Service Manual
Contents
1. 0 00 eee 117 Piston Connecting Rod and Bearing Removal 00 00 eee eee 118 Piston and Connecting Rod Disassembly ooooccooocco teeta 119 Piston and Connecting Rod and Bearings Clean and Inspect 0 00 eee ee ee 119 Piston Selection ioca ch A eee EQ ae ens a ERAN uL ow adele Ree aes 122 Piston Connecting Rod and Bearing Installation llle 123 Piston and Connecting Rod Assembly cooocccoo e 124 Gasoline Carburetor i vex vw A A E E NER REUS ERE M RE EE E ME 127 Carburetor Assembly Upper o o ooooooo rrr 129 Carburetor Assembly Lower lslsssllleeeeeeeeel RR rrr 131 Carburetor Disassembly exem eer EVA Ux AY ate ee ee e RO Rn RR de dela 132 Air Horn Disassembly iss n omm mr s ch R CR A ASA UR e m ELE e Ee Yel ata 132 TABLE OF CONTENTS Carburetor Inspection 50x xm porte ae a cabe ttes Se ipis Des e ONE Ter Eb acd gn 137 Carburetor Assembly 3 perl a medie ime sce Mens 138 Air Horn Assembly x 2e expe ener AA Boe ea ie EM EM Mg mme Uo KREY 140 Carburetor Adjustment xs REG o RE a eee a A ee RUE RUE ee eee 144 Operational Adjustments trepa d e due bx veda rea eet lela a Be bles EN Ra Ed 147 Carburetor Installation rs ia irasra eapi aie hh hr 148 Electrical Throttle and Governor Control System leeren 149 oystem OperatloD zu I orc icuRiwuxee Re docete RU Ee e eoe giras Sue an Rte Meu dad don dct RE dati eh Shea 149 EGU Input Output Interfac2. 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 dis
3. F CONTENTS Oil Pan Pump and Filler 2222 sc clero a ee kon nomm RR ROW LR LR Roma ee n 57 Oil Pan Bemoval ze xr eG bie RExeteE De Edd S AREE T RR ERG ERR EN AEN Rods 58 Oil Pump Removal niis a Dyn JEA E EAE ER AERE GE RETRR RR RR R DE quA DUE RES e 59 Oil Filter Adapter R rmoval 5 2 nz E EE ERU x Red AAA RUE S doi E E 60 Oil Pump Disassembly Tui aia Lx Dodd xr ee ERR E e SS nC E dE 60 Oil Pump Assemble siu E ERE DR mx eR LER REESE RR dale ee EU EE YES 62 Oil Filter Adapter Installatlon evita da peu RE durs 63 Oil P rmp Installa tlori i lE SIMI teli WIRE A 2 A Bate EEA og 64 Oil Pan Installation ze reb eee Rex EEA phage tea dex e ab d Lec ee PUES 65 Front Cover Timing Chain and Crankshaft Balancer llle 67 Engine Front Cover Removal o ocoooccoooo eh mu 68 Engine Front Cover Oil Seal Removal oooocoocccco rr 68 Timing Chain and Sprockets Removal o ooooococco m eee 68 Crankshaft Balancer Removal rsi rroneris o earet ennari een hme 70 Crankshaft Balancer Installation 0 0 0 m rn 71 Timing Chain and Sprockets Installation 2 0 2 0 cents 72 Engine Front Cover Oil Seal Installation 0 0 0 eae 73 Engine Front Cover Installation 0 6 Enr a A a n m EEN A 73 Balancer and Camshaft iii a a a mea ees 77 Balance Shaft Removal 22 22 pw ke a bbe to a REND WE Ed 78 Gamshaft Removal A Telit Eg A A A a eee et 80 Camshaft Bearing Removal akeyi sitas stire
4. KREASE ee mh mh 80 Camshaft and Bearings Clean and Inspect ooooccooccrro ee 82 Camshaft Bearing Installation lllieeeeeeee e m m 83 Gamshatt Installation 3 525 x de REB ERE XR es We RU RUE ERA WE Ree xa RE 84 Balance Shaft and Bearing Clean and Inspect o ooooccocooccrr eren 85 Balance Shaft Installation ses rridu aeae a a e E m rh 86 Crankshaft Flywheel Rear Seal and Bearings ococococcnrnrn eee 89 Engine Flywheel Removal 00 00 cee EN ENA EENE E E hh R RA 90 Crankshaft Rear Oil Seal and Housing Removal leere 90 Crankshaft and Bearings Removal ir iseis se ninen a aE n mh 91 Crankshaft and Bearings Clean and Inspect ooooccooccccroor ee 91 Service Prior to Assembly essea dats iee aa RR nn 94 Crankshaft and Bearings Installation lise 94 Bearing Clearance Measuring Procedures o oocoooocooo rr 95 Micrometer Method for Crankshaft Bearings ooooocoroccorr re 95 Crankshaft Rear Oil Seal and Housing Installation llle 103 Engine Flywheel Installation lille RA HI E AEN 105 Cylinder Block nme 107 Engine Block Plug Removal ooooooococo e m rh 108 Cylinder Block Clean and Inspect oooocoooccoo RR m 3 110 Cylinder Boring and Honing rss iecere aseye EEEE ENA ENNE RR RR I e ut 111 Reboring the Cylinders oooocoococor eh m Inn 112 Cylinder Block Plug Installation csper cerus eee RII RM 113 Piston and Connecting Rod
