Crown Forklift IC Hamech D-4TNVE98 DIESEL ENGINE Service Manual – PDF DOWNLOAD

Crown Forklift IC Hamech D-4TNVE98 DIESEL ENGINE Service Manual – PDF DOWNLOAD

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Crown Forklift IC Hamech D-4TNVE98 DIESEL ENGINE Service Manual – PDF DOWNLOAD

Language : English
Pages :1409
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Crown Forklift IC Hamech D-4TNVE98 DIESEL ENGINE Service Manual – PDF DOWNLOAD

GROUP 00 (D-4TNE98) DIESEL ENGINE 1
Section 1 GENERAL SERVICE INFORMATION 3
COMPONENT IDENTIFICATION 3
LOCATION OF LABELS 3
DIESEL FUEL 4
ENGINE OIL 5
ENGINE COOLANT 7
SPECIFICATIONS 9
ENGINE SERVICE INFORMATION 11
TIGHTENING TORQUES FOR STANDARD BOLTS AND NUTS 12
STANDARD TORQUE CHART 13
Section 2 Periodic Maintenance 15
PERIODIC MAINTENANCE PROCEDURES 17
Daily 17
Every 250 Hours of Operation 19
Every 500 Hours of Operation 23
Every 1000 Hours of Operation 25
Every 2000 Hours of Operation 30
Every 4000 Hours of Operation 31
Section 3 ENGINE 33
ENGINE SERVICE INFORMATION 34
ENGINE SPECIAL TORQUE CHART 40
SPECIAL SERVICE TOOLS 41
CYlinder Head Components 46
Disassembly of Cylinder Head 47
Removal of Glow Plugs 48
Removal of Valve Cover 48
Removal of Rocker Arm Assembly 48
Disassembly of Rocker Arm Assembly 49
Removal of Cylinder Head 49
Removal of Intake / Exhaust Valves 50
Removal of Valve Guides 50
Cleaning of Cylinder Head Components 51
Inspection of Cylinder Head Components 51
Assembly of Cylinder Head 54
Assembly of Intake and Exhaust Valves 54
Assembly of Cylinder Head 55
Assembly of Rocker Arm Assembly 56
Assembly of the Valve Cover 57
Assembly of Glow Plugs 57
MEASURING AND ADJUSTING VALVE CLEARANCE 58
DRIVE TRAIN AND CAMSHAFT COMPONENTS 60
Disassembly of Drive Train andCamshaft Components 61
Removal of Oil Pan 62
Removal of Oil Sump Pump 62
Removal of Timing Gears 63
Removal of Pistons 63
Removal of Crankshaft 64
Removal of Gear Case 66
Inspection of Drive Train and Camshaft Components 67
Honing and Boring 73
Assembly of Drive Train andCamshaft Components 74
Assembly of Pistons 74
Installation of Gear Case 75
Installation of Crankshaft 75
Installation of Pistons 76
Installation of Camshaft 77
Installation of Timing Gears 77
Installation of Gear Case Cover 78
Installation of Oil Sump Pump 78
Installation of Oil Pan 78
Section 4 FUEL SYSTEM 81
FUEL SYSTEM COMPONENTS 82
FUEL SYSTEM DIAGRAM 83
STRUCTURE AND OPERATION OF FUEL INJECTION PUMP 84
PLUNGER OPERATION 88
ALL -SPEED GOVERNOR 93
STRUCTURE AND OPERATION OF TIMER 100
REMOVAL OF FUEL INJECTION PUMP 102
INSTALLATION OF THE FUEL INJECTION PUMP 105
CHECKING / ADJUSTMENT OF FUEL INJECTION TIMING 107
SERVICING THE FUEL INJECTORS 108
Section 5 COOLING SYSTEM 113
ENGINE COOLANT PUMP COMPONENTS 114
ENGINE COOLANT SYSTEMCHECK 115
DISASSEMBLY OF ENGINE COOLANTPUMP 115
CLEANING AND INSPECTION 117
ASSEMBLY OF ENGINE COOLANTPUMP 118
Section 6 LUBRICATION SYSTEM 121
LUBRICATION SYSTEM DIAGRAM 122
CHECKING ENGINE OIL PRESSURE 123
Section 7 STARTER MOTOR 127
STARTER MOTOR TROUBLESHOOTING 128
STARTER MOTOR PRECAUTIONS 129
STARTER MOTOR SERVICING 130
Section 8 ALTERNATOR 141
ALTERNATOR TROUBLESHOOTING 142
ALTERNATOR COMPONENTS 143
Section 9 TROUBLESHOOTING 157
TROUBLESHOOTING BY MEASURING COMPRESSION PRESSURE 158
QUICK REFERENCE TABLE FOR TROUBLESHOOTING 160
Section 0 SAFETY 165
Safety Precautions 166
SERVICE AREA 166
WORK – WEAR (GARMENTS) 166
TOOLS 167
GENUINE PARTS and MATERIALS 167
FASTENER TORQUE 167
