This service manual covers maintenance and repair procedures for the GM 4.3L gasoline engine installed in Mitsubishi forklift trucks. It provides detailed instructions grouped by systems as a reference for technicians. Proper servicing as outlined in the manual is important for the long productive life of the forklift. Safety precautions are emphasized, including wearing protective equipment and blocking trucks securely before working on them. The manual explains how to properly separate parts during disassembly to ensure correct reinstallation.
Caterpillar cat dp70 forklift lift trucks service repair manual sn:t20 c 6000...jsemd suekd
This document is a service manual that provides instructions for servicing lift trucks. It begins with safety warnings and precautions for technicians working on the trucks. The manual then outlines the various systems that will be covered, including the cooling system, electrical system, powertrain, transmissions, front axle, and rear axle. Technicians are advised to carefully read the relevant sections before working on components and to follow all safety procedures.
Mitsubishi fd80 n forklift trucks service repair manual snf32c 10011-upjksjdmd
This service manual provides maintenance and repair information for Mitsubishi forklift truck models FD80N and FD90N powered by a Mitsubishi 6M60-TL diesel engine. It includes specifications, diagrams, removal and installation instructions, and troubleshooting guides for the cooling, electrical, powertrain, transmission, axles, brakes, steering, hydraulic, mast and other systems. Safety precautions are outlined and the manual is organized for easy reference by system.
This is the Highly Detailed factory service repair manual for theCATERPILLAR CAT DP100N FORKLIFT LIFT TRUCKS, this Service Manual has detailed illustrations as well as step by step instructions,It is 100 percents complete and intact. they are specifically written for the do-it-yourself-er as well as the experienced mechanic.CATERPILLAR CAT DP100N FORKLIFT LIFT TRUCKS Service Repair Workshop Manual provides step-by-step instructions based on the complete dis-assembly of the machine. It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure. Complete download comes in pdf format which can work under all PC based windows operating system and Mac also, All pages are printable. Using this repair manual is an inexpensive way to keep your vehicle working properly.
Service Repair Manual Covers:
Chassis, Mast and Options: Foreword
Chassis, Mast and Options: General Information
Chassis, Mast and Options: Cooling System
Chassis, Mast and Options: Electrical System
Chassis, Mast and Options: Controller
Chassis, Mast and Options: Tiltable System
Chassis, Mast and Options: Power Train
Chassis, Mast and Options: Power shift Transmissions
Chassis, Mast and Options: Front Axle and Reduction Differential
Chassis, Mast and Options: Rear Axle
Chassis, Mast and Options: Brake System
Chassis, Mast and Options: Steering System
Chassis, Mast and Options: Hydraulic System
Chassis, Mast and Options: Masts and Forks
Chassis, Mast and Options: Fork Positioner
Chassis, Mast and Options: Service Data
6M60-TL Diesel Engine: Foreword
6M60-TL Diesel Engine: General
6M60-TL Diesel Engine: Engine
6M60-TL Diesel Engine: Lubrication
6M60-TL Diesel Engine: Fuel and Engine Control
6M60-TL Diesel Engine: Electronic Controlled Fuel System
6M60-TL Diesel Engine: Cooling
6M60-TL Diesel Engine: Intake and Exhaust
6M60-TL Diesel Engine: Emission Control
6M60-TL Diesel Engine: Electrical
6M60-TL Diesel Engine: Special Equipment
File Format: PDF
Compatible: All Versions of Windows & Mac
Language: English
Requirements: Adobe PDF Reader
NO waiting, Buy from responsible seller and get INSTANT DOWNLOAD, Without wasting your hard-owned money on uncertainty or surprise! All pages are is great to haveCATERPILLAR CAT DP100N FORKLIFT LIFT TRUCKS Service Repair Workshop Manual.
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This document provides a service manual for cooling system components on certain Cat lift truck models. It includes specifications, component layout diagrams, removal and installation instructions, and inspection/adjustment procedures. The cooling system uses a water-cooled, forced circulation design with a corrugated fin radiator, centrifugal water pump, and wax pellet thermostat. Instructions are provided for inspecting and adjusting the fan belt tension.
Caterpillar cat dp40 k forklift lift trucks chassis and mast service repair m...jksjdmd
This service manual provides information for servicing Caterpillar lift trucks. It covers GP and DP series trucks powered by gasoline or diesel engines. The manual includes sections on general information, cooling, electrical, powertrain, brake and other systems. Safety precautions are outlined and each section provides descriptions, specifications, removal/installation instructions, and disassembly/reassembly procedures. Dimensional data and technical specifications are provided for each truck model.
Komatsu ck30 1 skid steer loader service repair manual (sn a30001 and up)fjkskmmdmme
This 3-page shop manual section provides information on servicing and repairing the Komatsu CK30-1 compact track loader. It includes an overview of the manual's contents and structure, safety precautions for working on the equipment, and guidance for how to read and update the manual. The document outlines the main components that will be covered, testing and adjustment procedures, removal and installation instructions, maintenance standards, and other information needed for repair work. Special symbols are used to mark important safety guidelines and quality points.
This is the Highly Detailed factory service repair manual for theCATERPILLAR CAT GC55K FORKLIFT LIFT TRUCKS, this Service Manual has detailed illustrations as well as step by step instructions,It is 100 percents complete and intact. they are specifically written for the do-it-yourself-er as well as the experienced mechanic.CATERPILLAR CAT GC55K FORKLIFT LIFT TRUCKS Service Repair Workshop Manual provides step-by-step instructions based on the complete dis-assembly of the machine. It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure. Complete download comes in pdf format which can work under all PC based windows operating system and Mac also, All pages are printable. Using this repair manual is an inexpensive way to keep your vehicle working properly.
Service Repair Manual Covers:
Chassis and Mast: Foreword
Chassis and Mast: General Information
Chassis and Mast: Cooling System
Chassis and Mast: Electrical System
Chassis and Mast: Power Train
Chassis and Mast: Power shift Transmission
Chassis and Mast: Front Axle and Reduction Differential
Chassis and Mast: Rear Axle
Chassis and Mast: Brake System
Chassis and Mast: Steering System
Chassis and Mast: Hydraulic System
Chassis and Mast: Mast and Forks
Chassis and Mast: Service Data
Chassis and Mast: Schematics
Options Supplement: Foreword
Options Supplement: Safety
Options Supplement: Rear Combination Kit
Options Supplement: Warning Lamp Kit
Options Supplement: Working Lamp Kit
Options Supplement: Creeper Speed Kit
Options Supplement: Foot Directional Control Group
Options Supplement: Engine Shutdown Kit (LPG Models Only)
Options Supplement: Enclosed Alternator Field Kit
Options Supplement: Disconnect Switch Kit
Options Supplement: UL Fuel Cap Kit (Gasoline models only)
Options Supplement: Key Kit
Options Supplement: Back Buzzer Kit
Options Supplement: Dual Element Air Cleaner
Options Supplement: Dust and Foundry Kit
Options Supplement: Back Mirror Kit
File Format: PDF
Compatible: All Versions of Windows & Mac
Language: English
Requirements: Adobe PDF Reader
NO waiting, Buy from responsible seller and get INSTANT DOWNLOAD, Without wasting your hard-owned money on uncertainty or surprise! All pages are is great to haveCATERPILLAR CAT GC55K FORKLIFT LIFT TRUCKS Service Repair Workshop Manual.
