuel can flow into the device where it is ignited by an ignition coil. The cold start aid is operated by a switch button on the instrument panel.

600 SRM 705

Air Compressor - Engines YG and YH

If the cold start aid is removed for cleaning or replacement, make sure that the surfaces between the induction manifold and the cold start aid are clean. Tighten the cold start aid to 31 Nâ&#x20AC;˘m (23 lbf ft). If air

is in the fuel system because the fuel line was disconnected, remove the air as described in Fuel System Air Removal.

Air Compressor - Engines YG and YH GENERAL The air compressor is installed in the PTO position on the rear face of the timing case. See Figure 165. The compressor is driven from the main idler gear through an idler gear for the compression. The cylinder head of the single cylinder compressor is cooled by coolant from the engine. The compressor is lubricated from the engine oil system of the engine. Engine oil flows through a pipe from the main oil passage in the engine to the crankcase of the compressor. The engine oil then flows through the bearings of the compressor and the bushing for the drive shaft. The engine oil returns to the oil sump through the timing case.

1. COOLANT HOSES 2. SPACERS (1W150R ONLY) 3. CAPSCREWS 4. SUPPORT BRACKET

5. CAPSCREWS 6. OIL TUBE, LUBRICATION 7. NUT

Figure 166. Bendix Compressor Removal and Installation 4. If an oil pump for the steering system is fastened to the back of the compressor housing, remove it. 5. Loosen the two capscrews. Remove the two capscrews. Remove the support bracket.

Figure 165. Air Compressor Installation

6. Remove the nut from the stud at the bottom of the compressor flange. Remove the nut from the stud at the front of the timing case and remove the air compressor from the engine.

REPAIR

Install

Remove

1. Set the piston of number one cylinder to TDC.

1. Drain the cooling system.

2. Install a new O-ring in its recess in the drive housing. See Figure 167.

2. Release the air pressure in the air system and disconnect all the pipe connections to and from the cylinder head of the compressor. 3. Remove the oil tube for the engine oil between the compressor and the engine block. See Figure 166.

3. Turn the crankshaft of the air compressor until the timing mark on the rear face of the crankshaft is aligned with the 6A line on the label at the rear face of the air compressor. See Figure 168.

Air Compressor - Engines YG and YH

600 SRM 705 5. Slide the compressor into the timing case until the teeth of the drive gear are against the teeth of the idler gear. Slowly turn the rear of the crankshaft of the air compressor clockwise until the teeth of the drive gear and the idler gear are fully engaged. Check that the timing mark on the crankshaft of the air compressor is aligned with the 6A area on the timing label. 6. Install the nut (Figure 166) on the stud. Install the nut on the stud (Figure 167). Tighten both nuts to 75 N•m (55 lbf ft).

1. THROUGH HOLE IN TIMING CASE 2. IDLER GEAR

3. STUD 4. STUD 5. O-RING

Figure 167. Bendix Compressor Installation into Drive Assembly 4. Install the end of the stud with the shortest thread into the flange of the air compressor. See Figure 167. Install the nut fully on the stud. Move the air compressor into its position and engage the stud in its hole in the timing case. Slide the compressor onto the stud for the bottom of the flange.

7. Install the support bracket. Install the capscrews loosely. See Figure 166. Install the spacers if used and the capscrews. Adjust the support bracket so that it only holds the air compressor and does not put tension on it. Tighten the two capscrews to 22 N•m (16 lbf ft). Tighten the two capscrews to 44 N•m (32 lbf ft). 8. Check that the O-ring in the cover at the rear of the air compressor is not damaged. Install the cover and tighten the two capscrews. 9. Make sure the oil tube (Figure 166) is in good condition and does not have a restriction. Make sure the engine stop solenoid is disconnected or the engine stop control is in the STOP position. Operate the started motor until engine oil flows from the oil tube. Connect the oil tube. Connect the engine stop solenoid. 10. Connect the coolant hoses and air pipes to the air compressor. 11. Install the engine coolant. When the engine can be operated, check for oil, air, and coolant leaks.

1. TIMING MARK (SHOWN ALIGNED FOR FOUR-CYLINDER ENGINES. ALIGN WITH 6A FOR SIX-CYLINDER ENGINES) Figure 168. Bendix Compressor Installation into Drive Assembly

600 SRM 705

Rotary Exhauster Replacement

Rotary Exhauster Replacement REMOVE WARNING Do not run the engine with the vacuum hose to brake booster disconnected and the supply port to exhauster open. To do so will cause the front seal of exhauster to push out and pressurize the engine crankcase. NOTE: Engines that are diagnosed with excessive crankcase blow-by must first have the rotary exhauster removed from the engine and the engine run for this diagnosis to be valid. A brake booster diaphragm failure may also cause the rotary exhauster front seal to be pushed out causing crankcase pressurization.

INSTALL 1. Install rotary exhauster into the back of timing case cover. Install capscrews and tighten to 35 Nâ&#x20AC;˘m (27 lbf ft). 2. Remove plugs from ports of the rotary exhauster and covers from lubricating oil and vacuum lines. Connect lubricating oil and vacuum lines to rotary exhauster.

NOTE: The rotary exhauster is used to provide vacuum for vehicle brake system. 1. Disconnect lubricating oil and vacuum lines from rotary exhauster. See Figure 169. Install covers on the oil and vacuum lines, and plugs in the open ports of the rotary exhauster to prevent dust and dirt from getting into the lines or the rotary exhauster. 2. Remove capscrews, rotary exhauster, and gasket from the back of timing case cover.

CLEAN

A. TO BRAKE BOOSTER

Clean all gasket material from timing case cover and rotary exhauster surfaces.

1. 2. 3. 4.

LUBRICATING OIL LINE VACUUM LINE CAPSCREW ROTARY EXHAUSTER Figure 169. Rotary Exhauster

Engine Specifications

600 SRM 705

Engine Specifications CYLINDER HEAD ASSEMBLY Refer to the following tables and figures for specifications for the cylinder head assembly. Table 1. Cylinder Head

Table 2. Valve Guides Inside diameter (finished surface) ............................ 9.000 to 9.022 mm (0.3543 to 0.3552 in.) Outside diameter

Angle of valve seat .......... 46 (88 included angle) or 31 (118 included angle)

Inlet ............................. 13.034 to 13.047 mm (0.5131 to 0.5137 in.)

Diameter of parent bore for valve guide

Exhaust ....................... 14.034 to 14.047 mm (0.5525 to 0.5530 in.)

Inlet ............................. 13.00 to 13.027 mm (0.5118 to 0.5128 in.) Exhaust ....................... 14.00 to 14.027 mm (0.5512 to 0.5522 in.) Leak test pressure........... 200 kPa (29 psi) Head thickness................ 102.79 to 103.59 mm (4.047 to 4.078 in.) Maximum distortion of cylinder head. See Figure 170.

Interference fit of valve guide in cylinder head..... 0.047 to 0.007 mm (0.0018 to 0.00027 in.) Total length ..................... 51.25 mm (2.018 in.) Extension from bottom of recess for valve spring .... 14.85 to 15.15 mm (0.585 to 0.596 in.)

Table 3. Inlet Valves Diameter, valve stem ....... 8.953 to 8.975 mm (0.3525 to 0.3533 in.) Clearance in valve guide ................................. 0.025 to 0.069 mm (0.001 to 0.0027 in.) Maximum clearance in valve guide Production limit ........... 0.089 mm (0.0035 in.) Service limit ................. 0.100 mm (0.004 in.)

Engine AR:

Engines YG, YH:

1 = 0.08 mm (0.003 in.) 2 = 0.15 mm (0.006 in.) 3 = 0.15 mm (0.006 in.)

1 = 0.13 mm (0.005 in.) 2 = 0.25 mm (0.010 in.) 3 = 0.25 mm (0.010 in.)

Figure 170. Cylinder Head Distortion Check

Diameter, valve head (Engine YG and YH).... 42.88 to 43.12 mm (1.688 to 1.698 in.) (Engine AR).................. 44.88 to 45.12 mm (1.766 to 1.776 in.) Angle of valve face ........... 45 or 30

600 SRM 705

Engine Specifications

Table 3. Inlet Valves (Continued) Depth of valve head below face of cylinder head to Production limit (see Figure 171 and Figure 172): (Engine YG and YH).... 1.40 to 1.70 mm (0.055 to 0.067 in.) (Engine AR).................. 0.40 to 0.60 mm (0.016 to 0.024 in.) Depth of valve head below face of cylinder head to Service limit (see Figure 171 and Figure 172):

Table 3. Inlet Valves (Continued) (Engine AR).................. 0.805 mm (0.032 in.) Total length (Engine YG and YH).... 122.67 to 123.30 mm (4.829 to 4.854 in.) (Engine AR).................. 123.75 to 124.40 mm (4.872 to 4.897 in.) Seal arrangement............. Rubber seal installed on valve guide (green)

(Engine YG and YH).... 1.95 mm (0.077 in.)

Engine Types YG to YH:

Engine Type AR:

Inlet Valves 1 = 10.585 to 10.715 mm (0.4167 to 0.4219 in.) 2 = 45.535 to 45.560 mm (1.7927 to 1.7937 in.) 3 = Radius 0.38 mm (0.015 in.) Maximum

Inlet Valves 1 = 10.585 to 10.715 mm (0.4167 to 0.4219 in.) 2 = 48.035 to 48.060 mm (1.8911 to 1.8921 in.) 3 = Radius 0.38 mm (0.015 in.) Maximum

Exhaust Valves 1 = 10.585 to 10.715 mm (0.4167 to 0.4219 in.) 2 = 43.535 to 43.560 mm (1.7139 to 1.7149 in.) 3 = Radius 0.38 mm (0.015 in.) Maximum

Exhaust Valves 1 = 10.585 to 10.715 mm (0.4167 to 0.4219 in.) 2 = 44.035 to 44.060 mm (1.7336 to 1.7346 in.) 3 = Radius 0.38 mm (0.015 in.) Maximum

Figure 171. Dimensions of Recesses for Valve Seat Inserts Table 4. Exhaust Valves

Table 4. Exhaust Valves (Continued)

Diameter, valve stem ...... 8.938 to 8.960 mm (0.351 to 0.3528 in.)

(Engine YG and YH)... 40.88 to 41.12 mm (1.609 to 1.619 in.)

Clearance in valve guide ................................ 0.040 to 0.84 mm (0.0016 to 0.0033 in.)

(Engine AR)................. 41.88 to 42.12 mm (1.649 to 1.658 in.)

Maximum clearance in valve guide Production limit .......... 0.104 mm (0.0041 in.) Service limit ................ 0.121 mm (0.0048 in.) Diameter, valve head

Angle of valve face .......... 45 or 30 Depth of valve head below face of cylinder head to Production limit (see Figure 171 and Figure 172): (Engine YG and YH)... 1.50 to 1.80 mm (0.059 to 0.071 in.) (Engine AR)................. 0.40 to 0.60 mm (0.016 to 0.024 in.)

Engine Specifications

Table 4. Exhaust Valves (Continued) Depth of valve head below face of cylinder head to Service limit (see Figure 171 and Figure 172): (Engine YG and YH)... 2.05 mm (0.081 in.) (Engine AR)................. 0.805 mm (0.032 in.)

600 SRM 705

Table 4. Exhaust Valves (Continued) (Engine AR)................. 123.75 to 124.40 mm (4.872 to 4.897 in.) Seal arrangement............ Rubber seal installed on valve guide (brown)

Total length (Engine YG and YH)... 122.65 to 123.30 mm (4.829 to 4.854 in.)

Engine Types YG to YH:

Engine Type AR:

Inlet Valves 1 = 1.5 mm (0.06 in.) 2 = 20 mm (0.800 in.) 3 = 7.0 mm (0.28 in.) 4 = 100 mm (4.00 in.) 5 = 37.25 to 37.45 mm (1.467 to 1.474 in.) 6 = 44.75 to 45.00 mm (1.762 to 1.772 in.) 7 = Radius 1.4 mm (0.055 in.) Maximum 8 = Radius 1.5 mm (0.06 in.) 9 = 1.5 mm (0.06 in.) 10 = 8.54 to 8.57 mm (0.336 to 0.337 in.)

Inlet Valves 1 = 1.5 mm (0.06 in.) 2 = 20 mm (0.800 in.) 3 = 7.0 mm (0.28 in.) 4 = 100 mm (4.00 in.) 5 = 37.82 to 38.02 mm (1.488 to 1.496 in.) 6 = 47.25 to 47.50 mm (1.860 to 1.870 in.) 7 = Radius 1.4 mm (0.055 in.) Maximum 8 = Radius 1.5 mm (0.06 in.) 9 = 1.5 mm (0.06 in.) 10 = 8.54 to 8.57 mm (0.336 to 0.337 in.)

Exhaust Valves 1 = 1.5 mm (0.06 in.) 2 = 20 mm (0.80 in.) 3 = 7.0 mm (0.28 in.) 4 = 100 mm (4.00 in.) 5 = 34.38 to 34.58 mm (1.354 to 1.361 in.) 6 = 42.75 to 43.00 mm (1.683 to 1.693 in.) 7 = Radius 1.4 mm (0.055 in.) Maximum 8 = Radius 1.5 mm (0.06 in.) 9 = 1.5 mm (0.06 in.) 10 = 8.54 to 8.57 mm (0.336 to 0.337 in.)

Exhaust Valves 1 = 1.5 mm (0.06 in.) 2 = 20 mm (0.80 in.) 3 = 7.0 mm (0.28 in.) 4 = 100 mm (4.00 in.) 5 = 36.62 to 36.82 mm (1.441 to 1.44961 in.) 6 = 43.25 to 43.50 mm (1.702 to 1.712 in.) 7 = Radius 1.4 mm (0.055 in.) Maximum 8 = Radius 1.5 mm (0.06 in.) 9 = 1.5 mm (0.06 in.) 10 = 8.54 to 8.57 mm (0.336 to 0.337 in.)

Figure 172. Pilot Tool to Insert Valve Seats for 45 or 30 Valves

600 SRM 705

Engine Specifications

Table 5. Valve Springs

Table 8. Rocker Arms and Bushings (Continued)

Installed length ............... 39.0 mm (1.54 in.) Load, installed length (Engine YG and YH)... 246 to 277.5 N (55.3 to 62.4 lbf) (Engine AR)................. 136.3 to 153.7 N (30.6 to 34.5 lbf) Active coils, number........ 3.3 Damper coils, number..... 0 Direction of coils.............. Left hand

Clearance between rocker arm and rocker arm shaft ......................... 0.03 to 0.09 mm (0.001 to 0.0035 in.) Maximum clearance (service) between rocker arm and rocker arm shaft ......................... 0.13 mm (0.005 in.)

PISTON AND CONNECTING RODS Refer to the following tables and Figure 173 for specifications for the piston and connecting rods.

Table 6. Tappets Table 9. Pistons (Engine AR) Diameter, tappet stem ..... 18.99 to 19.01 mm (0.7475 to 0.7485 in.) Diameter, tappet bore in cylinder block ................... 19.05 to 19.08 mm (0.7500 to 0.7512 in.) Clearance of tappet in engine block...................... 0.04 to 0.09 mm (0.0015 to 0.0035 in.)

Table 7. Rocker Arm Shaft Outside diameter ............ 19.01 to 19.04 mm (0.7484 to 0.7496 in.)

Table 8. Rocker Arms and Bushings Diameter, bore in rocker arm for bushing............... 22.23 to 22.26 mm (0.8752 to 0.8764 in.) Diameter, outside of bushing ............................ 22.28 to 22.31 mm (0.8772 to 0.8783 in.) Interference fit of bushing in rocker arm................... 0.020 to 0.089 mm (0.0008 to 0.0035 in.) Internal diameter, bushing (finished size) .... 19.06 to 19.10 mm (0.7505 to 0.7520 in.)

Type: Fastram combustion bowl, top ring groove has insert, graphite skirt. Diameter, bore for piston pin ..................................... 39.703 to 39.709 mm (1.5631 to 1.5633 in.) Height of piston above top face of engine block .......... 0.38 to 0.50 mm (0.015 to 0.020 in.) Width of groove for top ring (engine AR) ............... 2.60 to 2.62 mm (0.1023 to 0.1031 in.) Width of groove for second ring (All engines).............. 2.56 to 2.58 mm (0.1008 to 0.1016 in.) Width of groove for third ring (engine AR) ............... 3.53 to 3.55 mm (0.1389 to 0.1397 in.)

Table 10. Pistons (Engines YG and YH) Type: Fastram combustion bowl, top ring groove has insert, graphite skirt. Diameter, bore for piston pin ..................................... 39.703 to 39.709 mm (1.5631 to 1.5633 in.) Height of piston above top face of engine block .......... 0.38 to 0.50 mm (0.015 to 0.020 in.)

Engine Specifications

Table 10. Pistons (Engines YG and YH) (Continued) Width of groove for top ring (engines YG and YH)............................. tapered Width of groove for second ring (All engines)............................. 2.56 to 2.58 mm (0.1008 to 0.1016 in.) Width of groove for third ring (engines YG and YH)............................. 3.54 to 3.56 mm (0.1393 to 0.1401 in.)

600 SRM 705

Table 11. Piston Rings (Engine AR) (Continued) Gap of second ring (engine AR) .................................... 0.30 to 0.63 mm (0.012 to 0.025 in.) Gap of third ring (engine AR) .................................... 0.30 to 0.63 mm (0.012 to 0.025 in.)

Table 12. Piston Rings (Engines YG and YH) Top compression ring (engines YG and YH) ....... Barrel face, molybdenum insert, wedge

Table 11. Piston Rings (Engine AR)

Second compression ring (All engines)...................... Taper face, cast iron, outside bottom step

Top compression ring (engine AR)....................... Barrel face, molybdenum insert, rectangular

Oil ring (All engines)........ Coil spring, chromium face

Second compression ring (All engines)...................... Taper face, cast iron, outside bottom step Oil ring (All engines)........ Coil spring chromium face Width of top ring (engine AR) .................................... 2.475 to 2.490 mm (0.097 to 0.98 in.) Width of second ring (All engines)............................. 2.48 to 2.49 mm (0.097 to 0.098 in.) Width of third ring (All engines)............................. 3.47 to 3.49 mm (0.1366 to 0.1374 in.) Clearance of top ring in groove (engine AR) ........... 0.110 to 0.145 mm (0.004 to 0.006 in.) Clearance of second ring in groove (All engines) ..... 0.07 to 0.1 mm (0.003 to 0.004 in.) Clearance of third ring in groove (All engines).......... 0.05 to 0.09 mm (0.002 to 0.003 in.) Gap of top ring (engine AR) .................................... 0.28 to 0.51 mm (0.011 to 0.020 in.)

Width of top ring (engines YG and YH) ...................... Tapered Width of second ring (All engines)............................. 2.48 to 2.49 mm (0.097 to 0.098 in.) Width of third ring (All engines)............................. 3.47 to 3.49 mm (0.1366 to 0.1374 in.) Clearance of top ring in groove (engines YG and YH).................................... Wedge Clearance of second ring in groove (All engines) ..... 0.07 to 0.1 mm (0.003 to 0.004 in.) Clearance of third ring in groove (All engines).......... 0.05 to 0.09 mm (0.002 to 0.003 in.) Gap of top ring (engines YG and YH) ...................... 0.28 to 0.63 mm (0.011 to 0.025 in.) Gap of second ring (engines YG and YH) ....... 0.40 to 0.85 mm (0.016 to 0.034 in.) Gap of third ring (engines YG and YH) ...................... 0.25 to 0.75 mm (0.010 to 0.030 in.)

600 SRM 705

Engine Specifications Table 13. Piston Pins

Type ................................. Full floating Outside diameter ............ 39.694 to 39.700 mm (1.5628 to 1.5630 in.) Clearance fit in piston .... 0.003 to 0.015 mm (0.0001 to 0.0006 in.)

Table 14. Connecting Rods Type ................................. "H" section, wedge shape at small end Location of cap to connecting rod ................. Flat joint face with dowels or serrations Diameter, parent bore at big end ............................. 67.21 to 67.22 mm (2.6460 to 2.6465 in.) Diameter, parent bore at small end ......................... 43.01 to 43.04 mm (1.693 to 1.694 in.)

Table 15. Small End Bushings Type .................................. Steel back, lead bronze tin bearing material Outside diameter ............. 43.11 to 43.15 mm (1.6972 to 1.6988 in.) Inside diameter ................ 39.723 to 39.738 mm (1.5638 to 1.5645 in.) Surface finish grade ......... Ra 0.8 micrometers Clearance between bushing and piston pin .... 0.023 to 0.044 mm (0.0009 to 0.0017 in.)

Table 16. Connecting Rod Bearings (Engines AR and YG) Type ................................. Steel back, aluminum to tin bearing material Width ............................... 31.62 to 31.88 mm (1.245 to 1.255 in.)

Length grades.................. F, G, H, J, K, L

Thickness......................... 1.835 to 1.842 mm (0.0723 to 0.0725 in.)

Length between centers .. 219.05 to 219.10 mm (8.624 to 8.626 in.)

Bearing clearance............ 0.035 to 0.081 mm (0.0014 to 0.0032 in.) Available undersize bearings ...........................

0.25 mm ( 0.010 in.) 0.51 mm ( 0.020 in.) 0.76 mm ( 0.030 in.)

Table 17. Connecting Rod Bearings (Engine YH) Type .................................. Steel back, lead bronze bearing material with lead finish Width ................................ 31.55 to 31.88 mm (1.240 to 1.255 in.) NOTE: THE LARGE AND SMALL BORES IN THE CONNECTING ROD MUST BE SQUARE AND PARALLEL WITH EACH OTHER WITHIN THE LIMITS OF ±0.25 mm (0.010 in.). THE MEASUREMENT IS MADE AT 127 mm (5.0 in.) ON EACH SIDE OF THE AXIS OF THE CONNECTING ROD. IF THE BUSHING IS INSTALLED IN THE SMALL END OF THE CONNECTING ROD, THE LIMITS ARE REDUCED TO ±0.06 mm (0.0025 in.).

Thickness.......................... 1.835 to 1.844 mm (0.0723 to 0.0726 in.) Bearing clearance............. 0.030 to 0.081 mm (0.0012 to 0.0032 in.) Available undersize bearings ............................

0.25 mm ( 0.010 in.) 0.51 mm ( 0.020 in.) 0.76 mm ( 0.030 in.)

Figure 173. Connecting Rod Alignment Check

Engine Specifications Table 18. Piston Cooling Jets Valve open pressure ........ 178 to 250 kPa (26 to 36 psi)

CRANKSHAFT ASSEMBLY Refer to the following tables for specifications for the crankshaft assembly. Table 19. Crankshaft Diameter, main journal (Engine AR)................. 76.16 to 76.18 mm (2.998 to 2.999 in.) (Engine YG and YH)... 76.159 to 76.190 mm (2.9984 to 2.9996 in.) Maximum wear and oval wear on main and crank journals............................ 0.004 mm (0.00016 in.) Width of front journal ..... 36.93 to 37.69 mm (1.454 to 1.484 in.) Width of center journal ... 44.15 to 44.22 mm (1.738 to 1.741 in.) Width of all other main journals............................ 39.24 to 39.35 mm (1.545 to 1.549 in.) Diameter of crank journal.............................. 63.47 to 63.49 mm (2.499 to 2.500 in.)

100

600 SRM 705

Table 19. Crankshaft (Continued) Width of crank journals ............................ 40.35 to 40.42 mm (1.589 to 1.591 in.) Diameter of flange........... 133.27 to 133.37 mm (5.247 to 5.251 in.) Depth of recess for spigot bearing (Engine AR)................. 20.22 to 20.98 mm (0.796 to 0.826 in.) (Engine YG and YH)... 14.72 to 15.48 mm (0.579 to 0.609 in.) Bore of recess for spigot bearing (Engine AR)................. 46.96 to 46.99 mm (1.849 to 1.850 in.) (Engine YG and YH)... 51.97 to 51.99 mm (2.046 to 2.047 in.) Axial movement .............. 0.05 to 0.38 mm (0.002 to 0.015 in.) Maximum axial movement (service) ......... 0.51 mm (0.020 in.) Fillet radii, all journals ............................ 3.68 to 3.96 mm (0.145 to 0.156 in.) Undersize journals, all....

0.25 mm ( 0.010 in.) 0.51 mm ( 0.020 in.) 0.76 mm ( 0.030 in.)

600 SRM 705

Engine Specifications

Table 20. Main Bearings Type ................................. Steel back, 20% tin to aluminum bearing material Width, center bearing (All engines)..................... 36.32 to 36.70 mm (1.430 to 1.445 in.) Width, other bearings (Engine AR) ..................... 31.62 to 31.88 mm (1.245 to 1.255 in.) Width, other bearings (Engines YG and YH) ..... 30.86 to 31.12 mm (1.215 to 1.225 in.) Bearing thickness (All engines)............................ 2.083 to 2.89 mm (0.0820 to 0.11378 in.) Bearing clearance (Engine AR) ..................... 0.057 to 0.117 mm (0.0022 to 0.0046 in.) Bearing clearance (Engines YG and YH) ..... 0.047 to 0.117 mm (0.0018 to 0.0046 in.) Available undersize bearings: ..........................

Table 21. Crankshaft Thrust Washers Type ................................. Steel back, lead bronze bearing material Position ............................ each side of the center main bearing Thickness: to Standard ................. 2.26 to 2.31 mm (0.089 to 0.091 in.) to Oversize................... 2.45 to 2.50 mm (0.096 to 0.098 in.)

Table 22. Crankshaft Heat Treatment The following part numbers are induction hardened: ..................... 3131H024 The following part numbers are nitrocarburized:............................ 3131H022 31315991 31315995 31315681 The following part numbers are 60-hour nitride: ............................ 3131H021

0.25 mm ( 0.010 in.) 0.51 mm ( 0.020 in.) 0.76 mm ( 0.030 in.)

101

Engine Specifications

600 SRM 705

Crankshaft Overhaul Induction hardened crankshafts do not need to be hardened after they have been machined undersize. Nitrocarburized crankshafts must be hardened again each time after they have been machined. If nitrocarburized or nitrided hardening methods are not available, the crank shaft must be replaced or exchanged with a crankshaft from the manufacturer.

Check the crankshaft for cracks before and after it is machined (ground). Remove any magnetism after the crankshaft has been checked for cracks. After the crankshaft has been machined, remove any sharp edges from the oil holes for lubrication. Surface finish and fillet radii must be according to the specifications. The finished sizes for machined crankshafts are shown in Table 23.

Crankshafts that have a 60-hour nitride treatment can be machined a maximum of 0.25 mm (0.010 in.) without the need to harden them again. Table 23. Crankshaft Overhaul Specifications Undersize

102

Item

0.25 mm (0.010 in.)

0.51 mm (0.020 in.)

0.76 mm (0.030 in.)

75.905 to 75.926 mm (2.9884 to 2.9892 in.)

75.651 to 75.672 mm (2.9784 to 2.9792 in.)

75.397 to 75.418 mm (2.9684 to 2.9692 in.)

63.216 to 63.236 mm (2.4888 to 2.4896 in.)

62.962 to 62.982 mm (2.4788 to 2.4796 in.)

62.708 to 62.728 mm (2.4688 to 2.4696 in.)

39.47 mm (1.554 in.) maximum

37.82 mm (1.489 in.) maximum

44.68 mm (1.759 in.) maximum

40.55 mm (1.596 in.) maximum

133.17 mm (5.243 in.) minimum

Do not machine this diameter

3.68 to 3.96 mm (0.145 to 0.156 in.)

600 SRM 705

Engine Specifications

Table 23. Crankshaft Overhaul Specifications (Continued) Undersize Item

0.25 mm (0.010 in.)

0.51 mm (0.020 in.)

0.76 mm (0.030 in.)

Surface finish for journals, crank fins and fillet radii must be 0.4 microns (16 micro inches). Surface finish for seal area of crankshaft palm must be 0.4 to 1.1 microns (16 to 43 micro inches).

When the crankshaft is on mounts at the front and rear main journals, the maximum variation (run-out) (total indicator reading) at the other main journals cannot be greater than in Table 24.

not be more than 0.10 mm (0.004 in.). The "run-out" on the crankshaft pulley diameter, rear oil seal diameter, and the rear flange diameter must not be more than 0.05 mm (0.002 in.) total indicator reading.

The "run-out" must not be opposite. The difference in "run-out" between one journal and the next one must

103

Engine Specifications

600 SRM 705 Table 24. Maximum Variation (Run-out)

Journal

Four-Cylinder Crankshafts

Six-Cylinder Crankshafts

Mount

0.08 mm (0.003 in.)

0.10 mm (0.004 in.)

0.15 mm (0.006 in.)

0.20 mm (0.008 in.)

0.08 mm (0.003 in.)

0.25 mm (0.010 in.)

Mount

0.20 mm (0.008 in.)

0.10 mm (0.004 in.)

Mount

TIMING CASE AND DRIVE ASSEMBLY Refer to the following tables for specifications for the timing case and drive assembly. Table 25. Camshaft

Table 25. Camshaft (Continued) Maximum out of round and wear on journals ...... 0.05 mm (0.0020 in.) Axial movement:

Diameter, journal No. 1 .. 50.71 to 50.74 mm (1.9965 to 1.9975 in.)

to Production limit...... 0.10 to 0.41 mm (0.004 to 0.016 in.)

Diameter, journal No. 2 .. 50.46 to 50.48 mm (1.9865 to 1.9875 in.)

to Service limit ............ 0.53 mm (0.021 in.)

Diameter, journal No. 3

Width, thrust washer space ................................ 5.64 to 5.89 mm (0.222 to 0.232 in.)

Engine AR ................... 49.95 to 49.98 mm (1.9665 to 1.9677 in.) Engines YG and YH.... 50.20 to 50.23 mm (1.9765 to 1.9775 in.) Diameter, journal No. 4 Engines YG and YH.... 49.95 to 49.98 mm (1.9665 to 1.9677 in.) Clearances, all journals .. 0.06 to 0.14 mm (0.0024 to 0.0055 in.) Cam lift to inlet: Engine AR ................... 8.58 mm (0.3378 in.) Cam lift to exhaust: Engine AR ................... 8.80 mm (0.3464 in.)

Table 26. Camshaft Thrust Washer Type ................................. 360 Clearance fit, thrust washer in engine block ... 5.46 to 5.54 mm (0.215 to 0.218 in.) Thickness, thrust washer ............................. 5.49 to 5.54 mm (0.216 to 0.218 in.) Extension of thrust washer beyond front face of engine block.................

0.05 to +0.08 mm ( 0.002 to +0.003 in.)

Cam lift to inlet: Engines YG and YH.... 7.62 to 7.69 mm (0.2999 to 0.3029 in.) Cam lift to exhaust: Engines YG and YH.... 7.71 to 7.79 mm (0.3036 to 0.3066 in.)

104

Table 27. Camshaft Gear No. of teeth....................... 56 Diameter, bore .................. 34.93 to 34.95 mm (1.3750 to 1.3760 in.)

600 SRM 705

Engine Specifications

Table 27. Camshaft Gear (Continued) Outside diameter, hub of camshaft ........................... 34.90 to 34.92 mm (1.3741 to 1.3747 in.) Clearance fit, gear on hub .................................... 0.008 to 0.048 mm (0.0003 to 0.0019 in.)

Table 28. Gear for Fuel Injection Pump No. of teeth...................... 56 Bore.................................. 36.00 to 36.06 mm (1.417 to 1.419 in.) 0.003 to 0.075 mm Clearance fit, gear on hub ................................... (0.0001 to 0.0030 in.)

Table 29. Crankshaft Gear

Table 30. Idler Gear and Hub (Continued) Outside diameter, hub if equipped with needle roller bearings .................. 54.987 to 55.000 mm (2.1648 to 2.1654 in.) Clearance, bushings on hub .................................... 0.04 to 0.10 mm (0.0016 to 0.0039 in.) Axial movement: to Production limit....... 0.10 to 0.20 mm (0.004 to 0.008 in.) to Service limit ............. 0.38 mm (0.015 in.) Axial movement if equipped with needle roller bearings .................. 0.24 to 0.33 mm (0.009 to 0.013 in.) to Service limit ............. 0.38 mm (0.015 in.) Gear clearance (all) .......... 0.08 mm (0.003 in.)

No. of teeth...................... 28 Diameter, bore................. 47.625 to 47.650 mm (1.8750 to 1.8760 in.) Diameter, hub for gear on 47.625 to 47.645 mm crankshaft........................ (1.8750 to 1.8758 in.) Press fit of gear on crankshaft........................

ENGINE BLOCK ASSEMBLY Refer to the following tables for specifications for the engine block assembly. Table 31. Cylinder Block (Engine AR)

0.020 to +0.048 mm ( 0.0008 to +0.0019 in.)

Height between top and bottom faces...................... 441.12 to 441.33 mm (17.367 to 17.375 in.)

No. of teeth....................... 63

Diameter of cylinder bore ................................... 103.000 to 103.025 mm (4.055 to 4.0561 in.)

Diameter, gear bore.......... 57.14 to 57.18 mm (2.2495 to 2.2512 in.)

Maximum wear of cylinder bore ..................... 0.15 mm (0.006 in.)

Diameter, gear bore if equipped with needle roller bearings .................. 69.01 to 69.03 mm (2.717 to 2.718 in.)

Diameter of first oversize cylinder bore ..................... 103.500 to 103.525 mm (4.0748 to 4.0757 in.)

Table 30. Idler Gear and Hub

Width, gear with split bushing assembly............. 30.14 to 30.16 mm (1.186 to 1.187 in.) Width, gear with flange bushing assembly............. 50.78 to 50.80 mm (1.9992 to 2.000 in.)

Diameter of second oversize cylinder bore ...... 104.000 to 104.025 mm (4.0944 to 4.0954 in.) NOTE: Two oversize pistons are available in service: 0.5 mm (0.020 in.) and 1.0 mm (0.040 in.)

Outside diameter, hub ..... 50.70 to 50.74 mm (1.9960 to 1.9975 in.)

105

Engine Specifications Table 32. Cylinder Bore Specifications

CAUTION Special training and equipment are needed to correctly flush the internal bore of a cylinder with a hone. Contact your nearest Perkins dealer. Preliminary Bore Final size of standard bore before it is honed..... 102.873 to 102.924 mm (4.0501 to 4.0521 in.) First oversize of bore before it is honed ............. 103.373 to 103.424 mm (4.0698 to 4.0718 in.) Second oversize of bore before it is honed ............. 103.873 to 103.924 mm (4.0894 to 4.0914 in.) Surface Finish ................. Ra 3.2 to 4.0 micrometers Maximum out-of-round and taper ......................... 0.02 mm (0.0008 in.) Diamond Hone Hone angle (cross hatch) ............................... 35 Finish size of standard bore, diamond honed....... 102.949 to 102.961 mm (4.0531 to 4.0536 in.) Finish size of first oversize bore, diamond honed ............................... 103.449 to 103.461 mm (4.0727 to 4.0732 in.)

600 SRM 705

Table 32. Cylinder Bore Specifications (Continued) Finish size of first oversize bore, silicone carbide base hone ............ 103.500 to 103.525 mm (4.0748 to 4.0757 in.) Finish size of second oversize bore, silicone carbide base hone ............ 104.000 to 104.025 mm (4.076 to 4.0954 in.) Surface Finish ................. Ra 1.3 to 1.6 micrometers Maximum out-of-round and taper ......................... 0.010 mm (0.0004 in.) Silicone Carbide Plateau Hone Finish size of standard bore, silicone carbide plateau hone .................... 103.000 to 103.025 mm (4.0551 to 4.0561 in.) Finish size of first oversize bore, silicone carbide plateau hone....... 103.500 to 103.525 mm (4.0748 to 4.0757 in.) Finish size of second oversize bore, silicone carbide plateau hone....... 104.000 to 104.025 mm (4.076 to 4.0954 in.) Surface Finish ................. Ra 0.65 to 1.3 micrometers Maximum out-of-round and taper ......................... 0.010 mm (0.0004 in.)

Finish size of second oversize bore, diamond honed ............................... 103.949 to 103.961 mm (4.0924 to 4.0929 in.)

Shaft Bores in Cylinder Block (Engine AR)

Surface Finish ................. Ra 2.2 to 3.0 micrometers

Diameter, camshaft bore (Engine AR):

Diameter of bore for main bearing ............................. 80.416 to 80.442 mm (3.1660 to 3.1670 in.)

Maximum out-of-round and taper ......................... 0.012 mm (0.0005 in.)

to No. 1 ........................ 55.56 to 55.59 mm (2.188 to 2.189 in.)

Silicone Carbide Base Hone

to No. 2 ........................ 50.55 to 50.60 mm (1.990 to 1.992 in.)

Hone angle (cross hatch) ............................... 35 Finish size of standard bore, silicone carbide base hone ......................... 103.000 to 103.025 mm (4.0551 to 4.0561 in.)

106

to No. 3 ........................ 50.04 to 50.09 mm (1.970 to 1.972 in.) Bore in bushing for No. 1 camshaft journal ............. 50.79 to 50.85 mm (2.000 to 2.002 in.)

600 SRM 705 Table 33. Cylinder Block (Engines YG and YH) Height between top and bottom faces...................... 441.12 to 441.33 mm (17.367 to 17.375 in.) Diameter, bore for cylinder liner .................... 104.20 to 104.23 mm (4.103 to 4.104 in.) Depth of space for flange of cylinder liner ................ 3.81 to 3.91 mm (0.150 to 0.154 in.) Diameter of space for flange of cylinder liner ..... 107.82 to 107.95 mm (4.245 to 4.250 in.) Diameter of bore for main bearing.............................. 80.416 to 80.442 mm (3.1660 to 3.1670 in.)

Engine Specifications

Table 34. Cylinder Liners (Engines YG and YH) (Continued) Inside diameter of service cylinder liner (installed) .. 100.00 to 100.06 mm (3.937 to 3.939 in.) Maximum wear of liner bore ................................... 0.25 mm (0.010 in.) Thickness of flange .......... 3.81 to 3.86 mm (0.150 to 0.152 in.) Top of flange even with face of engine block .......... 0.10 mm (0.004 in.) above 0.10 mm (0.004 in.) below

Table 35. Cylinder Liner Specifications (Partially Finished)

Diameter, camshaft bore (Engines YG and YH): to No. 1 ......................... 55.56 to 55.59 mm (2.188 to 2.189 in.) to No. 2 ......................... 50.55 to 50.60 mm (1.990 to 1.992 in.) to No. 3 ......................... 50.29 to 50.34 mm (1.980 to 1.982 in.) to No. 4 ......................... 50.04 to 50.09 mm (1.970 to 1.972 in.) Bore in bushing for No. 1 camshaft journal .............. 50.79 to 50.85 mm (2.000 to 2.002 in.)

Table 34. Cylinder Liners (Engines YG and YH) Outside diameter, production cylinder liner................................... 104.25 to 104.28 mm (4.105 to 4.106 in.) Fit of production cylinder liner................................... 0.03 to 0.08 mm (0.001 to 0.003 in.) Inside diameter of production cylinder liner................................... 100.00 to 100.03 mm (3.937 to 3.9385 in.) Fit of service cylinder liner................................... Âą0.03 mm (Âą0.001 in.)

CAUTION Special training and equipment is needed to machine the finish of a partially finished line. For further information contact your nearest Perkins Distributor. Partially finished liner Interference fit of liner in parent bore ...................... 0.025 to 0.076 mm (0.0010 to 0.0030 in.) Inside diameter of partially machined liner.................................. 99.162 to 99.415 mm (3.9040 to 3.9139 in.) Preliminary bore Final size of liner before it is honed ........................ 99.873 to 99.924 mm (3.9320 to 3.9340 in.) Surface finish .................. Ra 3.2 to 4.0 micrometers Maximum ovality and taper................................. 0.02 mm (0.0008 in.) Diamond hone Hone angle (cross hatch) ............................... 35 Finish size, diamond honed ............................... 99.95 mm (3.9350 in.) Surface finish .................. Ra 2.2 to 3.0 micrometers

107

Engine Specifications

Table 35. Cylinder Liner Specifications (Partially Finished) (Continued) Maximum ovality and taper................................. 0.012 mm (0.0005 in.) Silicone carbide base hone Hone angle (cross hatch) ............................... 35 Finish size, silicone carbide base hone ............ 100.012 mm (3.9374 in.) Surface finish .................. Ra 1.3 to 1.6 micrometers Maximum ovality and taper................................. 0.010 mm (0.0004 in.) Silicone carbide plateau hone Final finish size, carbide (plateau hone).................. 100.017 mm (3.9376 in.) Final surface finish grade ................................ 0.65 to 1.3 micrometers

CAUTION Special training and equipment are needed to correctly finish the internal bore of a cylinder liner with a hone. Contact your nearest Perkins dealer.

TURBOCHARGER

600 SRM 705

Table 36. Oil Pump (Engine AR) (Continued) Clearance of outer rotor to pump body ................... 0.15 to 0.34 mm (0.006 to 0.013 in.) Clearance of inner rotor to outer rotor ................... 0.04 to 0.13 mm (0.0015 to 0.0050 in.) Axial movement, rotor .... 0.03 to 0.10 mm (0.001 to 0.004 in.) Axial clearance of idler gear .................................. 0.012 to 0.643 mm (0.0005 to 0.0253 in.)

Table 37. Oil Pump (Engines YG and YH) Type .................................. Differential rotor, gear driven Number of lobes ............... Inner rotor 4, outer rotor 5 Clearance of outer rotor to pump body .................... 0.15 to 0.34 mm (0.006 to 0.013 in.) Clearance of inner rotor to outer rotor .................... 0.04 to 0.13 mm (0.0015 to 0.0050 in.) End clearance, Engine YG

Refer to the following table for specifications for the turbocharger.

to Inner rotor................ 0.05 to 0.12 mm (0.002 to 0.005 in.)

Engine YH ....................... Garrett T32

to Outer rotor ............... 0.04 to 0.11 mm (0.0015 to 0.0044 in.)

LUBRICATION SYSTEM Refer to the following tables for specifications for the lubrication system. Table 36. Oil Pump (Engine AR) Type ................................. Differential rotor, gear driven Number of lobes .............. Inner rotor 6, outer rotor 7

108

End clearance, Engine YH to Inner rotor................ 0.043 to 0.118 mm (0.0017 to 0.0046 in.) to Outer rotor ............... 0.031 to 0.106 mm (0.0012 to 0.0042 in.) Axial clearance of idler gear ................................... 0.020 to 0.650 mm (0.0008 to 0.0256 in.)

600 SRM 705

Engine Specifications

Table 38. Idler Gear for Oil Pump End float: Engine AR .................... 0.012 to 0.643 mm (0.0005 to 0.0253 in.) Engine YG and YH ...... 0.020 to 0.650 mm (0.0008 to 0.0256 in.) Inside diameter of bush (fitted) ............................... 22.23 to 22.26 mm (0.875 to 0.876 in.) Outside diameter of idler shaft .................................. 22.19 to 22.21 mm (0.873 to 0.874 in.) Clearance of bush of idler gear on shaft..................... 0.020 to 0.066 mm (0.0008 to 0.0026 in.)

Table 39. Relief Valve Diameter, bore for plunger............................. 18.24 to 18.27 mm (0.718 to 0.719 in.) Outside diameter, plunger............................. 18.16 to 18.18 mm (0.715 to 0.716 in.)

Table 39. Relief Valve (Continued) Load on spring, installed (Engines YG and YH) ..... 12.9 to 18.6 N (2.9 to 4.2 lbf) Pressure to open valve (Engine AR) ..................... 415 to 470 kPa (60 to 68 psi) Pressure to open valve (Engines YG and YH) ..... 345 to 414 kPa (50 to 60 psi)

Table 40. Oil Filter Type ................................. Full flow, canister Pressure to open bypass valve in oil filter .............. 55 to 83 kPa (8 to 12 psi) Pressure to open bypass valve in oil cooler............. 172 kPa (25 psi)

FUEL SYSTEM Refer to the following tables for specifications for the fuel system. Table 41. Lucas Fuel Injection Pump

Clearance of plunger in bore .................................. 0.06 to 0.11 mm (0.002 to 0.004 in.)

Type (Engines AR and YG) ................................... DP200 series

Length of spring, installed (Engine AR)...... 59.8 mm (2.4 in.)

Type (Engine YH)............ DP200 series with boost control

Length of spring, installed (Engines YG and YH)............................ 55.6 mm (2.2 in.)

Direction of rotation (from drive end)............... Clockwise

Load on spring, installed (Engine AR) ..................... 15.9 to 23.1 N (3.6 to 5.2 lbf)

Static timing: Timing pin and with the engine set with number one piston at TDC on the compression stroke. The pump is checked with the pump set at the start of injection for cylinder number one.

109

Engine Specifications

600 SRM 705 Table 42. Fuel Injector Codes

Code

Holder

Nozzle

Set and reset Pressure atm

(lbf/in 2)

MPa

2645A308

2645A624

300

4410

30.4

2645A309

2645A625

290

4263

29.4

2645A310

2645A626

290

4263

29.4

2645A311

2645A627

290

4337

29.9

2645A311

2645A628

295

4337

29.9

2645A314

2645A629

300

4410

30.4

2645A314

2645A630

290

4263

29.4

2645A315

2645A631

250

3675

25.3

2645A312

2645A632

300

4410

30.4

2645A312

2645A633

300

4410

30.4

2645A313

2645A634

300

4410

30.4

2645A315

2645A635

290

4263

29.4

2645A311

2645A636

290

4410

30.4

2645A311

2645A608

290

4263

29.4

2645A311

2645A638

290

4263

29.4

2645A316

2645A637

290

4263

29.4

2645A317

2645A627

290

4322

29.8

2645A304

2645L615

250

3675

25.3

2645A311

2645K609

290

4263

29.4

2645L306

2645L617

290

4263

29.4

2645L308

2645L618

290

4263

29.4

2645L307

2645L619

290

4263

29.4

2645L309

2645L620

290

4263

29.4

2645L310

2645L621

290

4263

29.4

2645L310

2645L622

290

4263

29.4

2645L310

2645L622

275

4043

27.9

0430 133 005

DSLA140P707

250

3675

25.3

2645F316

2645F620

250

3675

25.3

2645F316

2645F621

250

3675

25.3

0430 133 06

DSLA150PV3378123

250

3675

25.3

The code letters are on the side of the fuel injector body and just below the connection for the nut of the high pressure line.

110

600 SRM 705

Engine Specifications

Table 43. Fuel Pump (Engine AR) Type ................................. A.C. Delco, types XD Method of drive ............... Eccentric on camshaft Static pressure (no delivery) ........................... 42 to 70 kPa (6 to 10 psi) Test pressure (75% of minimum static pressure) .......................... 31 kPa (4.5 psi)

Table 47. Thermostat Type, Engine AR ............. Single, wax element, bypass blanking Type, Engines YG and YH .................................... Twin, wax element, bypass blanking "Start to open" ................. 77 to 85 C (170 to 185 F) "Fully open" ..................... 92 to 98 C (198 to 208 F) Valve lift, fully open ........ 9.0 mm (0.35 in.)

Table 44. Fuel Pump (Engines YG and YH) Type ................................. A.C. Delco, types LU Method of drive ............... Eccentric on camshaft Static pressure (no delivery) ........................... 34.5 to 55.2 kPa (5 to 8 psi) Test pressure (75% of minimum static pressure) .......................... 26 kPa (3.77 psi)

Table 45. Fuel Filter Type ................................. single element

Table 48. Fan Drive Housing Bore of housing for bearing ............................. 41.9655 to 41.9785 mm (1.6529 to 1.6522 in.) Outside diameter, bearing ............................. 41.987 to 42.00 mm (1.6535 to 1.6530 in.) Press fit, bearing in housing ............................ 0.0085 to 0.0345 mm (0.00033 to 0.00136 in.) Bore of hub ...................... 21.938 to 21.958 mm (0.8637 to 0.8645 in.)

(YG and YH engines are equipped with twin parallel flow filters)

Outside diameter of shaft ................................. 21.987 to 22.00 mm (0.8656 to 0.8661 in.)

COOLING SYSTEM

Press fit, shaft in hub ..... 0.029 to 0.062 mm (0.0011 to 0.0024 in.)

Refer to the following tables for specifications for the cooling system.

Maximum axial movement ........................ 0.200 mm (0.0079 in.)

Table 46. Coolant Pump Type ................................. centrifugal, gear drive

FLYWHEEL AND HOUSING Refer to the following table for specifications for the flywheel and housing.

111

Torque Specifications

600 SRM 705

Table 49. Limits for Flywheel Run Out and Alignment (Total Indicator Reading)

Table 50. Alternator Type ................................. Delco Remy or Motorola

Diameter of Housing Maximum Limit (Total Flange Bore Indicator Reading) Table 51. Starter Motor

in.

362

14.25

0.23

0.009

410

16.14

0.25

0.010

448

17.63

0.28

0.011

511

20.11

0.30

0.012

584

22.99

0.36

0.014

Type .................................. Diesel fuel, electrically operated heater

648

25.51

0.41

0.016

Voltage .............................. 12 volts

787

30.98

0.48

0.019

Fuel flow ........................... 3.5 to 5.9 milliliters/ minute

Type .................................. Delco Remy

Table 52. Cold Start Aid

ELECTRICAL EQUIPMENT Refer to the following tables for specifications for the electrical equipment.