Electrical 168
WASTE MANAGEMENT 168
FURTHER PRECAUTIONS 169
Precautions for Service Work 170
How to Read this Manual 170
Section 1 GENERAL 173
Fuel Oil, Lubricating Oil andCooling Water 176
Exhaust gas emission regulation 178
Section 2 Inspection and Adjustment 183
Periodic Inspection and Maintenance Procedure 184
Inspection every 1,000 hours or one year 195
Section 3 Troubleshooting 211
Section 4 Disassembly, Inspection and Reassembly of Engines 219
Complete disassembly 224
Cylinder Head: Disassembly, Inspection and Reassembly 229
Gear Train and Camshaft 240
Cylinder Block 246
Section 5 LUBRICATION SYSTEM 261
Section 6 COOLING SYSTEM 265
Section 7 FUEL INJECTION PUMP/GOVERNOR 267
Section 8 ALTERNATOR 273
Section 9 ELECTRIC WIRING 277
Section 10 SERVICE STANDARDS 282
Engine Body 283
Gear train and camshaft 284
Cylinder block 285
Lubricating Oil System (Trochoid Pump) 288
Section 11 TIGHTENING TORQUE for BOLTS and NUTS 290
Section1 Safety 294
Section2 Lifting, Jacking, and Blocking the Truck 298
Safe Parking 299
Lifting, Blocking, and Jacking Points 299
Raising Drive Wheels Off Floor 299
Raising Truck with A Hoist 300
Blocking the Upright In Raised Position 301
Raising Rear of Truck 301
Raising Entire Truck 302
Shipping Tie-Down Instructions 303
Section3 Towing 304
GROUP 00 (L-GM) ENGINE (GM 30 LPG) 308
Section 1 Specifications and Information 310
Section 2 Diagnostic Information and Procedures 314
Section 3 Engine Removal and Installation 318
Section 4 Description and Operation 378
Section 1 General Information 386
Section 2 Specification and Troubleshooting 394
Specifications 0
Tightening Torque 0
Compression Pressure Inspection 0
Valve Clearance and Adjustment 0
Troubleshooting 0
Special service tools 0
Section 3 Disassembly and Reassembly 410
TIMING SYSTEM 0
Removal 0
Inspection 0
Installation 0
CYLINDER HEAD ASSEMBLY 0
Removal 0
Disassembly 0
Inspection 0
Cylinder Head 0
Valve And Valve Spring 0
MLA 0
Camshaft 0
Reassembly 0
CYLINDER BLOCK ASSEMBLY 0
Disassembley 0
Inspection 0
Connecting Rod And Crankshaft 0
Cylinder Block 0
Piston And Rings 0
Piston Pins 0
Reassembly 0
COOLING SYSTEM 0
Removal 0
Water pump 0
Thermostat 0
Inspection 0
Water pump 0
Thermostat 0
Installation 0
Thermostat 0
Troubleshooting 0
Water pump 0
Thermostat 0
Intake manifold 0
Removal 0
Installation 0
Exaust manifold 0
Removal 0
Installation 0
Section 4 Lubrication System 458
Oil Pump 0
Engine Oil 0
Oil Pressure Switch 0
Selection Of Engine Oil 0
Section 5 Electrical System 464
Specification 0
Trouble Shooting 0
Special Service Tool 0
Ignition system 0
Description 0
Repair procedures 0
Spark Test 0
On-vehicle Inspection 0
Inspect Spark Plug 0
Inspect Ignition Coil 0
Charging system 0
Inspect Drive Belt 0
Inspect Charging System 0
Output Current Test 0
Regulated Voltage Test 0
Alternator 0
Starting system 0
Inspection 0
Description 0
Starter 0
Removal 0
Disassembly 0
Inspection 0
Armature Inspection And Test 0
Inspect Starter Brush 0
Starter Brush Holder Test 0
Inspect Overrunning Clutch 0
Cleaning 0
Starter relay 0
Section 6 Emission Control System 486
PCV(positive crankcase ventilation) VALVE 0
FUEL SYSTEM 0
Specifications 0
Sensor 0
Tightening torques 0
Troubleshooting 0
Basic inspection procedure 0
Engine control system 0
MAPS (Manifold Absolute Pressure Sensor) 0
IATS (Intake Air Temperature Sensor) 0
ECTS (Engine Coolant Temperature Sensor) 0
CMPS (Camshaft Position Sensor) 0
CKPS (Crankshaft Position Sensor) 0
HO2S (Heated Oxygen Sensor) 0
