F300 CHASSIS (LP) H04565-1-HOSEKIT

Hose Location Fitting #1 Fitting #2 Hose Length Hose Part # Hose Size Hose ASM # Qty
CYLINDER BRAKES TO TEE H00826-1 H00826-1 13" H01390 #4 H03275-8 2
Manifold to Pilot Valve H00826-1 H00827-1 16" H01390 #4 H04416 1
Breather to Drive Axle H00827-1 H04675 17" H01390 #4 H03275-7 1
Multi Gauge 1 to Main Pressure H00826-1 H00827-1 20" H01390 #4 H03473-3 1
Multi Gauge 0 to Tank H00826-1 H00826-1 30" H01390 #4 H03275-4 1
Multi Gauge 4 to Lift H00826-1 H00827-1 34" H01390 #4 H03473-1 1
Multi Gauge 3 to LS H00826-1 H00826-1 37" H01390 #4 H03275-5 1
Multi Gauge 2 to Steer Pressure H00826-1 H00827-1 46" H01390 #4 H03275-6 1
Multi Gauge 5 to Brake Accumulator H00826-1 H00827-1 58" H01390 #4 H04416-6 1
Multi Gauge 6 to Brake Tee H00826-1 H00827-1 62" H01390 #4 H03466-6 1

Pilot Valve to Tank H00828-1 H00828-1 14" H01372 #6 H04438-3 1

Brake Valve to Tee Brake H00828-1 H00828-1 15" H01372 #6 H04438-2 1
Pilot Valve to Main Valve H00828-1 H00828-1 16" H01372 #6 H04438-4 1
Flow Divider to Valve H00828-1 H00829-1 22" H01372 #6 H04439-2 1
Flow Divider to Valve H00828-1 H00829-1 28" H01372 #6 H04439-16 1
Flow Divider to Valve H00828-1 H00829-1 24" H01372 #6 H04439-8 1
Flow Divider to Valve H00828-1 H00829-1 26" H01372 #6 H02140 1
Control Valve Pilot to Tank H00828-1 H00829-1 40" H01372 #6 H04439-6 1
Brake V. to Charge V. H00828-1 H01659-1 42" H01372 #6 H04437-2 1
Check Valve - Steer Column H00828-1 H00829-1 52" H01372 #6 H04439-9 1

Tilt Limit To Tilt Cylinder RF H00830-1 H00831-1 13" H00956 #8 H03273-5 1

Tilt Limit To Tilt Cylinder LF H00830-1 H00831-1 14" H00956 #8 H03273-6 1
Tilt Limit To Tilt Cylinder RR H00830-1 H00831-1 20" H00956 #8 H03273-8 1
Tilt Limit To Tilt Cylinder LR H00830-1 H00830-1 20" H00956 #8 H03303-6 1
Pressure Manifold to Charge Valve H00830-1 H00831-1 21" H00956 #8 H03273-3 1
Charge Valve to Accumulator H00830-1 H00830-1 22" H00956 #8 H03303-2 1
Manifold - Steer Column Pressure H00830-1 H00830-1 37" H00956 #8 H04411-2 1
Charge Valve to Tank H00830-1 H00831-1 45" H00956 #8 H03273-9 1
Tilt Accumulator - Valve Tee H00830-1 H01660-1 50" H00956 #8 H04570-2 1
Brake Valve - Tank H00830-1 H01660-1 68" H00956 #8 H04570-3 1
Steer Column - Tank H00830-1 H00830-1 70" H00956 #8 H03303-3 1
Steer Axle - Column L H00830-1 H00830-1 110" H00956 #8 H03303-4 1
Steer Axle - Column R H00830-1 H00830-1 129" H00956 #8 H03303-5 1

Valve Tee Lift - Lift Accumulator (optional) H00834-1 H00835-1 14" H00957 #12 H03276-6 1
Steer Pump to Manifold Pressure H00834-1 H00835-1 16" H00957 #12 H04439-4 1
Steer Pump to Tank H00834-1 H00834-1 25" H00957 #12 H03276-2 1
Trans Filter to Pump H00834-1 H00835-1 35" H00957 #12 H03276-4 1
Trans Filter to Pump H00834-1 H01662-1 37" H00957 #12 H03276-7 1
Cooler to Transmission H00834-1 H01662-1 48" H00957 #12 H03272-4 1
Cooler to Transmission H02425 H01662-1 53" H00957 #12 H04566 1

Return Filter - Tank H00838-2 H02336-2 30" H00822 #20 H04567-2 1

Control Valve - Filter H00838-2 H00839-2 35" H00822 #20 H04435-1 1

SUCTION HOSE 62" H01244 2 ID H01244L06200 1

SUCTION HOSE 68" H01244 2 ID H01244L06800 1
Item Description Qty Built Item# Rev RPT? M Kit? Cost PRI
00546 WARNING NAMEPLATE, ALUMINUM 1 _ 0 1 $3.50
A00114 NO STANDING UNDER/OVER FORKS DEC 2 _ 0 1 $2.22
A01114 FINGERS IN FAN 2 _ 1 $0.44
A01117 INSTAL COVER 1 _ 1 $0.99
M13620 DECAL OVAL HOIST LOGO 12 X 17 3 _ 1 $1.89
M16886 VEHICLE MAKES WIDE TURNS 2 _ 1 $8.47
M16890 DANGER STAY CLEAR DECAL LCH 1 _ 1 $8.47
M00016 TIPOVER WARNING DECAL 1 100 0 1 $0.46
M03907 2.34FORKLIFT HOOK 5 102 1 $0.87
M05500 OPERATING MANUAL POUCH 1 105 1 $5.82
A00004 WARNING PLATE 1 20 0 1 $1.85
A00112 LPG FUEL CYL REPLACEMENT PROCED 2 30 0 1 $1.02
A00113 MAINT. PROC. FOR LP GAS FORKLIFTS D 2 40 0 1 $1.02
A00115 NO RIDERS DECAL 1 50 0 1 $2.22
A00123 MADE IN AMERICA AND FLAG DECAL 2 60 0 1 $0.69
A01115 WARNING PARKBRAKE 1 70 1 $0.69
A01116 MOVING MAST 2 80 1 $0.15
A01630 WARNING DATA PLATE 1 90 1 1 $4.60