Torque Specifications CYLINDER HEAD ASSEMBLY Capscrews, Cylinder Head 1/2 UNF (Special Procedure, see Cylinder Head Assembly, Install)

Banjo Bolts, Piston Cooling Jets 3/8 UNF 27 N•m (20 lbf ft)

CRANKSHAFT ASSEMBLY

Fasteners, Rocker Arm Brackets Aluminum M12 40 N•m (30 lbf ft) Cast Iron M12 75 N•m (55 lbf ft)

Capscrews, Main Bearings (Six-Cylinder Engines) 5/8 UNF 265 N•m (195 lbf ft)

Cap Nuts, Valve Cover M12 20 N•m (15 lbf ft)

Capscrews, Crankshaft Pulley 7/16 UNF 115 N•m (85 lbf ft)

Capscrews, Inlet Manifold to Cylinder Head M10 44 N•m (32 lbf ft)

Capscrews, Viscous Damper to Crankshaft Pulley M12 75 N•m (55 lbf ft)

Nuts (Cadmium Plated), Exhaust Manifold to Cylinder Head M10 44 N•m (32 lbf ft) Capscrews, Engine Lift Brackets M10 44 N•m (32 lbf ft)

PISTON AND CONNECTING ROD ASSEMBLIES Nuts, Connecting Rods 1/2 UNF 125 N•m (92 lbf ft) Capscrews, Connecting Rods 1/2 UNF 155 N•m (114 lbf ft)

112

Capscrews, Damper to Crankshaft Pulley M8 35 N•m (26 lbf ft) Capscrews, Rear Oil Seal Housing to Engine Block M8 22 N•m (16 lbf ft) Capscrews, Bridge Piece to Cylinder Block M6 16 N•m (12 lbf ft) Capscrews, Rear Oil Seal Housing to Bridge Piece M6 13 N•m (10 lbf ft)

600 SRM 705 Torx-screw, Rear Oil Seal Housing to Engine Block M8 18 N•m (13 lbf ft)

TIMING CASE AND DRIVE ASSEMBLY Capscrews, Timing Case to Engine Block M8 22 N•m (16 lbf ft) Capscrews, Timing Case to Engine Block M10 44 N•m (32 lbf ft) Capscrews, Hub of Idler Gear M10 44 N•m (32 lbf ft) Capscrew, Camshaft Gear M12 95 N•m (70 lbf ft) Capscrews, Timing Case Cover to Timing Case M8 22 N•m (16 lbf ft) Nuts, Timing Case Cover to Timing Case M8 22 N•m (16 lbf ft)

Torque Specifications Nut for Fuel Injector Body 40 N•m (30 lbf ft) Capscrews for Gear of Fuel Injection Pump M10 28 N•m (20 lbf ft) Special (Torx) Screws for Gear of Fuel Injection Pump M10 22 N•m (16 lbf ft) Nuts for Flange of Fuel Injection Pump M8 22 N•m (16 lbf ft) Locking Screw of Lucas DP 200 Fuel Injection Pump 10A/F 10 N•m (7 lbf ft)

COOLING SYSTEM Capscrews for Fan Drive Housing to Timing Case M10 44 N•m (32 lbf ft)

TURBOCHARGER

Capscrews, Fan Drive Pulley to Hub M8 22 N•m (16 lbf ft)

Nuts, Turbocharger to Manifold M10 44 N•m (32 lbf ft)

Capscrews, Fan Drive Pulley to Hub M10 44 N•m (32 lbf ft)

LUBRICATION SYSTEM

Capscrews, Fan M8 22 N•m (16 lbf ft)

Drain Plug, Oil Sump 3/4 UNF 34 N•m (25 lbf ft)

FLYWHEEL

Capscrews, Oil Pump to Front Bearing Cap M8 22 N•m (16 lbf ft)

Capscrews, Flywheel to Crankshaft 1/2 UNF 105 N•m (77 lbf ft)

Capscrews, Cover for Oil Pump M8 28 N•m (21 lbf ft)

AUXILIARY EQUIPMENT

Fasteners, Oil Sump M8 22 N•m (16 lbf ft)

Nut, Air Compressor Drive Gear to Compressor Drive Shaft 5/8 UNF 120 N•m (88 lbf ft)

FUEL SYSTEM Nuts, High to Pressure Fuel Lines M12 22 N•m (16 lbf ft) Bolt, Leak-Off Connection M8 9 N•m (7 lbf ft) Capscrews, Fuel Lift Pump M8 22 N•m (16 lbf ft)

Nut, (30 A/F) Air Compressor Gears M20 130 N•m (96 lbf ft) Capscrew, Bracket to Idler Hub M10 60 N•m (44 lbf ft) Capscrew, Bracket to Timing Case M8 35 N•m (26 lbf ft)

113

Special Torque Specifications

600 SRM 705

Special Torque Specifications FLYWHEEL AND HOUSING

ELECTRICAL EQUIPMENT

Capscrews, Flywheel to Crankshaft 1/2 UNF 105 N•m (77 lbf ft)

Nut, Alternator Pulley CAV AC5RA and AC5RS 5/8 UNF 55 N•m (40 lbf ft) Thin Nut A127, and Motorola Pulley, 22 mm A/F M17 60 N•m (44 lbf ft) Thick Nut A127, and Motorola Pulley, 24 mm A/F M17 80 N•m (59 lbf ft) Bosch 55A M14 45 N•m (33 lbf ft) Bosch 55A M16 50 N•m (37 lbf ft) Butec 5524 5/8 UNF 78 N•m (58 lbf ft)

Capscrews, Cast Iron Flywheel Housing to Cylinder Block M10 44 N•m (32 lbf ft) Head Stamped 8.8 M12 75 N•m (55 lbf ft) Head Stamped 10.9 M10 63 N•m (46 lbf ft) Head Stamped 10.9 M12 115 N•m (85 lbf ft) Capscrews, Aluminum Flywheel Housing to Cylinder Block M10 70 N•m (52 lbf ft) Capscrews, Flywheel Housing to Cylinder Block (Paper Joint) M10 70 N•m (52 lbf ft)

TURBOCHARGER Nuts, Turbocharger to Manifold M10 44 N•m (32 lbf ft)

Fuelled Start Aid to Induction Manifold 7/8 UNF 31 N•m (23 lbf ft) Port Heater to Induction Manifold M22 60 N•m (44 lbf ft) Nut/Screw, Starter Motor 3/8 UNF 30 N•m (22 lbf ft)

AUXILIARY EQUIPMENT Nut, Compressor Drive Gear to Compressor Crankshaft 5/8 UNF 120 N•m (88 lbf ft) Nut (30 A/F), Compressor Gears M20 130 N•m (96 lbf ft) Capscrew, Bracket to Idler Hub M10 60 N•m (44 lbf ft) Capscrew, Bracket to Timing Case M8 35 N•m (26 lbf ft)

114

600 SRM 705

Special Tools*

Special Tools* Remove and replace tool for valve guides.

Adapter tool for use with tool for valve guides.

Adapter tool (inlet valves) for use with tool for valve guides.

Adapter tool (exhaust valves) for use with tool for valve guides.

Timing pin for Lucas fuel injection pumps.

Gauge for piston height, valve depth, and cylinder liner flange; for use with dial gauge.

Contact your Perkins dealer for special tools.

115

Special Tools*

600 SRM 705

Dial gauge for use with gauge for piston height, valve depth, and cylinder liner flange.

Replacement tool for rear seal of crankshaft.

Remove and replace tool for cylinder liner.

Adapters for use with tool for cylinder liner.

Puller for camshaft gear.

Adapters for use with puller for camshaft gear.

Contact your Perkins dealer for special tools.

116

600 SRM 705

Special Tools*

Alignment tool for timing case cover (four-cylinder engines).

Alignment tool for timing case cover (six-cylinder engines).

Replacement tool for seal of timing case cover.

Pressure plate for use with tool for seal of timing case cover.

Fastener plate for use with tool for seal of timing case cover.

Sleeve for use with tool for seal of timing case cover.

Contact your Perkins dealer for special tools.

117

Special Tools*

600 SRM 705

Seal adapter for use with tool for seal of timing case cover.

Replacement tool for pistons.

Valve spring compressor.

Stud adapter for use with valve spring compressor.

Capscrew adapter for use with valve spring compressor.

Angle gauge to tighten cylinder head capscrews.

Contact your Perkins dealer for special tools.

118

600 SRM 705

Special Tools*

Set of adjustable cutters for valve seats.

Handle set for valve seat cutters.

Coolant pump oil seal replacer tool.

Angle gauge to tighten cylinder head capscrews.

Contact your Perkins dealer for special tools.

119

Troubleshooting

600 SRM 705

Troubleshooting Trouble

Possible Causes Checks by the user

Checks by service personnel

The starter motor turns the engine too slowly

1, 2, 3, 4

13, 34, 35, 36, 37, 38, 40, 42, 43 44

The engine is difficult to start

5, 6, 7, 8, 9, 10, 12, 14, 15, 17

13, 34, 36, 37, 38, 40, 42, 43, 44

Not enough power

8, 9, 10, 11, 12, 16, 17, 18, 19, 20, 21

13, 34, 36, 37, 38, 39, 42, 43, 44, 61, 63

Misfire

8, 9, 10, 11, 12, 15, 20, 22

13, 34, 36, 37, 38, 39, 40, 41, 43

Uses too much fuel

11, 15, 17, 18, 19, 21, 22

13, 34, 36, 37, 38, 39, 40, 42, 43, 44, 63

Black exhaust smoke

11, 15, 17, 19, 21, 22

13, 34, 36, 37, 38, 39, 40, 42, 43, 44, 61, 63

Blue or white exhaust smoke

4, 15, 21, 23

36, 37, 38, 39, 42, 44, 45, 52, 58, 62

The engine oil pressure is too low

4, 24, 25, 26

46, 47, 48, 50, 51, 59

The engine "knocks"

9, 15, 17, 20, 22, 23

13, 36, 37, 40, 42, 44, 46, 52, 53, 60

The engine operation is not constant

7, 8, 9, 10, 11, 12, 15, 16, 18, 20, 22, 23

13, 34, 38, 40, 41, 44, 52, 60

Unusual vibration

18, 20, 27, 28

13, 34, 38, 39, 40, 41, 44, 52, 54

The engine oil pressure is too high

4, 25

The engine temperature is too high

11, 15, 19, 27, 29, 30, 32

13, 34, 36, 37, 39, 52, 55, 56, 57

High crankcase pressure

31, 33

39, 42, 44, 45, 52

Bad compression

11, 22

37, 39, 40, 42, 43, 44, 45, 53, 60

The engine starts and stops

10, 11, 12

Table 53. List of Possible Causes

Table 53. List of Possible Causes (Continued)

Battery capacity is low.

Bad electrical connections.

11 Restriction in air cleaner or air induction system.

Fault in starter motor.

12 Air in fuel system.

Wrong grade of lubricating oil.

13 Fault in fuel injector.

Starter motor turns too slowly.

14 Cold start air used wrong.

Fuel tank is empty.

15 Fault in cold start system.

Fault in engine "STOP" control.

16 Restriction in vent of fuel tank.

Restriction in fuel line.

17 Wrong type or wrong grade of fuel.

Fault in fuel pump.

18 Malfunction in engine speed control.

10 Dirty fuel element.

19 Restriction in exhaust pipe. 20 Engine temperature is too high.

120

600 SRM 705

Troubleshooting

Table 53. List of Possible Causes (Continued)

21 Engine temperature is too low.

43 Leaks between a valve and its seat.

22 Valve clearances are wrong.

44 Piston rings are worn, broken, or frozen in piston.

23 Air filter has a restriction. 24 Not enough engine oil in the sump. 25 Pressure gauge has a malfunction. 26 Filter for engine oil is dirty. 27 Cooling fan is damaged. 28 Engine mount has a problem.

45 Valve stems and valve guides are worn. 46 Crankshaft bearings are worn or damaged. 47 Engine oil pump is worn. 48 Relief valve on engine oil pump does not close. 49 Relief valve on engine oil pump does not open.

29 Too much engine oil in the sump.

50 Relief valve spring on engine oil pump is broken.

30 Restriction in the air or coolant passages in the radiator.

51 Fault in suction pipe of engine oil pump.

31 Restriction in the breather pipe. 32 Cooling system needs coolant. 33 Engine vent system has a restriction. 34 Fuel injection pump has a fault.

52 A piston is damaged. 53 The height of a piston is wrong. 54 Flywheel or flywheel housing is not aligned correctly.

35 Broken drive on fuel injection pump.

55 Thermostat has a fault or is the wrong temperature range.

36 Timing on fuel injection pump is wrong.

57 Coolant pump is damaged.

37 Valve timing is wrong.

58 A seal on a valve stem is leaking.

38 Low compression.

59 Restriction in the strainer in the oil sump.

39 Leak in cylinder head gasket.

60 A valve spring is broken.

40 A valve is damaged.

61 Turbocharger impeller is damaged or dirty.

41 High pressure fuel lines are wrong.

62 Lubrication oil seal of turbocharger leaks.

42 Worn cylinder bores.

63 Induction system (with turbocharger) leaks.

121

122

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21.

WIRE CODES WIRE COLOR A BLUE B WHITE C RED D YELLOW E BLUE F RED G DREEN H BLACK J WHITE K RED L BLACK M BLACK N WHITE P YELLOW Q WHITE R BROWN S WHITE T GREEN U YELLOW V RED W BLACK X RED Y YELLOW Z BLACK

ALTERNATOR, D RATING STARTER BATTERY (2) SHUT–OFF, ENGINE SENDER, ENGINE OIL PRESSURE SENDER, COOLANT TEMPERATURE COLD START ELEMENT ALTERNATOR, DS RATING DISCONNECT SWITCH, DS ONLY FUEL LEVEL SENDER TEMPERATURE SWITCH, TRANSMISSION OIL OR OIL PRESSURE SWITCH FOR OIL CLUTCH MONOTROL PEDAL (OPTION) IGNITION SWITCH INSTRUMENT PANEL, RIGHT–HAND CLUSTER HORN BUTTON INSTRUMENT PANEL, LEFT–HAND CLUSTER HORN INDICATOR LIGHT, DS ONLY HORN RELAY SWITCH, COLD START AID PARKING BRAKE SWITCH WHEN EQUIPPED WITH MONOTROL PEDAL

WIRE CODES WIRE COLOR AA BROWN CC YELLOW DD BLACK EE RED FF BROWN HH BLACK KK ORANGE LL WHITE MM BLACK RR GREEN HM YELLOW PM BLACK XM RED KR WHITE XX WHITE ZZ BLACK KC RED

GAUGE 16 14 16 16 16 16 14 16 14 16 16 16 16 16 16 16 16 16 14 16 14 16 16 16

GAUGE 14 14 14 14 10 16 16 14 16 14 16 16 16 14 16 16 16

XX MM DD

ENGINE COMPARTMENT SCHEMATIC

G A

1 2 BATT

KR RR MM CC K A R S

CC K CC

FF K

KR U RR

–

COLD START ELEMENT

BLACK

7 DD YEL

EXC REG BATT

TO STARTER SOLENOID Y

BLU

A RED

ORG

FF ORG 1312685

U G

TO BATTERY

HYSTER COMPANY 1992

X V

CC W

W B CC

CC B

FUEL LEVEL SENDER

LL TRANSMISSION NEUTRAL START SWITCH (WHEN EQUIPPED WITH A FORWARD AND REVERSE LEVER)

REVERSE SOLENOID

FORWARD SOLENOID

TRANSMISSION NEUTRAL START SWITCH (WHEN EQUIPPED WITH MONOTROL PEDAL) EE Z

BATT MM

J V

V C

T Z

21 J

W E BRAKE ON BRAKE OFF

W MM

L D Q R A IGN FUEL GRD GAUGE SEND

C L

COWL GROUND

KR RR MM CC KA A R S

KA H

IGN GRD

U AA KR

LIGHT KIT FUSE BLOCKS

AA U

20A

CAB

D N

10A

F H S

COOLANT IGN TEMP GRD GAUGE SEND

MN P

AA U G

HOUR METER

3 2 1 HORN RELAY

19 18

INSTRUMENT PANEL ELECTRICAL SCHEMATIC

FIGURE 1. DIESEL ENGINE WIRING SCHEMATIC 2

5 FUEL PUMP RELAY

FUEL PUMP PRIME

ALDL

MAP

9 TPS IAC

8 INJECTOR 1

TBI INJECTOR 2

6 GOVERNOR MOTOR

ELECTRONIC CONTROL MODULE (ECM)

SET TIMING CONNECTOR

ALDL POWER CONNECTOR

GOVERNOR CONTROLLER

COOLANT TEMPERATURE SENSOR (ECM) TACHOMETER

EST DISTRIBUTOR

COIL

LEAD

15 14 13

1345976a

16 FUEL PUMP

FUEL LEVEL SENDER

BATTERY FUEL PUMP FUSE

ECM FUSE

CRANK FUSE

FUEL TANK

ENGINE GROUND

ALTERNATOR

19 STARTER SOLENOID

COOLANT TEMPERATURE SENDER (GAUGE)

ENGINE OIL PRESSURE SWITCH (LIGHT)

ENGINE TO CHASSIS GROUND WIRE

ENGINE COMPARTMENT ELECTRICAL SCHEMATIC

FIGURE 2. 4.3 LITRE GM Vâ&#x20AC;&#x201C;6 ENGINE, GASOLINE WIRING SCHEMATIC (1 of 2) 4

24A

MONOTROL PEDAL

PARKING BRAKE SWITCH WITH MONOTROL ONLY

POWERSHIFT TRANSMISSION ONLY POWERSHIFT TRANSMISSION WITH MONOTROL ONLY OIL CLUTCH OR POWERSHIFT TRANSMISSION WITH FORWARD/REVERSE LEVER ONLY

IGNITION SWITCH

PS TRANSMISSION OIL TEMPERATURE OR OIL CLUTCH OIL PRESSURE DISCHARGE INDICATOR CHECK ENGINE ENGINE OIL PRESSURE

FUEL GAUGE

RH CLUSTER HORN BUTTON

31 HOUR METER

COOLANT TEMPERATURE GAUGE LH CLUSTER

COWL FUSE BLOCK

34 32 INSTRUMENT PANEL ELECTRICAL SCHEMATIC

33 1345976b

WIRE CODES WIRE COLOR A BLUE B WHITE C RED D YELLOW E BLUE F YELLOW H BLACK J WHITE K RED L BLACK M BLACK N WHITE P YELLOW S WHITE T GREEN V RED W BLACK X RED Y YELLOW Z PINK BB WHITE CC YELLOW DD BLACK EE RED FF BROWN GB PINK GC PURPLE GD BROWN GE PINK/BLACK GF GRAY GG BROWN GH GRAY GJ BROWN GL GRAY GM BLACK GQ YELLOW GR GRAY GS GRAY GT GRAY GU DARK BLUE GV BROWN/WHITE GW WHITE GX TAN/BLACK GY TAN/BLACK GZ PURPLE/WHITE HA DARK GREEN HB GRAY HC ORANGE HD ORANGE HE WHITE HF YELLOW HG BLUE/WHITE HH BLACK HJ GREEN/WHITE HK GREEN/BLACK HL BLACK HN BLACK/WHITE HP BLACK/WHITE HQ BLACK/WHITE HR BLACK

GAUGE 16 14 16 16 16 16 16 14 16 16 16 16 16 16 16 16 14 16 16 16 16 14 14 10 10 16 18 18 16 18 16 16 16 16 16 18 18 18 18 18 18 18 18 18 18 18 16 18 18 16 16 16 16 18 18 18 16 18 18 16

WIRE CODES WIRE COLOR HS WHITE/BLACK HT BLACK/PINK HU BLACK HV BLACK/PINK HX BLACK/RED HY PURPLE HZ ORANGE JA GREEN/WHITE JB DARK BLUE JC DARK GREEN JD RED JE RED JF RED JG PINK/BLACK JH ORANGE JJ ORANGE JK ORANGE JL ORANGE JM PURPLE/WHITE JN PURPLE/WHITE JP DARK BLUE JQ BROWN JR DARK GREEN JT BLUE/BLACK JU ORANGE JV ORANGE JW BLACK/WHITE JX BLACK JY ORANGE JZ PINK/BLACK KA BLACK KB BLACK KC RED KD BLACK KE BLACK KR WHITE RR GREEN JBA DARK BLUE JCA DARK GREEN JMA PURPLE/WHITE JNA PURPLE/WHITE

GAUGE 18 18 18 18 18 18 18 18 18 18 16 18 16 18 16 16 16 16 18 18 16 16 18 18 16 14 16 18 16 16 10 10 14 12 12 14 14 18 18 16 16

1. 2. 3. 4. 5.

GROUND NO. 2, ENGINE HEAD FUEL PUMP RELAY ASSEMBLY LINE DIAGNOSTIC LINK MAP SENSOR PRESSURE SWITCH, ENGINE OIL SENSOR TO ECM 6. THROTTLE BODY INJECTOR ASSEMBLY 7. GOVERNOR MOTOR 8. IDLE AIR CONTROL (IAC) 9. THROTTLE POSITION SENSOR (TPS) 10. ELECTRONIC SPARK TIMING (EST) DISTRIBUTOR 11. IGNITION COIL 12. COOLANT TEMPERATURE SENSOR TO ECM 13. GOVERNOR CONTROLLER 14. ALDL POWER CONNECTOR 15. GROUND NO. 1, ENGINE INLET MANIFOLD 16. FUEL TANK 17. FUEL PUMP INSIDE OF FUEL TANK 18. BATTERY 19. STARTER 20. ALTERNATOR 21. COOLANT TEMPERATURE SENDER, GAUGE 22. PRESSURE SWITCH, ENGINE OIL (LIGHT) 23. SWITCHES USED WITH POWERSHIFT TRANSMISSION AND MONOTROL 24. TEMPERATURE SWITCH, POWERSHIFT TRANSMISSION AND MONOTROL 24A. PRESSURE SWITCH, OIL CLUTCH PRESSURE OR TEMPERATURE SWITCH, POWERSHIFT TRANSMISSION WITH FORWARD/REVERSELEVER 25. SWITCHES USED WITH POWERSHIFT TRANSMISSION AND FORWARD/REVERSE LEVER OR OIL CLUTCH TRANSMISSION 26. PARKING BRAKE SWITCH, MONOTROL ONLY 27. SWITCH ARRANGEMENT, MONOTROL PEDAL 28. IGNITION SWITCH 29. INDICATOR LIGHTS AND GAUGE, RIGHT–HAND CLUSTER 30. GAUGES, LEFT–HAND CLUSTER 31. HORN BUTTON 32. HORN 33. HORN RELAY 34. FUSE BLOCK, COWL

FIGURE 2. 4.3 LITRE GM V–6 ENGINE, GASOLINE WIRING SCHEMATIC (2 of 2) 6

MSTS CONTROLLER A B

C D E F G H

J K

MAP C B

L M N P

A B

BG BC

BB BD

BG BN

BE BF

BJ BK

4 NN

BM BA GB

GB BC BD BB BE

ENGINE COMPARTMENT SCHEMATIC

7 BR

DD CC EE KC

CC EE

KC A

1 2 BATT

RR KR

8 CC FF A GD S GB

RR EE

RR KC KR

â&#x20AC;&#x201C;

10 13 DD MM

G EXC REG BATT

TO STARTER SOLENOID

Y BLU

A RED

ORG

FF ORG

TO BATTERY

CC W

W B CC

CC B

X NN XX

TRANSMISSION NEUTRAL START SWITCH (WHEN EQUIPPED WITH A FORWARD AND REVERSE LEVER)

REVERSE SOLENOID

FORWARD SOLENOID

TRANSMISSION NEUTRAL START SWITCH (WHEN EQUIPPED WITH MONOTROL PEDAL) EE Z JV

BATT GB

J V

V C

GB HH

BRAKE ON BRAKE OFF J X

T Z

GC GV D HH GD A C

CC EE

COWL GROUND

RR KR

A GD S GB GC GV JD HB

A GD

GC GV JD HB

KR LIGHT KIT FUSE BLOCK

D N

10A

E T

IGN GRD F H S

COOLANT IGN TEMP GRD GAUGE SEND

S TT

ENGINE HEAD

COWL

NN TT YY

YY VV

HOUR METER

SIG IN GND GOVERNOR GOVCONTROLLER SOL BATT

MN P

3 2 1 HORN RELAY

26 22

INSTRUMENT PANEL ELECTRICAL SCHEMATIC

FIGURE 3. 4.3 LITRE GM Vâ&#x20AC;&#x201C;6 ENGINE, LPG WIRING SCHEMATIC (1 of 2) 8

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26.

MSTS CONTROLLER INITIAL TIMING CONNECTOR MAP SENSOR MSTS DISTRIBUTOR IGNITION COIL COOLANT TEMPERATURE SENSOR GROUND CONNECTION, ENGINE HEAD ALTERNATOR (TYPE LP) STARTER BATTERY SENDER, ENGINE OIL PRESSURE SENDER, COOLANT TEMPERATURE GOVERNOR SOLENOID ALTERNATOR (TYPE LPS) DISCONNECT SWITCH (LPS ONLY) MONOTROL PEDAL (OPTION) IGNITION SWITCH INSTRUMENT PANEL, RIGHT–HAND CLUSTER HORN SWITCH INSTRUMENT PANEL, LEFT–HAND CLUSTER HORN INDICATOR LIGHT (LPS ONLY) TEMPERATURE SWITCH, TRANSMISSION OIL BRAKE SWITCH WHEN EQUIPPED WITH MONOTROL OPTION GOVERNOR CONTROLLER HORN RELAY

WIRE CODES WIRE COLOR GAUGE A BLUE 16 B WHITE 14 C RED 16 D YELLOW 16 E BLUE 16 F YELLOW 16 H BLACK 16 J WHITE 14 K RED 16 L BLACK 16 M BLACK 16 N WHITE 16 P YELLOW 16 S WHITE 16 T GREEN 16 V RED 16 W BLACK 14 X RED 16 Y YELLOW 16 Z PINK 16 BA PINK 18 BB WHITE 18 BC PURPLE 18 BD BROWN 18 BE BLACK 18 BF ORANGE 18 BG DARK BLUE 18 BH BLACK/WHITE STRIPE 18 BJ RED 18 BK BROWN 18 BL BLACK/WHITE STRIPE 18 BM BLACK/WHITE STRIPE 18 BN DARK GREEN 18 BP BLACK/WHITE STRIPE 18 BQ BLACK 12 BR BLACK 12 CC YELLOW 14 DD BLACK 10 EE RED 10 FF BROWN 10 GC PURPLE 18 GD BROWN 18 GV BROWN/WHITE STRIPE18 HB GRAY 16 HH BLACK 16 HM YELLOW 18 JD RED 16 JU ORANGE 16 JV ORANGE 14 KC RED 14 KR WHITE 14 LL WHITE 14 NN BLACK 16 PM BLACK 18 RR GREEN 14 TT WHITE 16 UU NON–INSULATED 18 VV YELLOW 16 XX CLEAR 16 YY RED 16 ZZ WHITE 16

FIGURE 3. 4.3 LITRE GM V–6 ENGINE, LPG WIRING SCHEMATIC (2 of 2) 9

21 18

16 19 15

14 11 10 9

8 4

3 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21.

1. TORQUE CONVERTER 2. TRANSMISSION PUMP 3. LUBRICATION FOR PUMP DRIVE CHAIN AND BEARING 4. SUMP SCREEN 5. FILTER 6. SOLENOID VALVE, FORWARD 7. SOLENOID VALVE, REVERSE 8. MONOTROL OPTION, FORWARD AND REVERSE SPOOL 9. CONTROL LEVER OPTION, FORWARD AND REVERSE SPOOL

353095 & 1300115

INCHING SPOOL BRAKE EFFORT INCREASE FORWARD REVERSE ACCUMULATOR DUMP ACCUMULATOR TRIM SPOOL TRANSMISSION CONTROL VALVE REGULATOR, TORQUE CONVERTER REGULATOR, CLUTCH PRESSURE REGULATOR, TRANSMISSION PUMP COOLER.

FIGURE 4. TRANSMISSION SCHEMATIC

1 5

3 10

2 6

11 7

353095

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

COOLER FILTER CLUTCH OIL PRESSURE SENDER TRANSMISSION PUMP COLD RELIEF VALVE CLUTCH DISK PUMP DRIVE CHAIN AND BEARING SUMP SCREEN OIL CLUTCH SUMP CLUTCH HOUSING FLYWHEEL HOUSING

FIGURE 5. OIL CLUTCH SCHEMATIC [H3.50–5.00XL (H70–1110XL)] 10

HEADER HOSES

AUX.

BACKWARD

TILT

FORWARD

8 5

LIFT DOWN

3 1. 2. 3. 4. 5. 6. 7. 8. 9.

MAIN CONTROL VALVE SECONDARY RELIEF VALVE RELIEF VALVE TEST PORT, HYDRAULIC PRESSURE TILT CYLINDER LIFT CYLINDER LOWERING CONTROL VALVE (INTERNAL) LOWERING CONTROL VALVE (EXTERNAL) SOLENOID VALVE FOR THREE–FUNCTION HYDRAULIC OPERATION S3.50–5.50 XL (S70–120XL)]

*SECONDARY RELIEF VALVE IS STANDARD ON 4–SPOOL VALVE AND OPTIONAL ON 3–SPOOL VALVE ONLY.

10 13

10. 11. 12. 13. 14. 15. 16. 17. 18.

HYDRAULIC TANK HYDRAULIC FILTER HYDRAULIC PUMP FLOW CONTROL VALVE BRAKE BOOSTER STEERING CYLINDER STEERING CONTROL UNIT RELIEF VALVE, STEERING TEST PORT, STEERING PRESSURE

FIGURE 6. HYDRAULIC SYSTEM SCHEMATIC 12

4 7 1

8 5

1. 2. 3. 4. 5. 6. 7. 8. 9.

WORK LIGHT, RIGHT GROUND WORK LIGHT, LEFT LIGHT SWITCH FUSE PANEL BRAKE PRESSURE SWITCH STOP AND TAIL LIGHT, RIGHT DRIVE LIGHT, REAR STOP AND TAIL LIGHT, LEFT

FIGURE 7. WIRE SCHEMATIC, LIGHTS OPTION FOR U.S. LIFT TRUCKS 13

132699

1 7 2

AMBER

AMB

WHITE

TAIL STOP

13 8

4 9

5 14 6 11 WHITE AMBER

STOP TAIL AMB

132699

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13 14.

MARKER LIGHT AND DIRECTION SIGNAL, RIGHT DRIVING LIGHT, RIGHT WORK LIGHT, RIGHT WORK LIGHT, LEFT DRIVING LIGHT, LEFT MARKER LIGHT AND DIRECTION SIGNAL, LEFT DIRECTION SIGNAL FLASHER DIRECTION SIGNAL SWITCH SWITCH, WORK LIGHTS AND REAR DRIVING LIGHT SWITCH. MARKER, TAIL AND DRIVE LIGHTS BRAKE PRESSURE SWITCH STOP, TAIL, AND DIRECTION LIGHTS, RIGHT REAR DRIVING LIGHT STOP, TAIL, AND DIRECTION LIGHTS, LEFT

FIGURE 8. WIRE SCHEMATIC, LIGHTS OPTION FOR EEC LIFT TRUCKS 14

FIGURE 1. ELECTRICAL SCHEMATIC (GASOLINE/LPG)

FIGURE 2. ELECTRICAL SCHEMATIC (DIESEL)

FIGURE 3. HYDRAULIC SCHEMATIC

FIGURE 4. HYDRAULIC SCHEMATIC, TRANSMISSION WITH MANUAL CONTROL

FIGURE 4. HYDRAULIC SCHEMATIC, TRANSMISSION WITH MONOTROL CONTROL

FIGURE 6. ELECTRICAL SCHEMATIC FOR THE LIGHT CIRCUIT

PERKINS DIESEL ENGINES, SERIES 1000

1.1 GENERAL This section has the description and repair instructions for four models of the Series 1000 Perkins diesel engine, The four diesel engines described in this section: 1004–4 (AA) 4–cylinder normally aspirated 1004–4T (AB) 4–cylinder turbocharged 1006–6 (YA) 6–cylinder normally aspirated 1006–6T (YB) 6–cylinder turbocharged

GENERAL SAFETY RULES WARNING Viton Seals Some seals used in this engine are made of a synthetic material called Viton. Viton is a safe material when used under normal conditions of operation. If Viton is burned, a dangerous acid is produced as a by–product. Never permit burned material to come into contact with the skin or the eyes. If it is necessary to handle components that have been burned, Use the following procedures: Make sure the components are cool. Use Neoprene gloves and discard the gloves after use.

Long term exposure to used engine oil can cause skin irritation or cancer. Wash with detergent and water

CAUTION Disposal of lubricants and fluids must meet local environmental regulations. Exhaust from internal combustion engines contains carbon monoxide and other harmful chemicals. Carbon monoxide is a colorless, odorless poison and can cause unconsciousness or death without warning. Long term exposure to exhaust or chemicals in the exhaust can cause cancer, birth defects and other reproductive harm. Avoid exposure to engine exhaust Do not use diesel engines indoors where soot can accumulate. If engines are operated in confined spaces maintain adequate ventilation or vent exhaust to the outside. Do not exceed applicable air contaminant limits. Follow the inspection and maintenance schedule and procedures in this manual. Do not alter exhaust, ignition or fuel systems. Disposal of batteries must meet local environmental regulations. The diodes and resistors in the electrical system can be damaged if the following cautions are not followed:

Wash the area with calcium hydroxide solution and then clean with water.

• Do not disconnect the battery when the engine

Discard the components and gloves in accordance with environmental regulations.

• Do not disconnect an electric wire before the

Burned Viton by–product that touches the skin or eyes must be immediately flushed with water or a calcium hydroxide solution. Get medical help immediately.

• Do not cause a short circuit by connection of

WARNING Disconnect the battery cables before doing any disassembly and repair of the engine or parts of the electrical system. Put a “DO NOT OPERATE” tag in the operator’s area and on the battery connectors.

is running. The voltage surge can damage the diodes and resistors. engine is stopped and the switches are “OFF”. the electric wires to the wrong terminals. Make sure a correct identification is made of the wire before it is connected.

• Make sure a battery is the correct voltage and polarity before it is connected.

• Do not check for current flow by making a spark because the electronic components can be damaged. 1

1004–4T DIESEL ENGINE SHOWN

1. FILLER CAP FOR ENGINE OIL 2. FUEL FILTER 3. OIL COOLER 4. FUEL INJECTION PUMP 5. DIPSTICK 6. OIL FILTER

14. INLET MANIFOLD 15. EXHAUST MANIFOLD 16. ALTERNATOR 17. TURBOCHARGER 18. STARTER MOTOR 19. OIL SUMP

7. DRAIN PLUG, ENGINE OIL 8. CRANKSHAFT PULLEY 9. DRIVE BELT 10. FAN 11. WATER PUMP 12. FUEL INJECTOR 13. COOLANT OUTLET

20. DRAIN PLUG ENGINE OIL 21. FLYWHEEL HOUSING 22. FLYWHEEL 23. FUEL PUMP 24. REAR LIFT BRACKET

FIGURE 1. 4–CYLINDER DIESEL ENGINES, PERKINS 1000 SERIES 2

1006–6 DIESEL ENGINE SHOWN

1. FILLER CAP FOR ENGINE OIL 2. FUEL FILTER 3. OIL COOLER 4. FUEL INJECTION PUMP 5. DIPSTICK, ENGINE OIL 6. DRAIN PLUG, ENGINE OIL

14. ALTERNATOR 15. OIL FILTER 16. STARTER MOTOR 17. OIL SUMP 18. DRAIN PLUG, ENGINE OIL

7. CRANKSHAFT PULLEY 8. FAN 9. WATER PUMP 10. FRONT LIFTING BRACKET 11. COOLANT OUTLET 12. FUEL INJECTOR

19. FLYWHEEL HOUSING 20. FLYWHEEL 21. FUEL PUMP 22. EXHAUST MANIFOLD 23. INLET MANIFOLD

FIGURE 2. 6–CYLINDER DIESEL ENGINES, PERKINS 1000 SERIES 3

1.2 DESCRIPTION The cylinder head is cast iron and has one inlet valve and one exhaust valve for each cylinder. The valve seats and the valve guides are replaceable on the turbocharged models. Valve seats can be installed during overhaul on the normally aspirated engines. The fuel injectors are in the cylinder head. The overhead valve assembly is actuated by a camshaft inside of the engine block. A gear train, turned by the crankshaft, turns the camshaft, coolant pump, injection pump, and a power–takeoff (PTO) is available for additional equipment. The hydraulic pump for the steering function or a compressor is normally turned by the PTO. The fuel pump is actuated by the camshaft. The crankshaft in the 6–cylinder models have seven main bearings. The crankshaft in the 4–cylinder models have five main bearings. The main bearing in the center of the crankshaft is the thrust bearing and has thrust washers on both sides of the bearing. The pistons are aluminum alloy with a steel insert in the piston skirt to control expansion. Each piston has three piston rings (two compression rings, and an oil control ring). The top compression ring has a special insert for the groove. A special jet for cooling oil to the bottom of the piston is installed on the engines with turbochargers. A special combustion chamber is cast in the top of the piston to increase the efficiency of the combustion process and reduce combustion noise.

The CAV DPS fuel injection pumps for the turbocharged engines have a boost control. The boost pressure from the turbocharger increases the fuel supply at higher engine speeds. At low engine speeds, the fuel supply is reduced to match the reduction in air supply to the cylinders. 1.3 Engine Serial Number Codes The engine number is on a label on the side or the rear of the engine block. A typical serial number has the following code: AB 80350 U 510327 S 1 2 3 4 5 where: 1 = Type of engine; (AA = 1004–4, AB = 1004–4T, YA = 1006–6, YB = 1006–6T) 2 = Parts list number 3 = Country of manufacture (U = manufactured in the United Kingdom) 4 = Serial number 5 = Year of manufacturer. The letter indicates the year of manufacture starting with “A” in 1974 (S=1988). The letters I, O, Q, R, and Z are not used. If parts or service are required for your engine, the complete engine number must be given to your dealer.

The cooling fan and the alternator are turned by a drive belt. The cooling fan is not connected to the coolant pump. The timing and quantity of fuel sent to the fuel injectors is controlled by a throttle and governor in the fuel injection pump. The static timing is set by the position of the fuel injection pump when it is installed. The throttle linkage must be correctly adjusted to control the quantity of fuel sent to the injectors. A mechanical governor is used to control the engine speed. A CAV DPA fuel injection pump is used on the normally aspirated engines AA and YA. A CAV DPS fuel injection pump is used on turbocharged engines AB an YB. Special tools are needed to repair a CAV injection pump and they are normally sent to an authorized CAV repair station if repairs are necessary. 4

FIGURE 3. SERIAL NUMBER LOCATIONS

1.4 Engine Data The specifications and tolerance details for engine repair are in a chart at the end of this chapter.

1.5 1004–4 ENGINE Power Rating at 2600 rpm . . . . . . . 63 kW (84.5 bhp) Number of cylinders . . . . . . . . . . . . . . . . . . . . . . . . 4 Firing order . . . . . . . . . . . . . . . . . . . . . . . . . 1–3–4–2 Bore and stroke . . . 100 x 127 mm (3.937 x 5.000 in) Displacement . . . . . . . . . . . . . . . . . . 4 litres (243 in2) Compression Ratio . . . . . . . . . . . . . . . . . . . . . . 16.5:1 Minimum oil pressure . . . . . . . . . . . 207 kPa (30 psi) (at 2600 rpm and normal operating temperature) Governor speed (no load) H3.50–5.00XL(H70–110XL) . . . . 2300 to 2400 rpm S3.50–5.50XL(S70–120XL) . . . . . 2400 to 2500 rpm S6.00–7.00XL (S135–155XL) . . . . 2400 to 2500 rpm H6.00–7.00XL(H135–155XL) . . . 2400 to 2500 rpm Idle speed H3.50–5.00XL(H70–110XL) . . . . . . 725 to 775 rpm S3.50–5.50XL(S70–120XL) . . . . . . . 625 to 800 rpm S6.00–7.00XL (S135–155XL) . . . . . . 725 to 775 rpm H6.00–7.00XL(H135–155XL) . . . . . 725 to 775 rpm Thermostat Begin to open . . . . . . . . . 77 to 85°C (170 to 185°F) Fully open . . . . . . . . . . . 92 to 98°C (198 to 208°F) Valve clearance (cold) Inlet . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.008 in) Exhaust . . . . . . . . . . . . . . . . . . . . 0.45 mm (0.018 in) 1.6 1004–4T ENGINE Power Rating at 2600 rpm . . . . . . . . 84 kW(113 bhp) Number of cylinders . . . . . . . . . . . . . . . . . . . . . . . . 4 Firing order . . . . . . . . . . . . . . . . . . . . . . . . . 1–3–4–2 Bore and stroke . . . 100 x 127 mm (3.937 x 5.000 in) Displacement . . . . . . . . . . . . . . . . . . 4 litres (243 in2) Compression Ratio . . . . . . . . . . . . . . . . . . . . . . 16.0:1 Minimum oil pressure . . . . . . . . . . . 280 kPa (40 psi) (at 2600 rpm and normal operating temperature) Governor speed (no load) . . . . . . . 2700 to 2800 rpm Idle speed . . . . . . . . . . . . . . . . . . . . . . 800 to 850 rpm Thermostat Begin to open . . . . . . . . 77 to 85°C (170 to 185°F) Fully open . . . . . . . . . . 92 to 98°C (198 to 208°F) Valve clearance (cold) Inlet . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.008 in) Exhaust . . . . . . . . . . . . . . . . . . . . 0.45 mm (0.018 in) 1.7 1006–6 ENGINE Power Rating at 2600 rpm . . . . . . . . 95 kW(127 bhp) Number of cylinders . . . . . . . . . . . . . . . . . . . . . . . . 6

Firing order . . . . . . . . . . . . . . . . . . . . . 1–5–3–6–2–4 Bore and stroke . . . 100 x 127 mm (3.937 x 5.000 in) Displacement . . . . . . . . . . . . . . . . . . 6 litres (365 in2) Compression Ratio . . . . . . . . . . . . . . . . . . . . . . 16.5:1 Minimum oil pressure . . . . . . . . . . . 207 kPa (30 psi) (at 2600 rpm and normal operating temperature) Governor speed (no load with sound reduction) H8.00–12.00XL(H165–280XL) . . 2460 to 2610 rpm H13.00–16.00XL (H300–360XL) . 2400 to 2550 rpm Governor speed (no load without sound reduction) H8.00–12.00XL(H165–280XL) . . 2660 to 2810 rpm H13.00–16.00XL (H300–360XL) . 2660 to 2810 rpm Idle speed H8.00–12.00XL(H165–280XL) . . . . 725 to 775 rpm H13.00–16.00XL (H300–360XL) . . . 725 to 775 rpm Thermostat Begin to open . . . . . . . . . 77 to 85°C (170 to 185°F) Fully open . . . . . . . . . . . 92 to 98°C (198 to 208°F) Valve clearance (cold) Inlet . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.008 in) Exhaust . . . . . . . . . . . . . . . . . . . . 0.45 mm (0.018 in) 1.8 1006–6T ENGINE Power Rating at 2600 rpm . . . . . . 127 kW (170 bhp) Number of cylinders . . . . . . . . . . . . . . . . . . . . . . . . 6 Firing order . . . . . . . . . . . . . . . . . . . . . 1–5–3–6–2–4 Bore and stroke . . . 100 x 127 mm (3.937 x 5.000 in) Displacement . . . . . . . . . . . . . . . . . . 6 litres (365 in2) Compression Ratio . . . . . . . . . . . . . . . . . . . . . . 16.0:1 Minimum oil pressure . . . . . . . . . . . 280 kPa (40 psi) (at 2600 rpm and normal operating temperature) Governor speed (no load) . . . . . . . 2700 to 2800 rpm Idle speed . . . . . . . . . . . . . . . . . . . . . . 800 to 850 rpm Thermostat Begin to open . . . . . . . . . 77 to 85°C (170 to 185°F) Fully open . . . . . . . . . . . 92 to 98°C (198 to 208°F) Valve clearance (cold) Inlet . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.008 in) Exhaust . . . . . . . . . . . . . . . . . . . . 0.45 mm (0.018 in)

1.9 REMOVAL AND INSTALLATION See the THE FRAME section for the procedure for removing the engine and transmission. See the TRANSMISSION section for the procedure to separate the transmission from the engine. 5

CYLINDER HEAD ASSEMBLY 1.10 VALVE COVER 1.11 Removal

1.13 ROCKER ARM ASSEMBLY 1.14 Removal 1. Remove the valve cover.

1. Disconnect the breather pipe. 2. Remove the cap nuts and the sealing washers from the top of the valve cover. See FIGURE 4. 3. Lift the valve cover, gasket, and seal from the cylinder head. The valve cover seal fits between the valve cover and the inlet manifold. 4. When the valve cover is installed, the cap nuts are tightened onto the nuts of the rocker brackets. When the cap nuts are removed, the nuts for the rocker brackets can be loosened. Check that the nuts for the rocker brackets are tight each time that the valve cover is removed.

2. Loosen the nuts evenly that fasten the brackets for the rocker arm shafts to the cylinder head. Loosen the brackets at each end of the cylinder head first and loosen the brackets in sequence towards the center. Remove the nuts and washers when the pressure is removed from the rocker arms. Lift the rocker arm assembly from the cylinder head. 3. See FIGURE 5. Remove the rubber seal from the oil supply connection or the hole for the oil supply in the cylinder head. 1.15 Installation 1. Install a new rubber seal in the hole for the oil supply in the cylinder head. 2. Check that the push rods fit correctly in the sockets for the tappets. Install the rocker arm assembly. Make sure that the oil supply connection fits correctly into the rubber seal.

1. VALVE COVER SEAL 2. CAP NUT AND SEAL WASHER

3. Make sure that the alignment of the rocker arms and the push rods are correct. Install the nuts and washers on the studs that hold the brackets for the rocker arm shafts to the cylinder head. Tighten the nuts evenly. Begin tightening the nuts at the center of the rocker arm shaft and tighten in sequence towards the ends of the shaft. The final torque on the nuts: aluminum brackets = 40 Nm (30 lbf ft) iron brackets = 75 Nm (55 lbf ft).

FIGURE 4. VALVE COVER 1.12 Installation 1. Check the condition of the valve cover gasket and the seal washers used under the cap nuts. Make sure that the surfaces are clean. 2. Install the valve cover, gasket, and seal on the cylinder head. Install the seal washers under the cap nuts. Tighten the cap nuts to 20 Nm (15 lbf ft). Do not tighten the cap nuts so that they are fastened to the nuts for the rocker brackets. 6

FIGURE 5. LOCATION OF RUBBER SEAL

1.16 Disassembly 1. Remove the clips from both ends of the rocker arm shaft. Make sure that the ends of the rocker arm shaft are not damaged. Loosen the location screw for the oil supply connection. 2. Make a note of the position of each component on the rocker arm shaft so that they can be assembled correctly. Remove the components from the rocker arm shaft. 1.17 Inspection 1. Clean and inspect all the components for wear and damage. Check the clearance of the rocker arms on the rocker arm shaft. If the clearance is greater than 0.13 mm (0.005 in), install a new bushing in the rocker arm or install a new rocker arm shaft if it is worn. 2. If the bushing in the rocker arm is worn, use a press to remove the bushing.

3. Use a press to install a new bushing in the rocker arm. Make sure that the lubrication hole in the bushing is aligned with the hole in the rocker arm. 4. Use a reamer in the bushing as necessary to give a clearance on the rocker arm shaft of 0.03 to 0.09 mm (0.001 to 0.004 in). 1.18 Assembly 1. Make sure that the lubrication holes in the rocker arms and the rocker arm shaft are open and clean. 2. Lubricate the components with clean engine oil as they are assembled on the rocker arm shaft. Make sure the components are assembled in the correct order. See FIGURE 6. Make sure that the location screw for the oil supply connection is fitted correctly in the rocker arm shaft. Install the clips at the ends of the rocker arm shaft.

FIGURE 6. ROCKER ARM ASSEMBLY

1.19 VALVE CLEARANCE ADJUSTMENTS The valve clearance is measured between the top of the valve stem and the rocker arm as shown in FIGURE 7. Valve clearance (cold) Inlet 0.20 mm (0.008 in) Exhaust 0.45 mm (0.018 in)

FIGURE 7. VALVE CLEARANCE ADJUSTMENT 7

Number 1 cylinder is at the end of the engine with the fan. The inlet valve is the first valve in the sequence. See FIGURE 8.

FIGURE 8. VALVE POSITIONS 1.20 Four Cylinder Engines 1. Turn the crankshaft in the normal direction of rotation until the inlet valve of number 4 cylinder has just opened and the exhaust valve of the same cylinder has not fully closed. Check the clearance of the valves of number 1 cylinder and adjust them as necessary. 2. Turn the crankshaft in the normal direction of rotation until the inlet valve of number 2 cylinder has just opened and the exhaust valve of the same cylinder has not fully closed. Check the valve clearances on number 3 cylinder and adjust them as necessary. 3. Turn the crankshaft in the normal direction of rotation until the inlet valve of number 1 cylinder has just opened and the exhaust valve of the same cylinder has not fully closed. Check the valve clearances on number 4 cylinder and adjust them as necessary. 4. Turn the crankshaft in the normal direction of rotation until the inlet valve of number 3 cylinder has just opened and the exhaust valve of the same cylinder has not fully closed. Check the valve clearances on number 2 cylinder and adjust them as necessary.

closed. Check the valve clearances on number 5 cylinder and adjust them as necessary. 3. Turn the crankshaft in the normal direction of rotation until the inlet valve of number 4 cylinder has just opened and the exhaust valve of the same cylinder has not fully closed. Check the valve clearances on number 3 cylinder and adjust them as necessary. 4. Turn the crankshaft in the normal direction of rotation until the inlet valve of number 1 cylinder has just opened and the exhaust valve of the same cylinder has not fully closed. Check the valve clearances on number 6 cylinder and adjust them as necessary. 5. Turn the crankshaft in the normal direction of rotation until the inlet valve of number 5 cylinder has just opened and the exhaust valve of the same cylinder has not fully closed. Check the valve clearances on number 2 cylinder and adjust them as necessary. 6. Turn the crankshaft in the normal direction of rotation until the inlet valve of number 3 cylinder has just opened and the exhaust valve of the same cylinder has not fully closed. Check the valve clearances on number 4 cylinder and adjust them as necessary.

1.22 VALVE SPRINGS NOTE: This procedure is normally for changing the valve springs of a single cylinder while the cylinder head is still installed on the engine. If the valves and springs must be removed from the cylinder head for repairs, see the procedures under 1.26 Valves And Valve Springs later in this section. Special Tools: Valve spring compressor Stud adaptor Setscrew adaptor 1. Remove the valve cover.

1.21 Six Cylinder Engines 1. Turn the crankshaft in the normal direction of rotation until the inlet valve of number 6 cylinder has just opened and the exhaust valve of the same cylinder has not fully closed. Check the clearance of the valves of number 1 cylinder and adjust them as necessary. 2. Turn the crankshaft in the normal direction of rotation until the inlet valve of number 2 cylinder has just opened and the exhaust valve of the same cylinder has not fully 8

piston in cylinder 2 is at TDC, the piston in cylinder 3 is also at TDC. ENGINES YA and YB. When the piston in cylinder 1 is at TDC, the piston in cylinder 6 is also at TDC. When the piston in cylinder 2 is at TDC, the piston in cylinder 5 is also at TDC. When the piston in cylinder 3 is at TDC, the piston in cylinder 4 is also at TDC.

1. VALVE SPRING COMPRESSOR 2. STUD ADAPTOR 3. SETSCREW ADAPTOR

FIGURE 9. VALVE SPRING COMPRESSOR 5. Compress the valve springs and remove the retainers. Make sure the valve springs are compressed parallel to the valve stems or the valve stems can be damaged. 6. Release the valve spring compressor and remove the retainer cap and valve springs. NOTE: Do not turn the crankshaft while the valve springs are removed. 7. Install the new valve springs. Make sure the closed damper coils of the valve springs are towards the cylinder head. 8. Install the retainer cap. 9. Use the valve spring compressor to compress the valve springs and install the retainers. Remove the valve spring compressor. 10. Install the rocker arm assembly. 11. Check the valve clearances. See 1.19 Valve Clearance Adjustments. 12. Install the valve cover. NOTE: Valve springs can be changed in two cylinders at a time. ENGINES AA and AB. When the piston in cylinder 1 is at TDC, the piston in cylinder 4 is also at TDC. When the

FIGURE 10. FIND TDC WITH THE VALVE SPRING COMPRESSOR

1.23 CYLINDER HEAD ASSEMBLY 1.24 Removal

8. Remove the low pressure fuel lines between the fuel injection pump and the fuel filter. Remove the fuel filter bracket and the fuel filter.

1. If the engine is still in the lift truck, do the following procedures:

9. Remove the high pressure fuel lines. Put plugs in the open ports of the fuel injection pump.

a. Drain the cooling system. b. Disconnect the battery terminals. c. Disconnect the sender unit for the coolant temperature gauge. 2. ENGINES AA and YA. Remove the hose from the air filter at the inlet manifold. ENGINES AB and YB. Remove air filter connection at the compressor inlet of the turbocharger. 3. Remove the fuel line between the cold start aid in the inlet manifold and the fuel filter. Disconnect the electrical connection.

10. Remove the return fuel line from the fuel injectors. 11. Remove the fuel injectors from the cylinder head. Keep the fuel injectors clean and prevent damage to the nozzles. 12. ENGINES YA and YB. If a compressor is installed, remove the coolant pipe between the cylinder head and the compressor. Remove the coolant pipe between the by–pass connection and the compressor. 13. Loosen the hose clamp and remove the coolant by– pass hose from the cylinder head. Remove the capscrews and remove the coolant by–pass connection and the hose. 14. ENGINES AA and AB. Remove the oil cooler. See 1.164 Oil Cooler, Removal.