KS (Knock Sensor) 0
Injector 0
Section 1 LPG Fuel System 508
LPG FUEL SYSTEM 508
Section 2 Fuel System Component Details 510
Description of Regulator/Vaporizer Operating States 512
Liquid-Phase Filter & Shutoff Valve 514
Fuel Rail 515
Gaseous Fuel Filter 516
Engine Control Unit 517
Wire Harness 520
Emissions Catalyst 522
Oxygen Sensors 523
Ignition Control System 525
Power Transistors 525
Locations of Major Sensors & Components 526
Section 3 Recommended Maintenance 528
General Maintenance Guideline 529
Fuel System Leak Testing 530
General Fluid Leaks 530
Coolant System 530
Electrical System & Harness 530
Ignition System 533
LPG Regulator Service 533
LPG Shutoff Valve – Option 1, Valtek 536
LPG Liquid Filter – Option 1, Valtek 536
Maintenance Kit for LPG Liquid Filter 537
LPG Shutoff Valve – Option 2, AFC 538
LPG Rail & Injectors 539
Throttle Body & Intake Tubing 541
TMAP Sensor 541
Exhaust System & Catalyst 541
Section 4 Diagnostic Trouble Codes (DTC) 542
SUPPORTED DTCS 545
Section 5 General Trouble Shooting 552
Engine cranks but will not start 552
Engine does not provide expected power output, slow to accelerate, stalls when lifting load 553
Engine speed hunting at idle and other speed and load conditions 554
Engine backfires 555
Engine knocking 556
Engine run-on after shut down 557
Engine misfires 557
Poor fuel economy 558
High idle speed (above the set point of 750 rpm) 558
Engine knocking 559
Section 6 TROUBLE SHOOTING BY DTC 560
Section 7 DIAGNOSTIC SERVICE TOOL 586
Section 1 General Information 604
Section 2 Maintenance 606
Section 3 LPG Fuel System 614
Section 4 Fuel System Diagnosis 620
Section 5 Electrical Section 636
Diagnostic Trouble Codes (DTCs) 663
OBD System Check/MIL (MalfunctionIndicator Lamp) 668
HVS Ignition Control System Diagnostics 669
Ignition Control System DiagnosticChart 670
Section 6 Definitions 822
Section 1 Engine Cooling System 830
Section 2 Troubleshooting 832
Section 3 Testing and Maintenance 834
Engine Coolant Level Check 835
Adding Coolant 836
Cooling System Inspection 836
Cooling System Tests 837
Testing the Radiator Cap 837
Testing Radiator and Cooling System 838
Testing the Thermostat 838
Engine Coolant Change 838
Draining Radiator and Cooling System 838
Cleaning and Flushing Cooling System 839
Filling Cooling System 839
Section 4 Engine Cooling System and Alternator Belt Service 842
Belt Checks 843
Gas/LPG Truck Belt Removal 843
Fan Drive Belt Removal 843
Alternator/Water Pump Belt Removal 844
Gas/LPG Truck Belt Replacement 844
Alternator/Water Pump Belt Replacement (V47) 844
Fan Drive Belt Replacement 844
Alternator/Water Pump Belt Tension (Gas/LPG Engines) 845
Fan Drive Belt Tension (Gas/LPG Engines) 845
Diesel truck fan drive belt replacement 846
Section 5 Radiator Removal and Replacement 828
Radiator Removal 849
Radiator Replacement 851
Section 1 Specifications and Description 856
Section 2 Intake System Troubleshooting 858
Section 3 Intake System Service 860
Section 4 Exhaust Systems 864
Section 1 Cautions for working on the electrical system 872
Section 2 Electrical system Specifications and features 874
Section 3 Electrical Circuit Diagram & Electrical Parts Arrangement 876
VL30-VL40s WIRING DIAGRAM 877
INSTALL ELECTRICAL COMPONENT & HARNESS MAIN 883
VL30-40s LPG Tier 4 886
VL30-40s Diesel Tier 3 887
VL30-40s Diesel Tier 3 889
VL30-40s Diesel Tier 3 882
VL40-VL70 WIRING DIAGRAM 892
VL40-VL70 Diesel Tier 3 895
INSTALL ELECTRICAL COMPONENTS & HARNESS MAIN 898