BOM Chec
Parts k
Save Can Rpt Built View Part Next Prev First Last Quit Assy
Needs
 FKS (H04565-2-HOSEKIT) (updated for new fittings)
HOSE LOCATION Fitting #1 Fitting #2 HOSE LENGTH Hose Part # HOSE SIZE HOSE ASM #
PILOT H00828-1 H01659-1 20.5" H01372 #6 H01550-2

TANK H00830-1 H01660-1 17.5" H00956 #8 H01550-1

PRESSURE H00830-1 H01660-1 17.5" H00956 #8 H01550-1
RIGHT H00830-1 H01660-1 17.5" H00956 #8 H01550-1
LEFT H00830-1 H01660-1 17.5" H00956 #8 H01550-1
M11903 Orange Seat belt w/Switch x1
 MD-3 MAIN DISPLAY PAGE

1) Water temperature gauge – Indicates water temperature of engine

2) Fuel level gauge – Indicates the fuel level of the engine
3) Oil pressure gauge – Indicates the oil pressure level of the engine
4) Tachometer – Indicates the rpm of the engine
5) Filter indicator – Displayed when either the transmission, air or hydraulic filter
element needs replacing
6) Air filter indicator – Displayed in conjunction with the filter indicator to indicate
that the air filter element needs to be replaced.
7) Hydraulic filter indicator – Displayed in conjunction with the filter indicator to
indicate that the hydraulic filter element needs to be replaced.
8) Transmission filter indicator – Displayed in conjunction with the filter indicator to
indicate that the transmission filter element needs to be replaced.
9) Battery indicator – Displayed when the charge of the engine battery is low
10) Parking brake indicator – Displayed when the parking brake is engaged
11) Oil pressure indicator – Displayed when the oil pressure of the engine is low
12) Fuel level indicator – Displayed when the engine fuel level is low
13) Transmission temperature indicator – Displayed when the transmission is at an
unsafe temperature.
14) Water temperature indicator – Displayed when the engine is at an unsafe
temperature.
15) Service indicator – Displayed when preventative maintenance of the vehicle needs
to be performed. (See adjustments section to reset after maintenancing)
16) Hour meter – Displays the number of hours of operation
17) F1 function key – Use to view overload display page if vehicle is equipped with a
shock sensor.
18) Menu key – Use to view the menu display page
19) F2 function key – This function key is inactive in this display page
20) F3 function key – This function key is inactive in this display page
21) F4 function key – This function key is inactive in this display page
22) Back function key – This function key is inactive in this display page
23) Up function key – This function key is inactive in this display page
24) Accept function key – This function key is inactive in this display page
25) Down function key – This function key is inactive in this display page
 MD-3 MENU DISPLAY PAGE

1) F1 function key – Use to view adjustment menu

2) F2 function key – Use to view measure menu
3) F3 function key – Use to view preferences menu
4) F4 function key – Use to view information menu
5) Back function key – Use to return to main display page
6) Menu function key – This function key can also be used to return to the main display page
7) Down function key – This function key is inactive in this display page
8) Accept function key – This function key is inactive in this display page
9) Up function key – This function key is inactive in this display page
MD-3 MAIN ADJUSTMENT DISPLAY PAGE

1) Adjustment group – Listed are all item groups that have adjustable parameters
2) Group security – If the listed adjustment group is password protected then an icon
of a lock will be displayed.
3) F1 Function key – Use to return to menu display page
4) F2 Function key – This function key is inactive in this display page
5) F3 Function key – This function key is inactive in this display page
6) F4 Function key – This function key is inactive in this display page
7) Back function key – Use to return to menu display page
8) Menu function key – Use to view main display page
9) Down function key – Use to scroll down and select between adjustment groups
10) Accept function key – Use to view adjustment group display page
11) Up function key – Use to scroll up and select between adjustment groups
 MD-3 SECURITY DISPLAY PAGE

1) Pin code – The proper pin code must be entered in for making adjustments to the
corresponding adjustment group** pin code 4200 to reset service hour meter1

2) F1 Function key – This key will tab the cursor to the first digit of the pin code
3) F2 Function key – This key will tab the cursor to the second digit of the pin code
4) F3 Function key – This key will tab the cursor to the third digit of the pin code
5) F4 Function key – This key will tab the cursor to the fourth digit of the pin code
6) Back function key – This key will return the display back to the adjustment page
7) Menu function key – This key will return the display back to the adjustment page
8) Down function key – Use to decrease the highlighted digit of the pin code
9) Accept function key – Use to accept the highlighted digit of the pin code
10) Up function key – Use to increase the highlighted digit of the pin code
 ADJUSTMENT GROUP DISPLAY PAGE
(TRANSMISSION ADJUSTMENT)