4. ENGINES AB and YB. Remove the boost control line between the front of the inlet manifold and the fuel injection pump.

15. Remove the valve cover. See 1.11 Valve Cover, Removal.

5. Remove the inlet manifold.

16. Remove the Rocker arm assembly. See 1.14 Rocker Arm Assembly, Removal.

6. ENGINES AB and YB. Disconnect all connections to the turbocharger and remove the turbocharger. See 1.108 Turbocharger, Removal. 7. Remove the exhaust manifold.

17. Remove the push rods. 18. Loosen the capscrews for the cylinder head evenly in a reverse sequence from the sequence shown in FIGURE 11. or FIGURE 12.

FIGURE 11. CYLINDER HEAD TIGHTENING SEQUENCE, 6–CYLINDER ENGINES

FIGURE 12. CYLINDER HEAD TIGHTENING SEQUENCE, 4–CYLINDER ENGINES

19. Lift the cylinder head from the engine block. Do not use a prybar between the cylinder head and the engine block that can cause damage to the gasket surfaces. See FIGURE 13.

1. STRAIGHT EDGE 2. CAPSCREW MUST BE STRAIGHT AND WITHOUT DISTORTION 3. THREADS MUST BE IN GOOD CONDITION AND NOT HAVE REDUCED DIAMETER

FIGURE 14. INSPECT THE CAPSCREWS 1.25 Installation Special Tools: Angle gauge to tighten the capscrews for the cylinder head. 1. Make sure the surfaces of the cylinder head and the top of the engine block are clean. Make sure that there is no dirt or objects in the cylinders. 2. Install the gasket for the cylinder head as shown in FIGURE 15. Make sure the “TOP FRONT” is in the correct position. Do not use any gasket sealant on any of the surfaces.

FIGURE 13. CYLINDER HEAD REMOVAL

20. Inspect the capscrews for the cylinder head with a straight edge. See FIGURE 14. Check that the capscrews are straight and do not have distortion. If there is a reduction in the diameter of the thread that has not been in engagement with the cylinder block, the capscrew must be discarded.

FIGURE 15. POSITION OF THE HEAD GASKET

3. Use two 1/2 UNF studs in positions 15 and 20 (see FIGURE 16. and FIGURE 17. to hold the gasket in position. Lower the cylinder head into position on the engine block.

the two studs and install the two capscrews in those positions. 5. Evenly tighten the capscrews in the sequence shown in FIGURE 17. or FIGURE 18. The final torque on the capscrews is 110 Nm (80 lbf ft). 6. Make sure all of the capscrews are tightened to the correct torque described in step 5. The capscrews must be further tightened in the sequence shown in FIGURE 17. or FIGURE 18. according to the following procedure: a. The short capscrews (S) must be tightened an additional 150° (2.5 flats). b. The medium capscrews (M) must be tightened an additional 180° (3.0 flats).

FIGURE 16. CYLINDER HEAD INSTALLATION

c. The long capscrews (L) must be tightened an additional 210° (3.5 flats).

CAUTION There are three lengths of capscrews. S = short, M = medium, L = long. FIGURE 17. and FIGURE 18. show their positions in the engine. Make sure that the capscrews are installed in the correct positions. 4. Lubricate the capscrews with a thin coat of oil and install them into their holes in the cylinder head. When the cylinder head and gasket are held in position, remove

FIGURE 17. CYLINDER HEAD TIGHTENING SEQUENCE, 4–CYLINDER ENGINES

FIGURE 18. CYLINDER HEAD TIGHTENING SEQUENCE, 6–CYLINDER ENGINES

NOTE: A special tool shown in FIGURE 19. can be used for this procedure to measure the tightening angles. If an angle gauge is not available, make a mark in a line with one of the corners of the capscrew. See FIGURE 20. Make another mark at the correct angle (counter–clockwise) on the edge of the flange of the cylinder head for each capscrew and according to the length of each capscrew. Tighten each capscrew in the correct sequence until the two marks are aligned.

10. Install the fuel injectors. See 1.143 Fuel Injectors, Installation. 11. Install the high pressure fuel lines between the fuel injection pump and the fuel injectors. 12. Install the fuel filter and bracket. Install the low– pressure fuel lines between the fuel filter and the fuel injection pump. 13. Install the coolant by–pass connection. Tighten the capscrews and the hose clamp. 14. ENGINES YA and YB. If a compressor is installed on the engine, install the coolant pipe between the cylinder head and the compressor. Install the pipe between the coolant by–pass and the compressor. 15. Install the oil cooler. See 1.167 Oil Cooler, Installation. 16. Install the exhaust manifold. Do not use sealant on the joints of the exhaust manifold. 17. ENGINES AB and YB. Install the turbocharger. See 1.109 Turbocharger, Installation.

FIGURE 19. ANGLE GAUGE 18. ENGINES AA and AB. Install the inlet manifold. The front and rear gaskets for the inlet manifold have notches. Make sure that the gaskets are installed with the notches installed in the top left position. See FIGURE 21. Do not use sealant on the joints of the inlet manifold.

FIGURE 20. TIGHTEN CYLINDER HEAD CAPSCREWS WITHOUT AN ANGLE GAUGE

7. Install the push rods in the engine. Make sure that the end of each push rod fits correctly in the tappet socket. 8. Install the rocker arm assembly. See 1.18 Rocker Arm Assembly, Installation. 9. Adjust the valve clearances. See 1.19 Valve Clearance Adjustments.

FIGURE 21. INLET MANIFOLD INSTALLATION, ENGINES AA AND AB

ENGINES YA and YB. Install the inlet manifold. Make sure that the gaskets are installed with the notch at the top and the straight edge towards the center of the engine. See FIGURE 22. Do not use sealant on the joints of the inlet manifold. 13

23. When the engine can be started, run it at low speed. Check that oil flows from the holes in the rocker arms. If the oil flow is correct, install the valve cover. See 1.12 Valve Cover, Installation.

1.26 VALVES AND VALVE SPRINGS Special Tools: Valve spring compressor Stud adapter Setscrew adaptor 1.27 Removal FIGURE 22. INLET MANIFOLD INSTALLATION, ENGINES YA AND YB

1. Remove the cylinder head. See 1.24 Cylinder Head Assembly, Removal.

19. Install the fuel line between the fuel pump and the fuel filter.

2. Clean the bottom face of the cylinder head and check the depth of the heads of the valves below the face of the cylinder head. See FIGURE 23.

20. Install the fuel line between the fuel filter and the cold start aid. If the engine is in the lift truck, install the electrical connection to the cold start aid. 21. ENGINES AB and YB. Install the boost control line between the front of the inlet manifold and the fuel injection pump. 22. If the engine is still in the lift truck, do the following procedures: a. Connect the sender unit for the coolant temperature gauge. b. ENGINES AB and YB. Install air filter connection at the compressor inlet of the turbocharger. ENGINES AA and YA. Install the hose from the air filter at the inlet manifold. c. Fill the cooling system. d. Connect the battery terminals. e. If the engine is ready to operate, remove the air from the fuel system. See the procedure described in 1.136 Remove Air From The Fuel System.

FIGURE 23. CHECK THE DEPTH OF THE VALVES Check the depth of the valves below the face of the cylinder head before the valve springs are removed. Put the dial indicator and fixture or other measuring tool on the face of the cylinder head and set the gauge to zero. Carefully put the dial indicator over the head of each valve and make a note of the measurement. The maximum service depth for the inlet valves is 1.85 mm (0.073 in) and for the exhaust valves is 2.08 mm (0.082 in). If a valve is below the depth limit, remove the valve and install a new valve in that position. If the valve depth is still below the limit, the valve seat must be replaced. See 1.37 Installation Of New Valve Seats.

3. If the valves will be used again, make a mark on each valve head so that they can be installed again in the same positions. 4. Use the valve spring compressor and the correct adaptor to compress the valve springs and remove the retainers. Make sure the valve springs are compressed parallel to the valve stems or the valve stems can be damaged. 5. Release the valve stem compressor. Remove the valve spring cap, valve springs, seal, and seat washer. 6. Repeat steps 4 and 5 to remove the other valves. 1.28 Inspection

Make sure the valve springs are compressed parallel to the valve stems or the valve stems can be damaged. 5. Repeat the installation procedure for each valve.

1.30 VALVE GUIDES 1.31 Inspection Check the valve guides for wear. The maximum clearance between the valve stem and the bore of the guide is 0.13 mm (0.005 in) for inlet valves and 0.15 mm (0.006 in) for exhaust valves. If the clearance is greater than the limit when a new valve is installed, the valve guide must be replaced.

Check the valves for cracks. Check the stems of the valves for wear and the correct clearance in their valve guides. See 1.30 Valve Guides. Check that the seat faces of the valves are not badly burned. A correction for minimum wear and damage to the valve and valve seat can be done by a process called â&#x20AC;&#x153;lappingâ&#x20AC;?. Seat faces of valves that are damaged, but can be repaired, must be checked for valve depth when they are installed. See FIGURE 23. When new valves are installed, the valve depth must be checked. Check that the load on the valve springs is correct at their installed length. See the ENGINE SPECIFICATIONS. Install new valve springs during a complete overhaul of the engine. 1.29 Installation 1. Lubricate the valve stems with engine oil when they are installed in their valve guides. 2. Install the seat washer. Install new seals on the valve guides. 3. Install the inner and outer valve springs on the seat washer. Make sure that the damper coils of the valve springs are towards the cylinder head. 4. Use the valve spring compressor and the correct adaptor to compress the valve springs. Install the retainers.

1. RETAINERS 2. VALVE SPRING CAP 3. VALVE SPRING, INNER 4. VALVE SPRING, OUTER

5. SEAL 6. SEAT WASHER 7. INLET VALVE 8. EXHAUST VALVE

FIGURE 24. VALVE COMPONENTS

1.32 Removal Install the tool for removal and replacement and the adaptor on the valve guide. Pull the valve guide from the cylinder head. See FIGURE 25.

FIGURE 26. INSTALLATION OF A VALVE GUIDE

1.34 CYLINDER HEAD AND VALVE SEATS 1.35 Inspection FIGURE 25. REMOVAL OF A VALVE GUIDE

1.33 Installation 1. Make sure the bore in the cylinder head is clean. 2. Lubricate the outer surface of the new valve guide with engine oil. 3. Install the valve guide on the special tool. See FIGURE 26. Use the special tool to pull the valve guide into the cylinder head. When the valve guide is correctly installed, the valve guide will extend 15.10 mm (0.594 in) above the seat of the valve spring. 16

The valves must be removed from the cylinder head before the valve seats can be inspected and repaired. Carefully clean the cylinder head. 1. Check the cylinder head for cracks. Carefully check the areas around the valve seats and around the holes for the fuel injectors. 2. Use a straight edge and spacer gauges to check the cylinder head for distortion across and along its face that joins the engine block. See the ENGINE SPECIFICATIONS. If the distortion is more than the specifications, the face can be machined. Remove only the minimum metal so that the thickness of the cylinder head will not be less than 120.48 mm (4.035 in) after the cylinder head has been machined.

NOTE: After the cylinder head has been machined, the valve seats must be checked for the correct depth. See 1.28 Valves And Valve Springs, Inspection. If the depth of the valve seats must be increased, use the minimum limit to allow for later wear.

2. When the valve seat has been cut, remove the cutter and pilot. Clean the port area and remove any particles.

3. Check the valve seats for wear and damage. Before any work is done on the valve seats, make sure the valve guides are good. See 1.31 Valve Guides, Inspection for inspection and replacement.

4. Check the valve depth. See 1.28 Valves And Valve Springs, Inspection. If the valve seat is badly damaged or worn, replace the valve seat as described in the following paragraphs.

4. A correction for minimum wear and damage to the valve and valve seat can be done by a process called “lapping”. When the valve seats are “lapped”, keep the valve seat as narrow as possible. Make sure all of the lapping compound is removed from the valve and valve seat when the process is completed.

NOTE: AA and YA engines do not have valve seat inserts installed when they are manufactured. A valve seat insert can be installed in these engines when the cylinder head is overhauled. Installation of new valves seats is described in 1.37 Installation Of New Valve Seats. AB and YB engines have valve seat inserts installed by the manufacturer.

5. Damaged valve seats can be repaired with a cutter tool. See FIGURE 27. If the valve seat can not be repaired so that the valve depth is within the specifications, the valve seat must be replaced. 1.36 Repair Special Tools: Cutter for inlet valve seats Cutter for exhaust valve seats Pilot for use with valve seat cutters Handle for valve seat cutters 1. Install the correct cutter into the valve seat that is to be repaired. Carefully turn the cutter in a clockwise direction. Remove only the minimum metal to repair the valve seat. Keep the valve seat as narrow as possible.

3. Use the “lapping” process to make sure the valve and valve seat fit tightly together.

1.37 Installation Of New Valve Seats 1. Remove the valve guide. Clean the bore and install a new valve guide. See 1.31 Valve Guides for inspection and replacement. 2. Use the bore of the new valve guide as a pilot and use a milling machine to remove the old valve seat. See the ENGINE SPECIFICATIONS. Clean the particles from the port and the area where the new valve seat will be installed. 3. If the bottom face of the cylinder head has been machined, the back face of the new valve seat must be machined so that it will not extend above the surface of the cylinder head. If the back face of the valve seat is machined, make sure that the outer edge of the back face has a 0.9 to 1.3 mm (0.0035 to 0.0510 in) chamfer at 30° to the vertical. 4. Use the bore of the valve guide as a pilot. Use a press to install the valve seat into the cylinder head. Make sure the valve seat is fully inserted into the cylinder head.

FIGURE 27. CUTTER FOR VALVE SEATS

5. Use a cutter to cut the valve seat at an angle of 88°. Use the “lapping” process to make sure the valve and valve seat fit tightly together. Check the valve depth as shown in FIGURE 23. Make sure that the dimensions are within the ENGINE SPECIFICATIONS.

PISTON AND CONNECTING ROD ASSEMBLIES 1.38 ROD BEARINGS

1.39 Removal

The connecting rods are forged from steel.

1. Drain the engine oil from the sump. Remove the oil sump. See 1.114 Oil Sump, Removal.

ENGINES AA and YA. Grooves are machined in the joint faces of the connecting rod and bearing cap to keep the alignment between the two parts. The bearing cap is fastened to the connecting rod with two nuts and special bolts. See FIGURE 28.

FIGURE 28. CONNECTING ROD ASSEMBLY, ENGINES AA AND YA ENGINES AB and YB. The pistons have an “anodized” surface on the top face of the piston. The pistons have a reduced diameter above the groove for the top piston ring. Two steel dowels are installed into the bearing cap to keep the alignment with the connecting rod. Two capscrews fasten the bearing cap to the connecting rod. See FIGURE 29.

2. Remove the suction pipe and oil strainer. See FIGURE 30. Remove the capscrew that holds the bracket to the main bearing cap. Remove the two capscrews from the flange of the suction pipe and remove the suction pipe and screen. Clean the faces of both flanges.

1. SUPPORT BRACKET, MAIN BEARING CAP 2. CAPSCREWS, FLANGE, SUCTION PIPE

FIGURE 30. REMOVE THE SUMP SCREEN 3. Turn the crankshaft until the connecting rod to be removed is at the lowest position on the crankshaft. 4. ENGINES AA and YA. Remove the nuts and remove the bearing cap. ENGINES AB and YB. Loosen the capscrews for the bearing cap approximately four turns. Lightly hit the heads of the capscrews with a soft hammer to separate the connecting rod from the bearing cap. Remove the capscrews and the bearing cap.

CAUTION Do not permit the connecting rods to hit the cooling jets for the pistons. If a cooling jet is hit, the alignment must be checked and the cooling jet replaced if necessary. 5. Remove the lower bearing half from the bearing cap. Keep the bearing half with its cap. FIGURE 29. CONNECTING ROD ASSEMBLY, ENGINES AB AND YB 18

6. Carefully push the connecting rod up the cylinder bore just enough to permit access to the upper bearing

half. Remove the upper bearing half from the connecting rod. Keep the bearing halves together. 1.40 Installation 1. Clean the bearing surfaces of the connecting rod and the crankshaft. Clean the bearing halves and lubricate them with clean engine oil. 2. Install the upper bearing half into the connecting rod. Make sure that the location tab is installed correctly into its position in the connecting rod. See FIGURE 31. FIGURE 32. BEARING CAP POSITION, CONNECTING ROD 5. Loosely assemble the bracket of the suction pipe to the main bearing cap. Install a new gasket and fasten the flanges of the suction line to the oil pump. Make sure that the suction pipe is aligned correctly and tighten the capscrew that holds the bracket to the main bearing cap. 6. Install the oil sump. See 1.115 Oil Sump, Installation.

1.41 PISTON AND CONNECTING ROD ASSEMBLY 1.42 Service Note

CAUTION 1. POSITION OF LOCATION TAB IN BEARING HALF AND CONNECTING ROD (BEARING CAP FOR AA AND YA ENGINES SHOWN)

FIGURE 31. POSITION OF ROD BEARINGS

3. Install the bearing cap on the connecting rod. Make sure that the assembly number on the bearing cap is the same as the number on the connecting rod. Make sure that the two assembly numbers are on the same side of the connecting rod as shown in FIGURE 32. 4. ENGINES AA and YA. Install and tighten the nuts evenly to a torque of 125 Nm (92 lbf ft). Make sure that the crankshaft turns freely. ENGINES AB and YB. Install and tighten the capscrews evenly to a torque of 155 Nm (114 lbf ft). Make sure that the crankshaft turns freely.

The design of the pistons and rings were changed in 1995 beginning with the following engine serial numbers: A––––––U664793Y (4–cylinder) A––––––U654110Y (4–cylinder turbocharged) Y––––––U576870Y (6–cylinder turbocharged) The pistons and piston rings are not interchangeable with earlier production parts and must be changed in complete engine sets. 1.43 Removal 1. If the engine is still in the lift truck, drain the engine oil and the coolant. 2. Remove the cylinder head assembly as described under 1.24 Cylinder Head, Removal. Remove the carbon from the tops of the bores of the cylinder liners. 3. Remove the oil sump. See 1.114 Oil Sump, Removal. 4. Remove the suction line and oil strainer. See FIGURE 30. Remove the capscrew that holds the 19

bracket to the main bearing cap. Remove the two capscrews from the flange of the suction line and remove the suction line and screen. Clean the faces of both flanges. 5. Remove the bearing cap and rod bearings as described under 1.39 Rod Bearings, Removal. Mark the bearing caps and rod bearings so that they can be installed again in their original positions. 6. Push the piston and connecting rod out of the top of the cylinder liner. FIGURE 33. PISTON INSTALLATION TOOL

CAUTION Do not permit the connecting rods to hit the cooling jets for the pistons. If a cooling jet is hit, the alignment must be checked and the cooling jet replaced if necessary.

7. Inspect the bearing surfaces on the crankshaft for damage. 1.44 Installation Special Tools: Piston installation tool (piston ring compressor) Piston height tool Dial indicator gauge

5. Put the spaces in the three piston rings so that they are 120° apart. Put the connecting rod through the piston installation tool and permit the piston to enter the tool. The piston and connecting rod must be turned so that the connecting rod does not hit the cooling jet for the piston. 6. When the connecting rod has passed the cooling jet during installation, the arrow or “FRONT” mark on the piston must be turned towards the end of the engine with the cooling fan. When the piston is in this position, the combustion bowl in the top of the piston will be towards the side of the engine with the fuel injection pump. See FIGURE 34.

FIGURE 34. POSITION OF THE PISTON IN BORE 7. Lubricate the lower half of the rod bearing and install in into the bearing cap. 8. Install the bearing cap on the connecting rod. Make sure that the assembly number on the bearing cap is the same as the number on the connecting rod. Make sure

that the two assembly numbers are on the same side of the connecting rod as shown in FIGURE 32.

12. Install the oil sump. See 1.115 Oil Sump, Installation.

9. ENGINES AB and YB. Install and tighten the nuts evenly to a torque of 125 Nm (92 lbf ft). Make sure that the crankshaft turns freely.

13. Install the cylinder head. See 1.25 Cylinder Head, Installation.

ENGINES AB and YB. Install and tighten the capscrews evenly to a torque of 155 Nm (114 lbf ft). Make sure that the crankshaft turns freely. 10. Measure the height of the piston above the top of the engine block with a dial indicator gauge. The crankshaft must be turned so that the piston is at TDC in the engine block. Put the dial indicator on the top of the engine block and measure the height of the piston above the face of the engine block. See FIGURE 35. The correct height of the piston above the engine block is 0.14 to 0.36 mm (0.005 to 0.014 in). Two piston heights are used by the manufacturer when a new engine is assembled. The pistons are marked “H” for high, and “L” for low. When replacement pistons are ordered from the manufacturer, only the “L” pistons are supplied. If an “L” piston is used to replace a “H” piston, the height of the piston can be a maximum of 0.19 mm (0.0075 in) below the bottom limit. The tops of the pistons must not be changed or machined.

1.45 PISTON RINGS 1.46 Removal Check that the piston rings can move freely in their grooves and are not broken. Remove the piston rings with a ring expander. Increase the diameter of the piston rings only enough to remove them without damaging the piston. 1.47 Inspection 1. Check the piston for wear and damage. 2. Clean the carbon from the top of the cylinder liners. Fit the piston rings in the top part of the cylinder liner and measure the clearance at the ends of the ring. See FIGURE 36. The spring must be installed in the oil control ring when its end clearance is measured. The clearance measurements for the piston rings are shown in the specifications. See 1.42 Service Note.

FIGURE 36. CHECK THE END CLEARANCE OF THE PISTON RING

FIGURE 35. MEASURE THE HEIGHT OF THE PISTON ABOVE THE ENGINE BLOCK 11. Loosely assemble the bracket of the suction pipe to the main bearing cap. Install a new gasket and fasten the flanges of the suction pipe to the oil pump. Make sure that the suction pipe is aligned correctly and tighten the capscrew that holds the bracket to the main bearing cap.

3. Install new piston rings on the piston and check the clearance in the grooves with a spacer gauge. See FIGURE 37. If the clearance between the piston rings and the piston are greater than the specifications, the piston must be replaced. See the ENGINE SPECIFICATIONS. ENGINES AB and YB. The clearance in the top groove of the pistons for these engines can not be checked because it has a taper. 21

ENGINES AA AND YA

FIGURE 37. CHECK THE PISTON RING CLEARANCE

1.48 Installation Install the piston rings with a ring expander. Increase the diameter of the piston rings only enough to remove them without damaging the piston.

FIGURE 39. INSTALLATION OF THE PISTON RINGS 2. Install the cast iron ring with the taper into the second groove of the piston. Make sure that the word “TOP” or the manufacturer’s symbol is towards the top of the piston. New piston rings have a green identification mark which must be on the left of the clearance at the ends of the ring when the ring is installed on the piston and the piston is upright. ENGINES AB AND YB

1. See FIGURE 39. and FIGURE 40. Install the spring for the oil control ring in the bottom groove of the piston. Install the latch pin inside both ends of the spring. See FIGURE 38. Install the oil control ring over the spring so that the end space in the oil control ring is 180° to the latch pin.

FIGURE 40. INSTALLATION OF THE PISTON RINGS 3. Install the barrel face ring with the molybdenum insert into the top groove of the piston. ENGINES AA and YA. The top ring has a chamfer on the inner top face. ENGINES AB and YB. The top ring has a shape like wedge. FIGURE 38. INSTALL THE SPRING FOR THE OIL CONTROL RING

Make sure that the word “TOP” or the manufacturer’s symbol is towards the top of the piston. New piston rings have a red identification mark which must be on the left

of the clearance at the ends of the ring when the ring is installed on the piston and the piston is upright. 4. Make sure that the clearances at the ends of the piston rings are installed in an orientation 120Â° apart before the piston is installed.

1.49 PISTON AND CONNECTING ROD 1.50 Disassembly 1. Remove the piston rings as described in 1.46 Piston Rings, Removal. 2. Make a mark on the piston to indicated the cylinder number as shown on the connecting rod. Make the mark on the same side of the piston as the number on the connecting rod. See FIGURE 41.

The large and small bores in the connecting rod must be square and parallel with each other within the limits of + 0.25 mm (0.010 in). The measurement is made at 127 mm (5.0 in) on each side of the axis of the connecting rod. If the bushing is installed in the small end of the connecting rod, the limits are reduced to + 0.06 mm (0.0025 in).

FIGURE 42. CHECK THE ALIGNMENT OF THE CONNECTING ROD 2. Check the clearance of the bushing in the connecting rod with the piston pin. If the clearance is greater than than 0.043 mm (0.0017 in) or is damaged, install a new bushing. 3. If the bushing in the connecting rod is worn, use a press to remove the bushing. 4. Use a press to install a new bushing in the connecting rod. Make sure that the lubrication hole in the bushing is aligned with the lubrication hole in the connecting rod.

FIGURE 41. MARK THE PISTON

5. Use a reamer in the bushing as necessary to give a clearance on the piston pin of 0.020 to 0.043 mm (0.0008 to 0.0017 in). 6. Machine the ends of the bushing to fit the shape of the connecting rod.

3. Remove the snap rings that hold the piston pin in the piston. Push the piston pin from the piston with your thumb. If the piston pin is tight, heat the piston and connecting rod to 40 to 50Â°C (100 to 120Â°F) to make removal of the piston pin easier.

1.52 Installation

1.51 Inspection

3. Turn the piston for access to install the connecting rod. Install the connecting rod in position in the piston. If the original piston is to installed again, make sure that the mark on the piston is aligned with the mark on the connecting rod as shown in FIGURE 41. Make sure that

1. Clean and inspect all the components for wear and damage. Check the alignment of the connecting rod with a test mandrel. See FIGURE 42.

1. Make sure that the parts are clean. Lubricate the parts with engine oil as they are assembled. 2. Install a new snap ring into one of the grooves to hold the piston pin.

the piston and connecting rod are installed in the same cylinder again. If a new piston or connecting rod is being installed, make sure that index slot in the connecting rod for the rod bearing is on the same side of the piston as the boss for the piston pin. See FIGURE 43.

1. ALIGNMENT DOWEL

FIGURE 44. PISTON COOLING JET 1.55 Installation 1. Check that the ball assembly moves freely against the spring pressure in the valve assembly and that the jet tube is not damaged. Replace any damaged or worn parts. FIGURE 43. ORIENTATION OF PISTON AND CONNECTING ROD

4. Install the piston pin to fasten the connecting rod to the piston. If the piston pin is tight, heat the piston to 40 to 50Â°C (100 to 120Â°F) to make installation of the piston pin easier. 5. Install the other snap ring to hold the piston pin in the piston.

2. Install the cooling jet. Make sure that the assembly is installed correctly on the alignment dowel in the cylinder block. Tighten the valve assembly to 27 Nm (20 lbf ft). 3. Check the alignment of the cooling jet. Insert a 1.70 mm (0.067 in) rod into the nozzle of the cooling jet. The length of the rod must extend out of the top of the cylinder. If a rod of the correct diameter is not available, grind one end of a thicker rod to the 1.70 mm (0.067 in) diameter for a length of 16.00 mm (0.630 in) so that it will fit into the nozzle of the cooling jet. See FIGURE 45. for checking the alignment of the cooling jet.

6. Install the piston rings as described under 1.48 Piston Rings, Installation.

1.53 PISTON COOLING JETS (Engines AB and YB) 1.54 Removal Release the valve assembly and remove the piston cooling jet. The crankshaft has been removed in FIGURE 44. to more clearly show the piston cooling jet. 24

FIGURE 45. ALIGNMENT OF THE PISTON COOLING JET

CRANKSHAFT ASSEMBLY 1.56 GENERAL The crankshaft is forged from chrome–molybdenum steel. The 4–cylinder engines have five main journals and the 6–cylinder engines have seven main journals. The center main bearing is the thrust bearing that controls the axial movement of the crankshaft. The thrust bearing has thrust washers on both sides of the bearing. The main bearings are an alloy of tin and aluminum. The center main bearing in the 6–cylinder engines is a lead and bronze alloy. The front and rear oils seals are lip seals with an additional dust seal outside of the main lip and oil return grooves on the face of the main lip. ENGINES AA and AB. The crankshaft has splines for the position of the front pulley. The crankshaft pulley is fastened to the crankshaft with a thrust block and three capscrews. A damper is part of the crankshaft pulley.

capscrews evenly to 115 Nm (85 lbf ft). Check each capscrew again for the correct torque. 2. Install the drive belts. See 1.178 Drive Belts. 1.60 Removal, Engines YA and YB 1. Remove the drive belts. 2. See FIGURE 47. Remove the three capscrews which hold the pulley to the crankshaft. Remove the thrust block. If the crankshaft pulley will not slide from the crankshaft, DO NOT use a puller to remove the pulley. Hold a wood block against the inner hub of the pulley and lightly hit the wood block with a hammer. See FIGURE 46. This action will loosen the inner ring (2) and outer ring (3) so that the pulley can be removed from the crankshaft as shown in FIGURE 47. 3. If a separate damper is connected to the crankshaft pulley, remove the capscrews and remove the damper.

ENGINES YA and YB. The crankshaft pulley is fastened to the crankshaft with a plain thrust block and three capscrews. A special arrangement holds the crankshaft pulley in position. See FIGURE 47. A separate damper is sometimes fastened to the rear face of the crankshaft pulley. Some engines have the damper as part of the crankshaft pulley.

1.57 CRANKSHAFT PULLEY 1.58 Removal, Engines AA and AB 1. Remove the drive belts. 2. Remove the three capscrews which hold the pulley to the crankshaft. Remove the thrust block and pulley. 3. Clean the parts and check for damage. Replace any damaged parts. 1.59 Installation, Engines AA and AB 1. Put the pulley into position on the crankshaft. Lubricate lightly the threads of the three capscrews. Install the thrust block and the three capscrews. Tighten the three

FIGURE 46. CRANKSHAFT PULLEY INSTALLATION, ENGINES YA AND YB 1.61 Installation, Engines YA and YB 1. If your engine has a separate damper that is connected to the crankshaft pulley and it was removed, install it on the crankshaft pulley. Install the clamp ring or the washers and tighten the capscrews gradually and evenly to 35 Nm ( 26 lbf ft).

2. Remove the flywheel and housing. See 1.172 Flywheel and 1.176 Flywheel Housing, Removal. 3. Remove the capscrews and remove the seal housing and seal assembly. Clean the parts. 4. Inspect the oil seal for wear and damage. If there is any question about the condition of the oil seal, replace the oil seal. 5. Check that the oil seal area and outer circumference of the crankshaft flange are not worn or damaged. 6. Press the oil seal out of the housing 1. SPACER RING 2. INNER RING 3. OUTER RING

4. THRUST BLOCK 5. Oâ&#x20AC;&#x201C;RING

FIGURE 47. CRANKSHAFT PULLEY ARRANGEMENT, ENGINES YA AND YB

7. Lubricate the oil seal with engine oil and carefully press the oil seal into one of the positions in the housing. The spring in the seal goes toward the housing. 8. There are four positions in which the oil seal can be installed in the seal housing. See FIGURE 48.

2. Clean the end of the crankshaft and the parts of the crankshaft pulley. Do not use a degreasing solution. See FIGURE 47. Do not make any changes to the inner ring (2) or the outer ring (3). 3. Put the crankshaft pulley on the crankshaft so that the key is engaged. Push the pulley onto the crankshaft. NOTE: If the rings (2) and (3) are not installed correctly, the crankshaft pulley will be very difficult to remove again. 4. Install the spacer ring (1), inner ring (2), and the outer ring (3) in the correct order.

FIGURE 48. OIL SEAL POSITIONS

5. Lightly lubricate the Oâ&#x20AC;&#x201C;ring (5) and the thrust faces of the capscrews with engine oil. Put the thrust block (4) and the capscrews in position.

Position 1 is used by the manufacturer or if a new oil seal is installed on a crankshaft that has a new surface ground on the crankshaft flange.

6. Gradually and evenly tighten the capscrews to push the crankshaft pulley on the crankshaft. Tighten the capscrews to 115 Nm (85 lbf ft). 7. Install the drive belts. See 1.178 Drive Belts.

1.62 REAR OIL SEAL

Position 2 is used when a new oil seal is installed and the crankshaft flange is worn at Position 1. Position 3 is used when a new oil seal is installed and the crankshaft flange is worn at Position 1 and Position 2. Position 4 can be used when a new oil seal is installed if a wet clutch is not installed.

Special Tools: Replacement tool for oil seal

If all positions have been used, the crankshaft must have a new surface ground on the crankshaft flange. See the ENGINE SPECIFICATIONS for the size limits.

1. Remove the drive components from the rear of the engine.

9. Make sure that the two position dowels are installed in the engine block. Use a new gasket. Do not use gasket compound on any of the surfaces.

1.63 Replacement

10. Make sure the lip of the seal is lubricated with engine oil where it touches the crankshaft flange. This lubrication of the oil seal is necessary to prevent damage to the oil seal when the engine is first started. 11. Put the oil seal and housing on the seal guide. Carefully push the oil seal assembly into position on the crankshaft flange and onto the dowels. See FIGURE 49.

install the capscrews on the main bearing cap, the timing case must be removed. The oil pump will be removed with the cap for the front main bearing. The suction pipe, oil strainer, delivery pipe, and relief valve must be removed. 1.65 Removal 1. Drain the engine oil and remove the oil sump. 2. Remove the necessary components for access to the bearing cap for the bearing that must be replaced. 3. Remove the capscrews and remove the bearing cap. Remove the lower half of the bearing from the bearing cap. 4. Use a thin flexible tool to push on the side of the upper bearing half that is opposite from the location tab. Push on the bearing half so that it begins to rotate out of the engine block. Carefully rotate crankshaft so that bearing will rotate out of the engine block.

1. SEAL GUIDE 2. OIL SEAL AND HOUSING 3. DOWEL (2)

FIGURE 49. INSTALLATION OF THE OIL SEAL 12. Remove the seal guide. Install the capscrews. Tighten the smaller capscrews to 18 Nm (13 lbf ft). Tighten the larger capscrews to 22 Nm (16 lbf ft).

5. Check that the bearing journal on the crankshaft is clean and in good condition. 1.66 Installation NOTE: Only the upper half of the bearing has lubrication holes and it must be installed into the engine block.

NOTES: The following procedure is for replacement of the main bearings without removing the crankshaft from the engine.

1. Lubricate the upper bearing half with engine oil. Install the plain end of the bearing between the crankshaft journal and the side of the bearing housing that has the location slot. Carefully slide the bearing half into the bearing housing until the location tab fits into the location slot.

If the rear main bearing must be replaced, the flywheel, flywheel housing, rear oil seal housing, and bridge piece must be removed.

2. Lubricate the lower bearing half with engine oil and install it into the bearing cap. Make sure the location tab is installed correctly into the location slot.

The front main bearing can be difficult to replace when the timing case is on the engine. The oil pump is installed on the front bearing cap. A special wrench can be required to apply the correct torque to the capscrews for removal and installation. If a wrench is not available to

3. Make sure that the location thimbles are installed in either the bearing cap or the bearing housing of the engine block. Make sure that the orientation of the location slots for the bearing halves are correct as shown in FIGURE 50. Install the bearing cap.

1.64 MAIN BEARINGS

1. LOCATION SLOTS FOR MAIN BEARING HALVES

FIGURE 51. THRUST WASHERS

FIGURE 50. ORIENTATION OF THE MAIN BEARING CAP

4. Make sure the capscrews are in good condition. Install the capscrews into the bearing cap. Tighten the capscrews gradually and evenly. Tighten the capscrews to a final torque of 265 Nm (196 lbf ft). 5. Make sure that the crankshaft rotates freely. If the thrust washers have been removed and installed again, the axial movement of the crankshaft must be checked. See 1.67 Thrust Washers in the following paragraphs. 6. Install the components that were removed for access to the main bearing.

FIGURE 52. MEASURE THE AXIAL CLEARANCE WITH A SPACER GAUGE

7. Install the oil sump.

1.67 THRUST WASHERS 1.68 Check The Axial Movement Of The Crankshaft The axial movement of the crankshaft is controlled by two half thrust washers installed on each side of the center main bearing. See FIGURE 51. The axial clearance can be checked with a spacer gauge inserted between the crankshaft and the thrust washer. See FIGURE 52. A dial indicator can be used to check the axial movement from the end of the crankshaft as shown in FIGURE 53. The normal axial movement is 0.05 to 0.38 mm (0.002 to 0.015 in). The maximum axial movement permitted is 0.51 mm (0.020 in). 28

FIGURE 53. MEASURE THE AXIAL MOVEMENT WITH A DIAL INDICATOR If the axial movement is greater than the specifications, oversize thrust washers can be installed on one side or both sides of the main bearing. The oversize thrust

washers are 0.019 mm (0.0075 in) larger than the standard thrust washers. 1.69 Removal 1. Drain the engine oil from the sump. Remove the oil sump. See 1.114 Oil Sump, Removal. 2. Remove the suction pipe and oil strainer. See FIGURE 30. Remove the capscrew that holds the bracket to the main bearing cap. Remove the two capscrews from the flange of the suction pipe and remove the suction pipe and screen. Clean the faces of both flanges. 3. Remove the capscrews for the center main bearing cap. Remove the bearing cap, lower bearing half, and the lower halves of the thrust washers. 4. Use a thin flexible tool to push the upper halves of the thrust washers from their positions next to the main bearing housing. See FIGURE 54. Use a small prybar as necessary to move the crankshaft to loosen a tight thrust washer.

2. Install the lower halves of the thrust washers into the main bearing cap. Make sure that the location tabs are in their correct positions. 3. Make sure that the location thimbles are installed in either the bearing cap or the bearing housing of the engine block. Make sure that the orientation of the location slots for the bearing halves are correct as shown in FIGURE 50. Lubricate the bearing and thrust washers with engine oil. Install the bearing cap. 4. Make sure the capscrews are in good condition. Install the capscrews into the bearing cap. Tighten the capscrews gradually and evenly. Tighten the capscrews to a final torque of 265 Nm (196 lbf ft). 5. Make sure that the crankshaft rotates freely. Check the axial movement of the crankshaft to make sure that it is within the specifications. 6. Loosely assemble the bracket of the suction line to the main bearing cap. Install a new gasket and fasten the flanges of the suction line to the oil pump. Make sure that the suction line is aligned correctly and tighten the capscrew that holds the bracket to the main bearing cap. 7. Install the oil sump. See 1.115 Oil Sump, Installation.

1.71 CRANKSHAFT 1.72 Removal 1. Remove the engine from the lift truck. See THE FRAME section. See the TRANSMISSION section for separating the engine from the transmission. 2. Remove the oil sump. See 1.114 Oil Sump, Removal. 3. Remove the fan, drive belts, fan drive pulley and housing, and the coolant pump. FIGURE 54. REMOVE THE UPPER HALF OF THE THRUST WASHER 1.70 Installation 1. Lubricate the thrust washers with engine oil. Slide the upper halves of the thrust washers into their positions in the engine block. Make sure that the sides of the thrust washers with the grooves are against the crankshaft.

4. Remove the crankshaft pulley. See 1.57 Crankshaft Pulley. 5. Remove the alternator and its mount bracket. 6. Remove the timing case cover. See 1.77 Timing Case Cover, Removal. 7. Remove the fuel injection pump. See 1.127 Fuel Injection Pump, Removal.

8. Remove the timing gears and the timing case. See the sections 1.75 through 1.92 Timing Case And Timing Gears. 9. Remove the flywheel and the flywheel housing. See 1.172 Flywheel and 1.176 Flywheel Housing, Removal. 10. Remove the rear oil seal housing. See 1.63 Oil Seal, Replacement. 11. If the engine is not already in a position with the crankshaft facing up, turn the engine to that position. Remove the suction pipe and oil strainer. See FIGURE 30. Remove the capscrew that holds the bracket to the main bearing cap. Remove the two capscrews from the flange of the suction pipe and remove the suction pipe and screen. Clean the faces of both flanges. Remove the oil pump, delivery tube and relief valve. See 1.117 through 1.121 on the oil pump and relief valve. 12. Remove the bridge piece over the rear main bearing. Make a note if there is a round rubber seal at each end of the bridge piece where it joins the crankcase. Some engines have rubber seals and other engines have sealant. 13. Remove the bearing caps and lower bearing halves from the connecting rods. Make an arrangement so that the parts for each connecting rod will be assembled again in their original positions. Carefully push the pistons into their bores a small amount so that the connecting rods are separated from the crankshaft.

CAUTION Make sure the cooling jets for the pistons are not damaged or moved out of alignment. If a cooling jet is hit, the alignment must be checked and the cooling jet replaced if necessary. 14. Make sure that the main bearing caps are marked with their position number. Remove the main bearing caps, lower bearing halves, and the upper and lower thrust washers. Keep all the parts in an arrangement so that the parts can be installed in their original positions. 15. Lift the crankshaft from the engine block. Remove the upper bearing halves and put each of them with their lower bearing half.

1.73 Inspection Check the crankshaft for wear and other damage. The maximum wear and outâ&#x20AC;&#x201C;ofâ&#x20AC;&#x201C;round on the bearing journals is 0.04 mm (0.0016 in). The bearing journals on standard crankshafts can be ground to the following diameters smaller than the original size: 0.25 mm (0.010 in) 0.50 mm (0.020 in) 0.75 mm (0.030 in) Special bearings are available for these sizes. The crankshaft must be replaced if the surface must be ground more than 0.75 mm (0.030 in). The area on the crankshaft flange for the rear oil seal can be machined to remove wear marks if the oil seal has been used in all four positions. See the ENGINE SPECIFICATIONS. The minimum diameter of this area is 133.17 mm (5.243 in). 1.74 Installation 1. Make sure that all of the oil passages are clean. 2. Make sure all of the bearings and bearing caps are clean. Install the upper bearing halves into their positions in the connecting rods and the housings for the main bearings. Make sure that the position tags of the bearings fit into their position slots. Lubricate the bearings with engine oil. 3. Install the crankshaft in position on the main bearings. 4. Lubricate the thrust washers with engine oil. Slide the upper halves of the thrust washers into their positions in the engine block. Make sure that the sides of the thrust washers with the grooves are against the crankshaft. 5. Install the lower halves of the thrust washers into the main bearing cap. Make sure that the location tags are in their correct positions. 6. Make sure that the location thimbles are installed in either the bearing cap or the bearing housing of the engine block. Make sure that the orientation of the location slots for the bearing halves are correct as shown in FIGURE 50. Lubricate the bearing and thrust washers with engine oil. Install the bearing cap.

7. Make sure the main bearing caps are installed according to their position numbers shown on the cap. The serial numbers on the main bearing caps will also be in alignment. The serial number on the main bearing caps must be the same as the number on the bottom face of the engine block. (The third and fifth bearing caps on 6â&#x20AC;&#x201C;cylinder engines are not marked with with a serial number.) 8. Make sure the capscrews are in good condition. Install the capscrews into the main bearing cap. Tighten the capscrews gradually and evenly. Tighten the capscrews to a final torque of 265 Nm (196 lbf ft). Repeat this step for all five main bearings.

FIGURE 56. ALIGN THE BRIDGE PIECE

9. Apply a thin coat of sealant in the corners and around the thread holes of the bridge piece where it joins the engine block. Install the bridge piece and the two rubber seals. See FIGURE 55.

11. Install the upper bearing half into the connecting rod. Make sure that the location tab is installed correctly into its position in the connecting rod. See FIGURE 31.

NOTE: Some engines do not have the two rubber seals installed and the grooves in the bridge piece are filled with sealant.

12. Install the bearing cap on the connecting rod. Make sure that the assembly number on the bearing cap is the same as the number on the connecting rod. Make sure that the two assembly numbers are on the same side of the connecting rod as shown in FIGURE 32. 13. Install and tighten the capscrews evenly to a torque of 155 Nm (114 lbf ft). Make sure that the crankshaft turns freely. 14. Install the oil pump, delivery pipe, and relief valve. See 1.119 through 1.124 for installation. Loosely assemble the bracket of the suction pipe to the main bearing cap. Install a new gasket and fasten the flanges of the suction line to the oil pump. Make sure that the suction pipe is aligned correctly and tighten the capscrew that holds the bracket to the main bearing cap. 15. Install the rear oil seal housing. See 1.62 Oil Seal.

FIGURE 55. BRIDGE PIECE AND RUBBER SEALS

10. Use a straight edge to make sure the the bridge piece is aligned with the rear face of the engine block. See FIGURE 56. Tighten the capscrews.

16. Install the flywheel and the flywheel housing. See 1.174 Flywheel and 1.177 Flywheel Housing, Installation. 17. Install the timing gears and the timing case. See the sections after 1.75 for the Timing Gears And Timing Case, Installation.

18. Install the fuel injection pump. See 1.128 Fuel Injection Pump, Installation.

22. Install the coolant pump, fan drive pulley and fan housing, drive belts, and the fan.

19. Install the timing case cover. See 1.78 Timing Case Cover, Installation.

23. Install the oil sump. See 1.115 Oil Sump, Installation.

20. Install the alternator and its mount bracket. 21. Install the crankshaft pulley. See 1.57 Crankshaft Pulley.

24. Install the engine into the lift truck. See THE FRAME section and the TRANSMISSION section for the lift truck.

TIMING CASE AND TIMING GEARS 1.75 GENERAL The timing case can be either cast aluminum or cast iron. The timing gears are steel. A PTO turns the hydraulic pump for the steering, brakes, and frame leveling functions. The gear train includes the crankshaft gear, idler gear, gear for the fuel injection pump, camshaft gear, and PTO gear. The timing case cover is aluminum and has the front oil seal for the crankshaft. The timing case cover has a noise shield on its front surface.

1. Use a new gasket and install the timing case cover on the timing case. Use two capscrews to hold the timing case cover in position. Install the special tool on the crankshaft. Use the special washer and the capscrews for the crankshaft pulley to hold the alignment tool in position. The purpose of the special tool is to make sure that the front oil seal evenly fits the circumference of the seal surface of the crankshaft pulley. See FIGURE 57.

The camshaft is made from cast iron. The lobes for the fuel pump are hardened.

1.76 TIMING CASE COVER 1.77 Removal 1. Drain the coolant. Remove the fan. 2. Remove the drive belts. 3. Remove the three capscrews which hold the crankshaft pulley to the crankshaft. Remove the thrust block and pulley. 4. Remove the fan drive pulley if additional clearance is needed. 5. Remove the coolant pump. See 1.154 Coolant Pump, Removal. 5. Remove the capscrews and nuts that hold the timing case cover to the timing case. Remove the timing case cover and the sound shield.

FIGURE 57. ALIGNMENT TOOL, FRONT OIL SEAL When the timing case cover is aligned with the crankshaft, install the capscrews and nuts in the timing case cover. Tighten the capscrews and nuts to 22 Nm (16 lbf ft). Remove the alignment tool. 2. Install the coolant pump. See 1.157 Coolant Pump, Installation.

1.78 Installation

3. Install the crankshaft pulley and thrust block. Install the three capscrews and tighten the three capscrews evenly to 115 Nm (85 lbf ft). Check each capscrew again for the correct torque.

Special Tools: Alignment tool, front oil seal

4. Install the fan drive pulley if it was removed.

5. Install the drive belts and adjust the tension. See 1.178 Drive Belts. 6. Install the fan. Fill the cooling system.

1.79 FRONT OIL SEAL

seal. If the crankshaft pulley is worn at that place, the front oil seal can be installed at a maximum depth of 9.3 mm (0.366 in). 1. Clean the oil seal housing. Inspect the oil seal for damage. Do not install a front oil seal that has a scratch or any damage on the lip of the seal.

1.80 Removal 1. Remove the fan and drive belts. 2. Remove the crankshaft pulley. 3. Use a prybar to remove the front oil seal from the timing gear cover. Put the prybar behind the main lip of the front oil seal. Make sure that the edge of the housing for the oil seal is not damaged during removal. 1.81 Installation Special Tools: Replacement tool for front oil seal Pressure plate Fastener plate Sleeve Seal adaptor

2. Lubricate the outer circumference of the oil seal with engine oil and install the front oil seal into the oil seal housing. Make sure that the lip of the seal is towards the inside of the cover for the timing gear case and the front oil seal is parallel to the bore of the oil seal housing. 3. Put the replacement tool for the front oil seal on the crankshaft as shown in FIGURE 58. Use the fastener plate (3) to fasten the installation tool to the crankshaft. Install the seal adaptor (5) so that the 9.3 mm mark is towards the front oil seal. Put the sleeve (4) and the pressure plate (2) into position and fasten it to the stud of the fastener plate as shown in FIGURE 58. 4. Install a rod through the hole in the end of the tool so that the tool will not turn. Turn the nut on the pressure plate (2) with a wrench and the front oil seal will be pushed into the housing. Push the seal into the correct depth. If the seal is to be pushed into the 9.3 mm position, turn the nut on the pressure plate (2) until the face of the seal adaptor (5) is against the oil seal housing. Remove the installation tool. 5. Lubricate the seal area of the crankshaft pulley with engine oil. Install the crankshaft pulley. See 1.57 Crankshaft Pulley. 6. Install the drive belts and adjust the belt tension. 7. Install the fan.

1. REPLACEMENT TOOL FOR FRONT OIL SEAL 2. PRESSURE PLATE 3. FASTENER PLATE 4. SLEEVE 5. SEAL ADAPTOR

FIGURE 58. INSTALLATION, FRONT OIL SEAL NOTE: The front oil seal is normally installed to a depth of 6.75 to 7.25 mm (0.266 to 0.285 in) from the front face of the oil seal housing to the flat front face of the oil

1.82 IDLER GEAR AND HUB 1.83 Removal 1. Remove the timing case cover. See 1.77 Timing Case Cover, Removal. 2. Turn the crankshaft until the marked teeth of the crankshaft gear, the camshaft gear, and the gear for the fuel injection pump are aligned as shown in FIGURE 59. The marked teeth on the idler gear will not necessarily be aligned with the marked teeth of

the other three gears because of the different speed of rotation of the idler gear.

TIMING MARKS ON GEARS: 4 = 4 Cylinder Engine 6 = 6 Cylinder Engine

3. Remove the three capscrews, remove the plate of the idler gear, and remove the idler gear. The gear for the fuel injection pump will turn a small amount in the counterâ&#x20AC;&#x201C;clockwise direction as the teeth become disengaged from the idler gear.

4 3

CAUTION Make sure that the crankshaft is not turned while the idler gear is removed. A piston can hit and damage a valve.

4. Inspect the idler gear and bushings for wear and damage. The idler gear and bushings are available as an assembly or as separate parts. 5. If the bushings must be replaced, use a puller to remove them from the idler gear. If a puller is not available, grind one of the faces from the bushings and use a press to remove them from the idler gear. Use a press to install new bushings. The bores and faces of the bushings will need machining to correctly fit the hub. See the ENGINE SPECIFICATIONS, Idler Gear And Hub for the measurements.

. . . . .

1. 2. 3. 4. 5.

CAMSHAFT GEAR CRANKSHAFT GEAR IDLER GEAR GEAR FOR FUEL INJECTION PUMP PTO GEAR

FIGURE 59. ALIGNMENT OF THE TIMING MARKS 3. Install the plate for the idler gear and the three capscrews. Tighten the capscrews to 44 Nm (33 lbf ft). 4. Check the clearance between the bushings of the idler gear and the plate of the idler gear. The correct clearance is 0.10 to 0.20 mm (0.004 to 0.008 in). A maximum service limit is 0.38 mm (0.015 in). See FIGURE 60.