VL40-70 LPG Tier 4 901
VL40-70 Diesel Tier 3 906
VL40-70 Diesel Tier 3 909
Section 4 Instrument Pod 914
1 Display Monitor 915
2 Explanation of function 916
3 Major function of truck 918
4 Functional setting and operation 920
41 Operating method for mode switch 920
42 Menu mode composition chart 921
# Menu Mode (Tree structure) 923
43 Menu mode check and adjusting method 924
44 Model set 926
45 Error history 926
46 Password change 927
47 Set on communication for option equipment 929
48 Optional function setting 929
49 DATE setting 937
5 Fault diagnosis 938
51 Self diagnostic function 938
52 Management of fault history 938
53 Error code 939
Section 5 Electrical Components Specification and Operation 940
Battery 941
Engine Accessories 942
Alternator 942
Starting Motor 943
Water Temp Sender 944
Switch-Eng Oil Pressure 945
LPG Pressure Switch 946
Switch-T/M Temp 947
Fuel Sender 948
Switches 949
Start Switch 949
Switch Fow & Rev 950
Switch – directional Indicator 951
Brake Stop Switch 952
Parking Brake Switch 953
Seat Switch 954
General Electrical Parts 955
Fuse / Relay Box 955
Engine Stop Relay 956
Flash Unit 957
Start and Preheat Relays 958
Horn 959
Backup Alarm 960
Lights 961
Lamp-Work 961
Lamp-Indicator 962
Combination Lamp 963
Lamp-Beacon 964
Directional Disable Function 965
1 Description of Operating the Neutral Shift Function 965
2 Description of Engine Shutdown Function action 966
Section 6 Troubleshooting of Electrical System 968
Fuel Gauge Malfunction 969
Hourmeter Malfunction 970
Coolant Temp Gage Malfunction 971
Transaxle Oil Malfunction 972
Engine Oil Gage Malfunction 973
Alternator Charge Malfunction 974
Preheat Plug Malfunction 975
Parking Brake Malfunction 976
Work Lamp Switch Malfunction 977
Rear Work Lamp Switch 978
All of Instrument Pod Lamps Fails to Turn On 979
Failure to Drive 980
Failure to engine shut down (Diesel-tier2) 981
Failure to engine shut down (GAS/LPG) 982
Failure to Start (GAS/LPG) 983
Failure to Start (Diesel) 984
Failure to Start (Diesel-Tier2) 985
Section 1 Specifications and Description 988
Section 2 Cushion Wheels and Tires 990
Section 3 Pneumatic Wheels and Tires 994
Pneumatic Tire Maintenance Precaution 995
General Tire Maintenance, Inspection, and Repair 996
Wheel Dismounting and Remounting 997
Drive and Steer Wheel Dismounting 997
Drive and Steer Wheel Remounting 998
Dual-Drive Wheel Dismounting(V47) 999
Dual-Drive Wheel Remounting(V47) 999
Wheel Disassembly and Tire Removal1000
Tire Replacement and Wheel Reassembly1002
Tire-to-Wheel Mounting1003
Filling Tires with Air1004
Filling Tires with Nitrogen1004
Checking and Adjusting Tire Pressure1005
Split-Rim Wheel Assemblies(V47)1006
Section 1 Braking / Inching System Specifications and Description1010
NOTE1010
Specifications1010
General Description1010
Service Brake and Inching System Arrangement1011
Inching Operation1012
Braking Operation1012
Service Requirements1012
Section 2 Service Brake Troubleshooting1014
Section 3 Brake/Inching Pedals and Linkages Adjustments1016
Section 4 Brake System Bleeding1020
Section 5 Brake Master Cylinder Service1022
Section 6 Service Brake Adjustment and Overhaul1026
External Inspection1026
Shoe-to-Drum Gap Adjustment1026
Internal Inspection and Repair1027
Brake Drum Removal and Replacement1027
Inspection1027
Brake Shoe Removal1027
Brake Shoe Replacement1027
Cylinder Removal and Replacement1028
Adjuster Removal and Replacement1028
Lubrication1028
Wheel Cylinder Overhaul1029