Looking for some other Service Repair Manual,please check:
https://www.aservicemanualpdf.com/
Thanks for visiting!
This shop manual provides instructions for servicing an SK1026-5 turbo skid-steer loader. It contains sections on structure and function, testing and adjusting, disassembly and assembly, and maintenance standards. Safety precautions are outlined, including wearing protective equipment and following proper lifting procedures. The document provides instructions for removing the engine hood and tilting the cab to access components.
Caterpillar cat dp70 forklift lift trucks service repair manual sn:t20 c 6000...jsemd suekd
This document is a service manual that provides instructions for servicing lift trucks. It begins with safety warnings and precautions for technicians working on the trucks. The manual then outlines the various systems that will be covered, including the cooling system, electrical system, powertrain, transmissions, front axle, and rear axle. Technicians are advised to carefully read the relevant sections before working on components and to follow all safety procedures.
Mitsubishi fd80 n forklift trucks service repair manual snf32c 10011-upjksjdmd
This service manual provides maintenance and repair information for Mitsubishi forklift truck models FD80N and FD90N powered by a Mitsubishi 6M60-TL diesel engine. It includes specifications, diagrams, removal and installation instructions, and troubleshooting guides for the cooling, electrical, powertrain, transmission, axles, brakes, steering, hydraulic, mast and other systems. Safety precautions are outlined and the manual is organized for easy reference by system.
This is the Highly Detailed factory service repair manual for theCATERPILLAR CAT DP100N FORKLIFT LIFT TRUCKS, this Service Manual has detailed illustrations as well as step by step instructions,It is 100 percents complete and intact. they are specifically written for the do-it-yourself-er as well as the experienced mechanic.CATERPILLAR CAT DP100N FORKLIFT LIFT TRUCKS Service Repair Workshop Manual provides step-by-step instructions based on the complete dis-assembly of the machine. It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure. Complete download comes in pdf format which can work under all PC based windows operating system and Mac also, All pages are printable. Using this repair manual is an inexpensive way to keep your vehicle working properly.
Service Repair Manual Covers:
Chassis, Mast and Options: Foreword
Chassis, Mast and Options: General Information
Chassis, Mast and Options: Cooling System
Chassis, Mast and Options: Electrical System
Chassis, Mast and Options: Controller
Chassis, Mast and Options: Tiltable System
Chassis, Mast and Options: Power Train
Chassis, Mast and Options: Power shift Transmissions
Chassis, Mast and Options: Front Axle and Reduction Differential
Chassis, Mast and Options: Rear Axle
Chassis, Mast and Options: Brake System
Chassis, Mast and Options: Steering System
Chassis, Mast and Options: Hydraulic System
Chassis, Mast and Options: Masts and Forks
Chassis, Mast and Options: Fork Positioner
Chassis, Mast and Options: Service Data
6M60-TL Diesel Engine: Foreword
6M60-TL Diesel Engine: General
6M60-TL Diesel Engine: Engine
6M60-TL Diesel Engine: Lubrication
6M60-TL Diesel Engine: Fuel and Engine Control
6M60-TL Diesel Engine: Electronic Controlled Fuel System
6M60-TL Diesel Engine: Cooling
6M60-TL Diesel Engine: Intake and Exhaust
6M60-TL Diesel Engine: Emission Control
6M60-TL Diesel Engine: Electrical
6M60-TL Diesel Engine: Special Equipment
File Format: PDF
Compatible: All Versions of Windows & Mac
Language: English
Requirements: Adobe PDF Reader
NO waiting, Buy from responsible seller and get INSTANT DOWNLOAD, Without wasting your hard-owned money on uncertainty or surprise! All pages are is great to haveCATERPILLAR CAT DP100N FORKLIFT LIFT TRUCKS Service Repair Workshop Manual.
Looking for some other Service Repair Manual,please check:
https://www.aservicemanualpdf.com/
Thanks for visiting!
This document provides a service manual for cooling system components on certain Cat lift truck models. It includes specifications, component layout diagrams, removal and installation instructions, and inspection/adjustment procedures. The cooling system uses a water-cooled, forced circulation design with a corrugated fin radiator, centrifugal water pump, and wax pellet thermostat. Instructions are provided for inspecting and adjusting the fan belt tension.
Caterpillar cat dp40 k forklift lift trucks chassis and mast service repair m...jksjdmd
This service manual provides information for servicing Caterpillar lift trucks. It covers GP and DP series trucks powered by gasoline or diesel engines. The manual includes sections on general information, cooling, electrical, powertrain, brake and other systems. Safety precautions are outlined and each section provides descriptions, specifications, removal/installation instructions, and disassembly/reassembly procedures. Dimensional data and technical specifications are provided for each truck model.
Komatsu ck30 1 skid steer loader service repair manual (sn a30001 and up)fjkskmmdmme
This 3-page shop manual section provides information on servicing and repairing the Komatsu CK30-1 compact track loader. It includes an overview of the manual's contents and structure, safety precautions for working on the equipment, and guidance for how to read and update the manual. The document outlines the main components that will be covered, testing and adjustment procedures, removal and installation instructions, maintenance standards, and other information needed for repair work. Special symbols are used to mark important safety guidelines and quality points.
This is the Highly Detailed factory service repair manual for theCATERPILLAR CAT GC55K FORKLIFT LIFT TRUCKS, this Service Manual has detailed illustrations as well as step by step instructions,It is 100 percents complete and intact. they are specifically written for the do-it-yourself-er as well as the experienced mechanic.CATERPILLAR CAT GC55K FORKLIFT LIFT TRUCKS Service Repair Workshop Manual provides step-by-step instructions based on the complete dis-assembly of the machine. It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure. Complete download comes in pdf format which can work under all PC based windows operating system and Mac also, All pages are printable. Using this repair manual is an inexpensive way to keep your vehicle working properly.