1.84 Installation 1. Use the three capscrews for the idler gear to make sure that the hub for the idler gear is in the correct position with the lubrication hole at the top. 2. Lubricate the bushings in the idler gear with engine oil. Align the timing marks on the idler gear with the marks on the crankshaft gear and the cam shaft gear. Turn the gear for the fuel injection pump clockwise as necessary to align the timing marks when the teeth of the idler gear engage the other gears. Make sure all of the alignment marks are aligned as shown in FIGURE 59.

FIGURE 60. CHECK THE HUB CLEARANCE ON THE IDLER GEAR

5. Check the timing gear clearances as shown in FIGURE 61. The minimum clearances for all gears is 0.08 mm (0.003 in).

FIGURE 62. REMOVE THE CAMSHAFT GEAR

FIGURE 61. CHECK THE TIMING GEAR CLEARANCES 6. Install the timing case cover, coolant pump, crankshaft pulley, fan drive pulley, drive belts, and fan. See 1.78 Timing Case Cover, Installation.

4. Gear for the fuel injection pump. Remove the nut and spring washer from the gear for the fuel injection pump. Use a puller and adaptor to remove the gear for the fuel injection pump. The gear has the letter M on the gear to indicate that the threads for the screws of the gear puller are metric. Make sure that the woodruff key in the shaft for the fuel injection pump is not lost. Inspect the gear for wear and damage. See FIGURE 63.

1.85 GEAR FOR THE FUEL INJECTION PUMP OR THE CAMSHAFT GEAR 1.86 Removal Special Tools: Gear puller with adaptors 1. Remove the timing case cover. See 1.77 Timing Case Cover, Removal. 2. Turn the crankshaft until the marked teeth of the crankshaft gear, the camshaft gear, and the gear for the fuel injection pump are aligned as shown in FIGURE 59. The marked teeth on the idler gear will not necessarily be aligned with the marked teeth of the other three gears because of the different speed of rotation of the idler gear.

CAUTION Make sure that the crankshaft is not turned while the camshaft gear is removed. A piston can hit and damage a valve. 3. Camshaft gear. Remove the capscrew and washer. Use a puller and adaptor to pull the gear from the camshaft. Make sure that the woodruff key in the camshaft is not lost. Inspect the camshaft gear for wear and damage. See FIGURE 62.

FIGURE 63. REMOVE THE GEAR FOR THE FUEL INJECTION PUMP 1.87 Installation

CAUTION If the crankshaft or the camshaft must be turned to permit the alignment of the marks on the timing gears, a piston can hit and damage a valve. The rocker arm assembly must be loosened so that the valves are closed when the crankshaft or the camshaft are turned. 1. Make sure that the woodruff key is installed correctly in the end of the camshaft. 35

2. Install the gear on the shaft with the marked teeth towards the idler gear. Use a soft hammer to push the gear onto the camshaft. Make sure that the timing marks are aligned correctly as the gear teeth are engaged. See FIGURE 59. 3. Camshaft gear. Install the capscrew and washer and tighten the capscrew to press the gear into position. Tighten the capscrew to 78 Nm (58 lbf ft). 4. Gear for the fuel injection pump. Install the nut and spring washer. Tighten the nut to 80 Nm (59 lbf ft). 5. If new gears have been installed, check the timing gear clearances as shown in FIGURE 61. The minimum clearances for all gears is 0.08 mm (0.003 in). 6. Install the timing case cover, coolant pump, crankshaft pulley, fan drive pulley, drive belts, and fan. See 1.78 Timing Case Cover, Installation.

1.90 Installation 1. Put the crankshaft gear in a pan of hot oil. Make sure that the temperature can be controlled. DO NOT heat the crankshaft gear more than 108°C (226°F). Use boiling water if a container of hot oil and a temperature control is not available. DO NOT use an open flame to heat the gear. 2. Align the gear with the key on the crankshaft and with the timing marks on the gear away from the engine. Push the gear onto the crankshaft. 3. Install the idler gear. See 1.84 Idler Gear, Installation. 4. Check the timing gear clearances as shown in FIGURE 61. The minimum clearances for all gears is 0.08 mm (0.003 in). 5. Install the timing case cover, coolant pump, crankshaft pulley, fan drive pulley, drive belts, and fan. See 1.78 Timing Case Cover, Installation.

1.88 CRANKSHAFT GEAR 1.91 TIMING CASE 1.89 Removal 1.92 Removal 1. Remove the timing case cover. See 1.77 Timing Case Cover, Removal. 2. Turn the crankshaft until the marked teeth of the crankshaft gear, the camshaft gear, and the gear for the fuel injection pump are aligned as shown in FIGURE 59. The marked teeth on the idler gear will not necessarily be aligned with the marked teeth of the other three gears because of the different speed of rotation of the idler gear.

CAUTION Make sure that the crankshaft is not turned while the idler gear or the crankshaft gear is removed. A piston can hit and damage a valve. 3. Remove the three capscrews, remove the plate of the idler gear, and remove the idler gear. The gear for the fuel injection pump can turn a small amount in the counter–clockwise direction as the teeth become disengaged from the idler gear. 4. The crankcase gear is pressed onto the crankshaft. Sometimes a puller will remove the crankcase gear. Sometimes the gear fits so tightly on the crankshaft that the crankshaft must be removed from the engine and the gear must be removed by destroying it. 36

1. Remove the timing case cover. See 1.77 Timing Case Cover, Removal. 2. Remove the alternator and its mount bracket, and the front support plate. 3. Remove the timing gears. See 1.82 through 1.90 for removal of the timing gears. 4. Remove the capscrews that hold the timing case to the engine block. Remove the capscrews that hold the oil sump to the timing gear case. 5. Remove the timing gear case, gasket, and hub for the idler gear. Do not permit the hub to fall and become damaged. 1.93 Installation 1. Make sure that the gasket for the oil sump is not damaged. If the gasket is damaged, remove the oil sump and install after the timing case has been installed. A damaged section of the gasket can be cut and a new section can be installed in its place, but the work must be carefully done to prevent oil leaks. 2. If the oil sump has been removed, install the hub for the idler gear on the front of the engine block. Use the three capscrews for the idler gear to hold the hub in posi-

tion. Make sure that the oil hole in the hub is towards the top of the engine. 3. Make sure that the thrust washer for the camshaft is in the correct position. 4. Install a new gasket for the timing case to the engine block. Cut the bottom ends of the gasket to correctly fit the space. Use gasket compound at the bottom ends of the gasket. 5. Put the timing case into position on the engine block. If the oil sump was not removed, install the hub for the idler gear. Use the three capscrews for the idler gear to hold the hub in position. Make sure that the oil hole in the hub is towards the top of the engine. Install the four capscrews that hold the hub of the idler gear to the engine block. See FIGURE 64.

NOTE: If a new timing case is being installed, remove the two studs from the timing case and clean the threads that fit into the timing case. Apply liquid sealant to the threads of the studs and install them into the new timing case. 7. Install the camshaft gear. Install the capscrew and washer and tighten the capscrew to press the gear into position. Tighten the capscrew to 78 Nm (58 lbf ft). 8. Lubricate the bushings in the idler gear with engine oil. Align the timing marks on the idler gear with the marks on the crankshaft gear and the cam shaft gear. Remove the three capscrews from the hub for the idler gear and install the idler gear. Make sure that the timing marks are aligned as shown in FIGURE 59. 9. If a new timing case was installed, put a new timing mark for the fuel injection pump on the rear face of the timing case. See 1.129 CAV Fuel Injection Pump, Checks And Adjustments. 10. Install the fuel injection pump. See 1.128 Fuel Injection Pump, Installation. Install the nut and spring washer. Tighten the nut to 80 Nm (59 lbf ft). 11. If new gears have been installed, check the timing gear clearances as shown in FIGURE 61. The minimum clearances for all gears is 0.08 mm (0.003 in). 12. If the oil sump was removed, install it. Make sure that any joints in the gaskets are fitted to prevent oil leaks.

1. CAPSCREWS FOR HUB 2. HUB FOR IDLER GEAR

FIGURE 64. INSTALL THE HUB FOR THE IDLER GEAR.

13. Install the timing case cover, coolant pump, crankshaft pulley, fan drive pulley, drive belts, and fan. See w 1.78 Timing Case Cover, Installation.

1.94 CAMSHAFT AND TAPPETS 6. Install the alternator and its front support plate in position and install the remainder of the capscrews into the timing case. If the front support plate has been separated from the alternator bracket, make sure that the support plate is even with the machined face of the engine block where the alternator bracket is installed. Tighten the M8 capscrews to 22 Nm (16 lbf ft). Tighten the M10 capscrews to 44 Nm (33 lbf ft).

NOTE: The removal and installation of the camshaft and tappets require disassembly of many components of the engine. The engine is normally removed from the lift truck for this operation. See THE FRAME section for procedures to remove the engine. See the TRANSMISSION section for procedures to separate the engine from the transmission.

1.95 Removal 1. Remove the timing case cover. See 1.77 Timing Case Cover, Removal. 2. Remove the timing gears. See 1.82 through 1.89 for removal of the timing gears. 3. Remove the timing case. See 1.92 Timing Case, Removal. 4. Remove the valve cover, rocker arm assembly, and push rods. 5. Remove the fuel pump. 6. Turn the engine so that the oil sump is up and remove the oil sump. 7. Remove the thrust washer for the camshaft. See FIGURE 65.

FIGURE 66. CAMSHAFT,REMOVAL AND INSTALLATION 1.96 Installation 1. Make sure all of the parts are clean. Lubricate the parts with engine oil as they are assembled. 2. Install the tappets in their positions. 3. Carefully install the camshaft. See FIGURE 66. 4. Install the thrust washer for the camshaft. Make sure the thrust washer fits correctly on the dowel. See FIGURE 65. 5. Use a new gasket and install the timing case. See 1.93 Timing Case, Installation. 6. Check the clearance of the camshaft. A dial indicator can be used to check the axial movement from the end of the camshaft. The normal axial movement is 0.10 to 0.41 mm (0.004 to 0.016 in). The maximum axial movement permitted is 0.53 mm (0.021 in). 7. Turn the camshaft until the cam for the fuel pump is at the minimum lift position. Install the fuel pump.

1. THRUST WASHER, CAMSHAFT 2. POSITION DOWEL

FIGURE 65. THRUST WASHER, CAMSHAFT

8. Carefully remove the camshaft. See FIGURE 66. 9. Remove the tappets. 10. Inspect the camshaft and the tappets for wear and damage. See the ENGINE SPECIFICATIONS for the measurements. Replace any bad parts. 38

8. Turn the engine to the upright position. Turn the crankshaft until the key slot in the crankshaft is towards the top. Install the timing gears. See 1.84 through 1.90 for installation of the timing gears. 9. Install the fuel injection pump. 10. Install the push rods and the rocker arm assembly. See 1.15 Rocker Arm Assembly, Installation. 11. Adjust the valve clearances. See 1.19 Valve Clearance Adjustments. 12. Install the oil pump.

13. Install the timing case cover. See 1.78 Timing Case Cover, Installation.

remove the air from the fuel system before operation.

14. Install the engine. When the engine can be operated,

ENGINE BLOCK ASSEMBLY 1.97 DESCRIPTION The engine block is made of cast iron. The removable cylinder liners are pressed into the engine block. A bushing is installed in the front of the engine block for the front journal of the camshaft. The other camshaft journals do not have bushings and run directly in the engine block.

12. Remove the timing gears and the timing case. See the sections 1.75 through 1.92 Timing Case and Timing Gears. 13. Remove the oil sump. See 1.114 Oil Sump, Removal. Remove the oil filter. 14. Remove the cylinder head assembly. See 1.24 Cylinder Head Assembly, Removal.

1.98 ENGINE BLOCK 1.99 Disassembly 1. Remove the engine from the lift truck. See THE FRAME section for procedures to remove the engine. See the TRANSMISSION section for procedures to separate the engine from the transmission. 2. Remove the fan, drive belts, fan drive pulley and housing, and the coolant pump. 3. ENGINES YA and YB. If the engine has a compressor, remove it. 4. Remove the crankshaft pulley. See 1.57 Crankshaft Pulley, Removal. 5. Remove the alternator and its mount bracket. 6. Remove the timing case cover. See 1.77 Timing Case Cover, Removal. 7. Remove the fuel injection pump. See 1.127 Fuel Injection Pump, Removal. 8. Remove the fuel injectors, fuel lines, fuel filter, and fuel pump. See the Fuel System sections beginning with 1.140 . 9. Remove the oil cooler. See 1.164 Oil Cooler, Removal. 10. ENGINES AB and YB. Remove the turbocharger. See 1.108 Turbocharger, Removal. 11. Remove the starter motor. See 1.181 Starter Motor, Removal.

15. Remove the flywheel and the flywheel housing. See 1.172 Flywheel And Flywheel Housing. 16. Remove the rear oil seal housing. See 1.63 Oil Seal, Replacement. 17. If the engine is not already in a position with the crankshaft facing up, turn the engine to that position. Remove the suction line and oil strainer. See FIGURE 75. Remove the capscrew that holds the bracket to the main bearing cap. Remove the two capscrews from the flange of the suction line and remove the suction line and screen. Clean the faces of both flanges. Remove the oil pump, delivery pipe and relief valve. See the sections 1.117 through 1.121 to remove the oil pump and relief valve. 18. Remove the bridge piece over the rear main bearing. Make a note if there is a round rubber seal at each end of the bridge piece where it joins the crankcase. Some engines have rubber seals and other engines have sealant. 19. Remove the bearing caps and lower bearing halves from the connecting rods. Make an arrangement so that the parts for each connecting rod will be assembled again in their original positions. Carefully push the pistons into their bores a small amount so that the connecting rods are separated from the crankshaft.

CAUTION Make sure the cooling jets for the pistons are not damaged or moved out of alignment. If a cooling jet 39

is hit, the alignment must be checked and the cooling jet replaced if necessary.

5. Install the flywheel housing and flywheel. See 1.174 Flywheel and 1.177 Flywheel Housing section.

20. Make sure that the main bearing caps are marked with their position number. Remove the main bearing caps, lower bearing halves, and the upper and lower thrust washers. Keep all the parts in an arrangement so that the parts can be installed in their original positions.

6. Install the tappets and the camshaft. See 1.96 Camshaft And Tappets, Installation.

21. Lift the crankshaft from the engine block. Remove the upper bearing halves and put each of them with their lower bearing half. 22. Carefully remove the pistons and connecting rod assemblies from the engine. 23. Remove the camshaft and tappets. See 1.95 Camshaft And Tappets, Removal.

7. Install the relief valve, oil pump, suction line and oil strainer. See the sections 1.119 through 1.124 . 8. Install the timing case and the timing gears. See The sections 1.78 through 1.93 Timing Case And Timing Gears 9. Install the cylinder head assembly. See 1.25 Cylinder Head Assembly, Installation. 10. Install the starter motor. 11. Install the fuel pump.

24. ENGINES AB and YB. Remove the cooling jets for the pistons.

12. ENGINES AB and YB. Install the turbocharger. See 1.109 Turbocharger, Installation.

1.100 Inspection

13. Install the oil filter assembly and the oil sump. See 1.115 Oil Sump, Installation.

1. Make sure all of the oil and coolant passages in the engine block are clean. 2. Check the engine block for cracks and damage.

14. Install the oil cooler. See 1.167 Oil Cooler, Installation.

NOTE: The top face of the engine block can not be machined because the cylinder liners and pistons will not fit.

15. Install the fuel injectors, fuel lines, fuel filter, and fuel injection pump. See 1.128 through 1.148 Fuel System sections.

3. Check the front bushing for the camshaft for wear. If a new bushing must be installed, use a puller to remove the old bushing. Make sure the oil hole for the new bushing is away from the engine when it is installed. Make sure the oil hole is aligned with the passage in the engine block when it is installed. Use a press to install a new bushing and align it in position in the engine block.

16. Install the coolant pump, fan drive pulley, and fan. See 1.157 through 1.162 Cooling System sections. 17. Install the alternator and mount brackets. R. Install the drive belts and adjust the tension. See 1.178 Drive Belts. 18. Install the engine into the lift truck.

1.101 Assembly 1. Make sure all the parts are clean. 2. Remove the screw plugs from the engine block and clean the threads. Apply a sealant to the threads of the plugs and install them in the engine block. 3. ENGINES AB and YB. Install the cooling jets for the pistons. See 1.55 Cooling Jets, Installation. 4. Install the crankshaft and the rear oil assembly. See 1.63 through 1.74 Crankshaft Assembly sections. 40

19. Remove the air from the fuel system before operating the engine. See 1.136 Remove Air From The Fuel System.

1.102 CYLINDER LINER 1.103 Inspection Check the cylinder liners for wear and damage. Check for wear in the liner as shown in FIGURE 67. and FIGURE 68. The wear limit is 0.25 mm (0.010 in).

If the cylinder liner has a very smooth finish (glaze), the engine will use oil at a rapid rate even though the cylinder liners are within specifications.

NOTE: If the glaze in a cylinder liner has been removed, the following recommendations are for the next five hours of engine operation:

Do not operate the engine at full load. Do not operate the engine at high speed. Do not permit the engine to operate at idle speed for long periods. 1.105 Removal Special Tools: Removal and installation tool and adaptors for cylinder liners. Piston height tool Dial indicator gauge FIGURE 67. CHECK THE WEAR IN THE CYLINDER LINER

FIGURE 68. WHERE TO MEASURE TO CHECK THE WEAR IN THE CYLINDER LINER 1.104 Hone Use a tool called a hone to correct the surface of the cylinder liner. The pistons, connecting rods, and piston cooling jets must be removed from the engine before the hone operation. Use a grade 80SC hone that can expand to 102 to 105 mm (4 to 4.2 in). Make sure the other parts of the engine are covered so that particles do not enter and damage the engine during operation.

3. Install the removal and installation tool over the center of the cylinder liner as shown in FIGURE 69. Make sure that the base of the tool is not on top of the flange of the next cylinder liner. 4. Make sure that the lugs on the top of the removal adaptor (6) engage flats on the threaded rod (1). Install the nut and washer on the threaded rod and tighten the nut against the removal adaptor (6). Turn the handle to remove the cylinder liner from the engine block. Use lubricating oil on the moving parts to reduce the friction.

1. 2. 3. 4. 5. 6.

THREADED ROD HANDLE BEARING SHELL REMOVAL ADAPTOR CYLINDER LINER REMOVAL ADAPTOR

FIGURE 69. CYLINDER LINER REMOVAL

1. 2. 3. 4. 5. 6.

THREADED ROD HANDLE BEARING INSTALLATION ADAPTOR CYLINDER LINER BASE, INSTALLATION ADAPTOR

FIGURE 70. CYLINDER LINER INSTALLATION

1.106 Installation NOTE: Some replacement cylinder liners are easier to install than others because of the manufacturing tolerances. A cylinder liner installation tool can be used to install a tight cylinder liner. See FIGURE 70. A press can also be used to install a tight cylinder liner. DO NOT use a hammer to install a cylinder liner.

2. Install the cylinder liner in the bore in the engine block. Make sure the cylinder liner is vertical and aligned with the bore in the engine block. Use the cylinder installation tool as shown in FIGURE 70. to press the cylinder liner into the engine block to within 50 mm (2 in) of the final position.

1. Make sure the parts are clean. Lubricate the bore in the engine block with engine oil. DO NOT lubricate the upper 50 mm (2 in) of the bore in the engine block. Sealant will be applied to this area.

3. Apply Loctite 602 to the upper 25 mm (1 in) of the outer surface of the cylinder liner. Apply Loctite 602 to the flange and the engine block where the flange of the cylinder liner will fit into the engine block.

4. Press the cylinder liner into its final position in the engine block. Remove the tool and clean the Loctite from the engine block. 5. Wait 15 minutes before the dimensions in the bore of the cylinder liner are checked. The Loctite will reach full strength after three hours. 6. Use the piston height tool and dial indicator gauge to check that the cylinder liner is in the correct position. See FIGURE 71. The flange of the cylinder liner must be between 0.10 mm (0.004 in) above to 0.10 mm (0.004 in) below the top surface of the engine block.

7. Install new piston rings on the piston. See 1.48 Piston Rings, Installation. 8. Install the piston and connecting rod assembly. See 1.52 Piston And Connecting Rod Assembly, Installation. 9. ENGINES AB and YB. Install the cooling jets for the pistons. See 1.55 Cooling Jets, Installation. 10. Install the cylinder head assembly. See 1.25 Cylinder Head Assembly, Installation. 11. Install the oil sump. See 1.115 Oil Sump, Installation. NOTE: If a new cylinder liner has been installed, the following recommendations are for the next five hours of engine operation:

Do not operate the engine at full load. Do not operate the engine at high speed.

FIGURE 71. CHECK THE CYLINDER LINER

Do not permit the engine to operate at idle speed for long periods.

TURBOCHARGER, ENGINES AB AND YB 1.107 GENERAL The turbocharger is installed between the inlet and exhaust manifolds. Exhaust gases turn the turbocharger and causes it to supply air to the inlet manifold at greater than atmospheric pressure. The bearings in the turbocharger are lubricated with engine oil from the main oil passage in the engine block. The oil passes through the bearing housing of the turbocharger and returns to the oil sump.

3. Remove the nuts and remove the exhaust elbow and its gasket from the turbocharger. 4. Release the hose clamps and push the hose from the compressor outlet up the elbow of the inlet manifold. 5. Disconnect the oil supply line at the flange at the top of the bearing housing of the turbocharger. Remove the oil supply line and gasket.

1. Clean the turbocharger. Remove the duct from the air filter where it connects to the inlet of the turbocharger.

2. Remove or disconnect the support bracket for the turbocharger. Remove the heat shield for the fuel pump if additional clearance is necessary.

7. Remove the nuts at the flange that holds the turbocharger to the exhaust manifold. Disconnect the turbocharger from the exhaust manifold. Remove the gasket.

1.108 Removal

8. Check the hoses, lines, and duct for cracks, wear, or damage.

8. Slide the hose on the elbow for the inlet manifold onto the outlet of the turbocharger. Install the hose clamps.

1.109 Installation

9. Make sure that there is no restriction in the duct from the air filter to the turbocharger. Install the duct on the turbocharger and tighten the fastener.

1. Check that the openings of the turbocharger and the manifolds are clean. Make sure that the compressor shaft in the turbocharger rotates freely. 2. Install a new gasket where the turbocharger connects to the exhaust manifold. See FIGURE 72. If the original nuts are to be used, make sure they are in good condition. Use a compound on the threads to prevent seizure of the nuts to the studs. 3. Install the turbocharger. Tighten the nuts to 44 Nm (33 lbf ft).

10. Check that the bearings in the turbocharger have an oil flow. Disconnect the electric stop control so that the engine can not start. Use the starter motor to operate the engine until engine oil flows from the oil drain line from the turbocharger. Connect the hose to the oil drain line. Connect the electric stop control. 1.110 Clean The Impeller And Compressor Housing NOTE: The compressor housing can sometimes be removed for cleaning without removing the turbocharger first. The compressor housing is held by a circlip and access to the circlip (large snap ring) is not always possible. 1. Clean the turbocharger. Remove the duct from the air filter where it connects to the inlet of the turbocharger. 2. Release the hose clamps and push the hose from the compressor outlet up the elbow of the inlet manifold.

1. GASKET

FIGURE 72. INSTALL THE TURBOCHARGER

4. Lubricate the bearing housing of the turbocharger with clean engine oil. Use a new gasket and install the oil supply line. 5. Use a new gasket and install the oil drain line. Tighten the capscrews, but do not connect the hose. 6. Install the exhaust elbow on the turbocharger. If the original nuts are to be used, make sure they are in good condition. Use a compound on the threads to prevent seizure of the nuts to the studs. New nuts have a coating on them to prevent seizure. Install a new gasket on the studs. 7. Install the support bracket for the turbocharger. Install the heat shield for the fuel pump if it was removed. 44

1. REFERENCE MARK

FIGURE 73. REMOVE THE COMPRESSOR HOUSING 3. Make a reference mark on the compressor housing and the bearing housing as shown in FIGURE 73. 4. Remove the circlip that holds the compressor housing. Carefully remove the compressor housing from the turbocharger as shown in FIGURE 73. If the compressor housing is a tight fit, use a soft hammer.

CAUTION Be careful that the blades of the impeller is not damaged. If the impeller is damaged, the turbocharger must be replaced or repaired by a special repair service. 5. Put the compressor housing in a container with a solvent that is not caustic. When the dirt has loosened, use a hard brush or a soft scraper to clean the compressor housing. Use compressed air at low pressure to dry the compressor housing.

7. Carefully push the impeller towards the bearing housing and turn the impeller with your hand. Check that the impeller turns freely and there is no noise that can indicate wear or damage. If there is a fault, the turbocharger must be replaced or repaired by a special repair service. 8. Install the compressor housing on the turbocharger. Make sure the reference marks are aligned. Install the circlip loosely on the bearing housing. Make sure that the face of the circlip with the bevel is towards the exhaust end of the turbocharger. Install the circlip in the groove. 9. Install the ducts on the inlet and outlet of the compressor housing and tighten the clamps.

6. Clean the impeller with a soft brush.

LUBRICATION SYSTEM 1.111 GENERAL The oil pump is turned by a gear on the crankshaft through an idler gear. A relief valve on the outlet of the oil pump controls the maximum oil pressure in the lubrication system. The engine oil flows from the oil pump through an oil cooler fastened on the side of the engine block. The oil flows from the oil cooler through the oil filter. The oil cooler has a byâ&#x20AC;&#x201C;pass valve that controls the oil pressure in the oil cooler and permits some cold oil to flow directly to the oil filter. The oil filter has a byâ&#x20AC;&#x201C;pass that permits oil flow directly to the main oil passage if the oil filter becomes too dirty. The normal oil flow is through the oil filter to the main oil passage in the engine block.

nected to the main oil passage for each cylinder. The cooling jets spray engine oil on the bottoms of the pistons for additional cooling.

1.112 OIL FILTER, REPLACEMENT 1. Change the oil filter when the engine oil is changed. Put a drain pan under the filter. Remove the filter cartridge. Make sure the adaptor stays in the filter head as shown in FIGURE 74. Discard the filter cartridge.

1. ADAPTOR

The hub of the idler gear has an oil passage to the main oil passage. The oil flow through the hub lubricates the timing gears.

2. Clean the filter head.

An outlet from the main oil passage supplies oil to the bearings of the turbocharger. The engine flows through the bearings of the turbocharger and returns to the oil sump. All turbocharged engines have a cooling jet con-

3. Add some clean engine oil to the new filter cartridge. Apply clean engine oil to the gasket. Turn the filter until the gasket touches the filter head. Tighten the filter cartridge 1/2 to 3/4 turn.

FIGURE 74. OIL FILTER

4. When new oil has been added and the engine can be operated, start the engine. Check the area around the filter for leaks.

mainder of the capscrews and the two nuts. Tighten all of the fasteners to 22 Nm (16 lbf ft).

1.113 OIL SUMP

3. Install the drain plug in the oil sump. Use a new Oâ&#x20AC;&#x201C; ring.

1.114 Removal

1.116 OIL PUMP

1. Drain the engine oil. Remove the capscrews and the two nuts that fasten the oil sump to the engine block. Lower the oil sump. Remove the gasket. 2. Clean the oil sump with mineral oil solvent. 3. If the suction line and oil strainer must be removed. See FIGURE 75. Remove the capscrew that holds the bracket to the main bearing cap. Remove the two capscrews from the flange of the suction line and remove the suction line and screen. Clean the faces of both flanges.

1.117 Removal 1. Drain the engine oil and remove the oil sump. Remove the oil strainer and suction line. See 1.114 Oil Sump, Removal. 2. Remove the relief valve and connection line. 3. The oil pump is fastened to the number 1 main bearing cap. Access to the capscrews on the main bearing can be difficult when the timing case is on the engine. A special wrench can be required to apply the correct torque to the capscrews for removal and installation. If a wrench is not available to install the capscrews on the main bearing cap, the timing case must be removed. See 1.77 through 1.92 for removal of the timing case. 4. Remove the snap ring that holds the idler gear to the oil pump. Remove the washer and the idler gear. See FIGURE 76.

1. SUPPORT BRACKET, MAIN BEARING CAP 2. CAPSCREWS, FLANGE, SUCTION PIPE

FIGURE 75. REMOVE THE OIL SUMP SCREEN 1.115 Installation 1. If the oil strainer and suction line was removed, loosely assemble the bracket of the suction line to the main bearing cap. Install a new gasket and fasten the flanges of the suction line to the oil pump. Make sure that the suction line is aligned correctly and tighten the capscrew that holds the bracket to the main bearing cap.

FIGURE 76. REMOVE THE IDLER GEAR, OIL PUMP

2. Use a new gasket and install the oil sump. Use capscrews on each side of the oil sump to align and hold the gasket in position during assembly. Install the re-

5. Remove the capscrews and remove the oil pump. See FIGURE 77.

1. WASHER 2. IDLER GEAR

3. BUSHING

FIGURE 77. REMOVE THE OIL PUMP

1.118 Inspection If the oil pump is worn so that the performance is decreased, the oil pump must be replaced.

FIGURE 79. CHECK THE CLEARANCES OF THE INNER ROTOR 5. Check end clearance and axial movement of the rotor. Use a spacer gauge and a straight edge. See FIGURE 80. See the ENGINE SPECIFICATIONS for the wear tolerances.

1. Remove the capscrews and remove the cover of the oil pump. 2. Remove the outer rotor and clean all of the parts. Check for damage and wear. 3. Install the outer rotor and check the clearances. See FIGURE 78. See the ENGINE SPECIFICATIONS for the wear tolerances.

FIGURE 80. CHECK THE END CLEARANCES OF THE ROTOR 6. When the parts are clean and inspected, install the cover to the oil pump. Tighten the capscrews to 28 Nm (21 lbf ft). 1.119 Installation

FIGURE 78. CHECK THE CLEARANCE OF THE OUTER ROTOR

1. Lubricate the internal parts of the oil pump with engine oil before installation. Install the oil pump on the main bearing cap and tighten the capscrews to 22 Nm (16 lbf ft).

4. Check the clearances of the inner rotor. See FIGURE 79. See the ENGINE SPECIFICATIONS for the wear tolerances.

2. Make sure the idler gear and bushing are in good condition. The bushing is available as a separate part. Install the idler gear, washer, and snap ring. Check the gear clearance. See FIGURE 81. The minimum clearance is 47

0.0076 mm (0.003 in) between the oil pump gear and the idler gear. 3. If the main bearing cap was removed, lubricate the bearing with engine oil and install the bearing cap. Tighten the capscrews to 265 Nm (196 lbf ft). Check the gear clearance. See FIGURE 81. The minimum clearance is 0.0076 mm (0.003 in) between the crankshaft gear and the idler gear.

1. THIMBLE, RELIEF VALVE 2. CONNECTION PIPE WITH Oâ&#x20AC;&#x201C;RINGS

FIGURE 82. REMOVE THE RELIEF VALVE, ENGINES AA AND AB ENGINES YA and YB. See FIGURE 83. Remove the capscrews (1) that fasten the cross flow pipe to the relief valve. Remove the flange. Remove the two capscrews that fasten the relief valve to the cylinder block and remove the relief valve. FIGURE 81. CHECK THE CLEARANCES BETWEEN THE OIL PUMP GEAR AND IDLER GEAR

4. If the timing case was removed, install the timing case. See 1.78 through 1.93 Timing Gears And Timing Case sections. 5. Install the relief valve and the connection line. See 1.124 Relief Valve, Installation. 6. Install the oil sump. See 1.115 Oil Sump, Installation.

1.120 RELIEF VALVE

1. CAPSCREW (2) 2. CAPSCREW (2)

FIGURE 83. REMOVE THE RELIEF VALVE, ENGINES YA AND YB

1.121 Removal

1.122 Disassembly

1. Drain the engine oil. Remove the oil sump. See 1.114 Oil Sump, Removal.

NOTE: The relief valve can be disassembled without removing it from the engine.

2. ENGINES AA and AB. Remove the capscrew and carefully pull the relief valve from the engine block. See FIGURE 82. Pull the relief valve from the connection line. Pull the connection line from the oil pump. 48

CAUTION The relief valve has a compressed spring. Do not permit the spring to be released so that it causes an injury.

1. See FIGURE 84. Apply pressure against the end plate (4) of the spring assembly. Remove the snap ring (5). Carefully release the end plate (4) and release the pressure on the compressed spring. Remove the end plate (4), spring (3), and the plunger (2). 1.123 Inspection 1. Clean the parts. Check the parts for wear and damage. Check the spring compression as necessary. The correct spring compression is 34 to 39 N (7.6 to 7.8 lbf) when the spring is compressed to 42.7 mm (1.7 in). 2. Check that the seat of the plunger is not damaged and that the plunger moves easily in its bore. 3. Lubricate the parts with engine oil during assembly. Install the plunger in the bore as shown in FIGURE 84. Install the spring and end cap. Compress the spring and end cap into the bore so that the snap ring can be installed. Install the snap ring.

1. BODY, RELIEF VALVE 2. PLUNGER 3. SPRING

4. END PLATE 5. SNAP RING

FIGURE 84. RELIEF VALVE ASSEMBLY 1.124 Installation 1. Install new Oâ&#x20AC;&#x201C;rings on the connection line. Lubricate the Oâ&#x20AC;&#x201C;rings with engine oil and push the connection line into position in the oil pump. 2. Push the relief valve onto the connection line and install the relief valve into position on the engine block. Install and tighten the capscrew. 3. Install the oil sump. See 1.115 Oil Sump, Installation.

FUEL SYSTEM 1.125 DESCRIPTION NOTE: Special tools and training are needed to repair the CAV injection pumps and they are normally sent to an authorized CAV repair station if repairs are necessary. Fuel injectors also require special equipment and training for repair. Most users have a special repair service do this work. A CAV DPA fuel injection pump is used on the normally aspirated engines AA and YA. See FIGURE 85.

FIGURE 85. FUEL INJECTION PUMP, ENGINES AA AND YA A CAV DPS fuel injection pump is used on turbocharged engines AB and YB. A boost control is added to the engine because of the turbocharger. See FIGURE 86. The boost control is a device that is affected by the pressure from the turbocharger and reduces the the maximum fuel flow at lower engine 49

speeds. When the engine speed is lower, there is a reduced air supply the the cylinders. A mechanical governor controls the maximum engine speed. The fuel injectors receive fuel under high pressure from the fuel injection pump. The fuel injectors are set by the manufacturer, but must be checked according to the maintenance schedules. See PERIODIC MAINTENANCE. The operation pressure of a fuel injector can be changed by adding or removing shims above the spring in the fuel injector.

1. Disconnect all of the fuel lines from the fuel injection pump. Disconnect the engine stop control. Disconnect the control rod to the fuel injection pump. 2. Remove the gear cover from the cover of the timing case. Remove the nut and lock washer for the gear. 3. Turn the crankshaft so that the woodruff key in the gear for the fuel injection pump is towards the top of the engine. See 1.86 Gear For The Fuel Injection Pump, Removal. 4. Remove the capscrew and the nut for the support bracket that is under the fuel injection pump. 5. Remove the flange nuts that hold the fuel injection pump to the timing case. A special wrench can be required if there is a limit to the access to the nuts.

1. BOOST CONTROL

FIGURE 86. FUEL INJECTION PUMP WITH BOOST CONTROL, ENGINES AB AND YB The fuel pump has a diaphragm that is actuated by a lever. The lever is actuated by a lobe on the camshaft. The fuel pump has a small lever that can be operated with your hand to â&#x20AC;&#x153;primeâ&#x20AC;? the fuel pump. NOTE: Good operation of the fuel injection system requires clean fuel and no dirt can be permitted in the system. Always clean carefully around a connection before it is disconnected. Install covers on open ports during maintenance. When the fuel system is opened for maintenance, the air must be removed from the fuel system before the engine is operated.

6. Use a puller to remove the gear for the fuel injection pump. Make sure that the woodruff key does not fall into the timing case. 7. Remove the fuel injection pump from the engine. 1.128 Installation 1. Align the timing marks on the timing gears as shown in FIGURE 88. See 1.87 Gear For The Fuel Injection Pump, Installation. 2. Turn the drive shaft of the fuel injection pump so that the key slot aligns with the key slot in the gear. Install the woodruff key and install the gear onto the drive shaft.

1.126 CAV FUEL INJECTION PUMP 1.127 Removal Special Tools: Gear Puller Adaptors for gear puller Wrench (spanner) for flange nuts

3. Align the mark on the flange of the fuel injection pump with the mark on the timing case. See FIGURE 87. Install the flange nuts for the fuel injection pump.

1. ALIGNMENT MARKS 2. ADJUSTMENT SCREW, IDLE 3. ADJUSTMENT SCREW, GOVERNOR SPEED

FIGURE 87. FUEL INJECTION PUMP

4. Install the support bracket, capscrew, and nut. Make sure that a force to the side is not applied to the fuel injection pump by the support bracket. 5. Install the nut and spring washer to the drive shaft of the fuel injection pump. Tighten the nut to 80 Nm (59 lbf ft). Install the gear cover on the timing case cover. 6. Connect the fuel lines. Connect the engine stop control and the control rod for the fuel injection pump. 7. Remove the air from the fuel system. See 1.136 Remove Air From The Fuel System.

2. Check the governed speed. The maximum engine speed can be adjusted with (3) shown in FIGURE 87. See the Engine Data at the beginning of this section for the correct governed speed. The setting code for the fuel injection pump is also found on a data plate fastened to the side of the pump. A typical setting code can be 2643M000AK/1/2750 where 2750 is the correct governed speed. The governed speed on an original fuel injection pump is set and sealed by the manufacturer. A replacement fuel injection pump must have the governed speed correctly set and the adjustment screw sealed. A setting that has been changed from the correct setting can affect the engine warranty. 1.130 Timing Gear Marks The timing gears have timing marks to make sure that they are installed on the engine correctly. When the number 1 piston is at TDC the marks on gears for the crankshaft, camshaft, fuel injection pump will be aligned as shown in FIGURE 88. The marks on the idler gear can be different than the illustration because of the different speeds at which the gears rotate. The gear for the fuel injection pump has timing marks for the 4â&#x20AC;&#x201C;cylinder and 6â&#x20AC;&#x201C;cylinder engines. The gear also has the letter C when a CAV fuel injection pump is installed. A letter M is on the gear to indicate that the threads for the screws of the gear puller are metric.

7. When the engine can be operated, do 1.129 Checks And Adjustments.

1.129 CAV FUEL INJECTION PUMP, CHECKS AND ADJUSTMENTS 1. Operate the engine until it reaches normal operating temperature and check the idle speed. The idle speed can be adjusted with the idle adjustment screw (2) shown in FIGURE 87. The correct idle speed is in sections 1.5 through 1.8 . NOTE: The idle speed and the the governed speed can be different than the Engine Data when these engines are installed some models of lift trucks. See the section, PERIODIC MAINTENANCE for the specifications that apply to a lift truck model.

TIMING MARKS ON GEARS: 4 = 4 Cylinder Engine 6 = 6 Cylinder Engine

FIGURE 88. ALIGNMENT OF THE TIMING MARKS

1.131 How To Set Number 1 Piston To TDC On The Compression Stroke Special Tools: Valve spring compressor Stud adaptor for valve spring compressor Capscrew adaptor for valve spring compressor 1. Fasten a temporary pointer to the timing case cover so that its tip is near the outer edge of the crankshaft pulley as shown in FIGURE 89. 2. Remove the valve cover. 3. Turn the crankshaft in a clockwise direction until the push rod for the rear cylinder just begins to push on the rocker arm for the inlet valve for the rear cylinder. 4. Remove the spring clip and the spacer from the front of the rocker arm shaft. Loosen the nuts from the first two brackets of the rocker arm shaft. Remove the rocker arm for the first inlet valve from the rocker arm shaft. Tighten the nuts on the first two brackets of the rocker arm shaft. 5. Use the valve spring compressor and adaptor to remove the valve springs from the first inlet valve.

7. Install a dial indicator so that its plunger touches the top of the valve stem as shown in FIGURE 89. Slowly turn the crankshaft in a clockwise direction until the dial indicator just shows that the piston is not raising in its cylinder. Make a mark on the crankshaft pulley that aligns with the temporary pointer. Slowly turn the crankshaft in a clockwise direction until the dial indicator just begins to show that the piston is lowering in its cylinder. Make another mark on the crankshaft pulley that aligns with the temporary pointer. Mark the center point between the two marks on the crankshaft pulley and remove the other two marks. 8. Turn the crankshaft approximately 45° counter– clockwise and then clockwise until the mark on the crankshaft pulley is aligned with the temporary pointer. Number 1 piston is now at TDC. 1.132 Check The Valve Timing 1. Use the procedure 1.131 , How To Set Number 1 Piston To TDC On The Compression Stroke. 2. Remove the dial indicator and install the valve springs and rocker arm. Tighten the nuts on the brackets for the rocker arm shaft to the correct torque. 3. Turn the crankshaft clockwise until the inlet valve for the rear cylinder is fully open. 4. Adjust the valve clearance on the inlet valve of number 1 cylinder to 1.5 mm (0.059 in). 5. Turn the crankshaft clockwise until the clearance between the push rod and the rocker arm begins to be removed. Check if the the marks on the crankshaft pulley is within 2–1/2° of the temporary pointer. 6. If the mark on the crankshaft pulley is more than 2–1/2° away from the temporary pointer, either the timing gears are not aligned correctly or the procedure to find TDC of number 1 piston was not correct.

1. POINTER, TEMPORARY 2. DIAL INDICATOR

FIGURE 89. PROCEDURE TO FIND TDC 6. Make sure that the valve will be held in its valve guide by the top of the piston. If the piston is not at approximately TDC to hold the valve, hold the valve so that it does not drop into the cylinder. Rotate the crankshaft so that the piston will hold the valve in position. 52

NOTE: One tooth on the camshaft gear is equal to 23.0 mm (0.90 in) of the circumference of the crankshaft pulley. 7. Turn the crankshaft clockwise until the inlet valve of the rear cylinder is fully open. Adjust the valve clearance on the inlet valve of number 1 cylinder to 0.20 mm (0.008 in). 8. Install the valve cover. See 1.12 Valve Cover, Installation. 9. Remove the temporary pointer.

1.133 Check The Timing Of The Fuel Injection Pump If the mark on the flange of the fuel injection pump is aligned with the mark on the timing case the timing of the fuel injection pump is normally correct. See FIGURE 90. If the alignment marks are correctly aligned and the operation of the engine indicates that the timing is wrong, use the following procedures, 1.134 Check The Timing Mark Of The Fuel Injection Pump and 1.135 Check The Engine Timing Mark, to check their positions.

marked W for 4–cylinder engines and Y for 6–cylinder engines.) Install a “banjo bolt” that does not have a pressure valve. 4. Connect the number 1 outlet to a tester for a fuel injector. See FIGURE 99. Operate the hand pump until there is a pressure of 30 atm (3000 kPa) (440 psi) indicated on the gauge.

FIGURE 91. INSTALL THE ADAPTOR GEAR ON THE FUEL INJECTION PUMP

FIGURE 90. ALIGNMENT MARKS 1.134 Check The Timing Mark Of The Fuel Injection Pump Special Tools: Universal timing tool Gear adaptor for the universal timing tool 1. Remove the fuel injection pump. See 1.127 CAV Fuel Injection Pump, Removal. 2. Install the gear adaptor on the shaft of the fuel injection pump. Fasten it with the nut from the gear for the fuel injection pump. See FIGURE 91. 3. Remove the special bolt (banjo bolt) from the high pressure outlet to cylinder number 1. (This outlet is

5. Loosen the screw (1) on the universal timing tool and set the tool to the correct angle shown in the ENGINE SPECIFICATIONS. Tighten the screw (1). See FIGURE 92. 6. Install the universal timing tool on the drive shaft of the fuel injection pump as shown in FIGURE 92. Turn the drive shaft of the fuel injection pump with your hand in the normal direction of rotation until the fuel pressure prevents movement. (See the arrow on the data plate for the direction of rotation.) When the rotation of the fuel pump is stopped, the fuel pump is set at the start of injection from number 1 outlet. 7. Loosen the screw (2) and slide the pointer (3) until it is over the center of the pump flange as shown in FIGURE 92. Check that the mark on the pump flange is in the center of the slot in the pointer.

Pointer Adaptor shaft with splines 1. Use the procedure described in the paragraphs with FIGURE 89. See 1.131 How To Set Number 1 Piston To TDC On The Compression Stroke. 2. Remove the fuel injection pump. See 1.127 CAV Fuel Injection Pump, Removal.

1. SCREW FOR POINTER ADJUSTMENT 2. SCREW FOR HORIZONTAL ADJUSTMENT 3. POINTER

3. Align the key in the adaptor with the key slot in the gear for the fuel injection pump. See FIGURE 93. Make sure that the adaptor is against the face of the timing case. Fasten the adaptor to the gear with the nut that is with the adaptor.

FIGURE 92. UNIVERSAL TIMING TOOL 8. If the timing mark on the flange is not correct, remove the universal timing tool and remove the mark. Install the universal timing tool again and make sure that the fuel injection pump is at the start of injection for number 1 cylinder. Slide the pointer (3) so that it covers the width of the flange and tighten the screw (2). Make a new mark on the flange through the slot in the pointer. 9. Remove the universal timing tool and adaptor gear. 10. Disconnect the tester for a fuel injector and install the original special bolt (banjo bolt) in the number 1 port (high pressure outlet). 11. Install the fuel injection pump. See 1.128 Fuel Injection Pump, Installation. 12. Remove the air from the fuel system See 1.136 Remove Air From The Fuel System 1.135 Check The Engine Timing Mark Special Tools: Universal timing tool Adaptor for the timing gear for the fuel injection pump.

FIGURE 93. INSTALL THE ADAPTOR IN THE GEAR FOR THE FUEL INJECTION PUMP 4. See FIGURE 94. Loosen the screw (1) on the universal timing tool. Set the universal timing tool to the correct engine check angle shown in the ENGINE SPECIFICATIONS and tighten the screw. Loosen the screw (2) and install the shaft with splines (5) into the universal timing tool. Loosen the screw (4) and install the 90Â° pointer (3) against the timing case. Tighten the screw (4).

1.136 REMOVE AIR FROM THE FUEL SYSTEM The engine can not be started if there is air in the fuel system. The air must be removed from the fuel system if any part of the fuel system has been disconnected or there is a leak in the low pressure part of the fuel system during operation of the engine. The following procedures are for removal of air from the fuel system. 1.137 Fuel Injection Pump With Vent Tube

1. SCREW FOR POINTER ADJUSTMENT 2. SCREW FOR HORIZONTAL ADJUSTMENT OF SHAFT WITH SPLINES 3. POINTER 4. SCREW FOR HORIZONTAL POINTER ADJUSTMENT 5. SHAFT WITH SPLINES

Some engines have a fuel injection pump with a tube installed in place of the vent screw. See FIGURE 95. Air can move through the tube from the pump to the fuel return line. It is not necessary to loosen plugs or connections to remove air from this type of injection pump. Use the procedure in Step 1 or Step 2 to remove air from a fuel system with an injection pump that has a vent tube.

FIGURE 94. INSTALLATION OF THE UNIVERSAL TIMING TOOL

5. Check that the mark on the timing case aligns with the pointer (3). If the timing mark is not correct, remove the universal timing tool. Remove the mark on the timing case. Install the universal timing tool again. Make sure that the pointer (3) is against the timing case and make a new timing mark on the timing case. 6. Remove the timing tool and the adaptor.

7. Install the fuel injection pump. See 1.128 CAV Injection Pump, Installation. 8. Return the engine to operating condition as described in the following steps: a. Turn the crankshaft clockwise until the inlet valve of the rear cylinder is fully open. Adjust the valve clearance on the inlet valve of number 1 cylinder to 0.20 mm (0.008 in). b. Install the valve cover. See 1.12 Valve Cover, Installation. c. Remove the temporary pointer. 9. Remove the air from the fuel system See 1.136 Remove Air From The Fuel System

1. VENT TUBE

12592

FIGURE 95. FUEL INJECTION PUMP WITH VENT TUBE 1. If the fuel system or a component in the fuel system has been drained: a. Turn the key switch to the ON position. b. Slowly operate the priming lever of the fuel pump for approximately two minutes. c. Operate the engine with the starter motor until the engine starts. 55

2. If air in the fuel system causes the engine to stop: a. Make sure that there is enough fuel in the tank. Check the system for leaks and make the necessary repairs. b. Operate the engine with the starter motor until the engine starts. 1.138 Fuel Injection Pump With Vent Screw Use the following procedure to remove air from the fuel system if the fuel injection pump has a vent screw as shown in FIGURE 96. STEP 2. Operate the priming lever on the fuel pump until fuel, without air bubbles, comes from the loosened connection bolt. If the lobe on the camshaft has moved the internal lever of the fuel pump to the highest point of its lift, the priming lever will not operate. The crankshaft must be rotated one revolution to move the lobe on the camshaft.

FIGURE 96. REMOVE AIR FROM THE FUEL SYSTEM (2 of 5)

STEP 1. Loosen the connection bolt (1) on top of the filter.

FIGURE 96. REMOVE AIR FROM THE FUEL SYSTEM (1 of 5)

STEP 3. Turn the key switch to the “R” position. Loosen the vent screw (1) on the top of the governor housing. Operate the priming lever on the fuel pump until fuel, without air bubbles, comes from the loosened vent screw.

FIGURE 96. REMOVE AIR FROM THE FUEL SYSTEM (3 of 5)

1.139 FUEL FILTER (REPLACEMENT) 1. Clean the outside of the fuel filter assembly. If there is a drain on the filter bowl, drain the fuel from the fuel filter. See FIGURE 97. 2. Hold the bowl and connector and loosen the through bolt from the top of the filter head. 3. Lower the bowl and filter element and discard the filter element. 4. Clean inside of the bowl and the filter head. STEP 4. Loosen the connection (1) on the inlet to the cold start aid. Operate the priming lever on the fuel pump until fuel, without air bubbles, comes from the loosened connection. Then tighten the connection.

5. Install new seal rings. Put the bowl on the new filter element and hold the bowl and filter element in position against the filter head. Install and tighten the through bolt. 6. Remove the air from the fuel system. See 1.136 Remove Air From The Fuel System.

FIGURE 96. REMOVE AIR FROM THE FUEL SYSTEM (4 of 5)

FIGURE 97. FUEL FILTER ASSEMBLY

1.140 FUEL INJECTORS STEP 5. Loosen the connections (1) at two of the inlets to the fuel injectors. Operate the engine with the starter motor until fuel, without air bubbles, comes from the loosened connections. Then tighten the connections.

FIGURE 96. REMOVE AIR FROM THE FUEL SYSTEM (5 of 5) The engine is now ready to start. if the engine runs correctly for a short time and then stops, or runs roughly, check for air in the fuel system. Make sure you check for leaks in the low pressure (suction) part of the fuel system.

The engine will run roughly if a fuel injector has a defect. To find which fuel injector has a defect, operate the engine at approximately 1000 rpm. Loosen and tighten the connection to the inlet of each fuel injector in a sequence. When the connection to the defective fuel injector is loosened, there will not be a change in the engine speed.

WARNING Do not put your hands on fuel lines under pressure. Diesel fuel can be injected into your body by the hydraulic pressure. 1.141 Removal 1. Disconnect the fuel return line from the fuel injector. 57

2. Disconnect the high pressure line at the inlet to the fuel injector. Disconnect the other end of the high pressure line from the fuel injection pump. Hold the outlet fitting from the fuel injection pump with a wrench so that it does not turn while the connection is loosened for the fuel line. Do not bend the fuel line. Remove the line clamps as necessary. 3. See FIGURE 98. Remove the capscrews from the flange (1) and remove the flange. Remove the fuel injector (2) and its washer (3). Remove the dust seal (4) and the spacer (5).