1) Transmission adjustment group – Listed are all transmission items that can be
adjusted
2) F1 Function key – Use to return to menu display page
3) F2 Function key – Use to set highlighted parameter to its default value
4) F3 Function key – This function key is inactive in this display page
5) F4 Function key – This function key is inactive in this display page
6) Back function key – Use to return to main adjustment display page
7) Menu function key – Use to view main display page
8) Down function key – Use to scroll down between transmission adjustments
9) Accept function key – Use to view highlighted parameter adjustment page
10) Up function key – Use to scroll up between transmission adjustments
 PARAMETER ADJUSTMENT PAGE
(TRANSMISSION UPSHIFT)

1) 2nd to 3rd Upshift value – Listed is the current RPM at which the transmission will
shift from 2nd gear to 3rd gear
2) F1 Function key – Use to return to menu display page
3) F2 Function key – Use to set highlighted parameter to its default value
4) F3 Function key – This function key is inactive in this display page
5) F4 Function key – This function key is inactive in this display page
6) Back function key – Use to return to transmission adjustment display page
7) Menu function key – Use to view main display page
8) Down function key – Use to decrease 2nd to 3rd upshift value
9) Accept function key – Use to set 2nd to 3rd upshift value
10) Up function key – Use to increase 2nd to 3rd upshift value
 MEASURE MENU DISPLAY PAGE

1) Measure group – Listed are all item groups that have parameters that can be
measured
2) F1 Function key – Use to return to menu display page
3) F2 Function key – This function key is inactive in this display page
4) F3 Function key – This function key is inactive in this display page
5) F4 Function key – This function key is inactive in this display page
6) Back function key – Use to return to menu display page
7) Menu function key – Use to view main display page
8) Down function key – Use to scroll down and select between measure groups
9) Accept function key – Use to view measure group display page
10) Up function key – Use to scroll up and select between measure groups
 MEASURE GROUP DISPLAY PAGE
(ENGINE DATA – SCALED VALUE)

1) Measure parameter – Listed are all parameters and there value/state

2) F1 Function key – Use to return to menu display page
3) F2 Function key – Use to change values/states from scaled value to raw value
4) F3 Function key – This function key is inactive in this display page
5) F4 Function key – This function key is inactive in this display page
6) Back function key – Use to return to measure menu display page
7) Menu function key – Use to view main display page
8) Down function key – Use to scroll down between measure parameters
9) Accept function key – This function key is inactive in this display page
10) Up function key – Use to scroll up between measure parameters
 MEASURE GROUP DISPLAY PAGE
(ENGINE DATA – RAW VALUE)

1) Measure parameter – Listed are all parameters and there raw value/state
2) F1 Function key – Use to return to menu display page
3) F2 Function key – Use to change values/states from raw value to scaled value
4) F3 Function key – This function key is inactive in this display page
5) F4 Function key – This function key is inactive in this display page
6) Back function key – Use to return to measure menu display page
7) Menu function key – Use to view main display page
8) Down function key – Use to scroll down between measure parameters
9) Accept function key – This function key is inactive in this display page
10) Up function key – Use to scroll up between measure parameters
 PREFERENCES MENU DISPLAY PAGE

1) F1 Function key – Use to go to display menu

2) F2 Function key – Use to go to date/time menu
3) F3 Function key – Use to go to language menu
4) F4 Function key – This function key is inactive in this display page
5) Back function key – Use to return to menu display page
6) Menu function key – Use to view main display page
7) Down function key – This function key is inactive in this display page
8) Accept function key – This function key is inactive in this display page
9) Up function key – This function key is inactive in this display page
 DISPLAY MENU DISPLAY PAGE

1) F1 Function key – Use to go to menu display page

2) F2 Function key – Use to select backlight setting
3) F3 Function key – Use to select screen saver setting
4) F4 Function key – This function key is inactive in this display page
5) Back function key – Use to return to preferences display page
6) Menu function key – Use to view main display page
7) Down function key – This function key is used to lower backlight and screen
saver settings when item is highlighted
8) Accept function key – Use to accept backlight and screen saver settings
9) Up function key – This function key is used to raise backlight and screen saver
settings when item is highlighted
 DATE/TIME MENU DISPLAY PAGE

1) F1 Function key – Use to select date setting

2) F2 Function key – Use to select time setting
3) F3 Function key – This function key is inactive in this display page
4) F4 Function key – This function key is inactive in this display page
5) Back function key – Use to return to preferences display page
6) Menu function key – Use to view main display page
7) Down function key – This function key is used to lower date and time settings
when item is highlighted
8) Accept function key – Use to accept date and time settings
9) Up function key – This function key is used to raise date and time settings when
item is highlighted
 LANGUAGE MENU DISPLAY PAGE

1) F1 Function key – Use to go to menu display page

2) F2 Function key – This function key is inactive in this display page
3) F3 Function key – This function key is inactive in this display page
4) F4 Function key – This function key is inactive in this display page
5) Back function key – Use to return to preferences menu display page
6) Menu function key – Use to view main display page
7) Down function key – This function key is inactive in this display page
8) Accept function key – Use to return to preferences menu display page
9) Up function key – This function key is inactive in this display page
 INFO MENU DISPLAY PAGE

1) F1 Function key – Use to go to modules menu display page

2) F2 Function key – This function key is inactive in this display page
3) F3 Function key – This function key is inactive in this display page
4) F4 Function key – This function key is inactive in this display page
5) Back function key – Use to return to menu display page
6) Menu function key – Use to view main display page
7) Down function key – This function key is inactive in this display page
8) Accept function key – This function key is inactive in this display page
9) Up function key – This function key is inactive in this display page
 MODULES MENU DISPLAY PAGE

1) F1 Function key – Use to go to the menu display page

2) F2 Function key – This function key is inactive in this display page
3) F3 Function key – This function key is inactive in this display page
4) F4 Function key – This function key is inactive in this display page
5) Back function key – Use to return to info display page
6) Menu function key – Use to view main display page
7) Down function key – This function key is used to select module
8) Accept function key – This function key is used to accept module
9) Up function key – This function key is used to select module
 BLOCK

REVISION 23SEP13 PAGE 1

 BLOCK CONT.