5. LPG occcccococo enhn 188 Special Tools and Equipment 0ccoccccc eer 189
6. MITSUBISHI FORKLIFT TRUCKS Service Manual GM 4 3L G6 Gasoline Engine 003103 up For use with the FGC35K FGC70K FG35 FG50 FG40K FG50K Chassis Service Manuals 99789 74120 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 manua
7. 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 i
8. assembling 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 e Piston and the piston pin Piston to the specific cylinder bore Piston rings to the specific cylinder bore e 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 VI 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 e Do not reuse any gasket unless specified e 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 e 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 e Do not use any other me
9. ble 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 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 q AD Indicates there are essential points for removal or disassembly D B 4 Indicates there are essential points for installation or reassembly Symbols for Lubrication Sealants and Adhesives Grease multi purpose grease unless there is a Information concerning the locations for lubrication brand or type specified 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 Sealant or adhesive Brake fluid automatic transmission fluid or air conditioner compressor oil Engine oil or gear oil Inspecting Only the inspections to be performed by using special tools or measuring instruments are covered General service procedures not
10. covered in this manual such as visual inspections and cleaning of parts should always be performed during actual service operations Removal and Installation Removal steps Plug Nut Bolt Pan Gasket Bolt Pin Pump Retainer 10 Shaft 11 Bolt 12 Pin 13 Cover dd 14 Screen OMNAORWN Lubricate all inter ME nal parts with engine oil during kv Pet OR REMOVAL SERVICE POINTS T 122 106 12 11 Aq Install the oil pump screen f removed replace the oil pump screen The oil pump screen must have a good press fit into the oil pump body 15 16 17 18 19 20 21 22 23 24 25 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 Unit kgf m Ib ft N m kgf m Ib in N m Plug Valve Spring Filter Fitting Valve Bolt Adapter Oil Filter Gasket Connector Gasket T 9 14 66 90 Denotes tightening 1 T2249 18 25 T 249 18 25 Operating procedures cautions etc on removal installation disassembly and reassembly are described This alphabetical letter corresponds to a part that is indentified in the drawing on the first page of each section The letter appears dur
11. e dm rn 6 Engine Specifications Gas and LP 6 General Specifications oo oooooooroor ehh rrr hn 8 Major Nuts and Bolts Tightening Torque lt lt lt lt lt lt lt ooo 11 Sealers Adhesives and Lubricants 000 cece eee eee nr 13 Use of RTV and Anaerobic Sealer Gasket Eliminator 0000 cc eee 14 Diagnostic Information and Procedures 0000 cece eee eee 16 Base Engine Misfire Diagnosis 0000 eee 16 Engin Compression Test 22s euo eum RR a hindus be ali ena RR RR ee p age misce ads n wee iala E AS eck 17 Engine Noise Diagnosis saei reme Sr aaa A ae gius 18 Valve Train Diagnosis General o o oooooooooorr hh 19 Valve Train Diagnosis Noise Diagnosis 2000 e eee eee eee eee 19 Engine Mechanical 4 2 keT Hee A EA RE PTS RES pr wb ace OE SR Bo ae 22 Oil Consumption Diagnosis a a aa a a he e rr 22 Low or No Oil Pressure Diagnosis and Testing 0 00 cece ee 22 Oil Leak Diagnosis ceci ek e ec LER uem t A I uq d ee ER E Pon Rd 22 Repairing ihe Loak ore oem LS tae en NIENTE ier RE EO a meh Oe DOREM en aoe 23 Engine Lubricatior sesteto Puma km REESE RO RUE a a GRE ER e dE 25 Intake Manifold ss oa is pk RR Ra Rs rx Ru EXE TROC RO RS REP YR 29 Intake Manifold Removal 2 2 RR Duae eme meh a er S dee ape amp 30 Intake Manifold Installation llle RR RR rrr 31 Exhaust Manifold 2 ccr a s m lr rh nur mnn ia A mc m LR RR RR Rm aaa 33 Oi