1. FLANGE 2. FUEL INJECTOR 3. WASHER

5. Check the spray pattern of the nozzle. See FIGURE 99. If the spray pattern is not correct, the needle valve is not against the valve seat. Remove carbon deposits or replace parts as required.

WARNING Make sure that the nozzle of the injector is away from the operator during a test. Test oil can be injected into your body by the hydraulic pressure.

4. DUST SEAL 5. SPACER

FIGURE 98. FUEL INJECTOR 1.142 Inspection NOTE: The inspection and repair of fuel injectors require special tools and training. Many users have a special repair service make repairs on injectors. Fuel injector nozzles that have a defect will cause black smoke in the exhaust, a decrease in engine power, and an increase in engine noise. 1. Start the engine and run it at approximately 1200 rpm. 2. Loosen the fitting for the high pressure fuel line at the injector. If the engine speed does not change, the injector has a defect. 3. Use an injector tester to check the pressure at which the nozzle operates. The correct pressure is 23.3 MPa (3381 psi) (230 atmospheres). 4. To change the pressure at which the nozzle operates, add or remove shims in the fuel injector. 58

FIGURE 99. CHECK THE FUEL INJECTORS 6. The operation of the fuel injector must be checked with an injection tester. The injection tester uses a special oil for calibration tests. Special oils for calibration tests: SHELL (UK) Calibration fluid C SHELL (worldwide) Calibration fluid B ESSO Calibration fluid IL 1838 CASTROL Calibration oil 8327 7. When the injector operates at the correct pressure, remove any oil from the tip of the nozzle. Apply a pressure of 22.0 MPa (3190 psi) (217 atmospheres) and hold the pressure for more than 10 seconds. Test oil must not leak

from the injector tip at this pressure. Do not try to stop leakage from the tip by tightening the nozzle cap nut. If the nozzle tip leaks test oil, the valve and nozzle must be replaced.

internal lever of the fuel pump to the highest point of its lift, the fuel pump can be difficult to remove. The crankshaft must be rotated one revolution to move the lobe on the camshaft.

8. Increase the pressure slowly to 22.9 MPa (3322 psi) (226 atmospheres) for a leak back test. Release the lever on the tester and make a note of the time required for the pressure to decrease to 15.2 MPa (2205 psi) (150 atmospheres). If the time to decrease is less than six seconds, the fuel injector has a problem and can not be used. (Make sure the test equipment operates correctly.) 9. Continue to check the decrease in pressure for the leak back test. The pressure must not decrease to less than 10 MPa (1450 psi) (99 atmospheres) in less than 45 seconds. 1.143 Installation 1. Use a new dust seal and spacer with the replacement fuel injector. Put the fuel injector and washer into position in the cylinder head. Install the flange and the capscrews. Make sure that the fuel injector fits correctly and is not tilted. Tighten the capscrews to 12 Nm (9 lbf ft). 2. Install the high pressure line and tighten the connections to 18 Nm (13 lbf ft). Hold the outlet fitting from the fuel injection pump with a wrench so that it does not turn while the connection is tightened for the fuel line. Install the line clamps if they were removed. 3. Install new seal washers and connect the fuel return line to the fuel injector. 4. Remove the air from the fuel system. See 1.136 Remove Air From The Fuel System. 5. When the engine can be operated, check for fuel leaks.

1.144 FUEL PUMP 1.145 Removal 1. Remove the heat shield for the fuel pump. Disconnect the fuel lines to the fuel pump. 2. Remove the capscrews and the lock plates. Remove the fuel pump. If the lobe on the camshaft has moved the

FIGURE 100. FUEL PUMP, REMOVAL AND INSTALLATION 1.146 Disassembly 1. Clean the outside surfaces of the fuel pump. Make a mark across the flanges of the two halves of the fuel pump to make sure that it is assembled again in the same positions. 2. See FIGURE 101. Remove the cover (1) and the screen (2). Remove the screws and separate the two halves of the fuel pump. 3. Turn the diaphragm assembly (5) 90Â° to release the pull rod from the link arm (8) and remove the diaphragm assembly. 4. Remove the stem seal (6), the spring seat washer (7), and the spring (12) from the pull rod. The diaphragm and pull rod assembly must be replaced as a unit. 5. The valves (4) are held in their seats by punch marks in the metal. The metal must be made smooth so that valves can be removed. 6. Remove the link arm (8). Hold the rocker lever (11) in a vise and hit the body of the fuel pump with a soft hammer to release the two retainers (10). Be careful that the joint face of the fuel pump body is not damaged. Remove the rocker lever (11), pin (9), link arm (8), and the return spring. 59

2. Install the rocker lever (11), pin (9), and the link arm assembly (8) into position in the body of the fuel pump. Install the return spring. Make sure that the ends of the return spring are in their correct positions. 3. Use a small hammer and a drift or a punch to install the retainers (10) in their grooves in the body of the fuel pump until they fasten the pin (9). Use a punch to close the ends of the grooves to fasten the retainers in position. 4. Install the diaphragm spring (12) into its position under the diaphragm (5). Put the spring seat washer (7) and the new stem seal (6) into position on the pull rod. Make sure that the small diameter at the top of the stem seal is on the round part of the pull rod. 5. Put the diaphragm assembly into position over the lower half of the body of the fuel pump. Align the blade of the pull rod with the slot in the link arm. Press down lightly on the diaphragm until the notch in the pull rod is in the slot in the link arm. Then turn the diaphragm 90Â° in either direction. This action will engage and retain the pull rod in the slot of the link arm.

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

COVER SCREEN SEAT WASHER (2) VALVE (2) DIAPHRAGM ASSEMBLY STEM SEAL SPRING SEAT WASHER LINK ARM PIN RETAINER (2) ROCKER LEVER DIAPHRAGM SPRING

FIGURE 101. FUEL PUMP, DISASSEMBLY

1.147 Assembly 1. Install new seat washers (2). Push new valves (4) into position. The valves are the same, but they are installed in the opposite directions from each other. See FIGURE 101. to make sure that the valves are installed in the correct position. When the valves are correctly installed, use a punch on the edge of the valve housings to hold the valves in position. Use the punch in six places around each valve to hold the valve in position. 60

6. Push the rocker arm towards the body of the fuel pump until the diaphragm is level the the flange half. Install the top half of the body in position. Align the reference marks. Keep the pressure on the rocker arm and install the lock washers and screws. Tighten the screws evenly around the circumference of the fuel pump. 7. Install the screen (2) and the cover (1). Make sure that the rubber seal is fitted correctly and tighten the screw that hold the cover. 1.148 Installation 1. See FIGURE 100. The lobe on the camshaft must be in the minimum lift position before the fuel pump is installed. Use a new gasket and install the fuel pump on the engine block. Install the lock plates and capscrews. Tighten the capscrews to 22 Nm (16 lbf ft). 2. Connect the fuel lines to the fuel pump. Install the heat shield. 3. Loosen the connection bolt on top of the filter as shown in FIGURE 96. 4. Operate the priming lever on the fuel pump until fuel, without air bubbles, comes from the loosened connection bolt. See (2 of 5) of FIGURE 96. 5. When the engine can be operated again, check for leaks.

1.149 Test 1. Disconnect the fuel line from the outlet of the fuel pump. Install a 0 to 70 kPa (0 to 10 psi) pressure gauge to the outlet of the fuel pump. Loosen the connection at the gauge and operate the priming lever on the fuel pump to remove air from the fuel pump and the connection to the pressure gauge. Then tighten the connection. 2. Use the starter motor to operate the engine for 10 seconds. See the maximum pressure indicated on the pressure gauge. If the pressure is less than 42 to 70 kPa (6 to 10 psi), repair or replace the fuel pump. Also check the rate at which the pressure reduces to half of the maxi-

mum pressure. If the rate is less than 30 seconds to reduce to half of the maximum pressure, repair or replace the fuel pump. 3. Remove the pressure gauge from the fuel pump. Connect the fuel line to the outlet of the fuel pump again. 4. Loosen the connection bolt on top of the filter as shown in FIGURE 96. Operate the priming lever on the fuel pump until fuel, without air bubbles, comes from the loosened connection bolt. 5. When the engine can be operated again, check for leaks.

COOLING SYSTEM 1.150 GENERAL Coolant from the bottom of the radiator flows through the centrifugal coolant pump which is installed on the front of the timing case. The coolant pump is gear driven from the gear for the fuel injection pump. The coolant goes from the coolant pump through a passage in the timing case to the front of the engine block. ENGINES AA and AB. The coolant flows through a passage in the left side of the engine block to the rear of the engine block. Some coolant flows around the oil cooler and then to the rear of the engine block. The coolant then flows around the cylinders and then into the cylinder head. The coolant leaves the cylinder head and flows through the thermostat housing. If the thermostat is closed, the coolant flows through a by–pass to the inlet of the coolant pump. If the thermostat is open, the thermostat closes the by–pass and the coolant flows to the top of the radiator. The coolant flows through a passage in the left side of the engine block to the rear of the engine block. If an oil cooler is installed, some coolant flows through the oil cooler. The coolant flows around the cylinders and then into the cylinder head. The coolant leaves the cylinder head and flows through the thermostat housing. If the thermostat is closed, the coolant flows through a by– pass to the inlet of the coolant pump. If the thermostat is open, the thermostat closes the by–pass and the coolant flows to the top of the radiator. ENGINES YA and YB. The coolant divides as it flows through a passage in the engine block. Most of the cool-

ant flows along the right side of the engine block and around the cylinders to the rear of the engine block. Some coolant flows through a passage on the left side of the engine block to the oil cooler. The coolant flows around the element of the oil cooler and then to the rear of the engine block. The coolant flows forward through the cylinder head and into the thermostat housing. These engines have two thermostats. If the thermostats are closed, the coolant flows through a by–pass to the inlet of the coolant pump. If the thermostats are open, the coolant flows to the top of the radiator.

1.151 THERMOSTAT 1.152 Replacement 1. Drain the cooling system so that the coolant level is below the thermostat position and disconnect the top hose from the outlet connection. 2. Remove the capscrews and remove the outlet connection. 3. Remove the thermostat. NOTE: Engines YA and YB have two parallel thermostats. See FIGURE 102. 4. Make sure that the surfaces for the joint in the outlet are clean. Install a new thermostat in the housing. 5. Use a new gasket and install the outlet connection. Tighten the capscrews. 6. Connect the top hose and fill the cooling system. 61

1.155 Disassembly Special tool: Gear puller 1. See FIGURE 104. Remove the three long studs and the O–ring (1) from the body (4) of the coolant pump. 2. Remove the front cover (8) and the gasket (9). 3. Use a puller to remove the gear (2). 4. Use a puller or prybar to remove the oil seal (3). Discard the oil seal.

1. THERMOSTAT

FIGURE 102. THERMOSTATS, ENGINES YA AND YB

5. If necessary, remove the studs from the pump body. Put a support under the impeller end of the pump body so that it is not damaged. Use a press and adaptor to push the shaft and bearing assembly (7), impeller (6), and the water seal (5) from the pump body. 6. Put a support under the impeller so that it is not damaged. Use a press to push the shaft and bearing assembly from the impeller. Be careful that the impeller is not damaged. Remove the water seal (5) and discard it.

1.153 COOLANT PUMP 1.154 Removal 1. Drain the cooling system and disconnect the hose at the inlet to the coolant pump. 2. Remove the capscrews from the flange for the coolant by–pass. Remove the three capscrews that hold the flange of the coolant pump to the timing gear cover. Remove the three nuts that hold the coolant pump to the timing gear case. 3. Remove the coolant pump. Make sure that the O–ring on the timing case cover is not lost. See FIGURE 103.

1. O–RING

2. O–RING

FIGURE 103. COOLANT PUMP CONNECTIONS

1. 2. 3. 4. 5.

O–RING GEAR OIL SEAL PUMP BODY WATER SEAL

6. IMPELLER 7. SHAFT AND BEARING ASSEMBLY 8. FRONT COVER 9. GASKET

FIGURE 104. COOLANT PUMP ASSEMBLY

1.156 Assembly 1. Clean the pump body. Give special attention to the bore for the bearing and the bore for the water seal. Both of these bores and their chamfers must be clean and free of corrosion.

shown in FIGURE 104. If the original gear is used, use Locktite 35 in the bore of the gear. 7. Use a new gasket (9) and install the front cover (8). Tighten the capscrews. 1.157 Installation

2. Apply a thin layer of Loctite 35 to the outer surface of the bearing. Make sure the Loctite is not applied to the ends of the bearing. Use a support under the side of the pump body for the gear and use a press to push the shaft and bearing assembly (7) into the pump body. See FIGURE 104. Put the shaft and bearing assembly in position in the bore of the pump body (4). The shortest end of the shaft goes into the pump body. Make sure the alignment is correct and the shaft is parallel with the bore. Apply the force from the press to the bearing and not to the shaft. Push the shaft and bearing assembly into the bore until the bearing is even with the bottom of the counterbore for the water seal. Remove any Loctite that is on the end of the bearing.

1. Make sure that the joint surfaces are clean. Use new O–rings.

3. Do not lubricate the water seal (5). It is important that there is no oil or grease on the water seal. Hold the water seal by the edges so that oil from your skin does not touch the seal material. The widest side of the water seal goes against the bearing (7). Push the water seal onto the shaft until it is against the chamfer of the counterbore. Make sure the water seal is correctly aligned with the counterbore and press the seal into the counterbore until the outer flange is against the pump body. Apply force only to the outer flange of the water seal when it is pushed into position. Hold the force on the water seal for approximately 10 seconds to make sure that it stays in position.

4. Install and tighten the three capscrews that hold the coolant pump to the timing case cover (two capscrews from the front and one capscrew from the rear).

4. Use a support under the shaft (7) and use a press to push the impeller (6) onto the shaft. If the original impeller is used again, use Loctite 35 in the bore of the impeller. Use an adaptor as necessary so that the impeller is not damaged. Check that the impeller and shaft will rotate smoothly. 5. Lightly lubricate the oil seal (3) with engine oil. Put the oil seal into position on the shaft with the flat face of the oil seal towards the bearing. Use a press to push the oil seal into the counterbore until the oil seal is even with the edge of the counterbore. 6. Put a support under the impeller end of the shaft. Use a press to push the gear (2) onto the shaft to the dimension

2. Check that drive gear for the coolant pump is in good condition. Replace a worn or damaged gear. 3. Lightly lubricate the O–ring (2) on the coolant pump with engine oil. Install the coolant pump on the timing case cover with the drive gear engaged with the gear for the fuel injection pump. The coolant pump will fit tightly in the timing case cover. The coolant pump can be pulled into position if the nuts that hold the coolant pump are gradually and evenly tightened. Make sure that the O–ring in the timing case cover stays in position while the coolant pump is being installed.

5. Install a new gasket in the flange of the coolant by– pass. Install the bypass and tighten the capscrews. 6. Connect the hose to the inlet of the coolant pump and fill the cooling system. Check for leaks.

1.158 FAN AND FAN DRIVE 1.159 Removal 1. Remove the capscrews and remove the fan. 2. Loosen the pivot fasteners for the alternator and the fastener for the adjustment bracket. Remove the drive belts. 3. Check the axial movement of the fan shaft. If the axial movement is greater than 0.25 mm (0.010 in), the fan bearing assembly must be repaired. 4. Remove capscrews and remove the fan drive from the timing case cover. 1.160 Disassembly 1. See FIGURE 105. Use a puller to pull the hub (1) from the fan shaft and bearing assembly (2). 2. Remove the snap ring (3) that holds the bearing in the housing (4). 63

3. Use a press and adaptor to push the bearing and shaft assembly from the front of the housing. Do not push on the fan shaft. Press on the bearing shell to remove the bearing and shaft assembly. 1.161 Assembly 1. See FIGURE 105. Use a press to push the bearing and shaft assembly into the housing. Do not use force on the shaft to push the bearing into the housing.

1. 2. 3. 4.

HOSE CLAMP CAPSCREW AND NUT SUPPORT BRACKET CAPSCREWS (6)

FIGURE 106. OIL COOLER, ENGINE AB 3. Remove the capscrew and nut (2) which fastens the lowâ&#x20AC;&#x201C;pressure fuel lines to the top of the oil cooler. 4. Loosen the hose clamp (1) at the top of the oil cooler. 1. HUB 2. FAN SHAFT AND BEARING ASSEMBLY

3. SNAP RING 4. HOUSING

FIGURE 105. FAN DRIVE 2. Install the snap ring (3) in the housing (4). 3. Use a support under the fan shaft so that force is not applied to the bearing. Use a press to push the hub onto the fan shaft to the dimensions shown in FIGURE 105. Make sure the edge of the hub with the chamfer is away from the engine.

5. Remove the six capscrews (4) that fasten the oil cooler to the engine. Remove the oil cooler. 1.165 Removal, Engines YA and YB 1. Drain the cooling system. 2. Disconnect the oil lines at the flange on the cover of the oil cooler. 3. Remove the capscrews and nuts from the cover of the oil cooler and remove the cover and element. See FIGURE 107.

1.162 Installation 1. Install the fan drive on the timing case cover and tighten the capscrews to 44 Nm (33 lbf ft). 2. Install the fan. Tighten the capscrews. 3. Install the drive belts and adjust the tension.

1.163 OIL COOLER 1.164 Removal, Engine AB 1. Drain the cooling system. 2. See FIGURE 106. Release the support bracket (3) at the oil cooler. 64

1. STUDS

FIGURE 107. OIL COOLER AND ELEMENT, ENGINES YA AND YB

1.166 Disassembly And Assembly 1. Remove the capscrews and remove the cover. 2. Engine AB. Remove the lock nuts at the back of the oil cooler and remove the cooler element. Engines YA and YB. Remove the nuts on the front of the cover and remove the cooler element from the cover.

3. Clean the cooler element and check for cracks. If a cleaning solution is used to clean the outside of the element, make sure that the cleaning solution does not enter the element. Check that there are no restrictions for the oil flow through the element. If the internal part of the element must be cleaned, use a cleaning solution that will not damage copper. Flush the element to remove the cleaning solution and dry the element with compressed air at low pressure. Then flush the internal part of the element with clean engine oil.

1. O–RINGS

FIGURE 109. JOINTS FOR THE COOLER ELEMENT, ENGINES YA AND YB 1.167 Installation, Engine AB 1. See FIGURE 110. Use new O–rings on the inlet connection (3) for the coolant and the outlet flange (5) for the coolant. Make sure that the joint surfaces are clean. Use a new gasket (4) for the oil line flange.

4. Use new O–rings on the flanges and studs as shown in FIGURE 108. or FIGURE 109. 5. Engine AB. Install the cooler on the back plate and tighten the lock nuts to 22 Nm (16 lbf ft). Engines YA and YB. Install the cooler element on the cover and tighten the nuts to 22 Nm (16 lbf ft).

1. VENT 2. VENT CONNECTION 3. O–RING, INLET

4. GASKET, OIL PIPE FLANGE 5. O–RING, OUTLET

FIGURE 110. OIL COOLER JOINTS, ENGINE AB 2. Lightly lubricate the bore of the vent connection (2) and the O–ring (2) on the inlet coolant connection with engine oil. 3. Loosely install the hose clamp on the vent connection. 1. O–RINGS

2. O–RINGS

FIGURE 108. JOINTS FOR THE COOLER ELEMENT, ENGINE AB

4. Install the oil cooler on the engine. Make sure that the vent (1) fits correctly in its connection. Install the six capscrews. Tighten the hose clamp on the vent connection. 65

5. Install and tighten the capscrew for the support bracket. 6. Install the capscrew and nut that fasten the low pressure fuel lines to the top of the oil cooler. 7. Fill the coolant system. 8. When the engine can be operated again, check for leaks.

1.169 By–Pass Valve, Oil Cooler 1. See FIGURE 111. Remove the cap and remove the by–pass valve. 2. Check the spring and the valve seat for damage. Replace the parts if they are damaged. 3. Use a new aluminum washer (1). Install the by–pass valve into the oil cooler and tighten the cap to 50 Nm (37 lbf ft).

1.168 Installation, Engines YA and YB 1. If the studs have been removed and will be used again, clean the threads on the studs and on the engine block, Use liquid sealant on the threads before they are installed in the engine block. 2. Use a new gasket and install the oil cooler assembly to the engine block. Tighten the capscrews and nuts to 22 Nm (16 lbf ft). 3. Use a new gasket and connect the oil lines to the flange on the cover and tighten the screws. 4. Fill the coolant system. 1. O–RING

5. When the engine can be operated again, check for leaks.

FIGURE 111. BY–PASS VALVE, OIL COOLER

FLYWHEEL AND FLYWHEEL HOUSING 1.170 GENERAL

1.173 Ring Gear (Replacement)

WARNING The steel flywheel has a hardened steel starter ring. The starter ring has 126 teeth. The flywheel housing is made of cast iron.

Wear eye protection for this operation to prevent eye injury from metal chips. You will be using a hammer and chisel to break the ring gear.

1.171 FLYWHEEL

Before the ring gear is removed, check the position of the chamfer on the teeth. Use a hammer and chisel to break the ring gear. Make sure that you do not damage the flywheel.

1.172 Removal 1. Remove two opposite capscrews from the flywheel and temporarily install two studs to help control the flywheel when the other capscrews are removed. 2. Remove the other capscrews that fasten the flywheel to the crankshaft. Remove the flywheel. 3. Check the flywheel and ring gear for damage. 66

The ring gear must be heated before it can be installed on the flywheel. Use an oven that has a temperature control. Make sure that the ring gear is not heated to more than 250°C (480°F). Install the ring gear on the flywheel. Make sure that the chamfer on the teeth is in the correct direction. 1.174 Installation 1. Make sure the surfaces of the crankshaft and flywheel are clean so that the two parts will fit together correctly.

2. Install the flywheel over the guide studs. Install four capscrews. Remove the two studs and install the remainder of the capscrews. Tighten the capscrews in a cross pattern to 120 Nm (88 lbf ft). 3. Check the concentric variation (often called the “run– out”) when the flywheel is turned. Use a dial indicator. See FIGURE 112. This measurement must be less than 0.30 mm (0.012 in) total indicator reading.

1.175 FLYWHEEL HOUSING 1.176 Removal 1. Remove the starter motor and the flywheel. See 1.181 Starter, Removal and 1.172 Flywheel, Removal. 2. Remove the capscrews that hold the flywheel housing to the engine block. Use a soft hammer to carefully hit the flywheel housing and remove it from the dowels. 1.177 Installation 1. Make sure the surfaces of the engine block and the flywheel housing are clean so that the two parts will fit together correctly. Make sure that the location dowels are installed correctly. 2. Install the flywheel housing onto the dowels. Install the capscrews, but do not tighten them to their final torque.

FIGURE 112. CHECK THE “RUN–OUT” OF THE FLYWHEEL

3. Check the flywheel housing for concentric measurements as shown in FIGURE 114. If any adjustments are made, check the measurements again. See the ENGINE SPECIFICATIONS for the measurements.

4. Check the alignment of the face of the flywheel with a dial indicator. See FIGURE 113. This measurement must not be greater than 0.03 mm (0.001 in) total indicator reading for every 25 mm (1.0 in) of the flywheel radius from the axis of the crankshaft to the indicator plunger. When this measurement is made, force must be applied against the flywheel to remove the axial movement of the crankshaft from the measurement.

FIGURE 114. CHECK THE CONCENTRIC MEASUREMENTS OF THE FLYWHEEL HOUSING 4. When the concentric measurements are correct, tighten the capscrews to the following torques: M10 capscrews = 44 Nm (33 lbf ft) M12 capscrews = 75 Nm (55 lbf ft)

FIGURE 113. CHECK THE ALIGNMENT OF THE FLYWHEEL FACE

5. Check the alignment of the flywheel housing with the crankshaft as shown in FIGURE 115. See the ENGINE SPECIFICATIONS for the measurements. Any necessary adjustments must be made to the flywheel housing and not to the engine block. 67

6. Install the flywheel. See 1.174 Flywheel, Installation. 7. Install the starter motor. See 1.182 Starter, Installation.

FIGURE 115. CHECK THE ALIGNMENT OF THE FLYWHEEL HOUSING

ELECTRICAL EQUIPMENT 1.178 DRIVE BELTS Check the drive belts for wear and damage. When a pair of drive belts are used, they must be replaced as a pair. When a pair of drive belts are used, adjust the tension for the tightest belt.

thumb pressure is 100 N (20 lbf), the correct deflection is approximately 13 mm (0.5 in).

A gauge is available that will indicate the tension in the drive belt. Fit the gauge at the center of the longest length of the drive belt and measure the tension. See FIGURE 116. The correct tension is approximately 355 N (80 lbf)

FIGURE 116. GAUGE TO CHECK DRIVE BELT TENSION Many service people press on the drive belt with their thumb at the center of the longest length of the drive belt and check the deflection. See FIGURE 117. When the 68

12593

1. PIVOT FASTENER 2. ADJUSTMENT LINK

FIGURE 117. CHECK AND ADJUST DRIVE BELT TENSION Loosen the bolt on the adjustment link (2) and the pivot fasteners (1) to adjust the tension of the drive belts.

Move the alternator pulley against the drive belts to adjust the tension. Tighten the adjustment link and pivot fasteners.

1.182 Installation

The drive belts are removed from the engine by loosening the tension and then removing them from the pulleys.

2. Connect the cables to the starter motor.

1.179 ALTERNATOR

1.183 COLD START AID

NOTE: The alternator normally used with this engine is made by Delco Remy or Motorola. See THE ALTERNATOR, 2200 SRM 2 for troubleshooting and repairs.

The cold start aid is an electrical device. A controlled amount of diesel fuel is inserted into the inlet manifold where it is ignited by the cold start aid to heat the induction air. A heater coil in the body of the cold start aid expands a valve holder so that fuel can flow into the device where it is ignited by an ignition coil. The cold start aid is operated by a switch button on the instrument panel.

1.180 STARTER MOTOR See THE STARTER, 2200 SRM 106 for troubleshooting and repairs for the starter motor. 1.181 Removal 1. Disconnect the battery. 2. Disconnect the cables to the starter motor. 3. Remove the capscrews and remove the starter motor.

1. Install the starter motor in position on the flywheel housing. Install and tighten the capscrews.

3. Connect the battery.

If the cold start aid is removed for cleaning or replacement, make sure that the surfaces between the inlet manifold and the cold start aid are clean. Tighten the cold start aid to 31 Nm (23 lbf ft). If air is in the fuel system because the fuel line was disconnected, remove the air as described in 1.136 Remove Air From The Fuel System.

AIR COMPRESSOR, ENGINES YA AND YB 1.184 GENERAL

with engine serial number Y––––––U661001Y. The operation of the air compressors is similar.

The air compressor is installed in the PTO position on the rear face of the timing case. There are two sizes of compressors available for these engines. The drive assembly has two gears of equal size on a common shaft. The forward gear is engaged with the idler gear in the timing gear train. The rear gear turns the compressor gear.

1.185 Air Compressor, Removal, WABCO

The cylinder head of the single cylinder compressor is cooled by coolant from the engine. The compressor is lubricated from the engine oil system of the engine. Engine oil flows through a pipe from the main oil passage in the engine to the crankcase of the compressor. The engine oil then flows through the bearings of the compressor and the bushing for the drive shaft. The engine oil returns to the oil sump through the timing case. During 1994 the WABCO (Clayton Dewandre) (Model 159 and Model 229) air compressor was replaced by the Bendix 1W150R or 1W250R air compressor beginning

NOTE: The compressor and its drive housing can be removed from the engine as an assembly or only the compressor can be removed. 1. Drain the cooling system. 2. Release the air pressure in the air system and disconnect all the pipe connections to and from the cylinder head of the compressor. 3. Remove the pipe for the engine oil between the compressor and the engine block. 4. If an oil pump for the steering system is fastened to the back of the compressor housing, remove it. 5. Remove the support bracket which is installed between the bottom of the compressor and the engine block. 6. If the drive housing must be removed, remove the capscrew (1) that goes through the timing case. See 69

FIGURE 118. If only the compressor is to be removed, remove the five capscrews that hold the compressor flange to the drive housing. Remove the other three capscrews that hold the compressor to the drive housing. 7. Remove the compressor from the drive housing or remove the compressor and its drive housing from the engine. Make sure that the alignment dowels are still in position.

1. BUSHING 2. ALIGNMENT DOWELS

FIGURE 119. AIR COMPRESSOR, REMOVAL FROM THE DRIVE ASSEMBLY, WABCO 4. If an oil pump for the steering system is fastened to the back of the compressor housing, install it. 5. Install the oil pipe between the compressor and the engine block. 1. CAPSCREW THROUGH TIMING CASE 2. O–RING 3. ALIGNMENT DOWEL

FIGURE 118. AIR COMPRESSOR REMOVAL AND INSTALLATION, WABCO 1.186 Compressor Drive, Inspection Check the drive gears for wear and damage. Check the bushing (1) for wear. See FIGURE 119. NOTE: For The Disassembly And Assembly Of The Air Compressor, see the SERVICE MANUAL section for your air compressor. 1.187 Air Compressor, Installation, WABCO 1. If the drive housing has been removed, install a new O–ring (2) and lubricate it with clean engine oil. See FIGURE 118. 2. See FIGURE 118. or FIGURE 119. Make sure the alignment dowels are installed correctly. Install the compressor or the compressor and drive housing. Install and tighten the capscrews. 3. Install the support bracket for the compressor. Make sure that a side force is not applied to the compressor when the support bracket is installed. 70

6. Install the pipe connections to the cylinder head of the compressor. 7. Fill the cooling system with correct coolant. 8. When the engine can be operated, check for leaks. 1.188 Compressor Drive, Disassembly, WABCO 1. See FIGURE 120. Raise the tabs on the lock washer (2). Hold the shaft so that it does not turn and remove the nut (1). Discard the lock washer (2). NOTE: Some compressor drives do not have a lock washer (2). Loctite thread adhesive is used to lock the nut (1) to the shaft (5). 2. Use a puller to remove the gear (3). 3. Remove the snap ring (4). 4. Raise the tabs on the lock washer (12). Hold the shaft so that it does not turn and remove the nut (13). Discard the lock washer (12). NOTE: Some compressor drives do not have a lock washer (12). Loctite thread adhesive is used to lock the nut (13) to the shaft (5). 5. Press the shaft (5) and bearing (7) from the side of the housing that fastens to the timing case.

6. Remove the gear (11) from the housing (8).

2. Use a press to push the shaft (5) into the bearing (7). Use an adaptor so that force is not applied to the outer parts of the bearing. Apply force only to the inner ball guide of the bearing. 3. If necessary, remove the alignment dowels (9) from the housing (8) of the compressor drive. Put the housing (8) on a support so that the shaft and bearing can be pushed into the housing. 4. Lubricate the bearing receptacle in the housing (8) with engine oil. Push the bearing and shaft into the housing. Use an adaptor so that force is not applied to the shaft or the inner parts of the bearing. Apply force only to the outer ball guide of the bearing. 5. Install the snap ring (4) in its groove. 6. If your compressor (Model 159) has a spacer (10), install it on the shaft. Install the woodruff keys (6) in the slots in the shaft. 7. Align the woodruff keys with the gears (3, 11) and install the gears on the shaft. The gear (11) has a boss on Model 229 compressor drives that must be toward the bearing when the gear is installed. Use a press to completely install the gears on the shaft. NOTE: Some compressor drives do not have a lock washer (2, 12). Loctiteď&#x203A;&#x161; thread adhesive is used to lock the nuts (1, 13) to the shaft (5).

1. 2. 3. 4. 5. 6. 7. 8.

NUT LOCK WASHER* GEAR SNAP RING SHAFT WOODRUFF KEY (2) BEARING HOUSING

9. ALIGNMENT DOWEL (2) 10. SPACER* 11. GEAR 12. LOCK WASHER* 13. NUT * NOT ON ALL COMPRESSOR DRIVES

FIGURE 120. COMPRESSOR DRIVE, WABCO

7. Remove the woodruff keys (6) and the spacer (10) from the shaft (5). [NOTE: Only the Model 159 compressor drive has a spacer (10).] Press the shaft from the bearing (7). Do not apply force to the outer parts of the bearing. Apply force only to the inner ball guide of the bearing.

8. Install new lock washers with tabs (2, 12) on the shaft. Install the nuts (1, 13). If the nut has a thickness of 6.4 mm (0.25 in), tighten the nut to 80 Nm (59 lbf ft). If the nut has a thickness of 10 mm (0.4 in), tighten the nut to 130 Nm (95 lbf ft). Bend the tabs on the lock washers to lock the nuts in position. 9. If the alignment dowels (9) were removed, install them in the housing. Install the compressor drive as described in 1.187 Compressor Drive, Installation. 1.190 Air Compressor, Removal, BENDIX (See FIGURE 121.) NOTE: The compressor and its drive housing can be removed from the engine as an assembly or only the compressor can be removed. 1. Drain the cooling system.

1.189 Compressor Drive, Assembly, WABCO 1. Clean the parts and check them for wear and damage. Replace any worn or damaged parts.

2. Release the air pressure in the air system and disconnect all the pipe connections to and from the cylinder head of the compressor. 71

3. Remove the oil tube (6) for the engine oil between the compressor and the engine block.

ing case. Slide the compressor onto the stud (3) for the bottom of the flange. 5. Slide the compressor into the timing case until the teeth of the drive gear are against the teeth of the idler gear (2). Slowly turn the rear of the crankshaft of the air compressor clockwise until the teeth of the drive gear and the idler gear are fully engaged. Check that the timing mark on the crankshaft of the air compressor is aligned with the 6A area on the timing label.

1. 2. 3. 4. 5. 6. 7.

COOLANT HOSES SPACERS (1W150R ONLY) CAPSCREWS SUPPORT BRACKET CAPSCREWS OIL TUBE, LUBRICATION NUT

FIGURE 121. COMPRESSOR REMOVAL AND INSTALLATION, BENDIX 4. If an oil pump for the steering system is fastened to the back of the compressor housing, remove it. 5. Loosen the two capscrews (3). Remove the two capscrews (5). Remove the support bracket (4).

1. 2. 3. 4. 5.

THROUGH HOLE IN TIMING CASE IDLER GEAR STUD STUD O–RING

FIGURE 122. COMPRESSOR, INSTALLATION INTO THE DRIVE ASSEMBLY, BENDIX

6. Remove the nut from the stud at the bottom of the compressor flange. Remove the nut (7) from the stud at the front of the timing case and remove the air compressor from the engine. 1.191 Air Compressor, Installation, BENDIX 1. Set the piston of number 1 cylinder to TDC. 2. See FIGURE 122. Install a new O–ring (5) in its recess in the drive housing. 3. See FIGURE 123. Turn the crankshaft of the air compressor until the timing mark (1) on the rear face of the crankshaft is aligned with the 6A line on the label at the rear face of the air compressor. 4. See FIGURE 122. Install the end of the stud (4) with the shortest thread into the flange of the air compressor. Install the nut fully on the stud. Move the air compressor into its position and engage the stud in its hole in the tim72

1. TIMING MARK (SHOWN ALIGNED FOR 4–CYLINDER ENGINES. ALIGN WITH 6A FOR 6–CYLINDER ENGINES)

FIGURE 123. COMPRESSOR, INSTALLATION INTO THE DRIVE ASSEMBLY, BENDIX

6. Install the nut (item 7, FIGURE 121.) on the stud. Install the nut on the stud (item 3, FIGURE 122.). Tighten both nuts to 75 Nm (55 lbf ft). 7. Install the support bracket. See FIGURE 121. Install the capscrews (5) loosely. Install the spacers (2) if used and the capscrews (3). Adjust the support bracket so that it only holds the air compressor and does not put tension on it. Tighten the two capscrews (3) to 22 Nm (16 lbf ft). Tighten the two capscrews (5) to 44 Nm (33 lbf ft). 8. Check that the O–ring in the cover at the rear of the air compressor is not damaged. Install the cover and tighten the two capscrews. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

9. Make sure the oil tube (item 6, FIGURE 121.) is in good condition and does not have a restriction. Make sure the engine stop solenoid is disconnected or the engine stop control is in the STOP position. Operate the started motor until engine oil flows from the oil tube. Connect the oil tube. Connect the engine stop solenoid. 10. Connect the coolant hoses and air pipes to the air compressor.

FIGURE 124. COMPRESSOR DRIVE, BENDIX

11. Install the engine coolant. When the engine can be operated, check for oil, air, and coolant leaks. 1.192 Compressor Drive, Disassembly, BENDIX

O–RING CAPSCREW BRACKET DRIVE GEAR, AIR COMPRESSOR TIMING CASE COVER,TIMING CASE NEEDLE BEARING CAPSCREW (3) IDLER HUB COVER PLATE IDLER GEAR ENGINE IDLER GEAR

CAUTION Do not turn the engine crankshaft nor the crankshaft for the air compressor. If either crankshafts are moved, the air compressor must be timed to the engine. 1. Remove the timing case cover as described in 1.77 Timing Case Cover, Removal. 2. Remove the three capscrews shown in (item 8, FIGURE 124.). Remove the cover plate (10). Remove the idler gear (11) and the needle bearings (7). 3. Remove the three capscrews (item 3, FIGURE 125.) which fasten the idler hub to the bracket (2). Remove the idler gear hub. 4. Remove and discard the O–ring (item 1, FIGURE 124.).

1. 2. 3. 4. 5.

TIMING CASE BRACKET, IDLER HUB CAPSCREWS (3) CAPSCREWS (4) IDLER GEAR

FIGURE 125. COMPRESSOR DRIVE, BENDIX 1.193 Compressor Drive, Assembly, BENDIX

5. Inspect the parts for wear or damage.

1. Install the O–ring (item 1, FIGURE 124.). 73

2. Check that the four capscrews which fasten the idler hub bracket (item 4, FIGURE 125.) to the timing case are tightened to 35 Nm (26 lbf ft). 3. Install the hub (item 9, FIGURE 124.) into the timing case. Install the three capscrews (item 3, FIGURE 125.) and tighten them to 60 Nm (44 lbf ft). Install the needle bearing assembly on the hub. 4. Lubricate the bore of the idler gear with clean engine oil and install the idler gear on the needle bearings. Install the cover plate (item 9, FIGURE 124.) and tighten three capscrews (8) to 22 Nm (16 lbf ft). 5. Check the clearance between the bushings of the idler gear and the plate of the idler gear. The correct clearance is 0.12 to 0.16 mm (0.005 to 0.006 in). A maximum service limit is 0.38 mm (0.015 in). See FIGURE 60.

6. Check the timing gear clearances as shown in FIGURE 61. The minimum clearance is 0.08 mm (0.003 in). 7. Install the timing case cover as described in 1.78 Timing Case Cover, Installation. 8. Install the air compressor as described in 1.191 Air Compressor, Installation, BENDIX. 9. Install the coolant pump. See 1.157 Coolant Pump, Installation. 10. Install the crankshaft pulley and thrust block. Install the three capscrews and tighten the three capscrews evenly to 115 Nm (85 lbf ft). Check each capscrew again for the correct torque. 11. Install the drive belts and adjust the tension. See 1.178 Drive Belts. 12. Install the fan. Fill the cooling system.

ENGINE SPECIFICATIONS 1.194 CYLINDER HEAD ASSEMBLY 1.195 Cylinder Head Angle of valve seat

46° (88° included angle)

Diameter of parent bore for valve guide 15.87 to 15.89 mm (0.6247 to 0.6257 in) Leak test pressure

200 kPa (29 psi)

Head thickness

102.70 to 103.50 mm (4.047 to 4.078 in)

Interference fit of valve guide in cylinder head 0.03 to 0.07 mm (0.0012 to 0.0027 in) Total length to Inlet to Exhaust

57.94 mm (2.281 in) 61.10 mm (2.406 in)

Extension from bottom of recess for valve spring 15.10 mm (0.594 in)

Minimum thickness of head in service 102.48 mm (4.035 in) Maximum distortion of cylinder head. See FIGURE 126.

ENGINES AA, AB: 1 = 0.08 mm (0.003 in) 2 = 0.15 mm (0.006 in) 3 = 0.15 mm (0.006 in) ENGINES YA, YB: 1 = 0.13 mm (0.005 in) 2 = 0.25 mm (0.010 in) 3 = 0.25 mm (0.010 in)

FIGURE 126. CHECK THE CYLINDER HEAD FOR DISTORTION 1.196 Valve Guides Inside diameter

9.51 to 9.56 mm (0.3744 to 0.3764 in)

Outside diameter

15.90 to 15.91 mm (0.6260 to 0.6265 in)

INLET VALVE: 1 = 1.59 mm (0.063 in) 2 = 19.05mm (0.750 in) 3 = 6.35 mm (0.250 in) 4 = 76.20 mm (3.00 in) 5 = 37.26 to 37.28 mm (1.467 to 1.468 in) 6 = 51.00 to 51.23 mm (2.008 to 2.017 in) 7 = 0.79 mm (0.031 in) 8 = 1.59 mm (0.063 in) 9 = 1.59 mm (0.063 in) 10 = 9.45 to 9.47 mm (0.372 to 0.373 in) EXHAUST VALVE: 1 = 1.59 mm (0.063 in) 2 = 19.05mm (0.750 in) 3 = 7.92 mm (0.312 in) 4 = 76.20 mm (3.00 in) 5 = 32.58 to 32.84 mm (1.283 to 1.293in) 6 = 42.39 to 42.62 mm (1.669 to 1.678 in) 7 = 0.79 mm (0.031 in) 8 = 1.59 mm (0.063 in) 9 = 1.59 mm (0.063 in) 10 = 9.45 to 9.47 mm (0.372 to 0.373 in)

FIGURE 127. PILOT TOOL TO INSERT VALVE SEATS

Maximum clearance in valve guide 0.15 mm (0.005 in) Diameter, valve head

37.26 to 37.52 mm (1.467 to 1.477 in)

Angle of valve face

45Â°

Depth of valve head below face of cylinder head: to Production limit 1.28 to 1.83 mm (0.050 to 0.072 in)

INLET VALVE: 1 = 7.19 to 7.32 mm (0.283 to 0.288 in) 2 = 51.22 to 51.24 mm (2.0165 to 2.0175 in) 3 = Maximum Radius 0.38 mm (0.015 in) EXHAUST VALVE: 1 = 9.52 to 9.65 mm (0.375 to 0.380 in) 2 = 46.62 to 42.65 mm (1.6780 to 1.6790 in) 3 = Maximum Radius 0.38 mm (0.015 in)

FIGURE 128. DIMENSIONS FOR VALVE SEAT INSERTS

to Service limit

2.08 mm (0.082 in)

Total length

123.07 to 123.57 mm (4.845 to 4.865 in)

Seal arrangement

Rubber seal installed on valve guide

1.199 Double Valve Springs To Outer Installed length

35.8 mm (1.41 in)

Load, installed length

176 to 195 N (39.5 to 43.7 lbf)

Active coils, number

3.6

Damper coils, number

Direction of coils

Left hand to damper coil to cylinder head

1.200 Double Valve Springs To Inner Installed length

1.197 Inlet Valves Diameter, valve stem

9.46 to 9.49 mm (0.3725 to 0.3735 in)

Clearance in valve guide 0.02 to 0.10 mm (0.0008 to 0.0039 in) Maximum clearance in valve guide 0.13 mm (0.005in)

35.8 mm (1.41 in)

Load, installed length

89 to 104 N (20 to 23 lbf)

Active coils, number

4.9

Damper coils, number

Direction of coils

Right hand to damper coil to cylinder head

1.201 Single Valve Springs Installed length

40.0 mm (1.57 in)

Diameter, valve head

44.86 to 45.11 mm (1.766 to 1.776 in)

Load, installed length

312 to 344 N (70.1 to 77.3 lbf)

Angle of valve face

45Â°

Active coils, number

4.5

Depth of valve head below face of cylinder head: to Production limit 1.27 to 1.60 mm (0.050 to 0.063 in)

Damper coils, number

Direction of coils

Left hand

to Service limit

1.85 mm (0.073 in)

1.202 Tappets

Total length

122.66 to 123.07 mm (4.829 to 4.845 in)

Diameter, tappet stem

Seal arrangement

Rubber seal installed on valve guide

1.198 Exhaust Valves Diameter, valve stem

9.43 to 9.46 mm (0.371 to 0.372 in)

Diameter, tappet bore in cylinder block 19.05 to 10.08 mm (0.7500 to 0.7512 in) Clearance of tappet in engine block 0.04 to 0.09 mm (0.0015 to 0.0037 in)

1.203 Rocker Arm Shaft

Clearance in valve guide 0.05 to 0.13 mm (0.002 to 0.005 in) 76

18.99 to 19.01 mm (0.7475 to 0.7485 in)

Outside diameter

19.01 to 19.04 mm (0.7485 to 0.7495 in)

1.204 Rocker Arms And Bushings Diameter, bore in rocker arm for bushing 22.23 to 22.26 mm (0.8750 to 0.8762 in) Diameter, outside of bushing 22.28 to 22.31 mm (0.8770 to 0.8785 in) Interference fit of bushing in rocker arm 0.020 to 0.089 mm (0.0008 to 0.0035 in) Internal diameter, bushing (finished size) 19.06 to 19.10 mm (0.7505 to 0.7520 in)

Width of groove for top ring tapered Width of groove for second ring 2.56 to 2.58 mm (0.1008 to 0.1016 in) Width of groove for third ring 4.04 to 4.06 mm (0.1591 to 0.1598 in)

1.208 Piston Rings, Engines AA And YA Top compression ring

Barrel face, molybdenum insert, chamfer at the top of the inner face

Second compression ring Taper face, cast iron

Clearance between rocker arm and rocker arm shaft 0.03 to 0.09 mm (0.001 to 0.0035 in)

Oil ring

Coil spring back to up, chromium face

Maximum clearance (service) between rocker arm and rocker arm shaft 0.13 mm (0.005in)

Width of top ring

2.48 to 2.49 mm (0.097 to 0.098 in)

Width of second ring

2.48 to 2.49 mm (0.097 to 0.098 in

Width of third ring

3.98 to 3.99 mm (0.156 to 0.157 in)

1.205 PISTON AND CONNECTING RODS 1.206 Pistons, Engines AA And YA Type: “Quadram” combustion bowl, controlled expansion, top ring groove has insert. Diameter, bore for piston pin 34.928 to 34.934 mm (1.3751 to 1.3754 in) Height of piston above top face of engine block 0.14 to 0.36 mm (0.005 to 0.014 in) Width of groove for top ring 2.57 to 2.59 mm (0.101 to 0.102 in) Width of groove for second ring 2.55 to 2.57 mm (0.100 to 0.101 in) Width of groove for third ring 4.03 to 4.06 mm (0.1587 to 0.1598 in)

1.207 Pistons, Engines AB And YB Type: “Quadram” combustion bowl, controlled expansion, top ring groove has insert, diameter of top land is reduced, anodized top face. Diameter, bore for piston pin 38.103 to 38.109 mm (1.500 to 1.5004 in) Height of piston above top face of engine block 0.14 to 0.36 mm (0.005 to 0.014 in)

Clearance of top ring in groove: 0.08 to 0.11 mm (0.003 to 0.004 in) Clearance of second ring in groove 0.06 to 0.09 mm (0.002 to 0.003 in) Clearance of third ring in groove 0.04 to 0.08 mm (0.002 to 0.003 in) Gap of top ring

0.30 to 0.76 mm (0.012 to 0.030 in)

Gap of second ring

0.30 to 0.76 mm 0.012 to 0.030 in)

See 1.42 Service Note. The gap for the second ring for later production engines 0.040 to 0.85 mm (0.016 to 0.033 in) Gap of third ring

0.38 to 0.84 mm (0.015 to 0.033 in)

1.209 Piston Rings, Engines AB And YB Top compression ring

Barrel face, molybdenum insert, wedge

Second compression ring Taper face, cast iron Oil ring

Coil spring back to up, chromium face

Width of top ring

Wedge

Width of second ring

2.48 to 2.49 mm (0.097 to 0.098 in 77

Width of third ring

3.98 to 3.99 mm (0.156 to 0.157 in)

Clearance of top ring in groove: Wedge Clearance of second ring in groove 0.07 to 0.11 mm (0.003 to 0.004 in) Clearance of third ring in groove 0.05 to 0.08 mm (0.002 to 0.003 in) Gap of top ring

0.35 to 0.75 mm (0.014 to 0.030 in)

Gap of second ring

0.30 to 0.76 mm 0.012 to 0.030 in)

Gap of third ring

0.38 to 0.84 mm (0.015 to 0.033 in)

1.210 Connecting Rods, Engines AA And YA Type

“H” section, square shape at small end

Location of cap to connecting rod Serrations Diameter, parent bore at big end 67.21 to 67.22 mm (2.6460 to 2.6465 in)

FIGURE 129. CHECK THE ALIGNMENT OF THE CONNECTING ROD 1.212 Piston Pins, Engines AA And YA Type

Full floating

Outside diameter

34.929 to 34.925 mm (1.3748 to 1.3750 in)

Clearance fit in piston

0.003 to 0.014 mm (0.0001 to 0.0006 in)

Diameter, parent bore at small end 38.89 to 38.92 mm (1.531 to 1.532 in)

1.213 Piston Pins, Engines AB and YB Type

Full floating

Length between centers

Outside diameter

38.095 to 38.100 mm (1.4998 to 1.5000 in)

Clearance fit in piston

0.003 to 0.014 mm (0.0001 to 0.0006 in)

219.05 to 219.10 mm (8.624 to 8.626 in)

1.211 Connecting Rods, Engines AB And YB Type

“H” section, wedge shape at small end

1.214 Small End Bushings, Engines AA And YA Type

Steel back, lead bronze bearing material

Location of cap to connecting rod Flat joint face with dowels

Outside diameter

38.94 to 39.03 mm (1.535 to 1.536 in)

Diameter, parent bore at big end 67.21 to 67.22 mm (2.6460 to 2.6465 in)

Inside diameter

34.94 to 34.96 mm (1.3758 to 1.3765 in)

Diameter, parent bore at small end 42.07 to 42.09 mm (1.656 to 1.657 in) Length between centers 219.05 to 219.10 mm (8.624 to 8.626 in) 78

Clearance between bushing and piston pin 0.020 to 0.043 mm (0.0008 to 0.0017 in)

1.215 Small End Bushings, Engines AB And YB Type

Steel back, lead bronze bearing material

Outside diameter

42.16 to 42.19 mm (1.6600 to 1.6613 in)

Inside diameter

38.12 to 38.14 mm (1.5008 to 1.5015 in)

1.219 CRANKSHAFT ASSEMBLY 1.220 Crankshaft

1.217 Connecting Rod Bearings, Engines AB And YB

76.16 to 76.18 mm (2.998 to 2.999 in) Maximum wear and oval wear on main and crank journals 0.04 mm (0.0016 in) Width of front journal 36.93 to 37.69 mm (1.454 to 1.484 in) Width of center journal 44.15 to 44.22 mm (1.738 to 1.741 in) Width of all other main journals 39.24 to 39.35 mm (1.545 to 1.549 in) Diameter of crank journal 63.47 to 63.49 mm (2.499 to 2.500 in) Width of crank journals 40.35 to 40.42 mm (1.589 to 1.591 in) Diameter of flange 133.27 to 133.37 mm (5.247 to 5.251 in) Axial movement 0.05 to 0.38 mm (0.002 to 0.015 in) Maximum axial movement (service) 0.51 mm (0.020 in) Fillet radii, all journals 3.68 to 3.96 mm (0.145 to 0.156 in) Undersize journals, all –0.25 mm ( –0.010 in) –0.51 mm ( –0.020 in) –0.76 mm ( –0.030 in)

Type

1.221 Crankshaft Heat Treatment

Clearance between bushing and piston pin 0.020 to 0.043 mm (0.0008 to 0.0017 in)

1.216 Connecting Rod Bearings, Engines AA And YA Type

Steel back, aluminum to tin bearing material

Width

31.62 to 31.88 mm (1.245 to 1.255 in)

Thickness

1.835 to 1.842 mm (0.0723 to 0.0725 in)

Inside diameter

63.525 to 63.548 mm (2.5010 to 2.5019 in)

Bearing clearance

0.025 to 0.076 mm (0.001 to 0.003 in)

Available undersize bearings: –0.25 mm ( –0.010 in) –0.51 mm ( –0.020 in) –0.76 mm ( –0.030 in)

Steel back, lead bronze bearing material with lead finish

Width

31.55 to 31.88 mm (1.240 to 1.255 in)

Thickness

1.835 to 1.842 mm (0.0723 to 0.0725 in)

Inside diameter

63.525 to 63.548 mm (2.5010 to 2.5019 in)

Bearing clearance

0.025 to 0.076 mm (0.001 to 0.003 in)

Available undersize bearings: –0.25 mm ( –0.010 in) –0.51 mm ( –0.020 in) –0.76 mm ( –0.030 in)

1.218 Piston Cooling Jets, Engines AB And YB Valve open pressure

178 to 250 kPa (26 to 36 psi)

Diameter, main journal

The following part numbers are induction hardened: 31315662 31315992 3131H024 The following part numbers are nitrocarburised: 31315661 31315991 3131H022

1.222 Crankshaft Overhaul Induction hardened crankshafts do not need to be hardened after they have been machined undersize. Nitrocarburised crankshafts must be hardened again each time after they have been machined. If nitrocarburised or nitrided hardening methods are not available, the crank shaft must be replaced or exchanged with a crankshaft from the manufacturer. Check the crankshaft for cracks before and after it is machined (ground). Remove any magnetism after the crankshaft has been checked for cracks. 79

After the crankshaft has been machined, remove any sharp edges from the oil holes for lubrication.

specifications. The finished sizes for machined crankshafts are shown in FIGURE 130.