Operational Explanation of the Auto Adjuster1030
Section 7 Parking Brake Service1032
Operation1032
Adjustment1032
Removal and Replacement1032
Parking Brake Cable Removal and Installation1034
Section 1 Steering System Specifications and Description1038
Section 2 Steering System Troubleshooting1040
Section 3 Steering Column and Component Removal and Replacement 0
Steering Column and Component Removal 0
Ignition Switch Removal 0
Hand Wheel, Horn Contact Ring, and Directional Control Assembly Removal 0
Column Tilt Lock Assembly Removal 0
Steering Gear and Lower Steering Column Removal 0
Steer Column and Component Replacement 0
Steering Gear and Lower Steering Column Replacement 0
Column Tilt Lock Assembly Replacement 0
Directional Control Assembly Reassembly 0
Directional Control Assembly and Ignition Switch Replacement 0
Steering Hand Wheel Replacement 0
Section 4 Steering System Relief Pressure Check and Adjustment 0
Section 5 Steering Gear Overhaul1056
Disassembly1057
Parts Inspection1059
Reassembly1059
Section 1 Steer Axle Specifications and Description 0
Section 2 Steer Axle Wheel Bearing Maintenance and Adjustment1068
Section 3 Steer Axle Removal and Replacement 0
Steer Axle Removal 0
Steer Axle Replacement 0
Section 4 Steer Axle Overhaul1078
Steer Axle Disassembly1079
Parts Inspection1080
Steer Axle Reassembly1080
Section 5 Steer Cylinder Removal and Replacement1082
Steer Cylinder Removal1082
Parts Inspection1083
Steer Cylinder Replacement1083
Section 6 Steer Cylinder Overhaul1086
Preparation for Steer Cylinder Disassemblyand Overhaul1087
Steer Cylinder Disassembly1087
Parts Inspection1087
Steer Cylinder Reassembly1088
Section 1 Hydraulic Sump, Filters, and Pump Specifications and Description 0
Section 2 Main Hydraulic Pump Troubleshooting1096
Section 3 Hydraulic Filters and Fluid Maintenance and Change 0
Section 4 Hydraulic Pump Removal and Replacement 0
Section 5 Hydraulic Pump Overhaul(Hanil Pump)-V471104
Pump Disassembly1105
Steering Priority and Steering Pressure Relief Valve Disassembly1108
Pump Reassembly1109
Steering Priority and Relief Valve Reassembly1110
Section 6 Hydraulic Pump Overhaul(Jinsung Pump)-V341114
Disassembly and Assembly1115
Inspection and Assessment1116
Trouble shooting1118
Start-up1119
Section 1 Hydraulic Control Valve/Lift Circuit Specifications and Description 0
Section 2 Hydraulic System Schematics1126
Section 3 Hydraulic System Troubleshooting1128
Section 4 Hydraulic System Pressure Checks and Adjustments 0
Relief Pressure Check 0
Main and Auxiliary Pressure Relief Adjustment 0
Flow Control Adjustment 0
Section 5 Hydraulic Control Valve Removal and Replacement1134
Hydraulic Control Valve Removal1135
Hydraulic Control Valve Replacement1136
Operational Checks1137
Section 6 Hydraulic Control Valve Overhaul For HANIL Valve (V47)1138
Preparation for Disassembly1138
Disassembly1139
Cleaning, Inspection, and Repair1140
Reassembly1141
Relief Valve Settings1141
Section 7 Hydraulic Control Valve Overhaul For EATON Valve (V34)1142
Precautions1142
Disassemble and reassemble1143
Trouble shooting1146
Section 1 Tilt Cylinder Specifications and Description1150
Section 2 Tilt Cylinder Checks and Adjustments1152
Section 3 Tilt Cylinder Removal and Replacement 0
Tilt Cylinder Removal 0
Parts Inspection 0
Tilt Cylinder Replacement 0
Section 4 Tilt Cylinder Overhaul 0
Preparation For Disassembly 0
Disassembly 0
Inspection 0
Reassembly 0
Section 1 Upright Specifications and Description1166