Service Repair Manual Covers:
Chassis and Mast: Foreword
Chassis and Mast: General Information
Chassis and Mast: Cooling System
Chassis and Mast: Electrical System
Chassis and Mast: Power Train
Chassis and Mast: Power shift Transmission
Chassis and Mast: Front Axle and Reduction Differential
Chassis and Mast: Rear Axle
Chassis and Mast: Brake System
Chassis and Mast: Steering System
Chassis and Mast: Hydraulic System
Chassis and Mast: Mast and Forks
Chassis and Mast: Service Data
Chassis and Mast: Schematics
Options Supplement: Foreword
Options Supplement: Safety
Options Supplement: Rear Combination Kit
Options Supplement: Warning Lamp Kit
Options Supplement: Working Lamp Kit
Options Supplement: Creeper Speed Kit
Options Supplement: Foot Directional Control Group
Options Supplement: Engine Shutdown Kit (LPG Models Only)
Options Supplement: Enclosed Alternator Field Kit
Options Supplement: Disconnect Switch Kit
Options Supplement: UL Fuel Cap Kit (Gasoline models only)
Options Supplement: Key Kit
Options Supplement: Back Buzzer Kit
Options Supplement: Dual Element Air Cleaner
Options Supplement: Dust and Foundry Kit
Options Supplement: Back Mirror Kit
File Format: PDF
Compatible: All Versions of Windows & Mac
Language: English
Requirements: Adobe PDF Reader
NO waiting, Buy from responsible seller and get INSTANT DOWNLOAD, Without wasting your hard-owned money on uncertainty or surprise! All pages are is great to haveCATERPILLAR CAT GC55K FORKLIFT LIFT TRUCKS Service Repair Workshop Manual.
Looking for some other Service Repair Manual,please check:
https://www.aservicemanualpdf.com/
Thanks for visiting!
This shop manual provides instructions for servicing an SK1026-5 turbo skid-steer loader. It contains sections on structure and function, testing and adjusting, disassembly and assembly, and maintenance standards. Safety precautions are outlined, including wearing protective equipment and following proper lifting procedures. The document provides instructions for removing the engine hood and tilting the cab to access components.
Caterpillar cat 950 k wheel loader (prefix j5m) service repair manual (j5m000...wedsrffcdgdv
This document provides instructions for removing and installing the crankshaft front seal on a Caterpillar 950K wheel loader. It describes using a special tool to press the seal out of and into the front cover. Cleanliness is emphasized to prevent premature wear. The instructions are part of a service manual for Caterpillar C7.1 engines.
Caterpillar cat 950 k wheel loader (prefix fer) service repair manual (fer000...wedsrffcdgdv
The document provides instructions for removing and installing a secondary steering pump and electric motor on a Caterpillar 950K wheel loader. It describes 28 steps to disassemble the steering pump, including removing valves, spools, springs, and other internal components. It then lists 34 steps for reassembling the steering pump. The summary advises checking axial shaft end play during installation and adjusting as needed with a shim.
This document provides instructions for disassembling a piston pump used in Caterpillar articulated trucks. It begins by listing the required tools. It then provides step-by-step instructions to disassemble the various components of the pump, including removing seals, springs, valves, and housing pieces. Detailed illustrations accompany each step. Safety notices are included to warn of potential injuries from released springs or pressurized components. The disassembly process yields all individual parts of the pump.
This document provides instructions for removing and installing a piston pump and pump control valve on a 725 Articulated Truck. It outlines 37 steps to disassemble the piston pump, checking components for wear, lubricating seals, and precisely adjusting preload on bearings. It then describes 4 steps to install the piston pump and connect hoses. Finally, it warns of hot oil and pressures in the hydraulic system and lists 1 step to remove identification marks from hoses when removing the pump control valve.
Caterpillar cat 336 f l excavator (prefix yfd) service repair manual (yfd0000...wedsrffcdgdv
This document provides instructions to disassemble a 336F excavator travel motor. It outlines 27 steps to remove components such as the motor head assembly, springs, seals, relief valves, plugs and more. Tools required include a transmission repair stand, lifting eye assembly, driver group, retaining ring pliers and other specialized tools. Safety precautions are provided to release spring forces and contain fluids.
Caterpillar cat 336 f l excavator (prefix nbl) service repair manual (nbl0000...wedsrffcdgdv
This document provides instructions for disassembling and assembling the travel motor of a 336F excavator. It begins by listing the required tools. The 30 step disassembly procedure describes how to remove components like springs, seals, plates, and housing pieces. The 28 step assembly procedure describes how to reinstall these components in reverse order and includes notes on lubrication and proper positioning. Personal safety cautions are provided throughout for parts under spring tension.
Caterpillar cat 336 f l excavator (prefix lcl) service repair manual (lcl0000...wedsrffcdgdv
This document provides disassembly instructions for a travel motor on a 336F excavator model. It outlines 27 steps to fully disassemble the travel motor, including removing the motor head assembly, piston assemblies, barrel assembly, swashplate, and other internal components. Various tools are required to remove retaining rings, seals, springs, and other parts in the proper sequence. Care must be taken to mark components' locations and ensure springs and other parts are released safely.
Caterpillar cat 336 f l excavator (prefix dsw) service repair manual (dsw0000...wedsrffcdgdv
This document provides instructions for disassembling the travel motor on 336F and 336F L excavator models. It outlines 27 steps to fully disassemble the travel motor, including removing the motor head assembly, piston assemblies, barrel assembly, friction plates, seals, springs, and other internal components. Detailed illustrations are provided to identify each part mentioned in the procedure. Safety notices advise wearing protective equipment when compressing springs or releasing pressurized components during disassembly.
Caterpillar cat 336 f excavator (prefix yfd) service repair manual (yfd00001 ...wedsrffcdgdv
This document provides instructions to disassemble a 336F excavator travel motor. It lists 27 steps to fully disassemble the travel motor, including removing components like the head, springs, pistons, plates, seals and more. Tools required include bolts, pins, drivers, pullers and stands to safely remove parts and release spring forces. Detailed illustrations accompany each step to show how to disassemble the various systems and components of the travel motor.
Caterpillar cat 336 f excavator (prefix nbl) service repair manual (nbl00001 ...wedsrffcdgdv
This document provides instructions for disassembling and assembling the travel motor of a 336F excavator. It begins by listing the required tools. The 30 step disassembly procedure describes how to remove components like springs, seals, plates, and housing pieces. The 28 step assembly procedure describes how to reinstall these components in reverse order and includes notes on lubrication and proper positioning. Personal safety warnings are provided throughout for components under spring pressure.
Caterpillar cat 336 f excavator (prefix lcl) service repair manual (lcl00001 ...wedsrffcdgdv
This document provides instructions for disassembling the travel motor on a 336F and 336F L excavator. The 27-step process includes removing components like the motor head assembly, piston assemblies, barrel assembly, swashplate, and seals. Special tools are required to remove parts and release spring forces safely. The detailed illustrations and part numbers allow technicians to accurately disassemble and reassemble the travel motor.
Bomag bw 177 single drum rollers service repair manualwedsrffcdgdv
The document provides a maintenance table for a single drum roller that outlines maintenance work to be performed at various operating hour intervals. It lists over 40 maintenance items ranging from daily checks of fluid levels to annual tasks like changing engine oil and filters. Performing regular maintenance according to the schedule is important to ensure the machine is ready for demanding construction work and all safety systems function properly.
Clark esm 12 25 forklift service repair manualwedsrffcdgdv
This document provides maintenance instructions for an electric lift truck. It outlines a planned maintenance program with periodic inspections and maintenance tasks to complete. The inspections and tasks are divided into groups to make the maintenance efficient. Safety practices for maintenance are also described. Completing regular planned maintenance is important for the safe operation and long life of the lift truck.