IMAGE # PART NUMBER DESCRIPTION QTY NOTE

102 M19822 PISTON 8
103 M19823 ROD 8
105 M19824 BEARING 8
106 NSS CAP
107 M19825 NUT 8
108 M19826 PIN 2
110 M18823 GASKET 1
111 M19827 PIN 1
112 M19460 SEAL 1
113 M19828 BOLT 2
115 M19829 NUT 2
116 M19830 STUD 2
117 M19831 STUD 1
118 M19832 EXPANSION PLUG 1
119 M19833 PLUG 2
120 M19833 PLUG 1
121 M19834 WATER PLUG 8
123 M19835 PLUG 1
124 M19836 PLUG 2
125 M19837 BEARING POS 2-5 2
126 M19838 BEARING POS 3-4 2
127 M19839 BEARING POS 1 1
128 M19840 PIN 1
129 M19841 CAMSHAFT HIGH OUTPUT 1
130 M19842 RETAINER 1
132 M19843 SPROCKET 1
133 M19844 RING 1
134 M19845 BOLT 3
135 NSS WEIGHT
136 M19846 BOLT 6
137 M17900 FLYWHEEL 1
138 M19847 GEAR 1
139 M19848 BEARING 1
140 M05800 SEAL 1
141 M19849 CRANKSHAFT 1
142 NSS BEARING
143 NSS BOLT 10
144 M19850 STUD AR
145 NSS CAP
146 NSS BEARING
147 M19851 SPROCKET 1
148 M19852 PIN AR
149 M19853 BOLT 1
150 M19854 WASHER 1

PAGE 2
 BOLCK CONT.

IMAGE # PART NUMBER DESCRIPTION QTY NOTE

151 M19855 BALANCER 1
152 M19856 CHAIN 1
153 M19857 KEY 2
154 NSS BEARING
155 NSS BEARING
156 M19858 PIN 1

**129 M19859 CAMSHAFT S

NSS NOT SOLD SEPERATELY

PAGE 3
CYLINDER HEAD

PAGE 4
 CYLINDER HEAD CONT.

IMAGE # PART NUMBER DESCRIPTION QTY NOTE

200 M19860 COVER 1
200 M19861 COVER 1
201 NSS SEAL
202 M18054 CAP 1
203 M19862 BOLT 8
204 M18304 VALVE 2
205 M19863 KIT 16
206 NSS NUT
207 NSS BALL
208 NSS ARM
209 M19864 ROD 16
210 M19865 STUD 16
211 M19866 HEAD 2
211 M16543 HEAD 2
212 M19867 EXHAUST VALVE 8
213 M19868 INTAKE VALVE 8
214 NSS BOLT
215 M19869 RETAINER 1
216 M19870 GUIDE 8
217 M19871 LIFTER 16
218 M19872 PIN 8
219 M18308 GASKET 2
220 M19873 PLUG 1
221 M17086 SPARK PLUG 8
222 M19874 BOLT 16
223 M19875 BOLT 4
224 M19876 BOLT 14
225 M19877 SEAL 8
226 M18355 SEAL 8
227 M19878 SPRING 16
228 M19879 CAP 16
229 M19880 KEY 32

NSS NOT SOLD SPEREATELY

PAGE 5
 WATER PUMP

IMAGE # PART NUMBER DESCRIPTION QTY NOTE

154 M19855 BALANCER 1
300 M19881 BOLT 4
301 M18685 WATER PUMP 1
302 M19882 GASKET 2
303 M19883 GASKET 1
304 NSS COVER
305 M19884 BOLT 1
306 M19885 GROMMET 8
307 M19886 BOLT 6
308 M19887 BOLT 2
309 M18065 SEAL 1
310 M17537 COVER 1
311 NSS SEAL
312 M14570 SENSOR 1
313 M19888 BOLT 1
314 M19889 PLUG 1

NSS NOT SOLD SEPERATELY

PAGE 6
OIL PAN

PAGE 7
 OIL PAN CONT.

IMAGE # PART NUMBER DESCRIPTION QTY NOTE

400 M19890 DEFLECTOR 1
401 M19891 NUT 5
402 M19892 SHAFT 1
403 M19840 PIN 2
404 M19893 RETAINER
405 M18255 PUMP 1
406 M19894 BOLT 1
407 NSS SPRING 1
408 NSS VALVE
409 NSS PLUG
410 M19895 SCREEN 1
411 M18067 GASKET 1
412 M19896 OIL PAN 1
413 M19897 REINFORCEMENT 1
414 M19898 SEAL 1
415 M19899 PLUG 1
416 M19900 BOLT 14
417 M19901 NUT 4
418 M19902 BOLT 4
419 NSS PIN
420 NSS PLUG
421 NSS COVER
422 NSS GEAR
423 NSS GEAR
424 NSS SHAFT
425 M19830 STUD 2
426 M19830 STUD 2

NSS NOT SOLD SEPERATELY

PAGE 8
 DISTRIBUTOR

IMAGE # PART NUMBER DESCRIPTION QTY NOTE

1 M17934 CAP 1
2 M17935 ROTOR 1
3 NSS GEAR
4 NSS GASKET
5 M18153 SENSOR
6 NSS BOLT
7 NSS BOLT
8 NSS BOLT
9 M19903 BOLT 1
9 M19904 BOLT 1
10 M19905 CLAMP 1
11 NSS HOUSING
12 NSS SHAFT
14 M19906 DISTRIBUTOR 1