12. ed 4 Be sure to use a torque wrench to tighten parts for which torques are specified 5 Replace gaskets and packings with new ones VII 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 OGFOIS QR e 00Y19 00F017 00F0 8 000511 Genuine Cat Parts 00F020 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 disassemb
13. es sata re We lve Wek dant koe hn n e n E cm oN a Rad RU e d RR dye enon apace 150 EGU Schematic edge te Muta du e it tede oy IM reum teething ad A eee 151 Method of Operation csie sa ea e soa iaia eee 152 Speed Gontrolz x sandi exte AN Aene A E a a AAA tt ae RC cR 152 GM 4 3L G6 Engine ECU Error Code Description eee 154 Ignition System and Distributor 1 0 0 000 ee 157 Ignition System Distributor 0 tenet ae 158 Distributor Removal 22 ERR IEEE ea hve wade ok E ERE en SA he pk USE RUE INE 159 Distributor Disassembly essem oe acrem dm en eH REGEL GR RUNE E dr de de ERR ae eno 159 Distributor Assembly 5 51 52 Rer A A A LIA WEIR a 159 Coil Removal ise EE REEL exe ERE dime READER AUR e ura Ee Ry RE aa 160 Coil Installation and Testing oooooooooonrror RR In 160 Ignition Sensing Coil Testing csi scie re seria siaa nena eka RR RII ae 160 Distributor Installation fo s fe DLE edi ly Mules UELLE e LEER 161 Ignition Timing eut o ret DA ee marec dh Re ase Se EN a Ec a doe sie Rae d ed eR Ra 163 Spark Pl g Inspectlonm zx ce a ER ns W Rs e pon eed d e E ei det NER EUN Rn RUE in 163 Alternator and V Belt Units built before 01 01 2004 oooooccccno nnn 165 Alternator ee eg a A E cue 167 Accessory Drive Belt Replacement ooooooocccoroo eR I mn 168 Starter Motor ie eee ec eee fo repr rre t xU rr rrr he ee E ER a xxx a Rien Ran 169 Starter Motor Testing usse xe ERU v ERR Pa meme cum cried da clc Rene adi
14. f 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
15. f Electrical System Shocks are harmful to sensors and relays Never drop or throw them 00Y586 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 16C385 16C386 16C387 16C388 16Y347 When connecting a lock type connector push the plug into the socket until it clicks X 00F021 00F028 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 TABLE OF CONTENTS ein cl cp MT l How to Read This Manual z iio a o A A E a aa lI Precautions 0 curo A d AEE A Ro Rr d E AAA A AO VI Precautions for Disassembly and Assembly o ooococcccoo eh VI General PrecautionS 0 lh hh hn nn VIII Determining When to Overhaul the Engine else 1 Engine Replacement 0 00 cece eee hhhhhhhhhhhhhh nnn nnn nnn nn 2 Removal Procedure este er held ER ER a mu Re Rao QR rd 2 Installation Procedure EVER IC RUE Be qeeed exerce uu eos Aa ey 2 Specificatlons zz eel Di A AA rw ES s Rus A doas La E eX Dua x R
16. ing an explanation of removal installation disassembly or reassembly steps The OPERATION amp MAINTENANCE MANUAL outlines the proper and safe lubrication and maintenance for the truck as recommended by Mitsubishi Forklift Trucks Read and understand the OPERATION amp 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 l