Clark cq202530 l forklift service repair manualwedsrffcdgdv
The document provides information on servicing and maintaining the CQ20-30 truck transaxle:
- The transaxle construction includes a torque converter, single-speed transmission, differential, drive axle, and drum brakes. Maintenance includes checking fluid levels, changing fluid and filters regularly, and adjusting the service brakes.
- Precautions for disassembly and assembly emphasize cleanliness to prevent contamination. The transaxle has openings for checking fluid levels and draining fluid. Filters should be replaced every 1,000 hours.
- Brake adjustments can be made through openings in the backing plate or wheel hub, aiming for a brake shoe to drum clearance of 0.255-0.304
Clark cq202530 d forklift service repair manualwedsrffcdgdv
The document provides information on servicing the CQ20-30 transaxle:
- It describes the construction of the TA18 transaxle assembly and its components.
- Maintenance procedures are outlined, including checking fluid level and changing fluid and filter every 1,000 hours.
- Pressure specifications and check points for the regulator valve, converter, clutches, and other components are provided.
- The process for adjusting the service brakes via the backing plate or wheel hub opening is described in detail. Cleanliness and proper adjustment are emphasized to prevent issues.
Clark cmp 70 forklift service repair manualwedsrffcdgdv
This document provides safety instructions for lifting, jacking, and blocking a CLARK forklift truck during maintenance. It identifies approved lifting points on the truck and describes procedures for safely raising different parts of the truck, including the drive wheels, front with a hoist, and upright carriage. Workers are instructed to use blocking and wheel cradles, and cautioned to ensure any lifting equipment is rated for the truck's weight.
Clark cmp 60 forklift service repair manualwedsrffcdgdv
This document provides safety instructions for lifting, jacking, and blocking a CLARK forklift truck during maintenance. It identifies approved lifting points on the truck and describes procedures for safely raising different parts of the truck, including the drive wheels, front with a hoist, and upright carriage. Workers are instructed to use blocking and wheel cradles, and cautioned to ensure any lifting equipment is rated for the truck's weight.
Clark cmp 50 forklift service repair manualwedsrffcdgdv
This document provides safety instructions for lifting, jacking, and blocking a CLARK forklift truck during maintenance. It identifies approved lifting points on the truck and describes procedures for safely raising different parts of the truck, including the drive wheels, front with a hoist, and upright carriage. Workers are instructed to use blocking and wheel cradles, and cautioned to ensure any lifting equipment is rated for the truck's weight.
Caterpillar cat d550 b articulated dump truck (prefix 5nd) service repair man...wedsrffcdgdv
This document provides instructions for servicing various components of a Caterpillar 3408 engine, including removing and installing the camshaft, camshaft bearings, timing gears, flywheel, and flywheel housing. The camshaft removal procedure involves using several tools to remove the camshaft gear, camshaft, and dowel. Camshaft bearing removal requires using a tool from the rear of the cylinder block. Timing gear removal involves removing the front balance gear and crankshaft gear. Flywheel removal requires fastening a tool and lifting the flywheel off. Flywheel housing removal requires removing mounting bolts and a bracket.
Caterpillar cat d400 e ii ejector truck (prefix apf) service repair manual (a...wedsrffcdgdv
This document provides instructions for removing and installing inlet and exhaust valves, valve guides, valve seat inserts, and the engine oil filter base on a D400E II Ejector Truck with a 3406E engine. The procedures describe draining fluids, using various specialty tools to compress springs, extract components, and properly position replacement parts. Safety precautions are provided to prevent injury when handling springs or draining fluids.
Caterpillar cat 950 k wheel loader (prefix j5m) service repair manual (j5m000...wedsrffcdgdv
This document provides instructions for removing and installing the crankshaft front seal on a Caterpillar 950K wheel loader. It describes using a special tool to press the seal out of and into the front cover. Cleanliness is emphasized to prevent premature wear. The instructions are part of a service manual for Caterpillar C7.1 engines.
Caterpillar cat 950 k wheel loader (prefix fer) service repair manual (fer000...wedsrffcdgdv
The document provides instructions for removing and installing a secondary steering pump and electric motor on a Caterpillar 950K wheel loader. It describes 28 steps to disassemble the steering pump, including removing valves, spools, springs, and other internal components. It then lists 34 steps for reassembling the steering pump. The summary advises checking axial shaft end play during installation and adjusting as needed with a shim.
This document provides instructions for disassembling a piston pump used in Caterpillar articulated trucks. It begins by listing the required tools. It then provides step-by-step instructions to disassemble the various components of the pump, including removing seals, springs, valves, and housing pieces. Detailed illustrations accompany each step. Safety notices are included to warn of potential injuries from released springs or pressurized components. The disassembly process yields all individual parts of the pump.
This document provides instructions for removing and installing a piston pump and pump control valve on a 725 Articulated Truck. It outlines 37 steps to disassemble the piston pump, checking components for wear, lubricating seals, and precisely adjusting preload on bearings. It then describes 4 steps to install the piston pump and connect hoses. Finally, it warns of hot oil and pressures in the hydraulic system and lists 1 step to remove identification marks from hoses when removing the pump control valve.
Caterpillar cat 336 f l excavator (prefix yfd) service repair manual (yfd0000...wedsrffcdgdv
This document provides instructions to disassemble a 336F excavator travel motor. It outlines 27 steps to remove components such as the motor head assembly, springs, seals, relief valves, plugs and more. Tools required include a transmission repair stand, lifting eye assembly, driver group, retaining ring pliers and other specialized tools. Safety precautions are provided to release spring forces and contain fluids.
Caterpillar cat 336 f l excavator (prefix nbl) service repair manual (nbl0000...wedsrffcdgdv
This document provides instructions for disassembling and assembling the travel motor of a 336F excavator. It begins by listing the required tools. The 30 step disassembly procedure describes how to remove components like springs, seals, plates, and housing pieces. The 28 step assembly procedure describes how to reinstall these components in reverse order and includes notes on lubrication and proper positioning. Personal safety cautions are provided throughout for parts under spring tension.
Caterpillar cat 336 f l excavator (prefix lcl) service repair manual (lcl0000...wedsrffcdgdv
This document provides disassembly instructions for a travel motor on a 336F excavator model. It outlines 27 steps to fully disassemble the travel motor, including removing the motor head assembly, piston assemblies, barrel assembly, swashplate, and other internal components. Various tools are required to remove retaining rings, seals, springs, and other parts in the proper sequence. Care must be taken to mark components' locations and ensure springs and other parts are released safely.
Caterpillar cat 336 f l excavator (prefix dsw) service repair manual (dsw0000...wedsrffcdgdv
This document provides instructions for disassembling the travel motor on 336F and 336F L excavator models. It outlines 27 steps to fully disassemble the travel motor, including removing the motor head assembly, piston assemblies, barrel assembly, friction plates, seals, springs, and other internal components. Detailed illustrations are provided to identify each part mentioned in the procedure. Safety notices advise wearing protective equipment when compressing springs or releasing pressurized components during disassembly.