NSS NOT SOLD SEPERATELY

REVISION 23SEP13 PAGE 9

 LOCK OFF VALVE

IMAGE # PART NUMBER DESCRIPTION QTY NOTE

1 M19907 FITTING 1
2 M19908 FITTING 1
3 M17938 VALVE 1

REVISION 23SEP13 PAGE 10

 EPR

38040534

IMAGE # PART NUMBER DESCRIPTION QTY NOTE

1 M19909 PLUG 1
2 M18093 EPR 1
3 M19910 FITTING 1
4 M19063 MIXER 1
5 M19911 BOLT 4
6 M19912 STUD 4
7 M19913 NUT 4

PAGE 11
 THERMOSTAT HOUSING

38040619

IMAGE # PART NUMBER DESCRIPTION QTY NOTE

1 M05239 GASKET 1
2 M05366 THERMOSTAT 1
3 M19914 COVER 1
4 M19915 BOLT 2

PAGE 12
 CRANKSHAFT PULLEY

IMAGE # PART NUMBER DESCRIPTION QTY NOTE

1 M05244 WASHER 1
2 M05371 PULLEY 1
3 M05268 BOLT 3
4 M19916 BOLT 1
5 M19917 WASHER 1

PAGE 13
 ADAPTER

IMAGE # PART NUMBER DESCRIPTION QTY NOTE

1 M19918 FILTER 1
2 M19221 ADAPTER 1
3 M19919 BOLT 2

PAGE 14
 DIPSTICK

IMAGE # PART NUMBER DESCRIPTION QTY NOTE

1 M18087 TUBE 1
2 M05372 DIPSTICK 1
3 M19920 SPACER 1
4 M19921 CLAMP 1

PAGE 15
 HI-FAN MOUNT

IMAGE # PART NUMBER DESCRIPTION QTY NOTE

1 M19922 BRACKET 1
2 M19923 STUD 1
3 M19924 STUD 2
4 M19925 NUT 4
5 M19926 STUD 2
6 M17845 MOUNT 1

PAGE 16
M18264
M17916
M18265
M17914
M17915
M18266
M18267
 FLYWHEEL HOUSING

NO IMAGE AVAILABLE

38050205

IMAGE # PART NUMBER DESCRIPTION QTY NOTE

1 M19927 PLATE 1
2 M19928 HOUSING 1
3 M05412 PLATE 1
4 M05255 WASHER 8
5 M05256 WASHER 8
6 M05257 BOLT 8
7 M05416 BOLT 6

PAGE 17
 FLYWHEEL ADAPTER

NO IMAGE AVAILABLE

IMAGE # PART NUMBER DESCRIPTION QTY NOTE

1 M19930 ADAPTER 1
2 M19931 BOLT 6

PAGE 18
 STARTER

IMAGE # PART NUMBER DESCRIPTION QTY NOTE

1 M05418 BOLT 2
2 M00693 STARTER 1

PAGE 19
 COIL AND DISTRIBUTOR

IMAGE # PART NUMBER DESCRIPTION QTY NOTE

1 M19933 BRACKET 1
2 M19934 CLAMP 1
3 M19935 BOLT 1
4 M19936 YOKE 1
5 M17936 COIL 1
6 M18397 DISTRIBUTOR 1
7 M19937 BOLT 1
8 M19938 BOLT 2

PAGE 20
 IGNITION WIRES

NO IMAGE AVAILABLE

38050340

IMAGE # PART NUMBER DESCRIPTION QTY NOTE

1 M19939 LOOM 78 IN
2 M19940 CLAMP 2
3 M17086 PLUG 8
4 M19941 COVER 4
5 M19942 RETAINER 4
6 M19943 PIN 2
7 M17939 WIRE 1
8 M19944 RETAINER 2
9 M19945 BOLT 2

PAGE 21
 ECU MOUNT

38050341

IMAGE # PART NUMBER DESCRIPTION QTY NOTE

1 M19946 BRACKET 1
2 M19947 BOLT 2
3 M19948 BOLT 4

PAGE 22
 FUSE BOX

IMAGE # PART NUMBER DESCRIPTION QTY NOTE

1 M19949 NUT 2
2 M19922 BRACKET 1
3 M19950 BRACKET 1
4 M19951 WASHER 1
5 M19952 WASHER 1
6 M19953 BOLT 2
7 M19954 BOLT 2

PAGE 23
 PULLEYS

IMAGE # PART NUMBER DESCRIPTION QTY NOTE

1 M19955 BOLT 2
2 M19956 PULLEY 1
3 M18964 PULLEY 1
4 M18765 TENSIONER 1
5 M18764 BOLT 1
6 M19925 NUT 1
7 M19938 BOLT 4

PAGE 24
 ALTERNATOR

IMAGE # PART NUMBER DESCRIPTION QTY NOTE

1 M19957 BOLT 1
2 M19958 BRACKET 1
3 M19959 SPACER 1
4 M05294 ALTERNATOR 1
5 M19960 NUT 1
6 M19961 WASHER 1
7 M19962 NUT 2
8 M19963 BOLT 1
9 M19964 BOLT 1

PAGE 25
 ELECTRICAL

NO IMAGE AVAILABLE

IMAGE # PART NUMBER DESCRIPTION QTY NOTE

1 M19965 WASHER 2
2 M19949 NUT 2
3 M19966 BUSHING 1
4 M18400 SENSOR 2
5 M18147 PROGRAMME GCP 1
6 M19940 CLAMP 2
7 M19967 CLAMP 1
8 M19968 ISOLATOR 2
9 M19969 SENSOR 1
10 M18104 SENSOR 1
11 M19970 SENDER 1
12 M19971 HARNESS 1
13 M19972 BRACKET 1
14 M19973 BOLT 2
15 M19974 WASHER 2
16 M19975 WASHER 1
17 M19976 BOLT 1
18 M19977 BOLT 1
19 M19945 BOLT 1
20 M19978 FITTING 1