General Specifications1166
Cylinder Types1166
Drift1166
Fastener and Fitting Torque Specifications1167
Service Intervals1167
Description1167
Section 2 Troubleshooting1182
Upright noise1182
No lift, tilt, or auxiliary function1182
No lift function but tilt operates1182
Load cannot be lifted to maximum height1183
Lift speed sluggish1183
Lowering speed sluggish1183
Load bounces excessively when lowering1183
Upright mis-staging (TSU lifting)1183
Upright mis-staging (TSU lowering)1184
Upright mis-staging (Standard and Hi-Lo upright lowering)1184
External leakage on primary cylinder1184
External leakage on lift (Standard) and secondary cylinder (TSUs and Hi-Lo)1185
Section 3 Upright Inspection1186
Basic Visual Inspection1187
Extended Inspection1188
Forks1188
Lift Chains1189
Carriage and Upright Weldments1190
Carriage and Upright Rollers1191
Cylinders1193
Hydraulic Plumbing1195
Upright Drift1195
Trunnion Bearings1196
Section 4 Carriage and Upright Roller Clearance Checks and Shim Adjustments1198
Introduction1198
Roller Side Clearance Checks1201
Internal Thrust Roller Adjustment(V47)1203
Oversize Rollers1204
Lift Roller Shimming1204
Carriage Roller Shimming1205
Upright Roller Shimming1205
Overshimming1208
Section 5 Cylinder Removal, Shimming, Overhaul, and Replacement1210
Cylinder Types1210
Lift Cylinder Shimming Procedure1210
Primary Cylinder Removal and Replacement (Hi-Lo & TSU)1211
Lift and Secondary Cylinder Removal and Replacement1212
Cylinder Overhaul1213
Section 6 Upright Chain Inspection, Adjustment, and Replacement1218
Periodic Inspections1220
Elongation1220
Edge Wear1220
Turning or Protruding Pins1220
Cracked Plates1220
Ultimate Strength Failure1221
Tight Joints1221
Chain Length Adjustments1222
Chain Lubrication1224
Chain Removal and Replacement1224
General Guidelines1224
Lift Chains (Standard and TSUs)1225
Primary Cylinder/Carriage Chains (TSU and Hi-Lo)1225
Other Chain Service Notes1226
Section 7 Fork and Carriage Removal and Replacement1228
Fork Removal1228
Fork Replacement1228
Carriage Removal1229
Carriage Replacement1230
Section 8 Upright Removal and Replacement1234
Upright Removal1235
Upright Replacement1236
Section 1 Counterweight Specifications and Description1240
Section 2 Counterweight Removal and Replacement1242
Section 3 Overhead Guard/Operator’s Cell Removal and Replacement1246
Section 4 Floorboard, Cowls, and Seat Deck Removal and Replacement1248
Floor Plate Removal and Replacement1249
Cowl Removal and Replacement1249
Radiator Cover Removal and Replacement1250
Operator’s Seat Deck Removal and Replacement1250
Section 5 Operator’s Seat Removal and Replacement1254
Section 1 Nameplates and Decals1260
Truck Data and Capacity Plate1261
Operator Safety Warning Plate1261
General Safety Decal1262
Seat Belt/Tip-Over Warning Decal1263
Hand Safety Warning Decal1263
Keep Away from Forks Decal1263
Fan Warning Decal1263
Nameplate, Decal Locations1264
Section 2 General Specifications1266
Weights and Performance Specifications1267
Capacities1267
Truck Weights and Axle Weights1267
Parking Brake Test1267
Maximum Gradeability1268
Drawbar Pull1268
Travel Speeds1268
Turning Radius (outside)1268
Critical Fastener Torque Specifications1269
Group Specifications1270
Group 00, V34 LPG Engine Specifications1270
Group 00, V47 LPG Engine Specifications1270
Group 00(D), V47 – 4TNE98 Diesel Engine Specifications1271
Group 01, Cooling System Specifications1272
Group 02(LP), LPG Fuel System Specifications1272