Caterpillar cat 336 f excavator (prefix yfd) service repair manual (yfd00001 ...wedsrffcdgdv
This document provides instructions to disassemble a 336F excavator travel motor. It lists 27 steps to fully disassemble the travel motor, including removing components like the head, springs, pistons, plates, seals and more. Tools required include bolts, pins, drivers, pullers and stands to safely remove parts and release spring forces. Detailed illustrations accompany each step to show how to disassemble the various systems and components of the travel motor.
Caterpillar cat 336 f excavator (prefix nbl) service repair manual (nbl00001 ...wedsrffcdgdv
This document provides instructions for disassembling and assembling the travel motor of a 336F excavator. It begins by listing the required tools. The 30 step disassembly procedure describes how to remove components like springs, seals, plates, and housing pieces. The 28 step assembly procedure describes how to reinstall these components in reverse order and includes notes on lubrication and proper positioning. Personal safety warnings are provided throughout for components under spring pressure.
Caterpillar cat 336 f excavator (prefix lcl) service repair manual (lcl00001 ...wedsrffcdgdv
This document provides instructions for disassembling the travel motor on a 336F and 336F L excavator. The 27-step process includes removing components like the motor head assembly, piston assemblies, barrel assembly, swashplate, and seals. Special tools are required to remove parts and release spring forces safely. The detailed illustrations and part numbers allow technicians to accurately disassemble and reassemble the travel motor.
Bomag bw 177 single drum rollers service repair manualwedsrffcdgdv
The document provides a maintenance table for a single drum roller that outlines maintenance work to be performed at various operating hour intervals. It lists over 40 maintenance items ranging from daily checks of fluid levels to annual tasks like changing engine oil and filters. Performing regular maintenance according to the schedule is important to ensure the machine is ready for demanding construction work and all safety systems function properly.
Clark esm 12 25 forklift service repair manualwedsrffcdgdv
This document provides maintenance instructions for an electric lift truck. It outlines a planned maintenance program with periodic inspections and maintenance tasks to complete. The inspections and tasks are divided into groups to make the maintenance efficient. Safety practices for maintenance are also described. Completing regular planned maintenance is important for the safe operation and long life of the lift truck.
Clark cq202530 l forklift service repair manualwedsrffcdgdv
The document provides information on servicing and maintaining the CQ20-30 truck transaxle:
- The transaxle construction includes a torque converter, single-speed transmission, differential, drive axle, and drum brakes. Maintenance includes checking fluid levels, changing fluid and filters regularly, and adjusting the service brakes.
- Precautions for disassembly and assembly emphasize cleanliness to prevent contamination. The transaxle has openings for checking fluid levels and draining fluid. Filters should be replaced every 1,000 hours.
- Brake adjustments can be made through openings in the backing plate or wheel hub, aiming for a brake shoe to drum clearance of 0.255-0.304
Clark cq202530 d forklift service repair manualwedsrffcdgdv
The document provides information on servicing the CQ20-30 transaxle:
- It describes the construction of the TA18 transaxle assembly and its components.
- Maintenance procedures are outlined, including checking fluid level and changing fluid and filter every 1,000 hours.
- Pressure specifications and check points for the regulator valve, converter, clutches, and other components are provided.
- The process for adjusting the service brakes via the backing plate or wheel hub opening is described in detail. Cleanliness and proper adjustment are emphasized to prevent issues.
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Mitsubishi fgc70 k forklift trucks (engine) service repair manual
1. Service Manual
99789-74120
For use with the FGC35K-FGC70K;
FG35-FG50; FG40K-FG50K Chassis Service Manuals.
GM 4.3L, G6 Gasoline Engine
003103-up
2. FOREWORD
This service manual covers the GM 4.3L Gasoline Engine installed in Mitsubishi Forklift Trucks and gives detailed
maintenance and repair information. For your convenience the instructions are grouped by systems as a ready reference.
The long productive life of your forklift truck(s) depends on regular and proper servicing. Servicing consistent with
what you will learn from this service manual. Read the respective sections of this manual carefully and familiarize
yourself with all the components before attempting to start a test, repair or rebuild job.
The descriptions, illustrations and specifications contained in this manual are for engines with serial numbers in
effect at the time of printing. Mitsubishi Forklift Trucks reserves the right to change specifications or design without
notice and without incurring obligation.
Whenever a question arises regarding this engine, or this manual, consult your Cat lift truck dealer for the
latest available information.
For items pertaining to the chassis, refer to the Chassis Service Manual. This service manual covers the fuel system
for units built before 01/01/2004. See fuel system supplements for units built after 01/01/2004.
Notes, Cautions, and Warnings
NOTES, CAUTIONS, and WARNINGS are used in this manual to emphasize important and critical instructions. They
are used for the following conditions:
To highlight an essential operating procedure or condition.
Operating procedures or practices that will result in damage to or destruction of the
engine if not strictly observed.
Operating procedures or practices that will result in serious injury or
loss of life if not correctly followed.
NOTE
CAUTION
!
WARNING
!
-I-
3. Inspecting
Only the inspections to be performed by using special tools or measuring instruments are covered. General service procedures
not covered in this manual, such as visual inspections and cleaning of parts should always be performed during actual service
operations.
Scope of Explanation
This book describes the service procedures for the engine removed from a vehicle.
For procedures concerning the removal of the engine from the vehicle and on-vehicle inspection and servicing,
refer to the appropriate service manuals separately prepared for the individual models.
Classification of Major Maintenance/Service Points
When there are major points relative to maintenance and
servicing procedures (such as essential maintenance and
service points, maintenance and service standard values,
information regarding the use of special tools, etc.), these are
arranged together as major maintenance and service points
and explained in detail.
Indicates there are essential points for removal or
disassembly.
Indicates there are essential points for installation or
reassembly.
A
B
Grease
(multi-purpose grease unless there is a
brand or type specified)
Sealant or adhesive
Brake fluid, automatic transmission fluid
or air conditioner compressor oil
Engine oil or gear oil
Symbols for Lubrication, Sealants and
Adhesives
Information concerning the locations for lubrication
and application of sealants and adhesives is
provided, by using symbols, in the diagram of
component parts, or on the page following the
component parts page, and explained.
Maintenance and Servicing Procedures
(1) Adiagram of the component parts is provided near
the front of each section in order to give the reader
a better understanding of the installed condition of
component parts.
(2) The numbers provided within the diagram indicate
the sequence for maintenance and servicing
procedures; the symbol indicates a non- reusable
part; the tightening torque is provided wher e
applicable.
• Removal Steps:
The part designation number corresponds to the number
in the illustration to indicate removal steps.
• Installation Steps:
Specified in case installation is impossible in reverse order
of removal steps. Omitted if installation is possible in reverse
order of removal steps.
• Disassembly Steps:
The part designation number corresponds to the number
in the illustration to indicate disassembly steps.