Surface finish and fillet radii must be according to the

Undersize Item

0.25 mm (0.010 in)

75.905 to 75.926 mm (2.9884 to 2.9892 in)

63.216 to 63.236 mm (2.4888 to 2.4896 in)

0.51 mm (0.020 in)

0.76 mm (0.030 in)

75.651 to 75.672 mm (2.9784 to 2.9792 in)

75.397 to 75.418 mm (2.9684 to 2.9692 in)

3 4 5 6 7 8

62.962 to 62.982 mm (2.4788 to 2.4796 in) 39.47 mm (1.554 in) maximum 37.82 mm (1.489 in) maximum 44.68 mm (1.759 in) maximum 40.55 mm (1.759 in) maximum 133.17 mm (5.243 in) maximum Do not machine this diameter

3.68 to 3.96 mm (0.145 to 0.156 in)

62.708 to 62.728 mm (2.4688 to 2.4696 in)

Surface finish for all bearing journals must be 0.4 microns (16 micro inches). Surface finish for all radii must be 1.3 microns (51 micro inches).

FIGURE 130. SPECIFICATIONS, CRANKSHAFT OVERHAUL

When the crankshaft is on mounts at the front and rear main journals, the maximum variation (run–out) (total indicator reading) at the other main journals can not be greater than the following table. The “run–out” must not be opposite. The difference in “run–out” between one journal and the next one must not be more than 0.10 mm (0.004 in). The “run–out” on the crankshaft pulley diameter, rear oil seal diameter, and the rear flange diameter must not be more than 0.05 mm (0.002 in) total indiactor reading. 4–cylinder crankshafts 6–cylinder crankshafts Journal 1 Mount Mount 2 0.08 mm (0.003 in) 0.10 mm (0.004 in) 3 0.15 mm (0.006 in) 0.20 mm (0.008 in) 4 0.08 mm (0.003 in) 0.25 mm (0.010 in) 5 Mount 0.20 mm (0.008 in) 6 0.10 mm (0.004 in) 7 Mount

1.223 Main Bearings

to Oversize

Type

Steel back, 20% tin to aluminum bearing material

Type, center bearing (Engines YA and YB)

Steel back, lead bronze bearing material with lead finish

2.45 to 2.50 mm (0.096 to 0.098 in)

1.225 TIMING CASE AND DRIVE ASSEMBLY 1.226 Camshaft

Width, center bearing (All engines)

36.32 to 36.70 mm (1.430 to 1.445 in)

Diameter, journal No.1

50.71 to 50.74 mm (1.9965 to 1.9975 in)

Width, other bearings (Engines AA and AB)

31.62 to 31.88 mm (1.245 to 1.255 in)

Diameter, journal No.2

50.46 to 50.48 mm (1.9865 to 1.9875 in)

Width, other bearings (Engines YA and YB)

30.86 to 31.12 mm (1.215 to 1.225 in)

Diameter, journal No.3 Engines AA and AB

Bearing thickness (All engines)

2.083 to 2.89 mm (0.0820 to 0.0823 in)

Bearing thickness, center bearing (Engines YA and YB only) 2.087 to 2.096 mm (0.0822 to 0.0825 in) Inside diameter

76.23 to 76.27 mm (3.0010 to 3.0025 in)

Bearing clearance

0.046 to 0.107 mm (0.0018 to 0.0042 in)

Available undersize bearings: –0.25 mm ( –0.010 in) –0.51 mm ( –0.020 in) –0.76 mm ( –0.030 in)

1.224 Crankshaft Thrust Washers Type

Steel back, lead bronze bearing material

Position

each side of the center main bearing

Thickness: to Standard

2.26 to 2.31 mm (0.089 to 0.091 in)

Engines YA and YB Diameter, journal No.4 Engines YA and YB

49.95 to 49.98 mm (1.9665 to 1.9775 in) 50.20 to 50.23 mm (1.9765 to 1.9775 in) 49.95 to 49.98 mm (1.9665 to 1.9775 in)

Clearances, all journals 0.06 to 0.14 mm (0.0025 to 0.0055 in) Cam lift: Inlet Exhaust

7.62 to 7.69 mm (0.2999 to 0.3029 in) 7.71 to 7.79 mm (0.3036 to 0.3066 in)

Maximum out of round and wear on journals 0.05 mm (0.021 in) Axial movement: Production limit Service limit

0.10 to 0.41 mm (0.004 to 0.016 in) 0.53 mm (0.0020 in)

Width, thrust washer space 5.64 to 5.89 mm (0.222 to 0.232 in)

1.227 Camshaft Thrust Washer Type

360° 81

Clearance fit, thrust washer in engine block 5.41 to 5.49 mm (0.213 to 0.216 in)

Axial movement: to Production limit

Thickness, thrust washer

to Service limit

0.10 to 0.20 mm (0.004 to 0.008 in) 0.38 mm (0.015 in)

Gear clearance (all)

0.08 mm (0.003 in)

5.49 to 5.54 mm (0.216 to 0.218 in) Extension of thrust washer beyond front face of engine block 0.00 to 0.13 mm (0.000 to 0.005 in)

1.228 Camshaft Gear No. of teeth

Diameter, bore

34.93 to 34.95 mm (1.3741 to 1.3747 in)

1.232 ENGINE BLOCK ASSEMBLY 1.233 Engine Block Height between top and bottom faces 441.12 to 441.33 mm (17.367 to 17.375 in) Diameter, bore for cylinder liner 104.20 to 104.23 mm (4.103 to 4.104 in)

Outside diameter, hub of camshaft 34.90 to 34.92 mm (1.3741 to 1.3747 in)

Depth of space for flange of cylinder liner 3.81 to 3.91 mm (0.150 to 0.154 in)

Clearance fit, gear on hub

Diameter of space for flange of cylinder liner 107.82 to 107.95 mm (4.245 to 4.250 in)

0.008 to 0.048 mm (0.0003 to 0.0019 in)

1.229 Gear For Fuel Injection Pump No. of teeth

Bore

Tapered

1.230 Crankshaft Gear No. of teeth

Diameter, bore

47.625 to 47.650 mm (1.8750 to 1.8760 in)

Diameter, hub for gear on crankshaft 47.625 to 47.645 mm (1.8750 to 1.8758 in) Press fit of gear on crankshaft â&#x20AC;&#x201C;0.020 to +0.048 mm (â&#x20AC;&#x201C;0.0008 to +0.0010 in)

1.231 Idler Gear And Hub No. of teeth

Diameter, gear bore

57.14 to 57.18 mm (2.2495 to 2.2512 in)

Width, gear with split bushing assembly 30.14 to 30.16 mm (1.186 to 1.187 in) Width, gear with flange bushing assembly 50.80 to 50.82 mm (1.9998 to 2.0007 in) Outside diameter, hub

50.70 to 50.74 mm (1.9960 to 1.9975 in)

Clearance, bushings on hub 0.058 to 0.119 mm (0.0023 to 0.0047 in) 82

Diameter of bore for main bearing 80.416 to 80.442 mm (3.1660 to 3.1670 in) Diameter, camshaft bore (Engines AA and AB): to No. 1 55.56 to 55.59 mm (2.188 to 2.189 in) to No. 2 50.55 to 50.60 mm (1.990 to 1.992 in) to No. 3 50.04 to 50.09 mm (1.970 to 1.972 in) Diameter, camshaft bore (Engines YA and YB): to No. 1 55.56 to 55.59 mm (2.188 to 2.189 in) to No. 2 50.55 to 50.60 mm (1.990 to 1.992 in) to No. 3 50.29 to 50.34 mm (1.980 to 1.982 in) to No. 4 50.04 to 50.09 mm (1.970 to 1.972 in) Bore in bushing for No. 1 camshaft journal 50.79 to 50.85 (2.000 to 2.002 in)

1.234 Cylinder Liners Outside diameter, production cylinder liner 104.25 to 104.28 mm (4.105 to 4.106 in) Fit of production cylinder liner 0.03 to 0.08 mm (0.001 to 0.003 in) Inside diameter of production cylinder liner 100.00 to 100.03 mm (3.937 to 3.9395 in)

Fit of service cylinder liner +0.03 mm (+0.001 in) Inside diameter of service cylinder liner (installed) 100.04 to 100.06 mm (3.9385 to 3.9395 in) Maximum wear of liner bore 0.25 mm (0.010 in) Thickness of flange

0.031 to 0.106 mm (0.0012 to 0.0042 in) Clearance, bushing of idler gear on shaft 0.020 to 0.066 mm (0.0008 to 0.0026 in)

1.239 Relief Valve Diameter, bore for plunger 18.24 to 18.27 mm (0.718 to 0.719 in)

3.81 to 3.86 mm (0.150 to 0.152 in)

Top of flange even with face of engine block +0.10 mm (+0.004 in)

1.235 TURBOCHARGER Engine AB

Airesearch T31 or Schwitzer S2A

Engine YB

Airesearch T04B

1.236 LUBRICATION SYSTEM 1.237 Oil Pump, Engines AA And AB Type

Differential rotor, gear driven

Number of lobes

Inner rotor 6, outer rotor 7

Clearance of outer rotor to pump body 0.15 to 0.34 mm (0.006 to 0.013 in) Clearance of inner rotor to outer rotor 0.04 to 0.13 mm (0.0015 to 0.0050 in) Axial movement, rotor

to Outer rotor

0.03 to 0.10 mm (0.001 to 0.004 in)

1.238 Oil Pump, Engines YA And YB Type

Differential rotor, gear driven

Number of lobes

Inner rotor 4, outer rotor 5

Clearance of outer rotor to pump body 0.15 to 0.34 mm (0.006 to 0.013 in) Clearance of inner rotor to outer rotor 0.04 to 0.13 mm (0.0015 to 0.0050 in) End clearance, Engine YA to Inner rotor 0.05 to 0.12 mm (0.002 to 0.005 in) to Outer rotor 0.04 to 0.11 mm (0.0015 to 0.0044 in) End clearance, Engine YB to Inner rotor 0.043 to 0.118 mm (0.0017 to 0.0046 in)

Outside diameter, plunger 18.16 to 18.18 mm 0.715 to 0.716 in) Clearance of plunger in bore 0.06 to 0.11 mm (0.002 to 0.004 in) Length of spring, installed (Engines AA and AB) 59.8 mm (2.4 in) Length of spring, installed (Engines YA and YB) 55.6 mm (2.2 in) Load on spring, installed (Engines AA and AB) 18.9 to 20.1 N (4.3 to 4.5 lbf) Load on spring, installed (Engines YA and YB) 15.2 to 16.2 N (3.4 to 3.6 lbf) Pressure to open valve, (Engine AA) 360 to 415 kPa (52 to 50 psi) Pressure to open valve, (Engine AB) 435 to 490 kPa (63 to 71 psi) Pressure to open valve, (Engines YA and YB) 345 to 414 kPa (50 to 60 psi)

1.240 Oil Filter Type Full flow, canister Pressure to open by to pass valve in oil filter 55 to 83 kPa (8 to 12 psi) Pressure to open by to pass valve in oil cooler 172 kPa (25 psi)

1.241 FUEL SYSTEM 1.242 Cav Fuel Injection Pump Type DPA (Engines AA and YA) Type DPS (Engines AB and YB) Direction of rotation, (from drive end) Clockwise Outlet for No. 1 cylinder: to Engines AA and AB Letter “W” to Engines YA and YB Letter “Y” 83

Static timing: The engine check angle must be used with special tool MS67B and with the engine set with No. 1 piston at TDC on the compression stroke. The pump is checked with the pump set at the start of injection for cylinder No. 1. The code letters are included in the setting code on the data plate on the fuel injection pump. A typical setting code is 2643C601BM/4/2700. In this example the code letters are “BM”.

Fuel pump code letters

Engine check angle (degrees)

Pump mark angle (degrees)

AK AM BM CM DM FK GK GM HK HM JK KK LK MK PK RK RM TK UK XM

325 1/2 282 281 282 1/2 282 1/4 325 1/2 324 282 327 282 325 1/2 325 326 1/2 325 326 327 1/2 282 1/2 327 325 1/2 282

336 290 1/2 291 291 1/2 290 1/2 336 336 290 1/2 336 291 334 334 337 1/2 336 334 336 290 1/2 334 334 291

FIGURE 131. STATIC TIMING CODES 1.243 FUEL INJECTORS The code letters are on the side of the fuel injector body and just below the connection for the nut of the high pressure line. FIGURE 132. FUEL INJECTOR CODES Code

Holder

Nozzle

Set and Reset Pressure atm

psi

MPa

LRB67014

JB6801022

220

3234

22.3

LRB67014

JB6801052

250

3675

25.3

LRB67014

JB6801029

220

3234

22.3

LRB67014

JB6801057

250

3675

25.3

LRB67014

JB6801058

250

3675

25.3

LRB67014

JB6801058

220

3234

22.3

LRB67032

JB6801052

250

3675

25.3

LRB67032

JB6801057

230

3381

23.3

LRB67014

JB6801084

250

3675

25.3

LRB67014

JB6801082

250

3675

25.3

LRB67014

JB6801088

220

3234

22.3

LRB67032

JB6801093

250

3675

25.3

LRB67032

JB6801100

250

3675

25.3

LRB67032

JB6801084

250

3675

25.3

LRB67032

JB6801104

250

3675

25.3

LRB67014

JB6801106

220

3234

22.3

LRB67014

JB6801157

250

3675

25.3

2645L304

2645L607

220

3234

22.3

2645L305

2645L609

225

3308

22.8

2645L305

2645L608

225

3308

22.8

2645L304

2645L611

230

3381

23.3

2645L303

2645L612

230

3381

23.3

2645L304

2645L613

220

3234

22.3

2645L303

2645L614

230

3381

23.3

2645L303

2645L612

250

3675

25.3

2645L304

2645L615

230

3381

23.3

2645L303

2645L605

220

3234

22.3

2645L304

2645L616

220

3234

22.3

2645L303

2645L613

220

3234

22.3

KBEL66S45

DLLA140S1039

250

3675

25.3

KBEL66S47

DLLA150S1055

250

3675

25.3

KBEL66S47

DLLA150S1072

250

3675

25.3

KBEL66S47

DLLA150S1087

250

3675

25.3

KBEL66S47

DLLA145S1172

270

3970

27.4

KBEL66P69

0433–175–044

250

3675

25.3

KBEL66P69

0433–175–067

250

3675

25.3

KBEL66P99

0433–175–044

250

3675

25.3

0433–176–079

DSLA140P292

250

3675

25.3

0433–175–079

3374287

250

3675

25.3

KPEL66P111

0433–175–044

250

3675

25.3

KPEL65P113

DSLA140P472

250

3675

25.3

2645F311

2645F610

250

3675

25.3

1.244 Fuel Pump, Engines AA And AB Type

A.C. Delco, types XD

Method of drive

Eccentric on camshaft

Static pressure (no delivery) 42 to 70 kPa (6 to 10 psi)

1.245 Fuel Pump, Engines YA And YB Type

A.C. Delco, types LU

Method of drive

Eccentric on camshaft

Static pressure (no delivery) 34.5 to 55.2 kPa (5 to 8 psi)

Outside diameter of shaft 15.91 to 15.92 mm (0.6264 to 0.6267 in) Diameter, bore of drive gear 15.88 to 15.89 mm (0.6252 to 0.6256 in) Press fit of drive gear on shaft 0.01 to 0.04 mm (0.0005 to 0.0016 in) Diameter, bore of impeller 15.87 to 15.89 mm (0.6249 to 0.6257 in)

Test pressure (75% of minimum static pressure) 26 kPa (3.75 psi)

Diameter, bearing

1.246 Fuel Filter

Diameter, bore for bearing

Type single element (some YA and YB engines are equipped with twin parallel flow filters)

1.247 COOLING SYSTEM 1.248 Coolant Pump Type

centrifugal, gear drive

29.99 to 30.00 mm (1.1807 to 1.1811 in) 29.96 to 29.98 mm (1.1795 to 1.1803 in)

Press fit, bearing in pump body 0.01 to 0.04 mm (0.0004 to 0.0016 in) Installed dimension, impeller boss to front face of pump body 8.1 to 8.5 mm (0.319 to 0.335 in) 85

Installed dimension, gear from rear face of pump body 0.6 to 2.6 mm (0.024 to 0.102 in)

1.249 Thermostat Type, Engines AA and AB

1.251 FLYWHEEL AND HOUSING 1.252 Limits for flywheel “run out” and alignment (total indicator reading). See FIGURE 133.

Single, wax pellet, by to pass blanking

Diameter of housing flange bore mm in

Type, Engines YA and YB Twin, wax pellet, by to pass blanking “Start to open”

77 to 85°C (170 to 185°F)

“Fully open”

92 to 98°C (198 to 208°F)

Valve lift, fully open

9.1 mm (0.358 in)

less than 362 362 to 511 511 to 648 over 648

Outside diameter, bearing 41.99 to 42.00 mm (1.6531 to 1.6535 in) Press fit, bearing in housing 0.00 to 0.02 mm (0.0000 to 0.0008 in) Bore of hub Press fit, shaft in hub

21.946 to 21.958 mm (0.8656 to 0.8661 in) 0.029 to 0.054 mm (0.0011 to 0.0021 in)

Maximum axial movement: 0.25 mm (0.010 in)

0.15 0.20 0.25 0.30

0.006 0.008 0.010 0.012

FIGURE 133. FLYWHEEL AND HOUSING LIMITS

1.250 Fan Drive Housing Bore of housing for bearing 41.98 to 41.99 mm (1.6527 to 1.6531 in)

less than 14.25 14.25 to 20.125 20.125 to 25.50 over 25.50

Maximum limit (total indicator limit) mm in

1.253 ELECTRICAL EQUIPMENT 1.254 Alternator Type

Delco Remy or Motorola

1.255 Starter Motor Type

Delco Remy

1.256 Cold Start Aid Type

Diesel fuel, electrically operated heater

Voltage

12 volts

Fuel flow

3.5 to 5.9 millilitres/minute

TORQUE SPECIFICATIONS DESCRIPTION Cylinder Head Assembly Capscrews, Cylinder head (See 1.25 Installation) Fasteners, rocker arm brackets: to Aluminum to Cast iron Cap nuts, valve cover

Thread Size

TORQUE N.m lbf ft

1/2 UNF M12 M12 M12

40 75 20

30 55 15

1/2 UNF 1/2 UNF 3/8 UNF

125 155 27

92 114 20

5/8 UNF 7/16 UNF

265 115

196 85

M8 M8

35 18

26 13

Capscrews, hub of idler gear Capscrew, camshaft gear Capscrews, timing case cover to timing case Nuts, timing case cover to timing case

M8 M10 M10 M12 M8 M8

22 44 44 78 22 22

16 33 33 58 16 16

Turbocharger Nuts, turbocharger to manifold

M10

3/4 UNF M8 M8 M8

34 22 28 22

25 16 21 16

Fuel System Nuts, high to pressure fuel lines Capscrews, fuel injectors Capscrews, fuel pump Nut for gear for fuel injection pump Nuts for flange of fuel injection pump

M12 M8 M8 M14 M8

18 12 22 80 22

14 9 16 59 16

Cooling System Capscrews for fan drive housing to timing case Capscrews, fan drive pulley to hub Capscrews, fan

M10 M8 M10

44 22 44

33 16 33

1/2 UNF M10 M12

120 44 75

88 33 55

3/4 UNF 3/4 UNF M20

80 130 130

59 95 95

Piston And Connecting Rod Assemblies Nuts, connecting rods Capscrews, connecting rods Banjo bolts, piston cooling jets Crankshaft Assembly Capscrews, main bearings Capscrews, crankshaft pulley Capscrews, damper to crankshaft pulley Capscrews, rear oil seal housing to engine block Capscrews, rear oil seal housing to bridge piece Timing Case And Drive Assembly Capscrews, timing case to engine block

Lubrication System Plug, oil sump Capscrews, oil pump to front bearing cap Capcrews, cover for oil pump Fasteners, oil sump

Flywheel And Flywheel Housing Capscrews, flywheel to crankshaft Capscrews, flywheel housing to engine block Auxiliary Equipment Nuts for gears of auxiliary drive (hydraulic pump or compressor) 6.4 mm (0.25 in) thick nut 10 mm (0.4 in) thick nut

SPECIAL TOOLS PD.1D Remove and replace tool for valve guides.

PD.1D–1A Adaptor tool for use with PD.1D.

PD.1C–6 Adaptor tool for use with PD.1D and PD.1D–1A.

PD.41D Gauge for piston height, valve depth and cylinder liner flange; for use with PD.208.

PD.67–2 Drive adaptor for use with MS.67B.

PD.67–3 Gear adaptor for use with MS.67B.

PD.67–4 Pointer for use with MS.67B.

PD.145D Replacement tool for rear seal of crankshaft.

PD.150B Remove and replace tool for cylinder liner.

PD.150B–17 Adaptors for use with PD.150B.

PD.155B Puller for camshaft and fuel pump gears

PD.155B–5 Adaptors for use with PD.155B.

PD.163A Alignment tool for timing case cover.

PD.170 Replacement tool for seal of timing case cover.

PD.170–1 Pressure plate for use with PD.170.

PD.170–2 Fastener plate for use with PD.170.

PD.170–3 Sleeve for use with PD.170.

PD.170–4 Seal adaptor for use with PD.170.

PD.199 Spanner (wrench) for flange nuts of fuel injection pump.

PD.206 Replacement tool for pistons.

PD.208 Dial gauge for use with PD.41D.

PD.6118B Valve spring compressor.

PD.6118–7 Stud adaptor for use with PD.6118B.

PD.6118–8 Capscrew adaptor for use with PD.6118B.

MS67B Timing gauge.

MS.73A Set of adjustable cutters for valve seats.

MS.76B Handle set for valve seat cutters (also included in MS.73A).

MS.99 Gear puller for coolant pump.

MS.107 Gear adaptor for use with MS.67B. MS.150â&#x20AC;&#x201C;9.5 Adjustable pilot for valve seat cutters (also included in MS.73A). MS.275 Cutter for exhaust valve seats (also included in MS.73A).

MS.281 Cutter for exhaust valve seats (also included in MS.73A).

MS.1531 Angle gauge to tighten cylinder head capsrews.

SINGLE-SPEED POWERSHIFT TRANSMISSION DESCRIPTION AND OPERATION S3.50-5.50XL (S70-120XL) [D004]; S3.50-5.50XM (S70-120XM) [E004, F004]

PART NO. 897322

1300 SRM 399

Single-Speed Powershift Transmission

Table of Contents

TABLE OF CONTENTS General ............................................................................................................................................................... Mechanical Description ..................................................................................................................................... General ........................................................................................................................................................... Torque Converter ........................................................................................................................................... Oil Pump ........................................................................................................................................................ Shaft Assemblies ........................................................................................................................................... Input Shaft ................................................................................................................................................ Reverse Clutch Shaft ................................................................................................................................ Countershaft.............................................................................................................................................. Ring Gear, Pinion, and Differential.......................................................................................................... Clutch Assemblies ..................................................................................................................................... Hydraulic Operation .......................................................................................................................................... Torque Converter ........................................................................................................................................... Shaft Assemblies ........................................................................................................................................... Control Valve.................................................................................................................................................. General....................................................................................................................................................... System Regulator ...................................................................................................................................... Clutch Pressure Regulator........................................................................................................................ Torque Converter Regulator ..................................................................................................................... Inching Spool ............................................................................................................................................. Direction Spool, Manual Control .............................................................................................................. Direction Spool, MONOTROL Pedal........................................................................................................ Modulation Spool....................................................................................................................................... Accumulator............................................................................................................................................... Drain Spool ................................................................................................................................................ MONOTROL Pedal........................................................................................................................................ Control Valve.................................................................................................................................................. General....................................................................................................................................................... Regulator for Clutch Pressure .................................................................................................................. Inching Spool Assembly ............................................................................................................................ Direction Spool .......................................................................................................................................... Direction Spool, Manual Control .............................................................................................................. Modulator Circuit...................................................................................................................................... Regulator for Torque Convertor................................................................................................................ Lubrication Circuit ........................................................................................................................................ Direction Control Lever................................................................................................................................. MONOTROL Pedal........................................................................................................................................ Start Circuit, MONOTROL Pedal ............................................................................................................ Creep Speed Switch................................................................................................................................... Oil Flow Diagrams......................................................................................................................................... Neutral....................................................................................................................................................... Forward...................................................................................................................................................... Forward-Inching........................................................................................................................................ Reverse.......................................................................................................................................................

1 1 1 1 1 1 1 1 2 2 3 4 4 5 5 5 5 5 5 5 7 7 7 7 7 7 9 9 9 9 12 13 13 13 13 13 14 14 15 15 15 15 15 15

This section is for the following models: S3.50-5.50XL (S70-120XL) [D004]; S3.50-5.50XM (S70-120XM) [E004, F004]

1300 SRM 399

Mechanical Description

General This section contains description and operating principles of the single speed powershift transmission. There are two parts in this section. The first part describes mechanical components of the transmission. The second part describes hydraulic operation of the transmission.

Mechanical Description GENERAL The transmission has a housing, torque converter, oil pump, control valve, three shaft assemblies, ring gear, pinion, and differential assembly.

TORQUE CONVERTER The torque converter is installed between engine and transmission. See Figure 1. The torque converter has three main parts: impeller, turbine, and stator.

The impeller is connected to the flywheel of the engine by a flexible disc. A flange on the impeller engages with the oil pump for the transmission and operates the pump when the engine is running. The turbine fits inside the impeller and engages with the input shaft of the transmission. The stator also fits inside the impeller and engages with the stator tube on the transmission.

OIL PUMP The transmission has its own hydraulic system. An oil pump is installed on the cover of the transmission inside the torque converter housing. The oil pump is driven by the impeller of the torque converter. The transmission cover has passages for oil to flow to and from the oil pump.

SHAFT ASSEMBLIES The three shaft assemblies are: input shaft (with forward clutch assembly), reverse clutch shaft (with reverse clutch assembly), and countershaft. See Figure 2.

Input Shaft The input shaft is driven by the engine through the torque converter and rotates in the direction of engine rotation. The input shaft has the forward clutch assembly. The clutch is installed in the forward clutch housing and has a piston, friction discs, separator plates, pressure plate, and return spring. The teeth on the forward clutch housing are engaged with the teeth on the reverse clutch housing. The hub for the forward clutch is engaged with the countershaft gear. 1. 2. 3. 4.

TURBINE IMPELLER STATOR ONE DIRECTION CLUTCH

5. STATOR TUBE 6. TRANSMISSION INPUT SHAFT 7. PUMP DRIVE SHAFT

Figure 1. Torque Converter

Reverse Clutch Shaft The reverse clutch shaft is installed next to the input shaft. The teeth on the reverse clutch housing are engaged with the teeth on the forward clutch housing. During operation, the reverse clutch shaft rotates in the opposite direction of engine rotation. The reverse

Mechanical Description

1300 SRM 399

clutch assembly has a piston, friction discs, separator plates, pressure plate, and return spring. The hub for the reverse clutch is engaged with the countershaft gear.

Countershaft The countershaft connects the direction clutches to the pinion shaft. The small gear on the countershaft is engaged with the drive gear for the pinion. The

1. INPUT SHAFT 2. FORWARD CLUTCH

3. REVERSE CLUTCH 4. COUNTERSHAFT

pinion, in turn, drives the ring gear and differential assembly.

Ring Gear, Pinion, and Differential The ring gear and pinion provide a gear reduction and change the direction of the power flow. The differential permits the drive wheels to turn at different speeds when the lift truck is turning a corner.

5. OUTPUT GEAR 6. PINION

Figure 2. Shafts Arrangement

7. RING GEAR

1300 SRM 399

Mechanical Description

Clutch Assemblies The two clutch assemblies use similar parts and operate in the same manner. See Figure 3 and Figure 4. Friction discs and separator plates are installed in the housing in a sequence. Each friction disc is next to a separator plate. Separator plates have a smooth surface while the friction discs have a friction material on the surface. The hub in each clutch assembly engages with the inner splines of the friction discs. Outer splines of the separator plates engage with the grooves in the clutch housing.

Legend for Figure 3 1. 2. 3. 4. 5. 6. 7. 8.

INPUT SHAFT ASSEMBLY FORWARD CLUTCH HOUSING FORWARD CLUTCH ASSEMBLY FORWARD CLUTCH HUB REVERSE CLUTCH SHAFT ASSEMBLY REVERSE CLUTCH HOUSING REVERSE CLUTCH ASSEMBLY REVERSE CLUTCH HUB

A pressure plate holds the friction discs and separator plates in the housing. A return spring keeps the piston retracted against the housing. There is an orifice in each piston. The orifice releases any oil pressure in the piston housing caused by centrifugal force after the clutch is disengaged. There is enough clearance in the clutch assemblies to let the friction discs rotate freely when a clutch assembly is not engaged.

A. REVERSE

B. FORWARD

1. FORWARD CLUTCH HUB 2. COUNTERSHAFT 3. REVERSE CLUTCH HUB

4. FORWARD CLUTCH HOUSING 5. REVERSE CLUTCH HOUSING 6. OUTPUT GEAR

Figure 4. Clutch Assemblies Operation Figure 3. Clutch Assemblies

Hydraulic Operation

1300 SRM 399

Hydraulic Operation TORQUE CONVERTER The torque converter has two main functions. It works as a fluid clutch to transfer power from the engine to the transmission. Also, the torque converter multiplies torque. The torque of the engine is increased by the torque converter when additional torque is needed to move the lift truck. If the need for additional torque is low, the torque converter works as a fluid coupling. The impeller has a set of curved blades that send oil out from the center of the impeller when the impeller turns. Oil is moving at high speed when it leaves the impeller. Because the impeller is curved, oil flows into the outer edge of the turbine. Oil pushes the turbine in the direction of the engine rotation. Oil then flows from the outside to the center of the turbine. Turbine blades change direction of oil flow so that oil leaving the center of the turbine is going in the direction opposite of engine rotation. See Figure 5. The stator is between the turbine and impeller in the center of the torque converter. When oil hits the stator blades, the one-direction clutch prevents the stator from turning against engine rotation. See Figure 6. Blades of the stator change direction of oil so that oil enters the impeller in the direction of engine rotation. The stator permits the torque converter to increase the torque of the engine. Force of the oil entering the impeller from the stator helps the impeller and engine turn.

1. TURBINE

2. STATOR

As the speed of the lift truck increases, the oil from the turbine flows toward the impeller. The centrifugal force of the rotating turbine sends the oil that is in the turbine against the oil flow from the impeller. The oil moving in this direction decreases the amount of oil flow to the impeller from the stator. Because the oil flow to the impeller decreases, the additional force on the impeller decreases. Less torque is available as the speed of the lift truck increases. When the lift truck is traveling at a constant speed on a level surface, the turbine and impeller turn at approximately the same speed. The centrifugal force of the oil is the same for both the impeller and turbine. The oil does not flow through the stator and no additional torque is transferred. The rotating oil hits the back of the stator blades and turns the stator in the direction of engine rotation. The one-direction clutch permits the stator to turn with engine rotation. The impeller, turbine, stator, and oil rotate as a unit when there is no load on the turbine. When the lift truck starts up a ramp, the turbine has a resistance to turning. The centrifugal force of the oil in the turbine decreases. The oil again flows from the impeller through the turbine and stator and enters the impeller with force. The torque converter again increases torque when the turbine speed is less than the impeller speed.

3. IMPELLER

Figure 5. Oil Flow through Torque Converter

4. OIL FLOW

1300 SRM 399

Hydraulic Operation there are two manually operated spools in the control valve: an inching spool and plunger, and a direction spool. On units with a MONOTROLÂŽ pedal, the direction spool is actuated by oil from two solenoid valves installed on the control valve. On all units the inching plunger is actuated by the inching/brake pedal.

System Regulator The system regulator is a spool and spring assembly that keeps the oil pressure for the operation of the transmission at 1032 to 1312 kPa (150 to 190 psi). See Figure 8. The regulator receives oil from the oil pump before the oil goes through the oil filter. Oil that is diverted by the regulator goes to the lubrication circuits. 1. OUTER RACE 2. ROLLERS

3. SPLINES ON INNER RACE

Figure 6. One Direction Clutch

SHAFT ASSEMBLIES The input shaft and the reverse clutch shaft have oil passages that connect the clutch assemblies to the control valve and the lubrication circuit. Seal rings are installed on the shafts to make sure the oil flows to the correct passages. The oil flow to engage a clutch enters at the groove in the shaft. The oil flow for lubrication enters the ports at the end of the shaft. See Figure 4.

CONTROL VALVE NOTE: The information below applies to early model S3.50-5.50XL (S70-120XL) (D004) lift trucks.

General The control valve is installed on the top of the transmission housing. See Figure 7. Holes in the control valve gasket permit oil to flow from the valve body to passages in the transmission housing. The control valve has several regulators and spools to control the oil pressure and oil flow in the transmission. The control valve has the pressure regulators for: system pressure, clutch pressure, and torque converter pressure. The pressure regulators for the lubrication circuit are in the output end of the housing. The control valve uses three spools for modulation of oil pressure to the clutch assemblies. See Figure 8. These spools are: a drain spool, a modulation valve, and an accumulator. On units with a direction control lever,

Clutch Pressure Regulator Oil flows to the clutch pressure regulator after it goes through the oil filter. The regulator is a spool and spring assembly that keeps the oil pressure for the clutch assemblies at 827 to 965 kPa (120 to 140 psi). See Figure 8. The oil supply from the regulator flows to the inching spool. Oil that flows past the regulator goes to the torque converter circuit.

Torque Converter Regulator The torque converter regulator is a spool and spring assembly that controls the pressure in the circuit for the torque converter. See Figure 8. The regulator keeps the pressure at 765 to 903 kPa (111 to 131 psi). Oil for the regulator comes from the oil that goes past the clutch pressure regulator. The torque converter regulator sends excess oil flow to the lubrication circuit.

Inching Spool The inching spool controls the oil supply for the clutch assemblies. See Figure 8. The inching spool receives oil from the oil filter. The inching spool can control the oil pressure from 476 to 588 kPa (69 to 81 psi) to 0 kPa (0 psi). The inching plunger is connected to the inching pedal. The movement of the inching plunger lets the inching spool move in its bore. When the inching plunger and inching spool are fully retracted, oil flows around the spool without restriction. As the inching plunger extends from the bore, the inching spool makes a restriction

Hydraulic Operation

1300 SRM 399

in the oil flow to the direction spool. When the inching plunger is fully extended, the inching spool stops the flow of oil to the direction spool. At the same time, the inching spool opens a passage to the sump

1. VALVE BODY 2. CLAMP 3. FORWARD/REVERSE SOLENOIDS 4. ADAPTER 5. O-RING 6. ACCUMULATOR SPOOL 7. SPRING 8. PLUG AND O-RING 9. BRACKET 10. MANUAL CONTROL NEUTRAL START SWITCH 11. STEEL BALL 12. MONOTROL NEUTRAL START SWITCH

for the oil from the direction spool. On units with a MONOTROL pedal, the inching plunger actuates the neutral start switch when the plunger is fully extended.

13. FITTING 14. TUBE 15. MODULATOR REGULATOR SPOOL 16. TRIMMER SPOOL 17. QUICK DUMP VALVE 18. OIL SEAL 19. INCHING SPOOL PLUNGER 20. WASHER 21. INCHING SPOOL 22. MONOTROL DIRECTION SPOOL 23. INCHING SPOOL STOP 24. DIRECTION SPOOL PLUG 25. SNAP RING

26. SPRING CAP 27. MANUAL CONTROL DIRECTION SPOOL 28. SLOTTED PIN 29. PACK REGULATOR SPOOL 30. MODULATOR REGULATOR SPOOL 31. GASKET 32. FILTER 33. NUT

Figure 7. Control Valve - Early Model S3.50-5.50XL (S70-120XL) Lift Trucks

1300 SRM 399

Direction Spool, Manual Control This direction spool is actuated by the direction control lever. See Figure 8. The spool has three positions: FORWARD, NEUTRAL, and REVERSE. The spool is held in each position by a detent ball. The spool actuates the neutral start switch. The oil flow to the direction spool comes from the inching spool. There is no oil flow past the direction spool when the spool is in the NEUTRAL position. When the spool is moved to FORWARD or REVERSE, oil flows to the accumulator through the drain spool, the modulation spool and the forward or reverse clutch.

Direction Spool, MONOTROL Pedal NOTE: Applying the parking brake actuates a switch that de-energizes the Forward and Reverse solenoids. This direction spool is actuated by the oil flow from two solenoids installed on the top of the control valve. See Figure 8. The spool has three positions: FORWARD, NEUTRAL, and REVERSE. The spool is held in the NEUTRAL position by a spring arrangement. The oil flow to the Forward and Reverse solenoids comes from the inching spool. There is no oil flow past the direction spool when the spool is in the NEUTRAL position. When the spool is actuated by one of the solenoids, oil flows to the accumulator through the drain spool, the modulation spool, and the forward or reverse clutch.

Modulation Spool The modulation spool works with the drain spool orifice to control the movement of the accumulator. See Figure 8. The oil flow that goes through the drain spool also pressurizes the modulation spool. The oil pressure can push against the modulation spool to open the drain passage. Oil that is not needed for modulation of the clutch assemblies flows through the drain passage. Figure 9 shows the pressure change in the modulation circuit when a clutch is being applied.

Accumulator The accumulator is used to slow the ratio of clutch engagement. See Figure 8. This delay reduces the shock and stress to the drive train when engaging

Hydraulic Operation the transmission or changing the direction of travel. When a clutch is engaged, the oil flow for the clutch must go to the accumulator and fill the chamber. The time it takes for the accumulator to fill controls the time it takes for the clutch to engage.

Drain Spool The drain spool is a spool and spring assembly that controls the flow of oil to and from the accumulator. See Figure 8. When a direction change is occurring, oil flows through an orifice in the drain spool and then flows to the accumulator. As the chamber for the accumulator fills, the oil pressure is adjusted by the modulation spool. When a direction change first starts, pressure to the drain spool decreases. The spring pressure of the accumulator causes the accumulator spool to push the oil from the cavity. The oil from the accumulator pushes the drain spool against its spring, letting the oil flow to the drain circuit.

MONOTROL PEDAL NOTE: The information below for the MONOTROL pedal applies to early model S3.50-5.50XL (S70120XL) (D004) lift trucks. The MONOTROL pedal controls the speed of the engine and the operation of the direction spool. See Figure 10 and Figure 11. The pedal pad is held to the pedal frame by a pivot shaft. The pedal pad rotates on the shaft and is held in the FORWARD or REVERSE position by magnets in the pedal frame. There are two switches in the MONOTROL pedal assembly. A switch on the cowl is actuated by the parking brake lever. The operation of this switch controls the flow of battery power to the MONOTROL pedal switches and the starter circuit. When the parking brake is applied, the starter circuit is energized and the MONOTROL circuit is de-energized. When the parking brake is released, the MONOTROL circuit is energized and the starter circuit is de-energized. The engine can only be started after applying the parking brake or depressing the inching/brake pedal. When the MONOTROL pedal is in the FORWARD position, both pedal switch buttons are actuated. Battery power flows through both pedal switches to energize the Forward solenoid. When the MONOTROL pedal is in the REVERSE position, both pedal switch buttons are released. Battery power flows through both pedal switches to energize the Reverse solenoid.

Hydraulic Operation

1300 SRM 399

Figure 8. Hydraulic Arrangement of Transmission

1300 SRM 399

Hydraulic Operation Legend for Figure 8

1. OIL PUMP 2. FILTER 3. SYSTEM PRESSURE REGULATOR 4. CLUTCH REGULATOR 5. TORQUE CONVERTER REGULATOR

6. 7. 8. 9. 10. 11. 12.

TORQUE CONVERTER OIL COOLER COLD OIL RELIEF VALVE INCHING SPOOL FORWARD SOLENOID REVERSE SOLENOID DIRECTION SPOOL

13. DRAIN SPOOL 14. ACCUMULATION AND MODULATION SPOOL 15. INPUT SHAFT (FORWARD) 16. REVERSE CLUTCH SHAFT 17. LUBRICATION CIRCUIT

CONTROL VALVE NOTE: The information below applies to later model S3.50-5.50XL (S70-120XL) lift trucks and S3.50-5.50XM (S70-120XM) model lift trucks. See Figure 12.

General

1. CLUTCH DISENGAGES 2. OTHER CLUTCH FILLS WITH OIL 3. MODULATOR CONTROLS INCREASE IN OIL PRESSURE 4. OTHER CLUTCH ENGAGED Figure 9. Modulation Circuit Operation

The control valve is installed on the top of the transmission. The inching spool, direction spool, modulator circuit, regulator for clutch pressure, and the regulator for the torque converter are part of the control valve. The position of the inching spool is controlled by the inching/brake pedal. The oil filter for the transmission is also mounted on the control valve. A manifold with two solenoid valves is installed on top of the control valve. The solenoid valves are actuated by the direction control lever or the MONOTROL pedal. The solenoids control the position of the direction spool. See Figure 12.

Regulator for Clutch Pressure The regulator for clutch pressure controls oil pressure for applying clutches to engage the transmission. The control pressure of the regulator is 862 to 1048 kPa (125 to 152 psi). Oil that flows to the regulator for clutch pressure flows to the torque converter circuit and oil lubrication circuit. An orifice in the valve body and transmission case makes sure that there is always some oil flow to the torque converter.

Inching Spool Assembly

1. 2. 3. 4.

PEDAL PAD SWITCH SWITCH BUTTON MAGNET

5. PLATE FOR MAGNET 6. PEDAL FRAME

Figure 10. MONOTROL Pedal

Inching is the slow movement of a lift truck while a high engine speed is used for faster operation of the hydraulic system. Inching function is normally used for fine movements of the lift truck when handling a load. Operation of inching pedal decreases the oil pressure to a clutch so that the clutch is not completely applied.

Hydraulic Operation

1. 2. 3. 4.

1300 SRM 399

Wire

Color

Gauge

B E J K T W X CC FF LL HM PM XM

Red Yellow White Red Black Black Red Yellow Brown White Yellow Black Red

14 16 14 14 16 14 16 14 10 14 18 18 18

BATTERY STARTER IGNITION SWITCH PARKING BRAKE SWITCH

5. 6. 7. 8.

FUSE BRAKE PRESSURE SWITCH NEUTRAL START SWITCH MONOTROL PEDAL SWITCH

9. 10. 11. 12.

REVERSE SOLENOID FORWARD SOLENOID TO ALTERNATOR TO IGNITION SWITCH

Figure 11. MONOTROL Pedal Electrical Circuit (All Lift Truck Models)

1300 SRM 399

Hydraulic Operation

The inching spool assembly has an inching spool, inching spool plunger, and three springs. Oil flows to the inching spool from the transmission pump. The inching spool controls the oil flow and pressure to the direction spool. When inching function is not used, oil flows through the inching spool to the direction spool. Operation of the inching function causes a restriction of oil flow to the direction spool and the

1. VALVE BODY 2. PRESSURE REGULATOR TORQUE CONVERTER 3. PRESSURE REGULATOR CLUTCH 4. SPRING 5. PLUG AND O-RING 6. INCHING SPOOL PLUNGER

7. 8. 9. 10. 11. 12. 13. 14.

clutch. This operation decreases the oil pressure to the direction spool (and clutch) as the inching spool plunger is extended. When the inching spool plunger is completely extended, oil pressure to the direction spool (and clutch) is approximately zero. The clutch is then released and the transmission is in NEUTRAL. See Figure 12.

OIL SEAL FITTING COPPER GASKET SNAP RING SPRING CAP DIRECTION SPOOL INCHING SPOOL MODULATOR REGULATOR

15. 16. 17. 18. 19. 20. 21.

QUICK DUMP VALVE MODULATOR PISTON FORWARD SOLENOID REVERSE SOLENOID MANIFOLD TUBE GASKET

Figure 12. Control Valve - Later Model S3.50-5.50XL (S70-120XL) Trucks and S3.50-5.50XM (S70-120XM) Trucks

Hydraulic Operation

Direction Spool The direction spool controls oil flow to the direction clutches. See Figure 13. The direction spool has three positions: FORWARD, NEUTRAL, and REVERSE. When the direction spool is in its FORWARD position, oil flow and pressure is sent to apply the forward-low clutch. When the direction spool is in its REVERSE position, oil flow and pressure is sent to apply the reverse clutch. When the direction spool is in its NEUTRAL position, oil pressure to both clutches is reduced to approximately zero. Both clutches are released and the transmission is in NEUTRAL. When the direction spool is moved to control a direction of travel, oil flows to and from the clutch assemblies and also to the modulator circuit.

1300 SRM 399 Two electric solenoids control the position of the direction spool in the transmission control valve. Electric switches in the MONOTROL pedal or direction control lever energize and de-energize the solenoids. The solenoids open and close small valves that send oil flow to the ends of the direction spool. Only one solenoid is energized for each direction. When a direction solenoid is energized, the oil pressure to one end of the direction spool moves the direction spool so that a clutch is applied. Oil flow and pressure on the ends of the direction spool move the spool to either its FORWARD or REVERSE position.

Figure 13. Control Valve - Later Model S3.50-5.50XL (S70-120XL) Trucks and S3.50-5.50XM (S70-120XM) Trucks

1300 SRM 399

Hydraulic Operation Legend for Figure 13

1. TORQUE CONVERTER REGULATOR 2. CLUTCH PRESSURE REGULATOR 3. INCHING SPOOL WITH MONOTROL CONTROL 4. DIRECTION SPOOL, MONOTROL CONTROL 5. TRIMMER SPOOL 6. CONTROL VALVE BODY

7. TRIMMER REGULATOR SPRING 8. ACCUMULATOR SPRING 9. ACCUMULATOR SPOOL 10. SPRING 11. QUICK DUMP SPOOL 12. DIRECTION SPOOL, MANUAL CONTROL 13. INCHING SPRING 14. INCHING PLUNGER SPRING

Direction Spool, Manual Control This direction spool is actuated by the direction control lever. See Figure 13. The spool has three positions: FORWARD, NEUTRAL, and REVERSE. The spool is held in each position by a detent ball. The spool actuates the neutral start switch. The oil flow to the direction spool comes from the inching spool. There is no oil flow past the direction spool when the spool is in the NEUTRAL position. When the spool is moved to FORWARD or REVERSE, oil flows to the accumulator through the drain spool, the modulation spool and the forward or reverse clutch.

15. PACK REGULATOR SPOOL 16. SNAP RING 17. CONVERTER REGULATOR SPOOL 18. CONVERTER REGULATOR SPRING 19. PACK REGULATOR SPRING 20. INCHING STOP

the torque converter opens, oil that does not go to the torque converter flows directly to the passage to cool and lubricate the parts of the transmission. Oil that flows to the torque converter goes through the oil cooler before entering the passage to cool and lubricate the clutches. See Figure 13.

LUBRICATION CIRCUIT Oil supply for the lubrication circuit comes from oil that flows past the system regulator, torque converter regulator, and oil cooler. There is a lubrication circuit for each clutch assembly. The lubrication circuit supplies oil at 96 to 138 kPa (14 to 20 psi).

Modulator Circuit A modulator circuit is used to control the rate of application of the clutches. When the direction spool is moved to select a direction of travel, the modulator circuit controls the application of the clutch during a 1.5 to 2.0 second period. The modulator circuit controls the pressure increase to apply the clutch smoothly. This delay and smooth application of pressure reduces the shock and stress to the drive train when engaging the transmission or changing directions. See Figure 12.

Regulator for Torque Convertor When the engine speed is low, oil flows to the torque converter through an orifice in the bore in the clutch pressure regulator. The pressure regulator for the torque converter stays closed until the pressure to the torque converter increases to 765 to 903 kPa (111 to 131 psi). When the pressure regulator for

DIRECTION CONTROL LEVER NOTE: The information in the following paragraph applies to S3.50-5.50XM (S70-120XM) (E004, F004) model trucks only. The direction control lever is used to control operation of direction solenoids. See Figure 14. When the lift truck has a direction control lever, an accelerator pedal is used to control the speed of the engine. The control lever actuates two switches. In the NEUTRAL position, both of the switches are closed. The lever must be in this position to start the lift truck. When the lever is moved to the FORWARD position, the forward switch is open and the reverse switch is closed. In this position the forward solenoid is energized. In the REVERSE position, the reverse switch is open and the forward switch is closed, energizing the circuit for the reverse solenoid.

Hydraulic Operation

1300 SRM 399 direction solenoids. When both of the solenoid valves close (de-energized), the centering spring moves the direction spool to the NEUTRAL position.

1. CONTROL LEVER 2. FORWARD SWITCH

3. SWITCH ACTUATOR 4. REVERSE SWITCH

Figure 14. Direction Control Lever

MONOTROL PEDAL NOTE: The information below for the MONOTROL pedal applies to later model S3.50-5.50XL (S70120XL) (D004) lift trucks and to S3.50-5.50XM (S70-120XM) (E004, F004) model lift trucks. The MONOTROL pedal controls speed of the engine and operation of direction solenoids. See Figure 11, Figure 15, and Figure 16. The pedal pad is held to the pedal frame by a pivot shaft. The pedal pad rotates on the shaft and is held in the FORWARD or REVERSE position by magnets in the pedal frame. There are two switches in the MONOTROL pedal assembly. When the MONOTROL pedal is in the FORWARD position, both pedal switch buttons are actuated. Battery power flows through both pedal switches to energize the forward solenoid. When the MONOTROL pedal is in the REVERSE position, both pedal switch buttons are released. Battery power flows through both pedal switches to energize the reverse solenoid.