PAGE 26
 CONVERTER

IMAGE # PART NUMBER DESCRIPTION QTY NOTE

1 M19979 FITTING 1
2 M19980 LOOM 12 IN
3 M19980 LOOM 14 IN
4 M19981 LOOM 18 IN
5 M19982 FITTING 1
6 M19983 FITTING 2
7 M19984 HOSE 2
8 M19985 HOSE 19 IN
9 M19986 FITTING 2
10 M17167 HOSE 8 IN
11 M19987 CLAMP 2
12 M19988 ELBOW 1
13 M19989 CLAMP 4
14 M19990 CLAMP 1
15 M17816 ECI 1

PAGE 27
 CONVERTER CONT.

IMAGE # PART NUMBER DESCRIPTION QTY NOTE

16 M19991 FITTING 1
17 M19992 FITTING 1
18 M19993 PLUG 1
19 M19994 BRACKET 1
20 M19995 PLATE 1
21 M19996 CLAMP 2
22 M19997 ISOLATOR 4
23 M19998 BELT 4
24 M05255 WASHER 4
25 M05256 WASHER 4
26 M05290 NUT 4
27 M19938 BOLT 2
28 M19999 BOLT 2

PAGE 28
 THROTTLE

IMAGE # PART NUMBER DESCRIPTION QTY NOTE

1 M19282 VALVE 1
2 M20000 STUD 2
3 M19704 ADAPTER 1
4 M20001 O-RING 2
5 M20002 SPACER 1
6 M20003 ADAPTER 1
7 M05352 GASKET 1
8 M19998 BOLT 4
9 M20004 WASHER 2
10 M05230 WASHER 2
11 M20005 NUT 2
12 M20006 BOLT 2
13 M20007 SCREW 4

PAGE 29
 INTAKE MANIFOLD

IMAGE # PART NUMBER DESCRIPTION QTY NOTE

1 M14693 BOLT 8
2 M05377 CLAMP 2
3 M19983 FITTING 1
4 M20008 HOSE 1
5 M18441 MANIFOLD 1
6 M19461 GASKET 2
7 M05360 PLUG 2
8 M20009 PLUG 1

PAGE 30
 BREATHER

IMAGE # PART NUMBER DESCRIPTION QTY NOTE

1 M05237 ELBOW 1
2 M13416 GROMMET 2
3 M19981 LOOM (NOT SHOWN) 8 IN
4 M05385 VALVE 1
5 M19985 HOSE 9 IN
6 M19987 CLAMP 2
7 M19988 ELBOW 1
8 M19991 FITTING 1

PAGE 31
 EXHAUST MANIFOLD

NO IMAGE AVAILABLE

IMAGE # PART NUMBER DESCRIPTION QTY NOTE

1 M20010 STUD 6
2 M19233 GASKET 1
3 M20011 MANIFOLD 2
4 M20012 BOLT 7
5 M20013 BOLT 1
6 M20014 BOLT 4
7 M19951 WASHER 12

PAGE 32
 Operation and Maintenance

Manual

PSI’s 4.3L OPU

Industrial Gasoline
and
Alternate Fueled Engines
1.6L, 3.0L, 4.3L, 5.7L, 7.4L and 8.1L Engines

A GM Powertrain Product
by Power Solutions, Inc.
Wood Dale, IL 60191
36100007/REV030101
Table of Contents

Page
Introduction 1

How to Use This Manual 1

Engine Identification 2
Parts and Service 2
Service Literature 2

Operating Instructions 3

Controls 3
Ignition Switch 3
Safety Gauges 3
Fuel Systems 3
Governors 4
Instruments 4
Oil Pressure Gauge 4
Temperature Gauge 4
Voltmeter 5
Tachometer/Hourmeter 5
Starting the Engine 5
Carbureted, Mechanical Governor, Manual Choke 5
Carbureted, Electric Choke, Electronic Governor 6
LPG or NG Fuel Systems, Velocity Governors 6
PSI, Inc. Fuel Injection (Gasoline) Integral Governor 6
PSI, Inc. Fuel Injection (Dual Fuel) Integral Governor 6
Zenith Z.E.E.M.S. Throttle Body Fuel Injection, Integral Governor 6
Stopping the Engine 7
Normal Conditions 7
Abnormal Conditions (Carbureted) 7
Abnormal Conditions (Fuel Injected) 7
Fuel Recommendations 7
Fuel Quality 7
Anti-Knock Index (Octane Rating) 8
Gasohol and Alcohol/Gasoline Fuels 8
Spark Plugs 8
Power Loss at Higher Elevations 9
Carbureted Engines 9
Fuel Injected Engines 9

Maintenance Instructions 10

Initial Start Up Maintenance 10

Routine Maintenance 10
Table of Contents (cont.)
Scheduled Preventive Maintenance 10

Engine Oil Level Check 10

Adding Engine Oil 10

Changing Engine Oil and Filter 11

Engine Oil Quality 11

Engine Oil Recommendation 11

Oil Filter 11

Engine Air Cleaner 12

Safety Element 12

Cooling System 12
Coolant Level 12
Radiator 13
Fan Belts 13
Sepentine Belt 14
V-Type Belt 14