17. l Level Indicator and Tube Removal o o occco ehh 34 Exhaust Manifold and Heat Shields Removal ocoocccccccoo ene 34 Exhaust Manifold Clean and Inspect oo oocccccoo hr nnn 34 Exhaust Manifold and Heat Shields Installation 0000 cee eee 35 Oil Level Indicator and Tube Installation oo ooococoooroooooo Ren 35 Cylinder Head and Valves 22 2 30 0 ai a ek ee Ce es 37 Valve Rocker Arm Cover Removal Left ooooocoocccccono eee 38 Valve Rocker Arm Cover Removal Right 0000 cee eee 38 Valve Rocker Arm and Push Rod Removal 00 cece eee eee tee 39 Valve Litter Removal 2 2 ea eee ee A A eS Se ee a ee ie d 41 Valve Stem Oil Seal and Valve Spring Removal 00 00 cee eh 42 Cylinder Head Removal 4 2 ag kpRbriagaaec ei ec e REG RR Aga 43 Cylinder Head Disassembly and Assembly oooccocoocc ne 45 Cylinder Head Clean and Inspect cooocooocc rr 46 Valve Guide Reaming Valve and Seat Grinding o ooooooocoooorcn eee 48 Valve Stem Oil Seal and Valve Spring Installation llle 49 Valve Litter Installation sues EI Re Go RR DEA p e ERa i GEAR cae ebony eee ER 50 Cylinder Head Installation 2l IIR IA A RM 51 Valve Rocker Arm and Push Rod Installation eee eee eens 53 Valve Rocker Arm Cover Left Installation o o o o oooooooooooooooo RR se 54 Valve Rocker Arm Cover Right Installation lille e 55 TABLE O
18. l 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 A CAUTION engine if not strictly observed Operating procedures or practices that will result in serious injury or WAR N i N G loss of life if not correctly followed How to Read This Manual Scope of Explanation This book describes the service procedures for the engine removed from a vehicle For procedures conceming 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 Maintenance and Servicing Procedures Removal Steps The part designation number corresponds to the number 1 Adiagram of the component parts is provided near in the illustration to indicate removal steps the front of each section in order to give the reader a better understanding of the installed condition of component parts Installation Steps o V Specified in case installation is impossible in reverse order 2 The numbers provided within the diagram indicate of removal steps Omitted if installation is possible in reverse the sequence for maintenance and servicing order of removal steps procedures the symbol IM indicates a non reusable part the tightening torque is provided wher e applica
19. ly 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 Handling o
20. o 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 specifi
21. oose 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 V 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 Ib 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 tube
22. s 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 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
23. thod 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 Assembling Components e 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 D
24. tus 170 Troubleshooting iss xe vete EX x ERREUR A EG GER PY D ERA E RI ELS 170 Fuel System Gasoline Units built before 01 01 2004 0ooocccnnnnna hh hh 173 Fuel Pump and Fuel Hose Units built before 01 01 2004 cece I mI 175 Fuel Pump Disassembly and Reassembly Units built before 01 01 2004 177 Inspection ini EA Peed See ee Sa oe ee Puer rua EE diia 178 Main Point of Heassembly zz ner EOT eae ee ces ey Bae os San ebay eee Gas 178 Fuel System LP Units built before 01 01 2004 1 cece ee 179 Maintenance Checks rrer erinan Ret a REV Gee ace Ea os Oe ris Sab ae EE RE 180 Vacuum Fuel Lockoff Filter exl a x aaa REPRE Rc EU EUR E 181 Model Regulator ci cage pte hae nea na HEP aa EYE 182 Pressure Regulator Converter Service Procedures 0 0 cece eens 182 On Truck Pressure Test e ied E Rx DEI xu a ER Ee ER echten are uestes a eia 183 Regulator Converter Disassembly Inspection Cleaning and Assembly oooooooococooooooo 183 Regulator Converter Bench Test o oooooccooccon eh nn 183 Pressure Converter Regulator Installation Tips 0 00 cect nne 183 Regulator Lockout Removal ooooooooccro hr rh rh 183 Impco CA 100 Air Fuel MiXer cx RR ey t9 EM E LER RIEF ERA NU RAS EET TER SR E ES 184 LPG Carburetor Adjustment Procedure co exhaust Analyzer o oooooccooccooo eee 187 Governor Speed Adjustment Procedure o ooooccccocc nn 187 Accelerator Cable Adjustment
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