Group 03, Intake and Exhaust Systems Specifications1272
Group 06(S), Standard Transaxle Specifications1272
Group 13, Instrument Pod & Electrical System Specifications1273
Group 22, Wheels and Tires Specifications1273
Group 23(G) brake/Inching System Specifications (Standard Transaxle)1274
Group 25, Steering Column and Gear Specifications1274
Group 26, Steer Axle Specifications1274
Group 29, Hydraulic Sump, Filters, and Pump Specifications1275
Group 30, Hydraulic Valve/Lift Circuit Specifications1275
Group 32, Tilt Cylinders Specifications1276
Group 34, Upright Specifications1276
Lift Speeds, Upright1277
Group 38, Counterweight and Chassis Specifications1277
Drift, Lift and Tilt Cylinders1277
Section 3 Hydraulic Fitting Tightening Procedure1278
Section1 Maintenance Schedulespdf1282
Maintenance Schedules1282
“Periodic Service” and “Planned Maintenance”1282
Determining Maintenance Intervals1282
Service Chart/Lubrication Points1283
Recommended Periodic Service Schedule1283
Section2 The Planned Maintenance Programpdf1288
Introduction to Planned Maintenance1289
PM Intervals1289
The PM Form1289
The Basic PM Procedures1289
The Recommended PM Task Chart1290
Listed by Service Manual Group1290
Visual Inspection1291
Functional Tests1293
Air Cleaning the Truck1295
Truck Chassis Inspection and Lubrication1296
Upright and Tilt Cylinder Lubrication1296
Lift Chain Lubrication1296
Under-the-Hood Inspection1296
Fluid Checks1296
Stall Test1297
Cranking Voltage Test1297
Critical Fastener Torque Checks1297
The Planned Maintenance Program1288
Section 1 Transaxle Specifications and Description 0
Construction 0
hydraulic circuit 0
SERVICE MAINTENANCE 0
Specification 0
Pressure specification 0
Pressure check points 0
Service brake adjustment 0
Section 2 Transaxle Disassembly1308
Wheel End1310
Brake Assembly Removal1312
Separation of Converter Housing and Adaptor Plate1313
Stator Support Removal From Adaptor Plate1314
Clutch Assembly, idler Gear & Pinion Shaft Removal1314
Section 3 Transaxle Reassembly1318
DIFFERENTIAL1319
Wheel End Final Assembly1327
Install brake assemblies1328
CLUTCH ASSEMBLY1330
Transmission assembly1332
Section 1 Transaxle Specifications and Description1338
Specifications1339
Description1341
Torque Converter1341
Charging Pump1342
Transmission1342
Forward/Reverse Clutch Packs1342
Solenoid Valves1342
Transaxle Control Valve1343
Differential1344
Drive Axle1345
Operation1346
Transaxle Hydraulic Schematic1348
Sectional View Along Turbine Shaft1349
Sectional View Along Drive Axle1350
Section 2 Transaxle Troubleshooting1352
Checks1354
Fluid Level Check1354
Fluid Leakage Checks1354
General Mechanical/Electrical Checks1354
Solenoid Valve Electrical Checks1354
Stall RPM Test1355
Transaxle Pressure Checks1355
Section 3 Transaxle Oil and Filter 1358
Section 4 Transaxle Oil Cooler1362
Flow Check1362
Pressure Check1362
Oil Cooler Removal1363
Oil Cooler Installation1364
Section 5 Transaxle Removal and Replacement1366
Transaxle Removal1367
Transaxle Replacement1369
Section 6 Transaxle Overhaul1372
General Practices to Follow1373
Disassembling Components1373
Cleaning Parts1373
Inspecting Parts1374
Repairing and Replacing Parts1374
Reassembling Components1375
Overhaul Procedures1376
Transaxle Disassembly1376
Differential Overhaul1384
Clutch Overhaul1385
Transaxle Control Valve Overhaul1389
Section 7 Drive Axle Ends Overhaul1404
Section 8 Transaxle Control Valve Overhaul1408

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