Fuel Filter 14
Carbureted Engines 14
Fuel Injected Engines 14

Ignition Systems 15
Types of Ignition Systems 15
Ignition Timing 15
Spark Plugs 15

Storage 16
One to Six Months 16
Extended Periods 16
Removing the Engine From Storage 16

Appendix

Timing Procedures I

Maintenance Schedule II

Capacities II

Filter Chart III

Fuel System Chart IV

Governor Chart IV

General Specifications V
Table of Contents (cont.)
Spark Plug Wire Routing 3.0L

Spark Plug Wire Routing 4.3L

Spark Plug Wire Routing 5.7L

Spark Plug Wire Routing 7.4L

Introduction
Power Solutions, Inc. is pleased that you have selected a GM Powertrain engine for your
requirements. Power Solutions, Inc. takes great pride in our tradition of quality products
produced from the GM Powertrain line of industrial gasoline and alternative fuel
engines.

Power Solutions engines are inspected and tested before leaving the factory. However,
certain checks should be made before placing the engine into regular service. Please read
the Initial Start-Up inspection requirements in the Maintenance Section of this
manual.

How to Use this Manual

This manual contains instructions on the safe operation and preventive maintenance of
your GM Powertrain industrial engine. We urge you to read this manual prior to start up
or operation of the engine.

The Table of Contents permits you to quickly open the manual to any section.

Power Solutions, Inc., engines are built with a variety of standard and/or optional
components to suit a broad range of customer requirements. This manual does not
identify equipment as standard or optional. All the equipment described in this manual
may not be found on your engine or power unit.

Please pay special attention to the NOTES, CAUTIONS, and WARNINGS.

WARNINGS remind you to be careful in areas where carelessness can cause personal
injury. CAUTIONS are given to prevent you from error that could cause damage to the
equipment. NOTES give you added information designed to help you.

The descriptions and specifications contained in this manual were in effect at the time of
publication. Power Solutions, Inc. reserves the right to discontinue models at any time,
or to change specifications or design without notice and without incurring obligation.

Power Solutions, Inc.

655 Wheat Lane
Wood Dale, IL 60191
1
Engine Identification
An identification label is affixed to the right side of the engine on the rocker cover when
looking at the engine from the flywheel end.. (The engine serial number is also stamped
into the left side of the cylinder block near the engine flywheel.) The label contains the
engine model number (i.e. 4.3L, 5.7L, etc.) and a serial number which identifies the
engine from other GM Powertrain engines provided by Power Solutions, Inc. The
engine model and serial number are required when seeking information concerning the
engine and/or ordering replacement service parts.

Insert Picture of the Label

Parts and Service

Replacement parts can be obtained from Power Solutions, Inc. by calling the Service
Parts Department at 800-551-2938. The engine model and serial number will be required
when seeking information and/or ordering parts.

Service and technical support for GM Powertrain engines supplied by Power Solutions,
Inc. can be obtained by contacting the Service Department at 800-551-2938.

Service Literature

Additional operator manuals and service manuals for specific GM Powertrain engines
provided by Power Solutions, Inc. can be obtained by contacting the Parts or Service
Department at 800-551-2938

2
 Operating Instructions

Controls

Ignition Switch

The ignition switch is located on the control panel. The switch is a 3 position switch,
OFF, RUN and START. The OFF position disconnects the electrical system from the
battery. The key can be removed from the switch when it is in this position.

In the RUN position, the electrical system is activated.

Engage the starter by turning the key to the START position. Release the key when the
engine starts and it will return to the ON position.

Safety Gauges

Power Solutions, Inc., industrial power units are equipped with instrument panels which
contain shut down gauges for High Engine Water Temperature and Low Engine Oil
Pressure. A push button ‘Tattletale’ relay is utilized with this system. When starting the
engine it is necessary to ‘depress’ the safety switch override button, until the engine starts
and engine oil pressure is obtained (usually 2 to 5 seconds). The engine will continue to
run when the button is released.

CAUTION: If the engine does not continue to run when the button is released, it
will be necessary to check the instrument panel fuse and/or the engine lubrication
system (i.e. oil level, etc.) before restarting the engine.

NOTE: Power Solutions, Inc. provides engines to many different original equipment
manufacturers. Not all manufacturers use the PSI instrument panel. Please refer to the
equipment Operators Manual for instructions on engine starting.

Fuel Systems
Several different fuel systems have been used on Power Solutions, Inc. GM Powertrain
engines. A chart identifiying the different types of fuel systems used by engine model can
be found in the back of this manual.

NOTE: Some fuel systems are installed by the original equipment manufacturer.
Therefore it may be necessary to contact the equipment manufacturer for information
pertaining to your specific fuel system if it cannot be found in the chart.

3
Governors
As with fuel systems, several different governor controls have also been used with the
Power Solutions, Inc. GM Powertrain engines. A chart identifying the different types of
governor systems used is included at the back of this manual.

NOTE: Some governors are installed by the original equipment manufacturer. If your
governor is not included in the chart, it will be necessary to contact the equipment
manufacturer.

Instruments

Insert Photo of the Instrument Panel

Oil Pressure Gauge

The oil pressure gauge show the engine lubrication system pressure in pounds per square
inch (psi) and should be checked frequently to ensure that the system is functioning
correctly. Should the pressure fluctuate or drop, stop the engine and find the cause. Do
not operate the engine at lower than normal oil pressure (see maintenance schedule for
minimum engine oil pressure).

CAUTION: Do not continue to operate your engine below the normal operating
range. Severe engine damage could occur.

Temperature Gauge

The temperature gauge registers the coolant temperature and will indicate overheating
which may arise from low coolant level, plugged radiator, loose fan belt or faulty
thermostat. Coolant level should be checked daily.