• Reassembly Steps:
Specified in case reassembly is impossible in reverse order
of disassembly steps. Omitted if reassembly is possible
in reverse order of disassembly steps.
N
How to Read This Manual
-II-
4. INSTALLATION OR REMOVAL SERVICE POINTS
Install the oil pump screen.
• If removed, replace the oil pump screen. The oil
pump screen must have a good press fit into the
oil pump body.
• Mount the oil pump in a soft jawed vise.
• Apply sealer to the end of the pipe.
• Use the (J 21882) and a soft-faced hammer to
tap the oil pump screen into the pump body. The
screen must align parallel with the bottom of the
oil pan when it is installed.
Removal steps
1. Plug
2. Nut
3. Bolt
4. Pan
5. Gasket
6. Bolt
7. Pin
8. Pump
9. Retainer
10. Shaft
11. Bolt
12. Pin
13. Cover
14. Screen
4
5
1
2
3
15. Plug
16. Valve
17. Spring
18. Filter
19. Fitting
20. Valve
21. Bolt
22. Adapter - Oil Filter
23. Gasket
24. Connector
25. Gasket 22
20
19
18
25
24
21
10
9
8
14
13
12
11
7
6
17
16
15
23
Lubricate all inter-
nal parts with
engine oil during
Unit: kgf-m (lb-ft) [N-m]
*kgf-m (lb-in.) [N-m]
T = 1.22 (106) [12]
Removal and Installation
➧A➧
➧A➧
Operating procedures, cautions, etc., on
removal, installation, disassembly and
reassembly are described.
Denotes tightening
torque.
This alphabetical letter corresponds to a part that is
indentified in the drawing on the first page of each
section. The letter appears during an explanation of
removal, installation, disassembly or reassembly steps.
Denotes
nonreusable part.
-III-
N
N
N
T = 9.14 (66) [90]
T = 2.08 (15) [20]
T = 2.49 (18) [25]
T = 2.49 (18) [25]
T = 2.49 (18) [25]
J 21882
5. WARNING
! WARNING
!
The OPERATION & MAINTENANCE MANUAL
outlines the proper and safe lubrication and
maintenance for the truck, as recommended by
Mitsubishi Forklift Trucks.
Read and understand the OPERATION &
MAINTENANCE MANUAL before performing any
lubrication or maintenance. Improperly
performed lubrication or maintenance
procedures are dangerous and could result in
injury or death.
Because the service mechanic may be unfamiliar
with many of the systems on this truck it is
important to use caution when performing service
work. Knowledge of the system and/or components
is important before the removal or disassembly of
any component.
Because of the size of some of the truck
components, the service mechanic should check
the weights noted in this Manual. Use proper lifting
procedures when removing any components.
Following is a list of basic precautions, cautions and
notices that should always be observed.
1. Read and understand all warning plates and
decals on the truck before operating, lubricating
or repairing the part or system.
2. Always wear protective glasses and protective
shoes when working around trucks. In particular,
wear protective glasses when pounding on any
part of the truck or its attachments with a
hammer or sledge. Use welder's gloves,
hood/goggles, apron and other protective
clothing appropriate to the welding job being
performed. Do not wear loose-fitting or torn
clothing. Remove all rings from fingers when
working on truck.
3. Do not work on any truck that is supported only
by lift jacks or a hoist. Always use blocks or
jack stands to support the truck before
performing any disassembly.
4. Lower the forks or other implements to the
ground before performing any work on the truck.
If this cannot be done, make sure the forks or
other implements are blocked correctly to
prevent them from dropping unexpectedly.
Do not operate this truck unless you have read
and understand the instructions in the
OPERATOR’S MANUAL. Improper truck
operation is dangerous and could result in injury
or death.
5. Use steps and grab handles (if applicable) when
mounting or dismounting a truck. Clean any
mud or debris from steps, walkways or work
platforms before using. Always face truck when
using steps, ladders and walkways. When it is
not possible to use the designed access
system, use ladders, scaffolds, or work
platforms to perform safe repair operations.
6. To reduce the risk of back injury, use hoist when
lifting components which weigh 23 kg (50 lb.) or
more. Make sure all chains, hooks, slings, etc.,
are in good condition and are of the correct
capacity. Be sure hooks are positioned
correctly. Lifting eyes are not to be side loaded
during a lifting operation.
7. To reduce the risk of burns, be alert for hot
parts on trucks which have just been stopped
and have hot fluids in lines, tubes and
compartments.
8. Be careful when removing cover plates.
Gradually back off the last two bolts or nuts
located at opposite ends of the cover or device
and pry cover loose to relieve any spring or
other pressure before completely removing the
last two bolts or nuts.
9. Be careful when removing filler caps, breather
and plugs on the truck. Hold a rag over the cap
or plug to prevent being sprayed or splashed by
liquids under pressure. The danger is even
greater if the truck has just been stopped
because fluids can be hot.
10. Always use tools that are in good condition and
understand how to correctly use them before
performing any service work.
11. Reinstall all fasteners with same part number.
Do not use a lesser quality fastener if
replacements are necessary. Do not mix metric
fasteners with standard nuts and bolts.
12. If possible, make all repairs with the truck
parked on a level, hard surface. Block the truck
so it does not roll while working on or under it.
13. Disconnect battery and discharge any
capacitors (electric trucks) before starting to
work on the truck. Hang “Do Not Operate” tag
in the Operator’s Compartment.
-IV-
6. WARNING
! WARNING
!
14. Repairs which require welding should be
performed only with the benefit of the
appropriate reference information and by
personnel adequately trained and
knowledgeable in welding procedures.
Determine the type of metal being welded and
select correct welding procedure and
electrodes, rods or wire to provide a weld metal
strength equivalent at least to that of parent
metal.
15. Do not damage wiring during removal
operations. Do not reinstall damaged wiring.
Reinstall the wiring so it will not be damaged in
operation by contacting sharp corners, or by
rubbing against an object or hot surface. Do not
connect wiring to a line containing fluid.
16. Be sure all protective devices, including guards
and shields, are properly installed and
functioning correctly before starting a repair. If a
guard or shield must be removed to perform the
repair work, use extra caution.
17. When the mast needs to be in the raised
position during maintenance and repairs, always
support the mast and carriage to keep the
carriage or attachments raised.
18. Loose or damaged fuel, lubricant and hydraulic
lines, or tubes and hoses can cause fires. Do
not bend or strike high pressure lines or install
ones that are bent or damaged. Inspect lines,
tubes and hoses carefully. Do not check for
leaks with your hands. Pin hole (very small)
leaks can result in a high velocity oil stream that
will be invisible upon close inspection of the
hose. This oil can penetrate the skin and cause
serious injury. Use cardboard or paper to locate
pin hole leaks.
19. Tighten connections to the correct torque.
Make sure all heat shields, clamps and guards
are installed correctly to avoid excessive heat,
vibration or rubbing against other parts during
operation. Shields must be correctly installed if
they protect against oil spray onto hot exhaust
components in the event of a line, tube, or seal
failure.