Start Circuit, MONOTROL Pedal For units with a MONOTROL pedal there are two switches on the bracket for the parking brake lever. The switch on the right-hand side of the bracket supplies power to the direction solenoids. When the parking brake is applied the switch de-energizes the

1. 2. 3. 4.

PEDAL PAD PEDAL FRAME MAGNET PIVOT SHAFT

5. SPRING 6. MAGNET PLATE 7. SWITCH

Figure 15. MONOTROL Pedal S3.50-5.50XL (S70-120XL) (Later Model) Lift Trucks The switch on the left-hand side of the bracket prevents the engine from starting unless the parking brake is applied. When inching/brake pedal is fully depressed, service brakes are applied and a disc on the end of the inching spool actuates the neutral start switch. Neutral start switch is in series electrically with pressure switch in the brake system. The disc actuates the neutral start switch and pressure in the brake system closes the brake switch. The pressure switch in the brake system makes sure that brakes are applied. When neutral start switch and brake switch are both closed, start circuit, controlled by ignition switch, can be energized. When inching/brake pedal is fully pushed down, oil pressure to the clutch pack is reduced to zero. This operation makes sure that

1300 SRM 399

Hydraulic Operation

the transmission clutch is disengaged and brakes are applied when the engine is started.

through Figure 20 apply to early model S3.50-5.50XL (S70-120XL) (D004) lift trucks. The diagrams shown in Figure 21 through Figure 24 apply to later model S3.50-5.50XL (S70-120XL) (D004) lift trucks and to S3.50-5.50XM (S70-120XM) (E004, F004) lift trucks.

Neutral When engine is running and transmission is in NEUTRAL, the oil pump supplies oil to the following regulators: system regulator, clutch regulator, inching spool, and forward and reverse solenoids or direction spool. See Figure 17 or Figure 21, depending on your model of lift truck.

Forward When the direction spool is moved to the FORWARD position, oil from the inching spool flows past the direction spool. See Figure 18 or Figure 22. Oil then flows to the drain spool, modulation spool, forward clutch, and lubrication regulator for the forward clutch. Oil flow at the clutch assembly pushes on the piston to engage the clutch.

Forward-Inching 1. 2. 3. 4.

PEDAL PAD PEDAL FRAME MAGNET PIVOT SHAFT

5. SPRING 6. MAGNET PLATE 7. SWITCH

Figure 16. MONOTROL Pedal S3.50-5.50XM (S70-120XM) Lift Trucks

Creep Speed Switch NOTE: The creep speed switch is an optional feature on S3.50-5.50XM (S70-120XM) model lift trucks. A switch is installed on the accelerator or MONOTROL pedal to slow movement of the lift truck at idle speed. When the accelerator or MONOTROL pedal is not applied, the switch opens the electric circuit to the transmission controller. As the pedal is depressed, the switch closes, energizing direction solenoids.

OIL FLOW DIAGRAMS NOTE: The following information applies to all lift truck models. The diagrams shown in Figure 17

Pushing on the inching/brake pedal while lift truck is moving decreases oil pressure to the direction spool. See Figure 19 or Figure 23, depending on your model of lift truck. Pressure in the accumulator shifts the drain spool so that some oil from the accumulator flows to the drain passage. Decrease in oil pressure that engages the forward clutch lets the clutch partially disengage. Clutch completely disengages when inching plunger is fully extended. Inching operation lets operator move the lift truck slowly while keeping a high engine speed for hydraulic functions.

Reverse As the direction spool moves for a direction change, it opens the drain circuit for the forward clutch and the accumulator. Oil in the accumulator chamber pushes against the drain valve and flows to the drain passage. When the direction spool is in REVERSE position, the drain passages for the accumulator are closed. See Figure 20 or Figure 24. Oil from the inching spool fills the accumulator chamber and engages the reverse clutch.

Hydraulic Operation

1300 SRM 399

Figure 17. Hydraulic Schematic for Neutral MONOTROL Control S3.50-5.50XL (S70-120XL) (Early Model)

1300 SRM 399

Hydraulic Operation Legend for Figure 17

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

TRANSMISSION HOUSING OIL PUMP CONTROL VALVE OIL FILTER TORQUE CONVERTER OIL COOLER COLD OIL RELIEF SYSTEM REGULATOR CLUTCH REGULATOR TORQUE CONVERTER REGULATOR INCHING SPOOL DIRECTION SPOOL FORWARD CLUTCH

14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25.

REVERSE CLUTCH FORWARD SOLENOID REVERSE SOLENOID MODULATION SPOOL ACCUMULATOR DRAIN SPOOL MODULATION CHECK PORT LUBRICATION PRESSURE CHECK PORT FORWARD CLUTCH CHECK PORT REVERSE CLUTCH CHECK PORT TORQUE CONVERTER CHECK PORT SYSTEM PRESSURE CHECK PORT

Hydraulic Operation

1300 SRM 399

Figure 18. Hydraulic Schematic for Forward MONOTROL Control S3.50-5.50XL (S70-120XL) (Early Model)

1300 SRM 399

Hydraulic Operation Legend for Figure 18

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25.

Hydraulic Operation

1300 SRM 399

Figure 19. Hydraulic Schematic for Forward-Inching MONOTROL Control S3.50-5.50XL (S70-120XL) (Early Model)

1300 SRM 399

Hydraulic Operation Legend for Figure 19

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25.

Hydraulic Operation

1300 SRM 399

Figure 20. Hydraulic Schematic for Reverse MONOTROL Control S3.50-5.50XL (S70-120XL) (Early Model)

1300 SRM 399

Hydraulic Operation Legend for Figure 20

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25.

Hydraulic Operation

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

TORQUE CONVERTER OIL COOLER TORQUE CONVERTER REGULATOR CLUTCH PRESSURE REGULATOR QUICK DUMP VALVE MODULATOR CHECK PORT MODULATOR REGULATOR INCHING SPOOL DIRECTION SPOOL REVERSE SOLENOID FORWARD SOLENOID

1300 SRM 399

12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.

REVERSE CLUTCH FORWARD CLUTCH REVERSE CHECK PORT FORWARD CHECK PORT PUMP PRESSURE CHECK PORT PUMP SCREEN PUMP RELIEF VALVE OIL FILTER TORQUE CONVERTER CHECK PORT LUBRICATION PRESSURE CHECK PORT

Figure 21. Hydraulic Schematic for Neutral S3.50-5.50XL (S70-120XL) and S3.50-5.50XM (S70-120XM) (Later Model)

1300 SRM 399

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

Hydraulic Operation

12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.

REVERSE CLUTCH FORWARD CLUTCH REVERSE CHECK PORT FORWARD CHECK PORT PUMP PRESSURE CHECK PORT PUMP SCREEN PUMP RELIEF VALVE OIL FILTER TORQUE CONVERTER CHECK PORT LUBRICATION PRESSURE CHECK PORT

Figure 22. Hydraulic Schematic for Forward S3.50-5.50XL (S70-120XL) and S3.50-5.50XM (S70-120XM) (Later Model)

Hydraulic Operation

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

1300 SRM 399

12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.

REVERSE CLUTCH FORWARD CLUTCH REVERSE CHECK PORT FORWARD CHECK PORT PUMP PRESSURE CHECK PORT PUMP SCREEN PUMP RELIEF VALVE OIL FILTER TORQUE CONVERTER CHECK PORT LUBRICATION PRESSURE CHECK PORT

Figure 23. Hydraulic Schematic for Forward-Inching S3.50-5.50XL (S70-120XL) and S3.50-5.50XM (S70-120XM) (Later Model)

1300 SRM 399

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

Hydraulic Operation

12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.

REVERSE CLUTCH FORWARD CLUTCH REVERSE CHECK PORT FORWARD CHECK PORT PUMP PRESSURE CHECK PORT PUMP SCREEN PUMP RELIEF VALVE OIL FILTER TORQUE CONVERTER CHECK PORT LUBRICATION PRESSURE CHECK PORT

Figure 24. Hydraulic Schematic for Reverse S3.50-5.50XL (S70-120XL) and S3.50-5.50XM (S70-120XM) (Later Model)

SINGLE-SPEED POWERSHIFT TRANSMISSION TROUBLESHOOTING AND REPAIR S3.50-5.50XL (S70-120XL) [D004]; S3.50-5.50XM (S70-120XM) [E004, F004]

PART NO. 897308

1300 SRM 397

Single-Speed Powershift Transmission

Table of Contents

TABLE OF CONTENTS General ............................................................................................................................................................... Transmission Repair .......................................................................................................................................... Remove ........................................................................................................................................................... Disassemble ................................................................................................................................................... Transmission, Disassemble....................................................................................................................... Input Shaft, Disassemble.......................................................................................................................... Reverse Clutch, Disassemble.................................................................................................................... Output Shaft (Pinion) and Differential, Remove and Disassemble........................................................ Clean and Inspect .......................................................................................................................................... Assemble ........................................................................................................................................................ Input Shaft, Assemble............................................................................................................................... Reverse Clutch, Assemble......................................................................................................................... Output Shaft (Pinion) and Differential, Assemble and Install............................................................... Transmission, Assemble............................................................................................................................ Control Valve, Install ................................................................................................................................ Install ............................................................................................................................................................. Control Valve Repair.......................................................................................................................................... Remove, Early Model S3.50-5.50XL (S70-120XL) Lift Trucks .................................................................... Disassemble, Early Model S3.50-5.50XL (S70-120XL) Lift Trucks ............................................................ Assemble, Early Model S3.50-5.50XL (S70-120XL) Lift Trucks ................................................................. Install, Early Model S3.50-5.50XL (S70-120XL) Lift Trucks ...................................................................... Remove and Disassemble, Later Model S3.50-5.50XL (S70-120XL) Trucks and S3.50-5.50XM (S70-120XM) Lift Truck Models.................................................................................................................... Inspect, Later Model S3.50-5.50XL (S70-120XL) Trucks and S3.50-5.50XM (S70-120XM) Lift Truck Models.................................................................................................................................................. Assemble and Install, Later Model S3.50-5.50XL (S70-120XL) Trucks and S3.50-5.50XM (S70-120XM) Lift Truck Models.................................................................................................................... MONOTROL® Pedal Repair .............................................................................................................................. Remove and Disassemble, S3.50-5.50XL (S70-120XL) Model Lift Trucks ................................................. Assemble and Install, S3.50-5.50XL (S70-120XL) Model Lift Trucks ........................................................ Remove and Disassemble, S3.50-5.50XM (S70-120XM) Model Lift Trucks ............................................... Assemble and Install, S3.50-5.50XM (S70-120XM) Model Lift Trucks ...................................................... Direction Control Lever Repair......................................................................................................................... Remove and Disassemble .............................................................................................................................. Assemble and Install ..................................................................................................................................... Stall Test............................................................................................................................................................. Linkages Adjustment......................................................................................................................................... Linkage for Inching/Brake Pedal, S3.50-5.50XL (S70-120XL) (D004) Lift Truck Models......................... Linkage for Direction Control Lever ............................................................................................................ Linkage for Inching/Brake Pedal, S3.50-5.50XM (S70-120XM) (E004, F004) Lift Truck Models ............ Brake Shoe Adjustment ............................................................................................................................ Inching/Brake Pedal Height Adjustment................................................................................................. Single Pedal Height Adjustment.......................................................................................................... Two Pedal Height Adjustment ............................................................................................................. Inching/Brake Linkage Adjustment......................................................................................................... Oil Pressures Check........................................................................................................................................... System Pressure Check Port......................................................................................................................... Torque Converter Check Port ....................................................................................................................... Clutch Pressure Check Port.......................................................................................................................... Inching Pressure............................................................................................................................................ Solenoid Check Ports (MONOTROL Control Only).....................................................................................

1 1 1 2 2 3 5 8 10 10 11 19 24 31 34 34 35 35 35 36 36 36 39 39 41 41 42 44 44 46 46 46 47 48 48 50 50 50 50 50 50 52 54 54 54 55 55 57

Table of Contents

Single-Speed Powershift Transmission

TABLE OF CONTENTS (Continued) Lubrication Pressure Check Ports................................................................................................................ System Pressure Check Port......................................................................................................................... Torque Converter Check Port ....................................................................................................................... Reverse Clutch Pressure Check Port............................................................................................................ Forward Clutch Pressure Check Port........................................................................................................... Lubrication Pressure Check Port ................................................................................................................. Modulator Pressure Check Port.................................................................................................................... Troubleshooting.................................................................................................................................................. This section is for the following models: S3.50-5.50XL (S70-120XL) [D004]; S3.50-5.50XM (S70-120XM) [E004, F004]

57 57 57 57 57 57 57 58

1300 SRM 397

Transmission Repair

General This section contains the repair procedures and troubleshooting table for the parts of the transmission assembly.

Transmission Repair REMOVE Remove engine, transmission, and torque converter as an assembly as follows: 1. Put lift truck on blocks. See Periodic Maintenance section for correct procedures to put lift truck on blocks. Remove cover between hood and counterweight. Remove overhead guard, hood, and hood cross bar. Remove floor plates. 2. Disconnect cables at battery. Remove battery and battery tray. 3. Remove radiator, fan, and fan shroud. Disconnect exhaust pipe at the exhaust headers. Remove air filter housing from frame. 4. Disconnect fuel lines at engine. Disconnect throttle linkage at engine. Disconnect wires and wiring harnesses at engine. 5. Disconnect hydraulic line between hydraulic filter and hydraulic tank. Put plugs in open holes and move filter toward cowl. Disconnect oil lines at hydraulic pump. Drain hydraulic tank and put plugs on open ports. 6. Remove accelerator or MONOTROLÂŽ pedal assembly. Remove brake pedal shaft. Disconnect lines at brake booster and remove brake booster and bracket. 7. Disconnect inching linkage at transmission. On lift trucks with manual control, disconnect direction control linkage at transmission. Disconnect supply line at main control valve and put a plug on supply line.

8. Drain oil from axle housing. Remove capscrews that hold axle shafts to hubs. Remove axle shafts. 9. Connect lifting device to engine and transmission. Make sure lifting device is holding weight of engine and transmission. Remove bolts that hold engine mounts to frame of lift truck. 10. Remove clamp for parking brake cable at bottom of transmission. Remove capscrews that hold drive axle housing to transmission housing. There are two holes with threads in drive axle housing. Use capscrews in these holes to separate housings. 11. Carefully lift engine and transmission from frame. Put engine in a position so it is stable and will not fall over. 12. Remove access cover in torque converter housing. Remove capscrews that hold drive plate to flywheel. Use a wire to hold torque converter to transmission. 13. Put straps around transmission and connect lifting device to straps. Make sure lifting device is holding weight of transmission. Remove capscrews that hold torque converter housing to flywheel housing. There are two holes in torque converter housing with threads. Use capscrews in these holes to push torque converter housing from flywheel housing. Remove transmission from engine, making sure torque converter does not fall from transmission. Also check that bearing for pump drive gear is out of torque converter housing.

Transmission Repair

1300 SRM 397

DISASSEMBLE Transmission, Disassemble Disassemble the transmission as follows: STEP 1. Remove torque converter from input shaft. Remove torque converter housing from transmission. Remove oil pump only for inspection or replacement. If oil pump is worn or damaged, it must be replaced as an assembly.

1. TORQUE CONVERTER HOUSING 2. OIL PUMP STEP 2. Put transmission in vertical position. Remove capscrews holding cover to transmission housing. Remove cover from housing. Do not damage seal ring on input shaft. Pull shaft assemblies from housing. Pull countershaft first, then the reverse clutch shaft, and the input shaft. Be careful not to damage seal rings on ends of shafts.

1. 2. 3. 4. 5. 6.

TRANSMISSION HOUSING SEAL RING INPUT SHAFT COUNTERSHAFT REVERSE CLUTCH SHAFT OUTPUT GEAR

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Transmission Repair

Input Shaft, Disassemble Disassemble input shaft as follows: NOTE: Keep parts for each clutch assembly together. Do not mix parts between shaft assemblies. If original friction discs and separator plates are going to be installed again, be sure to keep them in the same sequence. STEP 1. Put clutch housing in vise. Remove seal ring from shaft. Pull bearing from shaft. Remove snap ring that holds bearing for hub on shaft. Remove clutch hub from shaft.

1. 2. 3. 4.

INPUT SHAFT SEAL RING BEARING CLUTCH HUB

1. 2. 3. 4.

HUB BEARING SNAP RING SPACER

STEP 2. If necessary, remove bearings, snap rings, and spacer from hub.

Transmission Repair

1300 SRM 397

STEP 3. Remove snap ring for pressure plate. Remove pressure plate. Remove separator plates and friction discs. For lift trucks with Exedy clutch assemblies, remove the conical plate, then remove the separator plates and friction discs.

NOTE: The conical plate is used only on lift trucks with Exedy clutch assemblies. 1. SNAP RING 2. PRESSURE PLATE 3. SEPARATOR PLATES, FRICTION DISCS AND CONICAL PLATE STEP 4. Remove piston only if there is a problem with piston or seals. Use two bars to push down on spring retainer. Remove snap ring for retainer. Remove retainer, spring, and piston.

1. 2. 3. 4. 5.

PRY BAR SNAP RING SPRING RETAINER SPRING PISTON

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Transmission Repair

STEP 5. Remove seal rings from shaft. Remove bearing from shaft.

1. SEAL RING 2. BEARING

Reverse Clutch, Disassemble Disassemble reverse shaft as follows: STEP 1. Put clutch housing in vise. Pull bearing from shaft. Remove snap ring that holds bearing for hub on shaft. Remove clutch hub from shaft.

1. BEARING 2. SNAP RING 3. HUB

Transmission Repair

1300 SRM 397

STEP 2. If necessary, remove bearings, snap rings, and spacer from hub.

1. 2. 3. 4.

HUB BEARING SNAP RING SPACER

NOTE: The conical plate is used only on lift trucks with Exedy clutch assemblies. 1. SNAP RING 2. PRESSURE PLATE 3. SEPARATOR PLATES, FRICTION DISCS AND CONICAL PLATE

1300 SRM 397

Transmission Repair

STEP 4. Remove piston only if there is a problem with piston or seals. Use two bars to push down on spring retainer. Remove snap ring for retainer. Remove retainer, spring, and piston.

1. 2. 3. 4. 5.

PRY BAR SNAP RING SPRING RETAINER SPRING PISTON

STEP 5. Remove seal rings from shaft. Remove bearing from shaft.

1. SEAL RING 2. BEARING

Transmission Repair

1300 SRM 397

Output Shaft (Pinion) and Differential, Remove and Disassemble Remove output shaft (pinion) as follows: STEP 1. Loosen nut that holds output gear on shaft.

1. OUTPUT GEAR 2. NUT 3. OUTPUT SHAFT (PINION) STEP 2. If the same parts for the differential (bearings and gears) are going to be installed again, check ring gear and pinion clearance. Use the procedures described in section Transmission, Assemble. Also, when removing adjustment rings, count the number of turns it takes to remove each adjustment ring. Use the number of turns during the assembly procedures to put adjustment rings in the same position.

1. RING GEAR 2. DIAL INDICATOR

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Transmission Repair

STEP 3. Make identification marks with a punch on bearing caps, adjustment rings, and housing. Bearing caps and adjustment rings must be assembled in the same position in the housing. See STEP 4. Remove lock plates that hold adjustment rings in position.

1. BEARING CAP 2. ADJUSTMENT RING 3. LOCK PLATE STEP 4. Loosen four capscrews for bearing caps. If necessary, remove adjustment rings as described in STEP 3. Remove bearing caps, adjustment rings, and bearing cups. Remove ring gear and differential assembly.

1. BEARING CAP 2. RING GEAR 3. DIFFERENTIAL

Transmission Repair

1300 SRM 397

STEP 5. Remove nut and output gear from output shaft. Remove output shaft and bearings from housing.

1. 2. 3. 4. 5. 6. 7. 8.

CLEAN AND INSPECT WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the recommendations of the manufacturer. 1. Clean parts of transmission with solvent. Make sure all passages in housing, cover, and shafts are clean. Clean gasket material from transmission housing, cover, and control valve. 2. Check edges of seal rings for wear or grooves. Check bore for seal rings for grooves. 3. Inspect bearings for damaged or worn rollers. Check bearing cups and thrust washers for worn surfaces or cracks. Check bearing surfaces of shafts for wear or damage. 4. Check all gears and shafts for damaged teeth or splines. 5. Inspect friction discs for burned lining. Check that friction discs still have grooves in lining.

OUTPUT SHAFT (PINION) SHIM BEARING CONE BEARING CUP SPACER OIL SEAL OUTPUT GEAR NUT

When new, grooves have a minimum depth of 0.38 mm (0.015 in.). On lift trucks without Exedy clutch assemblies, replace friction discs when depth of grooves is less than 0.13 mm (0.005 in.). On lift trucks with Exedy clutch assemblies, replace friction discs when depth of grooves is less than 2.2 mm (0.087 in.). NOTE: The conical plate is used only on lift trucks with Exedy clutch assemblies. 6. Check separator plates and conical plate to ensure they are not bent and do not have burned areas on them. Inspect teeth on separator plates and friction discs for damage. 7. Check pistons and bores for scratches.

ASSEMBLE NOTE: Lubricate all parts with clean transmission fluid during assembly. If removed, install output shaft before installing clutch assemblies. See Output Shaft (Pinion) and Differential, Assemble and Install.

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Transmission Repair

Input Shaft, Assemble Assemble input shaft (forward clutch) as follows (see Figure 1 and Figure 2): STEP 1. Lubricate and install O-ring for piston on shaft. Lubricate and install piston seal on piston. Make sure lip of seal is away from clutch plates. Use another ring (large O-ring) to hold piston seal in position for 5 minutes. Install piston in clutch housing for forward clutch.

1. 2. 3. 4.

O-RING SHAFT PISTON PISTON SEAL

Transmission Repair

1300 SRM 397

STEP 2. Install spring and spring retainer. Use two bars to hold spring retainer and install snap ring on shaft.

1. 2. 3. 4.

PISTON PRY BAR SPRING RETAINER SNAP RING

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Transmission Repair

STEP 3. Install separator plates and friction discs alternately in clutch housing. Start with a separator plate against piston. There are eight separator plates and eight friction discs for clutch assembly. Install pressure plate and snap ring. For lift trucks with Exedy clutch assemblies, install the conical plate with the cone side pressing against the piston.

A. LIFT TRUCKS WITHOUT EXEDY CLUTCH ASSEMBLIES B. LIFT TRUCKS WITH EXEDY CLUTCH ASSEMBLIES 1. 2. 3. 4. 5.

SEPARATOR PLATE FRICTION DISC PRESSURE PLATE SNAP RING CONICAL PLATE

Transmission Repair

1300 SRM 397

NOTE: Use this check only to make sure all friction discs and separator plates have been installed. Do not use this dimension to check for wear in clutch parts. Clearance dimension is only for new parts. The procedure in STEP 4 applies only to trucks without Exedy clutch assemblies. For lift trucks with Exedy clutch assemblies, go to STEP 5. STEP 4. Use a dial indicator to check clearance within clutch assembly. Hold pressure plate down and set gauge at zero. Use air pressure to move piston and engage clutch assembly. Check distance that pressure plate moves. With new parts installed, correct clearance (movement of the needle) in clutch assembly is 2.26 to 3.81 mm (0.089 to 0.150 in.).

1. PRESSURE PLATE 2. DIAL INDICATOR STEP 5. Install snap rings for bearings in hub. Install spacer and bearings in hub. Make sure seals in bearings are toward outside of hub (away from each other).

1. 2. 3. 4.

HUB BEARING SNAP RING SPACER

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Transmission Repair

STEP 6. Install hub on shaft. Make sure teeth on hub align with all friction discs. Install snap ring on shaft.

1. HUB 2. SNAP RING STEP 7. Install bearings on both ends of shaft. Install seal rings on shaft. Make sure ends of seal rings are connected together.

1. BEARINGS 2. SEAL RINGS

Transmission Repair

1. 2. 3. 4. 5. 6.

HUB PRESSURE PLATE FRICTION DISC SEPARATOR PLATE SNAP RING SPRING RETAINER

1300 SRM 397

7. 8. 9. 10. 11. 12.

SPRING PISTON PISTON SEAL CLUTCH HOUSING SEAL RING BEARING

Figure 1. Input (Forward) Clutch Assembly, Lift Trucks Without Exedy Clutch Assemblies

Figure 2. Input (Forward) Clutch Assembly, Lift Trucks With Exedy Clutch Assemblies

1300 SRM 397

Transmission Repair Legend for Figure 2

1. 2. 3. 4. 5. 6. 7. 8.

HUB PRESSURE PLATE FRICTION DISC SEPARATOR PLATE SNAP RING SPRING RETAINER SPRING PISTON

9. 10. 11. 12. 13. 14. 15. 16.

PISTON SEAL CLUTCH HOUSING SEAL RING BEARING CONICAL PLATE SPACER SEAL RING O-RING

1. 2. 3. 4. 5. 6.

HUB PRESSURE PLATE FRICTION DISC SEPARATOR PLATE SNAP RING SPRING RETAINER

7. 8. 9. 10. 11. 12.

SPRING PISTON PISTON SEAL CLUTCH HOUSING BEARING SEAL RING

Figure 3. Counter (Reverse) Clutch Assembly, Lift Trucks Without Exedy Clutch Assemblies

Transmission Repair

1. 2. 3. 4. 5. 6. 7.

HUB PRESSURE PLATE FRICTION DISC SEPARATOR PLATE SNAP RING SPRING RETAINER SPRING

1300 SRM 397

8. 9. 10. 11. 12. 13. 14.

PISTON PISTON SEAL CLUTCH HOUSING BALL BEARING SPACER CONICAL PLATE O-RING

Figure 4. Counter (Reverse) Clutch Assembly, Lift Trucks With Exedy Clutch Assemblies

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Transmission Repair

Reverse Clutch, Assemble Assemble reverse clutch assembly as follows (see Figure 3 and Figure 4): STEP 1. Lubricate and install O-ring for piston on shaft. Lubricate and install piston seal on piston. Make sure lip of seal is away from clutch plates. Use another ring (large O-ring) to hold piston seal in position for 5 minutes. Install piston in clutch housing.

1. 2. 3. 4.

O-RING SHAFT PISTON PISTON SEAL

Transmission Repair

1300 SRM 397

STEP 2. Install spring and spring retainer. Use two bars to hold spring retainer and install snap ring on shaft.

1. 2. 3. 4.

PISTON PRY BAR SPRING RETAINER SNAP RING

1300 SRM 397

Transmission Repair

A. LIFT TRUCKS WITHOUT EXEDY CLUTCH ASSEMBLIES B. LIFT TRUCKS WITH EXEDY CLUTCH ASSEMBLIES 1. 2. 3. 4. 5.

SEPARATOR PLATE FRICTION DISC PRESSURE PLATE SNAP RING CONICAL PLATE

Transmission Repair

1300 SRM 397

NOTE: Use this check only to make sure all friction discs and separator plates have been installed. Do not use this dimension to check for wear in clutch parts. Clearance dimension is only for new parts. The procedure in STEP 4 applies only to lift trucks without Exedy clutch assemblies. For lift trucks with Exedy clutch assemblies, go to STEP 5. STEP 4. Use a dial indicator to check clearance within the clutch assembly. Hold pressure plate down and set gauge at zero. Use air pressure to move piston and engage clutch assembly. Check distance that pressure plate moves. With new parts installed, correct clearance (movement of the needle) in clutch assembly is 2.26 to 3.81 mm (0.089 to 0.150 in.).

1. PRESSURE PLATE 2. DIAL INDICATOR STEP 5. Install snap rings for bearings in hub. Install spacer and bearings in hub. Make sure seals in bearings are toward outside of hub (away from each other).

1. 2. 3. 4.

HUB BEARING SNAP RING SPACER

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Transmission Repair

STEP 6. Install hub on shaft. Make sure teeth on hub align with all friction discs. Install snap ring on shaft.

1. HUB 2. SNAP RING STEP 7. Install bearings on both ends of shaft. Install seal rings on shaft. Make sure ends of seal rings are connected together. If pinion was not removed, proceed to Transmission, Assemble. If pinion needs to be installed, proceed to Output Shaft (Pinion) and Differential, Assemble and Install.

1. BEARINGS 2. SEAL RINGS

Transmission Repair

1300 SRM 397

Output Shaft (Pinion) and Differential, Assemble and Install Assemble and install output shaft (pinion) and differential as follows: STEP 1. Lubricate and install an axle gear and thrust washer in the differential case. Put spider gears and thrust washers on the spider. Put spider and gears in case. Install second axle gear and thrust washer. Align punch marks and put two halves of differential case together. Use a thread locking compound (Hyster Part No. 257291) on capscrews. Use four capscrews at equal places. Check that differential gears rotate correctly. Install remaining capscrews and tighten all capscrews to 140 N•m (105 lbf ft). If ring gear was removed from differential case, it must be heated in water before installation. Heat ring gear in water to 82 to 105 C (180 to 220 F) for 10 minutes. Remove ring gear from water and put it on differential case. Do not use a press or a hammer to install ring gear on differential case. Tighten capscrews to 65 N•m (50 lbf ft) according to pattern shown. Tighten capscrews to 140 N•m (105 lbf ft) according to pattern. Install bearing cones on differential case.

1. 2. 3. 4.

AXLE GEAR THRUST WASHER SPIDER GEAR DIFFERENTIAL CASE HALF

5. SPIDER 6. RING GEAR 7. BEARING CONE

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Transmission Repair

STEP 2. If the same ring and pinion and pinion bearings are to be installed again, use the same shim and spacer arrangement that was removed. If a new ring gear and pinion or new bearings must be installed, see the instructions in STEP 3 for installation of a new pinion assembly.

1. 2. 3. 4. 5. 6. 7. 8.

PINION BEARING CONE BEARING CUP SHIM SPACER OUTPUT GEAR NUT OIL SEAL

STEP 3. Install bearing cups for pinion in transmission housing. Do not install oil seal at this time. Install shims on pinion. Use a press to install bearing cone on pinion. Install pinion in transmission housing. Install spacer, shim, and bearing cone on pinion. Install output gear and nut. NOTE: The special nut for the output gear can be used only once. The installation and removal of the special nut several times can damage the threads on the pinion. When making adjustments, use a nut with tapered end removed. When adjustment is correct, install new nut. STEP 4. Tighten nut for output gear to 750 Nâ&#x20AC;˘m (550 lbf ft). Check rotating torque of pinion caused by preload on bearings. The limits are 1.7 to 3.4 Nâ&#x20AC;˘m (15 to 30 lbf in). Add or remove shims between spacer and bearing cone near output gear to adjust bearing preload. When adjustment is correct, check adjustment of ring gear and pinion as described in STEP 5 through STEP 12. STEP 5. The ring gear and pinion are made in sets. Both the ring gear and pinion must have the same number. The adjustments of the ring gear and pinion are correct when the gear clearance, contact pattern, and bearing preload are correct. STEP 6. The dimension on the end of the pinion is the variation from the standard Gauge Distance. The Gauge Distance is the distance from the center of the ring gear to the bearing shoulder behind the pinion. Shims must be added between the pinion and the outer bearing cone to adjust for manufacturing tolerances.

Transmission Repair

1300 SRM 397

STEP 7. Look at the number on the pinion that was removed. Subtract the variation number that is on the new pinion. The remainder is the amount of shim thickness that must be adjusted from the shim set on the pinion that was removed (see table below). In examples 3 and 4, you can see that shims must be added. Examples 1 and 2 show that shims must be subtracted from the original shim set. Use this shim set as a reference. The final adjustment of the shims is set according to the contact pattern on the teeth of the ring gear. See Ring and Pinion Tooth Contact Adjustment.

Shims Adjustment Examples Number on OLD PINION Number on (NEW PINION) SHIMS TO BE REMOVED FROM OR ADDED TO THE OLD SET

+0.31 (+0.26)

+0.31 ( 0.26)

+0.26 (+0.31)

0.26 (+0.31)

0.05 mm REMOVE

0.57 mm REMOVE

0.05 mm ADD

0.57 mm ADD

STEP 8. Install parts for pinion, and check and adjust bearing preload as described in STEP 4. Make sure oil seal is installed and nut is tightened to 750 Nâ&#x20AC;˘m (550 lbf ft) when adjustments are correct. Install differential assembly, bearing cups, adjustment rings, and bearing caps. Align marks on bearing caps with marks on housing. Only tighten capscrews for bearing caps so adjustment rings can be installed, held in alignment, and rotated for adjustment.

1300 SRM 397

Transmission Repair

STEP 9. Tighten adjustment rings to 15 Nâ&#x20AC;˘m (133 lbf in) to remove clearance between adjusting rings and bearings. Make sure there is clearance between ring gear and pinion. Loosen adjustment rings only until there is zero clearance between the bearings and adjusting nuts. Tighten one adjustment ring four notches more than zero clearance to put a preload on bearings.

1. RING GEAR 2. ADJUSTMENT RING 3. BEARING CAP STEP 10. Check clearance between ring gear and pinion. Ring gear and pinion must have a clearance of 0.25 to 0.33 mm (0.010 to 0.013 in.). Move ring gear toward pinion to decrease clearance. Move ring gear away from pinion to increase clearance. Loosen adjustment ring on opposite side the same amount, while the other adjustment ring is tightened, to adjust clearance between ring gear and pinion.

1. 2. 3. 4.

RING GEAR ADJUSTMENT RING BEARING CAP DIAL INDICATOR

Transmission Repair

1300 SRM 397

STEP 11. Check contact pattern of gear teeth as shown in Ring and Pinion Tooth Contact Adjustment. Apply grease to teeth of ring gear. Put a pry bar between ring gear and housing to keep ring gear from turning freely. Turn pinion. Compare pattern with Ring and Pinion Tooth Contact Adjustment. Adjust gear clearances as necessary. STEP 12. Install lock plates for adjustment rings. Tighten capscrews to 20 Nâ&#x20AC;˘m (177 lbf in). Install thrust bolt. Tighten thrust bolt until it touches ring gear. Loosen bolt until there is 0.39 to 0.50 mm (0.015 to 0.020 in.) clearance between bolt and ring gear. Tighten lock nut.

1. THRUST BOLT 2. LOCK NUT 3. RING GEAR

1300 SRM 397

Transmission Repair Table 1. Ring and Pinion Tooth Contact Adjustment

1. Apply a colored dye or grease to approximately 12 of the ring gear teeth. 2. Rotate ring gear forward and backward so that the 12 gear teeth go past the drive six times to get to the contact patterns. Repeat if needed to get a clearer pattern. 3. Check the tooth contact pattern on the ring gear. Make sure that the pattern is checked on the side of the tooth where the pinion applies the force.

Correct Tooth Contact The contact area is the center between the top and bottom of the tooth. The contact area is toward the inner circumference of the ring gear.

NOTE: Normal pattern during adjustment shown.

The contact area is the center between the top and the bottom of the tooth. The contact area will be almost the full length of the tooth.

NOTE: Wear pattern from operation shown.

Transmission Repair

1300 SRM 397

Table 1. Ring and Pinion Tooth Contact Adjustment (Continued) Incorrect Tooth Contact The pinion is too far away from the center of the gear. Add shims to move pinion toward ring gear. Check that the clearance is correct. Some movement of ring gear away from pinion may be necessary.

The pinion is too close to the center of the ring gear. Remove shims to move pinion away from the ring gear. Check that the clearance is correct. Some movement of the ring gear toward the pinion may be necessary.

1300 SRM 397

Transmission Repair

Transmission, Assemble STEP 1. Put transmission housing in vertical position. Install input shaft, reverse clutch shaft, and countershaft. Be careful not to damage seal rings on ends of each shaft. Clean flanges of housing and cover. Apply a sealant (Hyster Part No. 264159) to flange of housing and install cover. Make sure seal ring on input shaft is not damaged. Tighten capscrews for cover to 40 Nâ&#x20AC;¢m (30 lbf ft). Install cold oil relief valve and spring in cover. Make sure other plugs are installed.

1. 2. 3. 4. 5. 6.

TRANSMISSION HOUSING SEAL RING INPUT SHAFT COUNTERSHAFT REVERSE CLUTCH SHAFT OUTPUT GEAR

Transmission Repair

1300 SRM 397

STEP 2. Install oil pump with O-ring and stator tube on housing. Tighten capscrews for oil pump to 40 Nâ&#x20AC;¢m (30 lbf ft).

1. 2. 3. 4. 5.

OIL PUMP ASSEMBLY TRANSMISSION COVER STATOR TUBE O-RING INPUT SHAFT

1300 SRM 397

Transmission Repair

STEP 3. Install oil strainer, spring, and plug in housing. Install sending unit in housing.

1. PLUG 2. SPRING 3. SENDING UNIT STEP 4. Install torque converter housing on transmission. Apply a sealant (Hyster Part No. 264159) to flange of transmission cover. Tighten capscrews for housing to 40 Nâ&#x20AC;¢m (30 lbf ft).

1. TORQUE CONVERTER

Transmission Repair

1300 SRM 397

Control Valve, Install Install the control valve as described in the section Control Valve Repair.

INSTALL 1. Install torque converter in transmission. Make sure teeth on torque converter are engaged with notches in oil pump. Use wire to hold torque converter in position. See Transmission, Assemble, STEP 4. 2. Put lifting straps around transmission and connect lifting device to straps. Use a sealant (Hyster Part No. 264159) on flange of torque converter housing. Remove wire from torque converter. Align torque converter housing with flywheel housing, making sure pilot on torque converter engages with flywheel. See Figure 5. Also check that bearing for drive gear of hydraulic pump is aligned with torque converter housing. 3. Install capscrews holding torque converter housing to flywheel housing. Tighten capscrews to 40 N•m (30 lbf ft). 4. Install capscrews that hold drive plate for torque converter to flywheel. Tighten capscrews to 45 N•m (35 lbf ft). Install access cover on torque converter housing. See Figure 5. 5. Connect lifting device to engine and transmission. Clean flanges on transmission housing and axle housing. Apply a sealant (Hyster Part No. 264159) to flange of transmission housing. 6. Install engine and transmission in lift truck. Carefully align transmission with axle housing. Install capscrews that hold axle housing to transmission. Tighten capscrews to 65 N•m (50 lbf ft). Install bolts for engine mounts. Tighten bolts to 120 N•m (90 lbf ft). 7. Install radiator, fan, and fan shroud. Connect radiator hoses and oil lines at radiator. Make sure all hoses are kept away from lower fan pulley. 8. Install brake booster. Connect oil lines to brake booster. Connect brake lines to master cylinder. Connect wires to brake switch on master cylinder. Connect oil lines to main control valve and transmission control valve.

1. TORQUE CONVERTER 2. DRIVE PLATE

3. FLYWHEEL 4. TORQUE CONVERTER HOUSING

Figure 5. Torque Converter 9. Install inching linkage and direction control linkage at transmission. Install inching/brake pedal shaft. Install accelerator or MONOTROL pedal. 10. Connect wiring harness and wires at engine and transmission. Connect throttle linkage and fuel lines at engine. Install and connect exhaust system. 11. Connect hydraulic lines for hydraulic pump and hydraulic filter. 12. Install battery tray and batteries. Install air filter assembly. 13. Check all fluid levels and fill as necessary. Remove air from brake system. Install floor plates and covers. Install hood. Install overhead guard. Connect cables at the battery.

1300 SRM 397

Control Valve Repair

Control Valve Repair REMOVE, EARLY MODEL S3.50-5.50XL (S70-120XL) LIFT TRUCKS NOTE: The procedures described below for removing the control valve pertain to early model S3.50-5.50XL (S70-120XL) (D004) lift trucks. To remove the control valve for later model S3.50-5.50XL (S70-120XL) (D004) lift trucks and for S3.50-5.50XM (S70-120XM) (E004, F004) lift trucks, see the Remove and Disassemble, Later Model S3.50-5.50XL (S70-120XL) Trucks and S3.50-5.50XM (S70-120XM) Lift Truck Models section. 1. Disconnect linkages at spools. Disconnect wires at switch on control valve. Disconnect return line for oil cooler at control valve.

Model S3.50-5.50XL (S70-120XL) Trucks and S3.50-5.50XM (S70-120XM) Lift Truck Models section. NOTE: Make sure the area for disassembling the control valve is clean. Keep parts from each bore together.

WARNING The springs behind the plugs in the control valve can release quickly when the plugs are removed. Be careful when disassembling the control valve. 1. Remove stop for inching plunger and direction spool (manual control). See Figure 7.

2. Remove oil filter from control valve. If transmission has a MONOTROL pedal, remove solenoid assemblies. Remove capscrews holding control valve to transmission. See Figure 6.

1. CONTROL VALVE 2. OIL FILTER 3. REVERSE SOLENOID

4. FORWARD SOLENOID 5. NEUTRAL START SWITCH

Figure 6. Control Valve With MONOTROL Control

DISASSEMBLE, EARLY MODEL S3.50-5.50XL (S70-120XL) LIFT TRUCKS NOTE: The procedures described below for disassembling the control valve pertain to early model S3.50-5.50XL (S70-120XL) (D004) lift trucks. To disassemble the control valve for later model S3.50-5.50XL (S70-120XL) (D004) lift trucks and for S3.50-5.50XM (S70-120XM) (E004, F004) lift trucks, see Remove and Disassemble, Later

1. STOP FOR INCHING PLUNGER 2. WASHER FOR INCHING SPOOL Figure 7. Control Valve Stops

Control Valve Repair 2. Remove detent ball assemblies and neutral start switch. Remove inching plunger and direction spool (manual control) from control valve. See Figure 6. 3. Remove plugs for pressure regulators, and remove regulator assemblies. Remove plug for direction spool (MONOTROL pedal) and remove spool. 4. Push on inching spool and remove washer from inching spool as shown in Figure 7. Remove inching spool and spring. 5. Clean surface of control valve. Make sure passages and orifices in valve body and spools are clean.

ASSEMBLE, EARLY MODEL S3.50-5.50XL (S70-120XL) LIFT TRUCKS NOTE: The procedures described below for assembling the control valve pertain to early model S3.505.50XL (S70-120XL) (D004) lift trucks. To assemble the control valve for later model S3.50-5.50XL (S70-120XL) (D004) lift trucks and for S3.50-5.50XM (S70-120XM) (E004, F004) lift trucks, see Assemble and Install, Later Model S3.50-5.50XL (S70-120XL) Trucks and S3.50-5.50XM (S70-120XM) Lift Truck Models section. Lubricate parts of control valve with clean transmission oil during assembly. See Figure 6. Make sure all spools move freely in their bores. Install O-rings on plugs for the spools. 1. Install regulator for torque converter and regulator for system pressure. Regulators are the same but springs are different. Spring for system relief regulator is longer. Install O-rings and plugs. 2. Install clutch pressure regulator and spring. Install accumulator spool and springs. Install O-rings and plugs. 3. Install spring and inching spool in bore. Install washer over end of spool. Install spring over end of inching spool. Install spring for inching plunger and inching plunger. 4. Install stop for inching plunger (see Figure 7). Install seal for inching plunger. 5. Install drain spool and spring. Install modulation spool and spring. Install O-rings and plugs. 6. Install direction spool as follows:

1300 SRM 397 a. For valves with solenoids, install washers, spring, and snap ring on spool. Install spool and plug in valve body. b. For valves with manual control, install spool in valve body. Install stop pin, making sure it is below the surface of the valve body. Install neutral start switch and detent ball assembly. Install seal for spool.

INSTALL, EARLY MODEL S3.50-5.50XL (S70-120XL) LIFT TRUCKS NOTE: The procedures described below for installing the control valve pertain to early model S3.50-5.50XL (S70-120XL) (D004) lift trucks. To install the control valve for later model S3.50-5.50XL (S70-120XL) (D004) lift trucks and for S3.50-5.50XM (S70-120XM) (E004, F004) lift trucks, see Assemble and Install, Later Model S3.50-5.50XL (S70-120XL) Trucks and S3.50-5.50XM (S70-120XM) Lift Truck Models section. 1. Make sure surfaces of transmission and control valve are clean. Install gasket, making sure holes align with transmission. See Figure 6. 2. Install gasket and control valve on transmission housing. Install all capscrews for control valve. Tighten capscrews in the pattern of a circle, beginning at center of valve body. Tighten capscrews to 20 Nâ&#x20AC;˘m (177 lbf in). 3. Install solenoid assemblies. Make sure O-rings and backup rings are installed correctly. Install tube at reverse solenoid. 4. Connect return line for oil cooler at fitting on control valve. Connect wires to switch and solenoids at control valve. Connect inching linkage and direction control linkage at control valve. Adjust linkages as described in Linkages Adjustment.

REMOVE AND DISASSEMBLE, LATER MODEL S3.50-5.50XL (S70-120XL) TRUCKS AND S3.50-5.50XM (S70-120XM) LIFT TRUCK MODELS NOTE: The removal and disassembly procedures described below pertain to later model S3.50-5.50XL (S70-120XL) lift trucks and S3.50-5.50XM (S70120XM) lift truck models. To remove and disassemble the control valve for early model S3.50-5.50XL

1300 SRM 397

Control Valve Repair

(S70-120XL) lift trucks, see section Remove, Early Model S3.50-5.50XL (S70-120XL) Lift Trucks and section Disassemble, Early Model S3.50-5.50XL (S70-120XL) Lift Trucks.

1. VALVE BODY 2. PRESSURE REGULATOR, TORQUE CONVERTER 3. PRESSURE REGULATOR, CLUTCH 4. SPRING 5. PLUG AND O-RING 6. INCHING SPOOL PLUNGER 7. OIL SEAL

8. 9. 10. 11. 12. 13. 14. 15. 16.

1. Clean area around control valve. See Figure 8. Remove transmission oil filter. Disconnect inching linkage at control valve. Remove capscrews holding brake pedal bracket to frame.

FITTING COPPER GASKET SNAP RING SPRING CAP DIRECTION SPOOL INCHING SPOOL MODULATOR REGULATOR QUICK DUMP VALVE MODULATOR PISTON

17. 18. 19. 20. 21. 22. 23. 24. 25.

FORWARD SOLENOID REVERSE SOLENOID MANIFOLD TUBE GASKET PIN STOP FOR INCHING SPOOL FITTING SEAL KIT

Figure 8. Control Valve

Control Valve Repair 2. Put identification tags on wires at solenoids and disconnect them. Remove manifold from control valve. Remove tube for direction spool. 3. Remove capscrews and control valve from transmission. Remove control valve. Cover top of transmission to keep dirt out. See Figure 9.

1300 SRM 397 plugs so that the compressed springs do not cause injury. 5. Remove cap for direction spool. Remove direction spool. 6. Remove clip used for the stop from under the inching spool. See Figure 8 and Figure 10. Remove inching spool plunger and spring. Push inching spool against its spring and remove retainer washer from bottom of control valve. See Figure 11 and Figure 12. 7. Carefully remove plug for modulator piston. Remove modulator piston, springs, and modulator regulator. See Figure 8. 8. Carefully remove plug for clutch pressure regulator. Remove spool and spring. See Figure 8. 9. Carefully remove plug for pressure regulator and torque converter. Remove spring and spool. 10. Carefully remove plug for the modulator valve. Remove spool and spring. See Figure 8.

1. MANIFOLD AND DIRECTION SOLENOIDS 2. CONTROL VALVE Figure 9. Control Valve Arrangement 4. Remove solenoids from manifold.

WARNING There are compressed springs under the plugs in the control valve. Carefully remove the

1. STOP FOR INCHING PLUNGER 2. WASHER FOR INCHING SPOOL Figure 10. Control Valve Stops

1300 SRM 397

1. 2. 3. 4. 5. 6.

INCHING/BRAKE PEDAL CONTROL VALVE MICROSWITCH INCHING LINKAGE CRANK LOCK NUT

Control Valve Repair

7. 8. 9. 10. 11.

SPRING LINK FLANGE BEARING BALL JOINT TEST PORT

Figure 11. Inching Linkage, Later Model S3.50-5.50XL (S70-120XL) Lift Trucks

INSPECT, LATER MODEL S3.50-5.50XL (S70-120XL) TRUCKS AND S3.50-5.50XM (S70-120XM) LIFT TRUCK MODELS 1. Make sure there are no scratches or damage on spools or in bores.

(S70-120XL) lift trucks and S3.50-5.50XM (S70120XM) lift truck models. To assemble and install the control valve for early model S3.50-5.50XL (S70-120XL) lift trucks, see section Assemble, Early Model S3.50-5.50XL (S70-120XL) Lift Trucks and section Install, Early Model S3.50-5.50XL (S70-120XL) Lift Trucks.

2. Make sure springs are not bent or damaged. 3. Make sure spools move freely in their bores.

Lubricate parts of control valve with clean transmission oil during assembly.

4. Make sure the orifices in the modulator valve and valve body at the clutch pressure regulator are clean.

1. Install spool and spring for pressure regulator and torque converter. Install plug with new O-ring. See Figure 8.

ASSEMBLE AND INSTALL, LATER MODEL S3.50-5.50XL (S70-120XL) TRUCKS AND S3.50-5.50XM (S70-120XM) LIFT TRUCK MODELS

2. Install spool and spring for clutch pressure regulator. Install plug with new O-ring.

NOTE: The assembly and installation procedures described below pertain to later model S3.50-5.50XL

3. Install modulator regulator and springs. Install small plug for modulator regulator. Install modulator piston and install large plug with new O-ring.

Control Valve Repair

1300 SRM 397

A. TOP VIEW

B. FRONT VIEW

1. 2. 3. 4. 5. 6.

7. 8. 9. 10. 11.

LINK LINKAGE TO INCHING SPOOL INCHING CRANK CONTROL VALVE MICRO SWITCH SPRING

FLANGED MOUNTING BRACKET NEUTRAL START DISK COTTER AND ROD END PINS INCHING SPOOL RETAINER WASHERS

Figure 12. Inching Linkage, S3.50-5.50XM (S70-120XM) Lift Truck Models 4. Install spring and modulator valve. Install plug. 5. Install new oil seal. Install spring, inching spool, and washer. Install two springs and inching plunger. Install clip used for inching plunger stop. See Figure 8 and Figure 10. 6. Install spring, spring caps, and snap ring on direction spool. Install direction spool in bore. Install fitting and copper washer for direction spool. 7. Use new O-rings and install solenoids in manifold.

8. Install control valve on transmission. See Figure 9. Install gasket and manifold. Tighten capscrews for control valve and manifold to 19 Nâ&#x20AC;¢m (168 lbf in). Make sure ground wires for solenoids are installed with capscrew for manifold. Connect tube assembly to direction spool fitting. 9. Connect wires to solenoids and switches. Connect linkage to inching spool. See Figure 11 and Figure 12.

MONOTROL® Pedal Repair

1300 SRM 397

MONOTROL® Pedal Repair REMOVE AND DISASSEMBLE, S3.50-5.50XL (S70-120XL) MODEL LIFT TRUCKS

1. Disconnect wiring harness at transmission. Remove capscrew that holds pedal to bracket. Remove pedal. See Figure 13.

NOTE: For the procedures to remove and disassemble the MONOTROL pedal for S3.50-5.50XM (S70120XM) (E004, F004) model lift trucks, go to Remove and Disassemble, S3.50-5.50XM (S70-120XM) Model Lift Trucks section.

2. Remove straps holding wiring harness to the pedal. Loosen setscrews in pedal pad three to four turns and remove pivot pin. Remove pedal pad and spring.

A. GASOLINE UNITS B. LPG AND DIESEL UNITS

C. DIESEL UNITS D. GASOLINE AND LPG UNITS

1. 2. 3. 4.