20. Relieve all pressure in air, oil or water systems
before any lines, fittings or related items are
disconnected or removed. Always make sure all
raised components are blocked correctly. Be
alert for possible pressure when disconnecting
any device from a system that uses pressure.
21. Do not operate a truck if any rotating part is
damaged or contacts any other part during
operation. Any high speed rotating component
that has been damaged or altered should be
checked for balance before reusing.
22. Caution should be used to avoid breathing dust
that may be generated when handling
components containing asbestos fibers. If this
dust is inhaled, it can be hazardous to your
health.
If dust containing asbestos is present, there are
several common sense guidelines that should
be followed.
a. Never use compressed air for cleaning.
b. Avoid brushing or grinding asbestos
containing materials.
c. For clean up, use wet methods or a vacuum
equipped with a high efficiency particulate air
(HEPA) filter.
d. Use exhaust ventilation on permanent
machining jobs.
e Wear an approved respirator if there is no
other way to control the dust.
f. Comply with applicable rules and regulations
for the work place.
g. Follow environmental rules and regulations
for disposal of asbestos.
h. Avoid areas where asbestos particles may be
in the air.
-V-
7. -VI-
Precautions
Precautions for Disassembly and
Assembly
This section contains basic safety precautions and
outlines basic recommended procedures, some of
which require special tools, devices or work methods.
However, the safety precautions contained herein
are not for all service work. It is the responsibility of
service personnel to know that specific require-
ments, precautions and work hazards exist and to
discuss these with a foreman or supervisor.
Disassembly
1. Always use tools that are in good condition.
Understand how to use them before performing
any service work.
2. Use an overhaul stand or a work bench, if
necessary. Also, use bins to keep engine parts
in order of removal.
3. Lay down the disassembled and cleaned parts
in the order in which they were removed to
save time for assembly.
4. Pay attention to marks on assemblies,
components and parts for their positions or
directions. If necessary, add marks to aid in
assembly.
5. During removal or cleaning, carefully check
each part for any sign of faulty condition. Signs
of wear or abnormalities that caused the engine
to work abnormally are more easily and
accurately spotted during removal or cleaning.
6. Get help when lifting or carrying a part that is
too heavy or awkward for one person to handle.
If necessary, use a jack or a hoist.
Separating Parts
Important: Many internal engine components will
develop specific wear patterns on their friction sur-
faces.
When disassembling the engine, internal components
MUST be separated, marked and organized in a
way to ensure reinstallation to the original location
and position.
Mark or identify the following components:
• Piston and the piston pin
• Piston to the specific cylinder bore
• Piston rings to the specific cylinder bore
• Connecting rod to the crankshaft journal
• Connecting rod to connecting rod cap
• Crankshaft bearings and connecting rod bearings
• Engine camshaft and valve lifters
• Valve lifters, valve rocker arms and valve rocker
arm supports
• Valve to valve guide
• Valve spring to cylinder head location
• Engine block bearing cap location and direction
• Oil pump drive and driven gears
Replacing Engine Gaskets
Gasket Reuse and Applying Sealant
• Do not reuse any gasket unless specified.
• Gaskets that can be reused will be identified in
the service procedure.
• Do not apply sealant to any gasket or sealing
surface unless specified in the service procedure.
Separating Components
• Use a rubber mallet in order to separate the
components.
• Bump the part sideways in order to loosen the
components.
• Bumping of the component should be done at
bends or reinforced areas of the component to
prevent distortion of the components.
Cleaning Gasket Surfaces
• Use care to avoid gouging or scraping the
sealing surfaces.
• Use a plastic or wood scraper in order to
remove all the sealant from the components.
• Do not use any other method or technique to
remove the sealant or the gasket material from
a part.
• Do not use abrasive pads, sand paper or
power tools to clean the gasket surfaces.
• These methods of cleaning can cause
damage to the component sealing surfaces.
• Abrasive pads also produce a fine grit
that the oil filter cannot remove from the
engine oil.
This fine grit is abrasive and can cause
internal engine damage.
Service Prior to Assembly
• Dirt will cause premature wear of the rebuilt
engine. Clean all the component.
• Use the proper tools to measure the compo-
nents when checking for excessive wear.
Components not within the manufacturer’s
specification must be repaired or replaced.
• When the components are re-installed into an
engine, return the components to the original
location, position and direction.
• During assembly, lubricate all the moving parts
with clean engine oil (unless otherwise specified).
The engine oil will provide the initial lubrication
when the engine is first started.
8. -VII-
Assembling Components
• Assemble components using only the sealant
(or equivalent) that is specified in the service
procedure.
• Sealing surfaces must be clean and free of
debris or oil.
• Specific components such as crankshaft oil
seals or valve stem oil seals may require
lubrication during assembly.
• Components requiring lubrication will be
identified in the service procedure.
• Apply only the amount of sealant specified in
the service procedure to a component.
• Do not allow the sealant to enter into any blind
threaded holes, as the sealant may prevent the
fastener from clamping properly or cause
component damage when tightened.
• Tighten fasteners to the proper specifications.
DO NOT overtighten the fasteners.
Assembly
Cleanliness and Care
This engine is a combination of many machined,
honed, polished and lapped surfaces with toler-
ances that are measured in ten thousandths of an
inch. Care and cleanliness are important when any
internal engine parts are serviced. During assembly,
a liberal coating of engine oil should be applied to
friction areas to protect and lubricate the surfaces
on initial operation. Throughout this section, it
should be understood that proper cleaning and
protection of truck surfaces and friction areas are
part of the repair procedure. This is considered
standard shop practice, even if not specifically stated.
When valve train components are removed for
service, they should be retained in order. At the
time of installation, they should be installed in the
same locations and with the same mating surface
as when removed.
1. Wash all parts, except for oil seals, O-rings,
rubber sheets, etc., with cleaning solvent and
dry them with air pressure.
2. Always use tools that are in good condition and
be sure you understand how to use them
before performing any service work.
3. Use only good-quality lubricants. Be sure to
apply a coat of oil, grease or sealant to parts as
specified.
4. Be sure to use a torque wrench to tighten parts
for which torques are specified.
5. Replace gaskets and packings with new ones.
Tools and Equipment
Special tools are listed and illustrated throughout
this manual. The tools (or equivalents) are specially
designed to quickly and safely accomplish the
operations for which the tools are intended. The use
of special tools will also minimize possible damage
to engine components. Some precision measuring
tools are required for inspection of certain critical
components. Torque wrenches and a torque angle
meter are necessary for the proper tightening of
various fasteners.
To properly service the engine assembly, the
following items should be readily available:
• Approved eye protection and safety gloves
• A clean, well-lit, work area
• A suitable parts cleaning tank
• A compressed air supply
• Trays or storage containers to keep parts and
fasteners organized
• An adequate set of hand tools
• Approved engine repair stand
• An approved engine lifting device that will
adequately support the weight of the
components
9. -VIII-
General Precautions
Removal and Disassembly
Confirm the location of the faulty part and find the
probable cause of the trouble. Then decide whether
removal or disassembly is required. If so, carry out
the removal or disassembly according to the steps
shown in this service manual.
To prevent erroneous installation and to facilitate
installation work, punch or draw alignment marks in
places where neither function nor appearance is
affected.
Make a distinction between the items removed from
one assembly and those removed from another
assembly, especially when disassembling a unit
having a large number of component parts or when
disassembling two or more similar parts. Always do
the following:
1. Keep the removed parts in order.
2. Make a distinction between the parts to be
replaced and the parts to be reused.
3. When replacing bolts and nuts, use only ones of
the specified size.
Special Tools
When specified, be sure to use the special tools for
the specific service work. Using other tools may
cause damage to parts and/or injury to workers.
Non-reusable Parts
Whenever any of the following parts are removed,
be sure to replace them with new ones.
1. Oil seals
2. Gaskets (except rocker cover gasket)
3. Packings
4. O-rings
5. Lock washers
6. Split pins
Recommended Replacement Parts
1. For replacement parts, use only genuine
Cat parts.
2. Use of the available sets and kits of service
parts is recommended.
3. To unify parts, or for other reasons, service parts
are subject to change. When replacing parts in
the engine, carefully check for possible
modifications by referring to the updated parts
catalog for the specific engine.
Genuine Cat Parts
10. -IX-
Handling of Electrical System
Shocks are harmful to sensors and relays. Never
drop or throw them.
When disconnecting a connector, do not pull the
harness. Hold the halves of the connector to
separate them from each other.
When disconnecting a lock type connector, push
the lock lever(s) in the direction(s) shown by the
arrow(s).
When connecting a lock type connector, push the
plug into the socket until it clicks.
11. -X-
Handling of Rubber Hoses and Tubes
Take care not to spill gasoline or oil on rubber hoses
or tubes, otherwise the rubber is likely to
deteriorate.
Greasing
During assembly or installation, coat the designated
surfaces with the specified grease or oil.
Cooperation
When two or more persons work together, each
worker should pay attention to the safety of the
other(s).
14. Thank you very much for
your reading. Please Click
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MANUAL. NO WAITING
NOTE:
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click on the link above,
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16. -1-
Determining When to
Overhaul the Engine
Deciding when to overhaul the engine is
determined by considering the following factors:
A drop in compression pressure as well as an
increase in lube oil consumption and excessive
blowby.
Lack of power, increase in fuel consumption, drop
in lube oil pressure, hard starting and abnormal
sound are also engine troubles. These troubles,
however, are not always the result of low
compression pressure and give no valid reason for
overhauling the engine.
The engine develops troubles of widely different
varieties when its compression pressure drops.
Following are the list of typical troubles caused by
this compression pressure fault.
1. Lack of power
2. Increase in fuel consumption
3. Increase in lube oil consumption
4. Excessive blowby through breather due to
worn cylinders, pistons, etc.
5. Excessive blowby due to poor seating of worn
inlet and exhaust valves
6. Hard starting
7. Abnormal sound
In most cases, these troubles occur concurrently.
Some of them are directly caused by low
compression pressure, but others are not. Among
the troubles listed above, 1, 2, and 6 could be
caused by low compression pressure.
The most valid reason for overhauling the engine is
(4). To determine when to overhaul the engine, it is
reasonable to take this trouble into consideration in
conjunction with the other troubles.
Engine Set-Up and Testing
After overhaul, the engine must be tested before it
is installed in the truck. If a suitable test stand is
not available, the following procedures can be used
after the engine is installed in the truck.
1. Fill the crankcase with the proper quantity and
grade of engine oil.
Notice: DO NOT use cooling system seal tabs (or
similar compounds) unless otherwise instructed.
The use of cooling system seal tabs (or similar
compounds) may restrict coolant flow through the
passages of the cooling system or the engine
components. Restricted coolant flow may cause
engine overheating and/or damage to the cooling
system or the engine components/assembly.
2. Fill the cooling system with the proper quantity
and grade of coolant.
3. With the ignition OFF or disconnected, crank the
engine several times. Listen for any unusual
noises or evidence that any of the parts are
binding.
4. Start the engine and listen for unusual noises.
5. Check the truck oil pressure gauge or light
and confirm that the engine has acceptable oil
pressure. If necessary, install an oil pressure
gauge and measure the engine oil pressure.
6. Operate the engine at about 1,000 RPM until
the engine has reached normal operating
temperature.
7. Listen for improperly adjusted or sticking valves,
sticking valve lifters or other unusual noises.
8. Inspect for oil and/or coolant leaks while the
engine is operating.
9. Verify that the distributor is properly positioned.
10. Perform a final inspection for the proper engine
oil and coolant levels.
17. -2-
Engine Replacement
Removal Procedure
If the engine is damaged internally and a new
engine assembly is installed in the truck, ensure
that all foreign material is flushed out of the cooling
system. It is also necessary to flush out the oil
cooler system. Failure to rid the oil cooler system of
debris can result in engine damage.
1. Disconnect battery.
2. Raise the truck and support with stands.
3. Drain fluids.
a. Remove the oil pan drain plug, and allow oil
to drain.
b. Remove the oil filter.
c. Remove both coolant drain plugs and allow
coolant to drain.
4. Remove the engine hood and overhead guard.
5. Disconnect the exhaust pipe from the exhaust
manifolds.
6. Disconnect the following items:
• The wiring harnesses
• The throttle cable
• The fuel lines
NOTE
7. Support engine using appropriate sling and
hoist. Use existing lifting eyes.
8. Disconnect the fuel line and fuel line clamp.
9. Remove the starter. Refer to Engine Electrical.
10. Disconnect the torque convertor bolts from the
flywheel.
11. Support the transmission with a jack.
12. Remove the transmission to engine bolts.
13. Remove the front engine mount bolts.
14. Remove the distributor.
15. Use the engine lifting device to remove the
engine from the truck.
Installation Procedure
If the engine is damaged internally and a new
engine assembly is installed in the truck, ensure
that all foreign material is flushed out of the cooling
system. It is also necessary to flush out the oil
cooler system. Failure to rid the oil cooler system of
debris can result in engine damage.
1. Use the engine lifting device to lower the engine
into place.
2. Install the engine into the truck.
3. Install the front engine mounts.
4. Install the distributor.
5. Install the following items:
• The wiring harnesses
• The vacuum lines
• The throttle cable
• The fuel lines
6. Install torque convertor to flywheel bolts.
7. Install the transmission to engine bolts.
8. Install the oil filter.
9. Install the pump drive shaft.
10. Install the starter. Refer to Engine Electrical.
11. Connect the fuel line and fuel line clamp.
12. Connect the exhaust pipe to the exhaust
manifolds.
13. Lower the truck.
14. Fill the crankcase with oil.
15. Fill radiator with coolant.
16. Connect battery.
17. Install engine hood and overhead guard.
NOTE