5. BLACK (FORWARD SOLENOID) 6. RED (BATTERY) 7. YELLOW (REVERSE SOLENOID)

PEDAL PAD LINK CRANK PEDAL FRAME

Figure 13. MONOTROL Pedal

MONOTROLÂ® Pedal Repair

1300 SRM 397

3. Remove retainer for wiring harness. Loosen screws for switches, then remove switches and wiring harness. 4. If necessary, remove lock nuts for magnets, then remove magnets from pedal frame.

ASSEMBLE AND INSTALL, S3.50-5.50XL (S70-120XL) MODEL LIFT TRUCKS NOTE: For the procedures to assemble and install the MONOTROL pedal for S3.50-5.50XM (S70-120XM) (E004, F004) model lift trucks, go to Assemble and Install, S3.50-5.50XM (S70-120XM) Model Lift Trucks section. NOTE: The switches and wiring harness must be replaced as an assembly.

1. 2. 3. 4.

PEDAL PAD SWITCH SURFACE OF MOUNT SURFACE OF SWITCH Figure 14. MONOTROL Pedal Switches

1. Install switches and wiring harness in pedal pad. See Figure 13. Align surface of switches with alignment surface of mount in pedal pad. Switches must be even with or below alignment surface as shown in Figure 14. Install retainer for wiring harness.

2. Install wiring harness through hole in pedal frame. Install spring and pedal pad on pedal frame. Install pivot pin. Apply a thread locking compound to setscrews. Install and tighten setscrews. Use straps to hold wiring harness to pedal frame.

A. FORWARD

B. REVERSE

1. LOCK NUT 2. MAGNET 3. PLATE

4. DIAL INDICATOR 5. PEDAL FRAME 6. PEDAL PAD Figure 15. MONOTROL Pedal Adjustment

MONOTROL® Pedal Repair

1300 SRM 397 3. Check and adjust pedal assembly (see Figure 15) as follows: a. Put pedal assembly in vise. Use dial indicator to measure movement of pedal pad. b. Push on REVERSE side of pedal. Place dial indicator on the REVERSE side of pedal pad as shown in Figure 15. Loosen lock nut and rotate screw for magnet counterclockwise until it stops. Set dial indicator to zero. Rotate screw for magnet clockwise until gauge needle moves 0.25 mm (0.01 in.) from zero. This adjustment makes sure magnet is in contact with plate in pedal pad. Rotate screw for magnet counterclockwise until gauge needle indicates zero. Rotate screw for magnet clockwise until gauge needle indicates 0.05 mm (0.002 in.) movement. Tighten lock nut to 5.2 N•m (46 lbf in) without changing adjustment. c. Push on FORWARD side of pedal. Place dial indicator on FORWARD side of pedal pad as shown in Figure 15. Loosen lock nut and rotate screw for magnet counterclockwise until it stops. Set dial indicator to zero. Rotate screw for magnet clockwise until gauge needle moves 0.25 mm (0.01 in.) from zero. This adjustment makes sure magnet is in contact with plate in pedal pad. Rotate screw for magnet counterclockwise until gauge needle indicates zero. Rotate screw for magnet clockwise until gauge needle indicates 0.05 mm (0.002 in.) movement. Tighten lock nut to 5.2 N•m (46 lbf in) without changing adjustment.

Pedal must move 1.00 mm (0.039 in.) minimum from FORWARD position before circuit is disconnected. 4. Use a dial indicator as shown in Figure 15. With pedal pad in either FORWARD or REVERSE position, check total amount of travel to opposite direction. Minimum amount of travel of pedal pad is 2.0 mm (0.079 in.). If pedal cannot be adjusted to obtain this dimension, replace pedal pad. 5. Test strength of magnets as follows (see Figure 16):

WARNING It is important for the correct operation of the MONOTROL pedal that the magnets have the correct strength. a. Place pedal assembly in vise. Use spring scale to change pedal from FORWARD and REVERSE positions. b. When pushing on spring scale, it must take 13.3 to 31.1 kg (29 to 69 lb) to change from FORWARD to REVERSE and REVERSE to FORWARD positions. If force is not within specifications, replace magnet(s). 6. Install capscrew, washers, tube, and nut that hold pedal assembly to bracket. Connect link between pedal and crank as shown in Figure 13. 7. Install pedal return springs. Make sure throttle cable is connected as shown in Figure 13.

1. PEDAL PAD

2. SPRING SCALE

Figure 16. MONOTROL Pedal Magnets Check

MONOTROLÂŽ Pedal Repair

1300 SRM 397

REMOVE AND DISASSEMBLE, S3.50-5.50XM (S70-120XM) MODEL LIFT TRUCKS NOTE: For the procedures to remove and disassemble the MONOTROL pedal for S3.50-5.50XL (S70120XL) (D004) model lift trucks, go to Remove and Disassemble, S3.50-5.50XL (S70-120XL) Model Lift Trucks section. 1. Disconnect wires at transmission. Remove capscrew that holds pedal to bracket, then remove pedal. See Figure 17. 2. Remove straps that hold wires to pedal. Loosen setscrews in pedal pad three to four turns and remove pivot pin. Remove pedal pad and spring. 3. Remove retainer for wires. Loosen screws for switches. Remove switches and wires. 4. If necessary, remove lock nuts for magnets, then remove magnets from pedal frame. Make sure screws are tight in magnets. Use a thread locking compound on screws if they are loose in magnets.

ASSEMBLE AND INSTALL, S3.50-5.50XM (S70-120XM) MODEL LIFT TRUCKS NOTE: For the procedures to assemble and install the MONOTROL pedal for S3.50-5.50XL (S70-120XL) (D004) model lift trucks, go to Assemble and Install, S3.50-5.50XL (S70-120XL) Model Lift Trucks section.

1. 2. 3. 4.

PEDAL PAD PEDAL FRAME MAGNET PIVOT SHAFT

5. SPRING 6. MAGNET PLATE 7. SWITCH

Figure 17. MONOTROL Pedal, S3.50-5.50XM (S70-120XM) Lift Trucks

2. Place wires through hole in pedal frame. Install spring and pedal pad on pedal frame. Install pivot pin. Apply a thread locking compound to setscrews. Install and tighten setscrews. Use straps to hold wires to pedal frame.

b. Push REVERSE side of pedal. Place dial indicator on REVERSE side of pedal pad as shown in Figure 15. Loosen lock nut and rotate screw for magnet counterclockwise until it stops. Set dial indicator to zero. Rotate screw for magnet clockwise until gauge needle moves 0.25 mm (0.01 in.) from zero. This adjustment makes sure magnet is in contact with plate in pedal pad. Rotate screw for magnet counterclockwise until gauge needle indicates zero. Rotate screw for magnet clockwise until gauge needle indicates 0.05 mm (0.002 in.) movement. Tighten lock nut to 5.2 Nâ&#x20AC;˘m (46 lbf in) without changing adjustment.

3. Perform the following procedure to check and adjust pedal assembly (see Figure 15):

c. Push on FORWARD side of pedal. Place dial indicator on FORWARD side of pedal pad as

NOTE: These sealed switches can only be replaced as an assembly. 1. Install switches and wires in pedal pad. See Figure 17. Align surface of switches with machined surface of mount in pedal pad. Switches must be even with or below alignment surface as shown in Figure 14. Install retainer for wires.

a. Place pedal assembly in vise. Use dial indicator to measure movement of pedal pad.

MONOTROL® Pedal Repair

1300 SRM 397 shown in Figure 15. Loosen lock nut and rotate screw for magnet counterclockwise until it stops. Set dial indicator to zero. Rotate screw for magnet clockwise until gauge needle moves 0.25 mm (0.01 in.) from zero. This adjustment makes sure magnet is in contact with plate in pedal pad. Rotate screw for magnet counterclockwise until gauge needle indicates zero. Rotate screw for magnet clockwise until gauge needle indicates 0.05 mm (0.002 in.) movement. Tighten lock nut to 5.2 N•m (46 lbf in) without changing adjustment.

(0.079 in.) is still not obtained, replace pedal pad. 6. Install capscrew, washers, tube, and nut that hold pedal assembly to bracket. Connect link between pedal and crank as shown in Figure 18. 7. Install pedal return springs. Make sure throttle cable is connected to correct position as shown in Figure 18.

d. Use an ohmmeter to check operation of switches. When FORWARD side of pedal is depressed, there must be a complete circuit between red (battery) and black (forward solenoid) wires. When REVERSE side of pedal is depressed, there must be a complete circuit between red (battery) and yellow (reverse solenoid) wires. e. Push on FORWARD side of pedal. Place dial indicator on FORWARD side of pedal pad as shown. Connect an ohmmeter between red and black wires. Check that there is a complete circuit between wires. Push on REVERSE side of pedal. Pedal must move 1.00 mm (0.039 in.) minimum from FORWARD position before circuit is disconnected. NOTE: It is important for correct operation of MONOTROL pedal that magnets have correct strength. 4. Test strength of magnets as follows (see Figure 16): a. Place pedal assembly in vise. Use spring scale to change pedal from FORWARD and REVERSE positions as shown in Figure 16. b. When pushing on spring scale, it must take 13.3 to 31.1 N (3.6 to 7.0 lbf) to change from FORWARD to REVERSE and REVERSE to FORWARD positions. If force is not within specifications, replace magnet(s). 5. With pad located in either FORWARD or REVERSE, check to assure a minimum of 2.0 mm (0.079 in.) total pad travel when changed to opposite position. If 2.0 mm (0.079 in.) is not obtained, do adjustment again. If 2.0 mm

A. GASOLINE TRUCKS B. LPG/DIESEL TRUCKS 1. PEDAL PAD 2. PEDAL FRAME 3. PEDAL RETURN STOP 4. LINK 5. CAPSCREW 6. CRANK 7. SWITCH CONNECTOR

8. REVERSE SOLENOID (WHITE WIRE) 9. FORWARD SOLENOID (GREEN WIRE) 10. BATTERY (RED WIRE)

Figure 18. MONOTROL Pedal, S3.50-5.50XM (S70-120XM) Lift Trucks

Direction Control Lever Repair

1300 SRM 397

Direction Control Lever Repair REMOVE AND DISASSEMBLE NOTE: The information contained below on removing and disassembling the direction control lever applies only to S3.50-5.50XM (S70-120XM) (E004, F004) lift truck models. 1. Remove steering wheel. 2. Remove back cover from steering column. 3. Disconnect wires at switches for direction control lever. See Figure 19. Make sure wires have identification tags for correct installation.

3. Use capscrews and install control lever assembly and switches on steering housing. 4. Connect wires to switches. 5. Start lift truck and operate direction control lever in FORWARD and REVERSE to make sure lever operates correctly. 6. Install back cover on steering housing. Install steering wheel. Tighten nut for steering wheel to 40 to 54 N•m (30 to 40 lbf ft).

4. Remove capscrews that hold bracket for control lever to steering housing. Remove control lever assembly and switches. 5. Disassemble control lever assembly as necessary.

ASSEMBLE AND INSTALL NOTE: The information contained below on assembling and installing the direction control lever applies only to S3.50-5.50XM (S70-120XM) (E004, F004) lift truck models. 1. Assemble control lever assembly as shown in Figure 19. Tighten nuts that hold control lever to crank to 6.3 N•m (56 lbf in). Make sure spring washers are between cranks and actuator plate. Tighten nuts for cranks to 10.8 N•m (96 lbf in). Install detent plungers until they touch crank, then loosen one turn. Fill detent areas with multipurpose grease. 2. Install switches on switch plate as shown in Figure 19.

1. CRANK 2. DIRECTION INDICATOR 3. LEVER 4. DETENT CRANK 5. DETENT PLUNGER

6. 7. 8. 9. 10.

SWITCH PLATE SWITCH MOUNT ACTUATOR PLATE SPRING WASHER

Figure 19. Direction Control Lever

1300 SRM 397

Stall Test

Stall Test CAUTION Do not hold the throttle open for more than 15 seconds. Run the engine at idle speed for 2 minutes between tests. Release the pedal immediately if the engine speed increases to the governor limit speed. Stall test checks condition of engine, transmission clutches, and one direction clutch in the torque converter. If engine is not operating correctly, stall speed cannot be reached. If one direction clutch does not hold, oil in torque converter flows into impeller in the direction that is opposite engine rotation. Instead of helping engine turn, oil flow prevents engine from reaching full speed. If engine speed is greater than given stall speed, clutches are not holding or wheels are turning. Clutches will not hold if application pressure is not high enough or clutches are worn. NOTE: Wheels must not turn during this test. Do a stall test to check operation of transmission clutches. Engine and hydraulic oil must be at operating temperature. Put capacity load on forks to prevent wheels from turning. Connect tachometer to engine. Put lift truck against an object that cannot move. Start engine and slowly push on accelerator or MONOTROL pedal to full throttle. Tachometer must indicate values shown in Table 2. If the engine speed is 50 to 200 rpm below the specification, the engine is not operating at full power. Check ignition timing, fuel system, and compression. If the engine speed is 250 to 500 rpm below the specification, the clutch in the torque converter has a defect. The torque converter must be replaced as a unit.

If the torque converter is not defective, check that torque converter housing is not full of oil. Also check ignition timing, fuel system, and compression. If the engine speed is greater than the specification, the clutch that is engaged is not holding. Test other clutch by changing direction control. If the engine rpm is again too high, do pressure checks. If engine speed is normal and one of the clutches is not holding when engaged, check circuits for that clutch. Table 2. Stall Speed Specifications Unit

Stall Speed

Gasoline New Engine

1660 to 1760 rpm

Engine with 50 hours

1760 to 1860 rpm

LPG New Engine

1585 to 1685 rpm

Engine with 50 hours

1685 to 1785 rpm

Diesel, S3.50-5.50XL (S70-120XL) New Engine

2040 rpm

Engine with 50 hours

2090 rpm

Diesel, S3.50-5.50XM (S70-120XM) New Engine

1950 to 2000 rpm

Engine with 50 hours

2050 to 3000 rpm

Linkages Adjustment

1300 SRM 397

Linkages Adjustment LINKAGE FOR INCHING/BRAKE PEDAL, S3.50-5.50XL (S70-120XL) (D004) LIFT TRUCK MODELS NOTE: The procedures described below are for adjusting the inching/brake pedal linkages on lift truck models S3.50-5.50XL (S70-120XL) (D004). For adjusting the inching/brake pedal linkages on lift truck models S3.50-5.50XM (S70-120XM) (E004, F004), see section Linkage for Inching/Brake Pedal, S3.50-5.50XM (S70-120XM) (E004, F004) Lift Truck Models. NOTE: If lift truck has been operated at least 25 hours and brakes operate normally, do not adjust brake shoes. If lift truck has been operated less than 25 hours with new brake shoes, adjust brake shoes as described in Step 1. 1. Put truck on blocks so drive tires do not touch the ground. Put a screwdriver through the slot in back plate and push automatic adjustment lever away from adjuster wheel. Turn adjuster wheel upward with an adjuster tool. Turn adjuster wheel until brake shoes are applied and drum will not rotate. Turn adjuster wheel at least 25 clicks downward to get clearance between brake shoes and drum. Remove blocks and drive lift truck in FORWARD and REVERSE while applying brake pedal. Make 10 stops in each direction while alternating direction of travel. This will make sure brake shoes are at their final adjustment. 2. Adjust height of inching/brake pedal so bottom of pedal pad is 98 mm (3.86 in.) from floor plate. Use capscrew and lock nut (4) behind the pedal to adjust height. 3. Make sure engine is not running and there is no pressure in brake booster. Loosen lock nut (6) on push rod. Loosen rubber boot on brake booster. Adjust push rod until it contacts plunger of brake booster. Then adjust for correct free travel of the pedal by turning push rod 2.5 turns counterclockwise. Tighten lock nut (6) for push rod. Check that free travel of pedal is 8 mm (0.31 in.).

4. Raise front of lift truck. Put blocks under outer upright weldments, then tilt upright forward until drive tires do not touch floor. Apply parking brake. Put blocks on both sides of steering tires so lift truck cannot move. 5. Make sure ball joint on link is installed on crank as shown in Figure 20. Ball joint must be in the second hole from crank pivot. Connect a pressure gauge to test port for common clutch pressure. Operate transmission until oil temperature is at least 82 C (180 F). Heat oil by engaging transmission while applying inching/brake pedal and increasing engine speed. 6. Release parking brake. Shift transmission to FORWARD or REVERSE and operate engine at 2000 rpm. 7. Loosen lock nuts (11 and 12) on link. Rotate link until inching plunger moves enough to reduce clutch pressure to 552 to 690 kPa (80 to 100 psi). Now rotate link 1.3 turns counterclockwise (viewed from the brake booster) to move inching plunger 3 mm (0.12 in.) into the valve body. Tighten lock nuts on link. This adjustment will cause clutch pressure to increase to 790 to 965 kPa (115 to 140 psi). Use this pressure as a system check, but do not use it to adjust inching linkage. NOTE: The above adjustment will give a small amount of overlap between the brake and inching functions. If further adjustment is necessary, follow the steps below. 8. If effort to push inching/brake pedal is too high, decrease overlap. Move ball joint to a hole in crank that is closer to control valve. 9. If there is too much free travel of inching/brake pedal, increase overlap. Move ball joint to a hole in crank that is further from control valve.

1300 SRM 397

Linkages Adjustment

Figure 20. Inching/Brake Pedal Linkage Adjustment

Linkages Adjustment

1300 SRM 397 Legend for Figure 20

1. 2. 3. 4. 5. 6. 7. 8.

INCHING/BRAKE PEDAL FLOOR PLATE CAPSCREW LOCK NUT BRAKE BOOSTER LOCK NUT PUSH ROD LINK

LINKAGE FOR DIRECTION CONTROL LEVER

9. 10. 11. 12. 13. 14. 15.

BALL JOINT CRANK LOCK NUT LOCK NUT INCHING PLUNGER TEST PORT RUBBER

Brake Shoe Adjustment

NOTE: The adjustment procedures described below for the direction control lever apply only to S3.505.50XL (S70-120XL) (D004) lift truck models.

If lift truck has been operated at least 25 hours and brakes operate normally, do not adjust brake shoes. If lift truck has been operated less than 25 hours with new brake shoes, adjust brake shoes as described in Brake System 1800 SRM 985.

1. Disconnect ball joint (3) from the crank (5). Place direction spool in the REVERSE detent position. See Figure 21.

Inching/Brake Pedal Height Adjustment

2. Place direction control lever in REVERSE position and hold it against the stop. 3. Adjust ball joint until it aligns with crank. Connect ball joint to crank. Tighten lock nut (4) for the ball joint. 4. Operate direction control lever to make sure spool stops at three detent positions for FORWARD, NEUTRAL, and REVERSE.

LINKAGE FOR INCHING/BRAKE PEDAL, S3.50-5.50XM (S70-120XM) (E004, F004) LIFT TRUCK MODELS NOTE: The procedures described below are for adjusting the inching/brake pedal linkages on lift truck models S3.50-5.50XM (S70-120XM) (E004, F004). For adjusting the inching/brake pedal linkages on lift truck models S3.50-5.50XL (S70-120XL) (D004), see section Linkage for Inching/Brake Pedal, S3.50-5.50XL (S70-120XL) (D004) Lift Truck Models.

Apply parking brake and put lift truck on blocks so drive tires are off ground. Put blocks under steer tires to prevent movement of lift truck.

Single Pedal Height Adjustment 1. Adjust height of inching/brake pedal so bottom of pedal pad is 89 mm (3.50 in.) from floor plate. Use capscrew and jam nut behind pedal to adjust height. See Figure 22.

Two Pedal Height Adjustment 1. Adjust height of inching/brake pedal so bottom of pedal pad is 89 mm (3.50 in.) from floor plate. See Figure 22. 2. Adjust pedal drive capscrew to align left hand pedal with right hand pedal. Tighten locking nut. Use capscrew and jam nut behind pedal to adjust height.

1300 SRM 397

1. 2. 3. 4.

Linkages Adjustment

DIRECTION CONTROL LEVER SHIFT ROD BALL JOINT LOCK NUT

5. CRANK 6. DIRECTION SPOOL 7. INDICATOR

Figure 21. Direction Control Lever Adjustment

Linkages Adjustment

1300 SRM 397

A. TWO PEDAL OPTION

B. SINGLE PEDAL OPTION

1. 2. 3. 4. 5.

7. 8. 9. 10. 11. 12.

BRAKE PEDAL INCHING/BRAKE PEDAL INCHING/BRAKE PEDAL LINK JAM NUTS (INCHING PEDAL/LINKAGE ADJUSTMENT) 6. INCHING PEDAL DRIVE SCREW AND LOCKING NUT

HEX (BRAKE) LINK INCHING LINK JAM NUT (BRAKE PEDAL ADJUSTMENT) TRUCK FRAME PIN SLOT

Figure 22. Pedal Height Adjustments

Inching/Brake Linkage Adjustment 1. To adjust brake booster, adjust capscrew so there is no movement when crank is moved. Loosen capscrew one hex point clockwise to provide clearance. Tighten lock nut. See Figure 23. NOTE: Perform adjustments described in Step 2, Step 3, and Step 4. These steps will provide a small amount of overlap between brake and inching functions. If further adjustment is necessary, go to Step 5. 2. Place inching capscrew onto inching crank. There should be no clearance between capscrew and inching crank. 3. Turn inching capscrew 1/8 turn for initial setting. Final setting is performed during pressure

adjustment process as outlined below (see Figure 23). a. Install a gauge that can measure 2000 kPa (300 psi) in the port for forward clutch pack. Transmission oil temperature must be at 50 to 80 C (120 to 180 F) during adjustment procedure. b. Start engine and move transmission control lever or MONOTROL pedal to FORWARD position. Release parking brake. c. Loosen locking nut at inching capscrew. Adjust inching capscrew until clutch pack pressure measures 862 to 1000 kPa (125 to 145 psi) at 2000 rpm.

1300 SRM 397

Linkages Adjustment

NOTE: MONOTROL PEDAL SHOWN. ADJUSTMENTS TO THE TWO-PEDAL OPTION ARE SIMILAR. SEE FIGURE 22. A. INCHING LINK ADJUSTMENT

B. BRAKE LINK ADJUSTMENT

1. 2. 3. 4. 5. 6.

9. 10. 11. 12. 13. 14. 15. 16. 17.

CAPSCREW (BRAKE BOOSTER) LOCK NUT INCHING CAPSCREW JAM NUT (BRAKE PEDAL ADJUSTMENT) HEX (BRAKE) LINKAGE JAM NUTS (INCHING PEDAL/LINKAGE ADJUSTMENT) 7. INCHING LINK 8. CRANK

CRANK/BOOSTER MOUNTING BRACKET PIN SLOT STRAIGHT LINK INCHING LINK ROD END JAM NUT (DECREASE OVERLAP) BRAKE PUSH ROD COTTER PIN FRAME

* PIN TO END OF SLOT Figure 23. Inching/Brake Linkage Adjustment

Oil Pressures Check

1300 SRM 397

d. Turn capscrew clockwise until pressure drops to 345 kPa (50 psi) at 2000 rpm. e. Rotate capscrew counterclockwise 1-1/4 turn to move inching plunger 4.5 mm (0.18 in.) into valve body. Tighten lock nuts on the link. Check pressure of forward clutch again. The correct pressure is 862 to 1000 kPa (125 to 145 psi) at 2000 rpm. f.

Turn off engine.

4. To adjust inching link, loosen jam nuts and adjust inching link so pin is at the end of the slot. Tighten jam nuts. See Figure 23. To adjust the brake link, loosen the jam nuts and move the pin horizontally until the pin is at the end of the slot. Tighten jam nuts. See Figure 23. When the pins are at the end of the slots, as shown in Figure 23, the linkages are in their starting position (no lash when crank is moved) of 0 mm (0 in.).

NOTE: More or less overlap may be required for certain applications. If an increase or decrease in overlap is required, perform one of the procedures in either Step 5 or Step 6. DO NOT do both procedures. See Figure 23. 5. Decrease Overlap: If too much pedal force is required to keep lift truck from moving on level ground, decrease overlap (move pin in slot away from starting position). See item B in Figure 23. To decrease overlap, loosen jam nut on brake master cylinder push rod. Adjust push rod to move pin in the slot. One turn of the rod equals 1.5 mm (0.06 in.). Tighten jam nut after adjustment is completed. 6. Increase Overlap: If there is too much free travel of inching/brake pedal, increase overlap (move pin in slot further away from starting position). See item A in Figure 23. Adjust lock nuts on inching link to move pin in the slot. One turn of the lock nuts equals 1.0 mm (0.04 in.). Tighten lock nuts once increase in overlap is achieved.

Oil Pressures Check See Troubleshooting section for causes of pressures that are not within specified limits. If correct pressure for a regulator cannot be obtained, replace spring for regulator. Regulators are not adjustable. Before making oil pressure checks, do the following: 1. Make sure adjustment of inching pedal is correct. Make sure adjustment of direction spool is correct. 2. Connect tachometer to engine (gas/LPG) or use a special tachometer for diesel engine. 3. Connect pressure gauges to test ports shown in Table 3 and Table 4. See charts for pressures. 4. Start engine and tilt mast back. Put blocks under outer mast weldments. Tilt mast forward to raise drive tires from floor. Put blocks on both sides of steer tires (front and back) so lift truck cannot move. 5. Make sure oil level in transmission is correct. Make sure temperature of oil is within specification as noted in Table 3 and Table 4. Heat oil by engaging transmission while applying brake

pedal and increasing engine speed. Release parking brake. Do not heat oil by using inching pedal to disengage transmission. NOTE: Check ports described below apply only to S3.50-5.50XL (S70-120XL) (D004) lift truck models. See Table 3.

SYSTEM PRESSURE CHECK PORT With engine running at 2000 rpm, correct pressure reading is 1032 to 1312 kPa (150 to 190 psi). This reading checks pressure from oil pump. Pressure from oil pump is controlled by system regulator that is in control valve body. If pressure is not correct, see Troubleshooting procedures.

TORQUE CONVERTER CHECK PORT With engine running at 2000 rpm, correct reading is 765 to 903 kPa (111 to 131 psi). This reading checks pressure of oil that goes to torque converter. Regulator for torque converter is in control valve body. If pressure is not correct, see Troubleshooting procedures.

1300 SRM 397

Oil Pressures Check

Table 3. Transmission Oil Pressure Check, Early Model S3.50-5.50XL (S70-120XL) Lift Trucks Port No.

Transmission Pressures*

System Pressure

1032 to 1312 kPa (150 to 190 psi)

Torque Converter Pressure

765 to 903 kPa (111 to 131 psi)

Clutch Pressure

827 to 965 kPa (120 to 140 psi)

4,5

Solenoid Pressure

927 to 1003 kPa (134 to 145 psi)

6,7

Lubrication Pressure

96 to 138 kPa (14 to 20 psi)

*Oil temperature is at least 82 C (180 F) and engine speed at 2000 rpm.

CLUTCH PRESSURE CHECK PORT

INCHING PRESSURE

There is a common check port for both clutch assemblies. With engine running at 2000 rpm, correct reading at common check port is 827 to 965 kPa (120 to 140 psi). Pressure at each of the four clutch check ports is the same. Pressure difference between the four check ports must not be more than 69 kPa (10 psi). If any pressures are not correct, see Troubleshooting procedures.

Use gauge at common clutch check port. With engine running at 2000 rpm, push on inching pedal. Pressure at gauge will drop quickly from clutch pressure of 927 to 1003 kPa (134 to 145 psi) to 476 to 558 kPa (69 to 81 psi). As inching pedal is depressed further, pressure will continue to decrease. When inching pedal is completely depressed, pressure will be zero. If inching function does not work correctly, see Troubleshooting procedures.

Oil Pressures Check

1300 SRM 397

Table 4. Transmission Oil Pressure Check, Later Model S3.50-5.50XL (S70-120XL) and S3.50-5.50XM (S70-120XM) Lift Trucks Port No.

Transmission Pressures*

System Pressure

Forward Clutch

895 to 1035 kPa (130 to 150 psi)

Reverse Clutch

895 to 1035 kPa (130 to 150 psi)

Torque Converter

655 to 760 kPa (95 to 110 psi)

Lubrication Pressure

35 to 105 kPa (5 to 15 psi)

Modulator Pressure

Pressure Variation

1170 to 1380** kPa (170 to 200 psi) **Relief pressure 1379 kPa (200 psi)

*Oil temperature is at least 50 to 65 C (120 to 150 F) and engine speed at 2000 rpm. NOTE: The difference between forward and reverse clutch pressure must not be more than: â&#x20AC;˘ Manufacturing limit 48 kPa (7 psi) â&#x20AC;˘ Service limit 70 kPa (10 psi)

1300 SRM 397

SOLENOID CHECK PORTS (MONOTROL CONTROL ONLY) With engine running at 2000 rpm, correct reading at forward and reverse solenoid check ports is 927 to 1003 kPa (134 to 145 psi). To check pressures, shift transmission to FORWARD and then REVERSE. If pressures are not correct, see Troubleshooting procedures.

LUBRICATION PRESSURE CHECK PORTS There are check ports for checking lubrication pressure for clutch assembly. Shift to FORWARD and then REVERSE. With engine running at 2000 rpm, correct reading is 96 to 138 kPa (14 to 20 psi). If pressures are not correct, see Troubleshooting procedures. NOTE: The check ports described below apply only to S3.50-5.50XM (S70-120XM) (E004, F004) lift truck models. See Table 4.

Oil Pressures Check 2. Run engine at 2000 rpm and push inching/brake pedal down. Clutch pressure must decrease to approximately zero pressure when inching/brake pedal is fully depressed. 3. The difference in forward and reverse clutch pressures cannot be more than 70 kPa (10 psi). A larger difference in clutch pressures indicates a problem.

FORWARD CLUTCH PRESSURE CHECK PORT 1. Place transmission in FORWARD. If pressure is not 895 to 1035 kPa (130 to 150 psi), see Troubleshooting procedures. 2. Run engine at 2000 rpm and push inching/brake pedal down. Clutch pressure must decrease to approximately zero pressure when inching/brake pedal is fully depressed.

LUBRICATION PRESSURE CHECK PORT SYSTEM PRESSURE CHECK PORT With engine running at 2000 rpm, correct pressure reading is 1170 to 1380 kPa (170 to 200 psi). This reading checks pressure from oil pump. Pressure from oil pump is controlled by system regulator that is in control valve body. If pressure is not correct, see Troubleshooting procedures. To check relief valve for transmission, apply parking brake (direction control lever only). Put direction control lever in NEUTRAL. If pressure from transmission is not 1379 kPa (200 psi), see Troubleshooting procedures.

TORQUE CONVERTER CHECK PORT With engine running at 2000 rpm, correct reading is 655 to 760 kPa (95 to 110 psi). This reading checks pressure of oil that goes to torque converter. Regulator for torque converter is in control valve body. If pressure is not correct, see Troubleshooting procedures.

REVERSE CLUTCH PRESSURE CHECK PORT 1. Put transmission in REVERSE. If pressure is not 895 to 1035 kPa (130 to 150 psi), see Troubleshooting procedures.

Remove plug at lubrication pressure test port. See Table 4. Install a 0 to 500 kPa (0 to 73 psi) gauge. Transmission oil must be at operating temperature of 50 to 65 C (120 to 150 F). Apply parking brake (direction control lever only). Place direction control lever in NEUTRAL position. Run engine at 2000 rpm. Correct pressure is 35 to 105 kPa (5 to 15 psi).

MODULATOR PRESSURE CHECK PORT This test checks operation of modulator. When direction spool is moved from one direction to another, modulator causes a 1.1 to 1.5 second delay in application of the clutch for new direction. Changes in modulator pressure are shown in Figure 24. Remove plug and install a fitting for the gauge. Connect a 0 to 2000 kPa (0 to 300 psi) gauge to fitting. Run engine at 1500 to 2000 rpm. Check pressure on gauge when you change position of direction spool. Use a stopwatch to measure operation of modulator. A pressure gauge will not operate quickly enough to show complete variation shown in Figure 24, but it will indicate decrease and increase of pressure in modulator. If operation of modulator is not correct, control valve must be repaired. See Control Valve Repair section.

Troubleshooting

1300 SRM 397 Legend for Figure 24 1. CLUTCH DISENGAGES 2. OTHER CLUTCH FILLS WITH OIL 3. MODULATOR CONTROLS INCREASE IN PRESSURE 4. OTHER CLUTCH ENGAGED

Figure 24. Pressure Variation In Modulator During Forward/Reverse Shift

Troubleshooting PROBLEM Transmission is too hot.

POSSIBLE CAUSE

PROCEDURE OR ACTION

Inching and operating the lift truck with loads greater than capacity.

Check nameplate for load limits.

Oil level is not correct.

Make sure oil level is correct.

Clutch does not engage completely.

Check oil pressure or clutch parts.

Inching/brake pedal is not adjusted correctly.

Make correct adjustments to inching/ brake pedal.

Worn or wrong friction discs or separator plates.

Install new parts.

Clutch pressure is too low.

Check for cause of low pressure.

Brakes are not adjusted correctly.

Make correct adjustment to brakes.

Oil cooler circuit has a restriction or damage.

Clean oil lines and oil cooler.

Defect in the torque converter.

Install new torque converter.

Clutch discs bent or not releasing.

Install new clutch discs.

Clutch assembly will not disengage completely because piston orifice has a restriction.

Clean piston orifice.

1300 SRM 397

Troubleshooting

PROBLEM

POSSIBLE CAUSE

Bubbles in the oil fill tube.

Inching operation smooth.

not

Loss of power.

Lift truck will not move in either direction.

PROCEDURE OR ACTION

Air leak on suction side of the oil pump.

Check pump mounting.

Oil level is not correct.

Make sure oil level is correct.

Oil is too hot.

Let oil cool.

Defect in the torque converter.

Install new torque converter.

Brakes are not correctly adjusted.

Adjust brakes.

Inching spool or plunger does not move freely.

Check linkage or install new spool or plunger.

Broken spring(s) for inching spool or plunger.

Install new spring(s).

Clutch piston does not move freely.

Check piston operation.

Control valve has leaks.

Repair control valve.

Clutch discs are bent.

Install new clutch discs.

Clutch that is engaged is not releasing.

Inspect clutch, replace as necessary.

Torque converter has a defect.

Replace torque converter.

Clutch does not engage completely.

Inspect clutch and replace as necessary.

Oil level is too low.

Fill to correct oil level.

Parking brake is applied.

Release parking brake.

Forward and reverse solenoids do not operate.

Repair solenoids or circuit.

Linkage to direction spool is disconnected.

Connect linkage to direction spool.

Linkage to inching spool is disconnected.

Connect linkage to inching spool.

Switches at MONOTROL pedal do not operate.

Connect wires switches.

install

new

Troubleshooting

PROBLEM Lift truck will not move in either direction. (Cont.)

Lift truck moves in one direction only.

Pressure at the system check port is below specifications.

Pressure at the system check port is above specifications.

1300 SRM 397

POSSIBLE CAUSE

PROCEDURE OR ACTION

Axle shaft(s) or differential is damaged.

Repair as necessary.

Direction spool will not move.

Check wiring or solenoids.

Forward or reverse solenoid does not operate.

Check solenoid, replace as necessary.

Spring on direction spool is damaged (MONOTROL).

Install new spring.

A clutch is damaged and will not release.

Install new clutch.

Spring for regulator is broken or is not correct.

Install new spring.

Clutch pressure regulator is in the open position.

Close clutch pressure regulator.

Oil pump is worn or damaged.

Install new oil pump.

Regulator is worn.

Install new regulator.

Oil filter is leaking.

Install new filter.

A regulator beyond the system regulator is leaking.

Troubleshoot the appropriate regulator.

Spring for the regulator is not correct.

Install new spring.

Regulator does not move freely in the bore.

Repair or replace regulator.

Oil in the transmission is not correct.

Fill with correct oil.

Oil is too cold.

Warm oil up.

There is a restriction in the lubrication circuit.

Clear restriction.

1300 SRM 397

PROBLEM Pressure at the common clutch pressure check port is below specifications.

Pressure at the common clutch pressure check port is above specifications.

Pressure at one of the individual clutch pressure check ports is below specifications.

Pressure at one of the individual clutch pressure check ports is above specifications.

Troubleshooting

POSSIBLE CAUSE

PROCEDURE OR ACTION

Spring for regulator is broken or is not correct.

Install new spring.

Oil filter has a restriction.

Clear restriction. Replace filter as needed.

Oil filter is leaking.

Replace filter.

Inching plunger and spool are not completely retracted in the bore.

Inspect plunger and spool. Replace as necessary.

Direction spool is not adjusted correctly.

Adjust direction spool.

Bores for direction spool or inching spool are worn.

Install new bores.

Spring for the regulator is not correct.

Install new spring.

Regulator does not move freely in the bore.

Repair or replace regulator.

The seal rings on the shaft are worn or damaged.

Install new seal rings.

The area for the seal rings in the housing is worn or damaged.

Replace with new seal rings.

The seals for the clutch piston are worn or damaged.

Install new seal.

Inching plunger and spool are not completely retracted in the bore.

Inspect plunger and spool. Replace as necessary.

Pressure at the common clutch pressure check port is above specifications.

Adjust pressure.

Orifice in the piston has a restriction.

Clear restriction.

Troubleshooting

PROBLEM Pressure at one of the solenoid clutch pressure check ports is below specifications.

1300 SRM 397

POSSIBLE CAUSE

PROCEDURE OR ACTION

Solenoid spool or seals are worn.

Install new spool or seals.

Solenoid assembly leaks.

Repair or replace solenoid assembly.

Pressure at one of the solenoid clutch pressure check ports is above specifications.

The clutch pressure regulator does not operate correctly.

Troubleshoot clutch pressure regulator.

Pressure at the torque converter check port is below specifications.

Spring for the torque converter regulator is broken or not correct.

Install new spring.

Pressure at the torque converter check port is above specifications.

Spring for the torque converter regulator is not correct.

Install new spring.

Torque converter regulator does not move freely in the bore.

Repair or replace regulator.

The supply pressure to the lubrication circuit is not correct.

Troubleshoot the lubrication circuit pressure.

The oil cooler has a restriction.

Clear restriction.

The oil pump is worn or damaged.

Replace with new pump.

The supply pressure to the lubrication circuit is not correct.

Troubleshoot the lubrication circuit pressure.

Pressure at the lubrication check port(s) is below specifications.

Pressure at the lubrication check port(s) is above specifications.

STARTER DELCO DELCO STARTERS USED ON HYSTER LIFT TRUCKS

PART NO. 910107

2200 SRM 106

Starter

Table of Contents

1 1 3 3 3 4 4 5 5 8

This section is for the following models: Delco Starters used on Hyster Lift Trucks

2200 SRM 106

Description and Operation

General This section has a description and the service procedures for the starter, the solenoid, and the solenoid switch.

NOTE: Information on starters manufactured outside the United States is in the SRM sections for lift trucks that use those starters.

Description and Operation The positive battery cable is connected to the "BAT" terminal on the starter solenoid. See Figure 1, Figure 2, and Figure 3. Battery voltage is not applied to the starter until the ignition switch, the solenoid switch (diesel units only), and the transmission neutral switch close. The solenoid moves the linkage and the drive clutch to engage the starter pinion with the ring gear. At the end of its stroke, the plunger of the solenoid closes the main solenoid contacts. The current then flows to the starter windings. The starter pinion turns the flywheel ring gear.

the START position. The solenoid switch closes the contacts that energize the solenoid of the starter.

The starter is a linkage type with a drive clutch mechanism. The solenoid is fastened to the starter. The pinion is part of the drive clutch. The drive clutch is moved on the armature shaft by the linkage connected to the solenoid plunger. When the engine starts, the pinion is still engaged with the ring gear. The pinion turns freely when driven by the ring gear. When the key is released, the pinion moves away from the ring gear and the starter circuit opens. When energized, the starter solenoid moves the linkage, closes the contacts, and energizes the starter. The solenoid has two windings. When energized, one winding pulls the solenoid plunger to close the contacts. The other winding holds the plunger in that position. The current for the winding that pulls must flow through the starter brushes to a ground. The ground for the winding that holds the plunger in position is the solenoid frame. When the key switch is closed, the current flows through both windings. When the plunger moves the linkage, the contacts close, which causes the winding that pulls to have a short circuit. That winding is deenergized, but the current continues to flow through the winding that holds the plunger. The winding that holds the plunger is deenergized when the key switch is released. The solenoid switch is a relay that is used in the diesel starter circuit. The solenoid for the starter of the diesel engine uses more current than does the solenoid for the starter of the gasoline engine. The solenoid switch is actuated by turning the key switch to

1. BATTERY 2. IGNITION SWITCH 3. NEUTRAL START SWITCH (CAN CONSIST OF SEVERAL RELAYS) 4. STARTER SOLENOID 5. STARTER 6. SOLENOID SWITCH (NOT ON ALL UNITS) Figure 1. Starting Circuit

Description and Operation

2200 SRM 106

Figure 2. Starter

2200 SRM 106

Starter Repair Legend for Figure 2

1. 2. 3. 4. 5. 6. 7. 8.

END FRAME GROUND BRUSH HOLDER BRUSH SPRING BRUSH SUPPORT INSULATED BRUSH HOLDER BRUSH POLE SHOE FIELD COIL

1. KEY SWITCH 2. NEUTRAL START SWITCH 3. HOLD WINDING 4. SOLENOID 5. PLUNGER

6. 7. 8. 9. 10. 11.

9. 10. 11. 12. 13. 14. 15. 16.

SPACER ARMATURE THROUGH BOLT SOLENOID PLUNGER LINKAGE DRIVE HOUSING LEVER HOUSING RETAINER

17. 18. 19. 20. 21. 22. 23. 24.

THRUST COLLAR DRIVE CLUTCH SNAP RING SOLENOID COVER SPRING GASKET CENTER BEARING PLATE AND SEAL

DRIVE LINKAGE DRIVE CLUTCH STARTER CONTACTS PULL WINDING TO BATTERY

Figure 3. Solenoid Windings

Starter Repair REMOVE NOTE: If the starter does not operate correctly, refer to General Checks and Adjustments before beginning any repair procedures.

WARNING Always disconnect the battery ground cable before making repairs to prevent possible damage and injury. Install a tag on the battery terminal so that no one connects the cable on the terminal.

1. Install labels on the starter wires and cables for correct connection during installation. Disconnect the wires and the cables to the starter. 2. Remove the capscrews that hold the starter to the flywheel housing. 3. If used, remove the spacers and the gaskets. 4. Remove the starter from the lift truck.

DISASSEMBLE 1. Remove the screw and lock washer connecting the field coil strap to the "M" terminal of the solenoid. See Figure 2 and Figure 4.

Starter Repair 2. Remove the two screws that hold the solenoid to the drive end housing. Turn the solenoid 1/4 turn and remove it from the starter. 3. Remove the two bolts that hold the commutator end frame and the field frame to the drive housing. Make alignment marks on the end frame and on the field frame for easy assembly. Pull the end frame from the field frame. On some models it is necessary to pull the brushes from the holders. Remove the field frame. 4. If used, remove the four screws holding the center bearing plate to the drive end housing. 5. Remove the armature from the drive end housing. Tilt the armature to disengage the linkage from the drive clutch. On some models it is necessary to remove the linkage before removing the armature.

2200 SRM 106 4. Install the shaft assembly in the drive end housing. Make sure the linkage is engaged in the drive clutch. Install and tighten the four screws for the bearing plate. 5. Install the field frame over the armature. Retract the brush springs and slide the brushes on the commutator. 6. Align the marks and install the thrust washer and the commutator end frame. Install and tighten the through bolts. 7. Make sure the solenoid cover is not damaged. Install the plunger spring and the solenoid. Install and tighten the solenoid mount screws. Connect the field coil strap to the "M" terminal with the screw and lock washer.

6. Remove the thrust collar from the armature shaft. Put a metal tube with a 13 mm (0.5 in.) inside diameter over the end of the shaft. See Figure 4. Hit the tube to move the retainer. Remove the snap ring. Remove the drive clutch. 7. Remove the center bearing plate. Remove the seal from the plate.

CLEAN CAUTION Never use solvent on the drive clutch, armature, or field windings. Use a cloth to clean these parts. Use solvent to clean all parts of the starter, except the windings and the drive clutch. Dry the parts with compressed air.

ASSEMBLE 1. Install a new seal in the center bearing plate. See Figure 2 and Figure 5. 2. Lubricate the armature shaft and the bushings with a silicone lubricant. 3. Put the center bearing plate, drive clutch, retainer, snap ring, and thrust washer on the armature shaft. Install the snap ring, thrust washer, and retainer as shown in Figure 5.

1. METAL TUBE, 13 mm (0.5 in.) INSIDE DIAMETER 2. RETAINER Figure 4. Retainer Removal

2200 SRM 106

General Checks and Adjustments

INSTALL 1. Make sure the surfaces of the flywheel housing, the spacer, and the starter are clean and smooth. Install the gaskets or use a sealant (Hyster part number 264159) that forms a gasket between metal parts. 2. Install the capscrews and washers as necessary. Tighten the capscrews. 3. Connect the wires and the cables to the starter according to the labels made during removal. 4. Connect the ground cable to the battery.

1. THRUST COLLAR 2. RETAINER

3. SNAP RING

Figure 5. Retainer Installation

General Checks and Adjustments 1. Before removing the starter, see Figure 6 and Figure 7. Make the following checks: a. Check the voltage of the battery.

CAUTION Do not operate the starter for more than 30 seconds. Be sure to wait at least two minutes between checks. b. Check the voltage at the motor terminal of the solenoid while the key switch is in the "START" position. See Figure 6. The voltage must be more than 9 volts for a 12-volt system or more than 18 volts for a 24-volt system. c. Inspect all the connections to the battery, starter solenoid, key switch, and neutral start switch. Clean and tighten, if necessary. d. Check the resistance of the connections with a voltmeter. See Figure 7. Each connection must not have more than a 0.5 volt loss for a 12-volt system or 1.0 loss for a 24-volt system.

e. Check the voltage at the "S" terminal of the solenoid. It must be more than 7 volts for a 12-volt system or more than 14 volts for a 24-volt system. 2. After removing the starter, but before disassembly, make the following checks: a. Check the ring gear (on the flywheel) for damage.

CAUTION The pinion will move toward the drive end housing when turned in the locked direction. Do not turn it too far or it will lock in the extended position. b. Check the pinion gear (on the drive clutch) for damage. The pinion must turn in one direction and lock in the other. Replace the complete assembly if any part has damage. c. Check the clearance of the armature bushings. d. Check for cracks in the drive end housing.

General Checks and Adjustments

2200 SRM 106 b. Check for wear in the linkage. c. Test for a ground in the armature windings. See Figure 8. Touch one wire of an ohmmeter to the shaft and the other to each commutator bar. The armature has a short-circuit to ground if the ohmmeter indicates a complete circuit.

1. MOTOR TERMINAL

2. GROUND ON ENGINE

Figure 6. Starter Voltage Test

Figure 8. Armature Ground Tests d. Test for open circuits in the armature. Put one wire of an ohmmeter on one commutator bar and the other on the bar 180 degrees opposite. The ohmmeter must indicate a complete circuit. Commutator bars that are burned indicate an open circuit.

1. 2. 3. 4.

KEY SWITCH "BAT" TERMINAL "S" TERMINAL STARTER

5. "M" TERMINAL 6. BATTERY 7. VOLTMETER

Figure 7. Resistance Test

e. Test for a ground in the field coil circuit. See Figure 9. Touch one wire of an ohmmeter to the field frame and the other to the field coil brushes. On some models it is necessary to disconnect the field ground strap. The field coils have a short-circuit to ground if the ohmmeter indicates a complete circuit. f.

Test for an open circuit in the field coils. See Figure 10. Connect the wires of an ohmmeter to the ends of the field coils. The ohmmeter must indicate a complete circuit.

3. When the starter is disassembled, make the following checks:

g. Check that the brush springs have enough tension.

a. Check that the seals are good on units that use an oil clutch or a powershift transmission.

h. Check the brushes for wear. The brushes must be at least one half the length of new ones.

2200 SRM 106

1. INSULATED BRUSH

General Checks and Adjustments

2. GROUND BRUSH

Figure 9. Field Coil Ground Test

1. FIELD COIL STRAP

2. GROUND BRUSH

Figure 10. Field Coil Open Circuit Test

CAUTION Remove only enough metal to clean the surface on the commutators with the plastic insulation. See Figure 11. Do not cut the insulation between the bars on the commutator. The plastic material is necessary to support the bars. The plastic material is softer than the bars and will wear at the same rate. i.

If the commutator is rough or is burned, it must be repaired with a lathe.

Check for bad solder connections at the commutator bars. Solder the connections that have damage.

1. COMMUTATOR WITH MICA INSULATION 2. COMMUTATOR WITH PLASTIC INSULATION (DO NOT CUT INSULATION) Figure 11. Two Types of Insulation

Troubleshooting

2200 SRM 106

Troubleshooting PROBLEM The starter will not turn; no noise at the solenoid.

The starter will not turn; the solenoid makes noise.

The starter will not turn. The ammeter indicates a large current draw.

POSSIBLE CAUSE

PROCEDURE OR ACTION

Battery is discharged or has damage.

Recharge or replace battery.

A fuse is burned out.

Replace fuse.

A wire in the control circuit is disconnected.

Connect wire.

The key switch has damage.

Install new parts.

The neutral start switch has damage.

Install new parts.

The cable connections are bad.

Install new parts.

The solenoid has damage.

Replace solenoid.

The starter brushes are worn or dirty.

Replace brushes.

The solenoid switch has damage.

Replace switch.

The battery is discharged or has damage.

Recharge or replace battery.

The starter brushes are worn or dirty.

Replace brushes.

The contacts in the solenoid are worn.

Install new parts.

The armature circuit has damage.

Repair or install new parts.

The cable connections have too much resistance.

Clean or install new parts.

The control circuit has a short circuit.

Check wiring for damage and repair.

The pinion is not engaging the ring gear.

Check the clutch on the starter for damage and repair.

The solenoid has damage.

Replace solenoid.

2200 SRM 106

PROBLEM The cables get too hot.

The starter turns too slowly.

Troubleshooting

POSSIBLE CAUSE

PROCEDURE OR ACTION

The battery is discharged or has damage.

Recharge or replace the battery.

The pinion is not disengaging from the ring gear.

Check the clutch on the starter for damage and repair.

The armature shaft is bent.

Repair or replace armature.

The cable has a short circuit.

Repair or replace cable.

The bushings are worn or damaged.

Replace bushings.

The engine has damage.

Repair or install new parts.

The battery is discharged or has damage.

Recharge or replace battery.

The cable connections have too much resistance.

Repair or install new parts.

The starter brushes are worn or dirty.

Clean or replace brushes.

The armature circuit has damage.

Repair or replace armature.

The field circuit has damage.

The starter turns, but the engine will not turn.

The starter brushes are worn or dirty.

Clean or replace brushes.

The ring gear has damage.

Install new parts.

The engine has damage.

Repair or install new parts.

The ignition timing is not correct.

Recalibrate the ignition timing.

The drive clutch has damage.

Install new parts.

The pinion is not disengaging from the ring gear.

Check the clutch on the starter for damage and repair.

The ring gear has damage.

Install new parts.

Troubleshooting

PROBLEM The starter makes too much noise.

2200 SRM 106

POSSIBLE CAUSE

PROCEDURE OR ACTION

The solenoid has damage.

Replace solenoid.

The ring gear has damage.

Install new parts.

The drive clutch has damage.

Install new parts.

The battery is discharged or has damage.

Recharge or replace battery.

The starter brushes are worn or dirty.

Replace brushes.