CAUTION: If the engine continues to overheat, have the cooling system checked
and serviced.
4
Instruments (cont.)
Voltmeter

The voltmeter indicates the battery charging voltage. If the meter consistently indicates
less than 13 volts or more than 15.7 volts under normal operating conditions, you should
have the engine electrical system checked by a qualified service technician.

Tachometer/Hourmeter

The tachometer indicates the engine speed in hundreds of revolutions per minute (rpm). It
serves, as a guide to insure that engine speed is set correctly.

The hourmeter records the hours of operation and is used to determine when periodic
maintenance is required.

Starting the Engine

Warning:
All internal combustion engines give off various fumes and gases while running. Do
no start or run the engine in a closed or poorly ventilated building where exhaust
gases can accumulate. Avoid breathing these gases as they may contain poisonous
carbon monoxide, which can endanger your health or life if inhaled steadily for even
a few minutes.

If the engine is equipped with a manual clutch it must be disengaged prior to starting the
engine. Starting the engine with the clutch engaged imposes unnecessary strain on the
battery, starter, and driven components.

CAUTION: If the engine stalls or falters during starting, wait 3 to 4 seconds

before re-engaging the starter. This will prevent possible damage to the starter or
the engine. DO NOT operate the starter for periods longer than 30 seconds at a
time. An interval of at least 1-minute should be observed between cranking periods
to protect the starter from overheating.

Carbureted, Mechanical Governor, Manual Choke

Pull the throttle cable out approximately ½ inch, and the choke out full. Turn the ignition
key to the START position. After the engine starts, release the key, decrease the throttle
setting and adjust the choke cable for fast idle warm-up. When the engine is at operating
temperature, push the choke in all the way.

When the engine is warm, it may not be necessary to use the choke for starting.

5
Carbureted, Electric Choke, Electronic Governor

Turn the On/Off switch on the instrument panel to the ON position. Turn the ignition key
to the ON position. This allows the electric choke to pre-set prior to starting. Turn the
ignition key to the START position. After the engine starts release the key to the ON
position. Allow a few minutes for the engine to warm up. Move the governor control
switch to the LOW position. Engage the clutch, then move the governor control switch to
the HI position.

LPG or NG Fuel Systems, Velocity Governors

Turn on the gas supply to the engine. Turn the ignition key to the START position. After
the engine starts release the key to the ON position.

PSI Fuel Injection (Gasoline)

Turn the ignition key to the ON position, this energizes the electric fuel pump to charge
the fuel system with fuel. Turn the ignition key to the START position. After the engine
starts release the key to the ON position.

PSI Fuel Injection (Gasoline/LPG)(Dual Fuel)

Select the desired fuel switch position for starting the engine (Gasoline/LPG). Turn the
ignition key switch ON, then move ignition key to the START position. After the engine
starts release the key to the ON position.

Zenith Z.E.E.M.S. Throttle Body Fuel Injection, Integral Governor

Turn the ignition key to the ON position to energize the fuel pump. Ensure that the Hi/Lo
switch on the instrument is in the Lo position. Turn the ignition key to the START
position. After the engine starts release the key to the ON position. Allowing a few
minutes for engine warm-up, move the Hi/Lo switch to the Hi position.

6
Stopping the Engine
Normal Conditions: Following normal operating conditions, lower the engine speed
to idle, pushing the throttle cable in on mechanical systems or with electronic systems
placing the Hi/Lo switch in the Lo position.

If the machine is equipped with a clutch, move the clutch lever to the disengaged
position.

Run engine for a few minutes at idle to allow the coolant system to cool down before
turning the ignition switch to the OFF position.

Abnormal Conditions (Carbureted): Under abnormally overheated conditions, the

engine may continue to run after the switch is turned OFF. If this is encountered, turn the
ignition switch to the ON position immediately and allow the engine to run at idle until it
has cooled down enough to stop.

(Fuel Injected) Fuel injected engines generally will not after run, even if hot. These
systems require that the fuel delivery be shut off completely when turning the ignition
switch to the OFF position.

WARNING:
Avoid injury when checking a Hot Engine. Allow the engine to cool down
before removing the radiator cap.

CAUTION: Before restarting the engine ensure that both the coolant system
and the engine oil level have been checked and re-filled if necessary.

Fuel Recommendations

Fuel Quality

Using a high quality unleaded gasoline will help maintain the power, fuel economy and
emissions performance of your engine. A properly formulated gasoline will be comprised
of well refined hydrocarbons and chemical additives and will perform the following
functions:

• Minimize varnish, lacquer, and other induction system deposits.

• Prevent gum formation or other deterioration during storage.

Protect fuel tank and other fuel system components from corrosion or degradation.

7
Fuel Recommendations (cont.)
• Provide the correct seasonally and geographically adjusted volatility which
should provide easy starting in the winter and summer.

• Avoid fuel system icing.

In addition, the fuel must be free of water, debris, and other impurities.

It is recommended that the fuel supply be kept fresh when the engine is in storage
(especially in hot weather). The fuel tank should be kept at least ¾ full.

Fuel stored for more than two months should be drained, properly discarded, and the fuel
tank re-filled.

Anti-Knock Index (Octane Rating)

This engine is designed to operate on unleaded 87 or 89 octane gasoline with an (R +

M)/2”minimum anti-knock index. Federal regulations require that each retail gasoline
dispensing pump must display a label bearing the minimum index rating.

Use of unleaded gasoline with anti-knock index rating lower than 87 can cause persistent,
heavy spark knock, which can lead to engine damage. If your engine knocks heavily
when you use gasoline with an anti-knock index rating of 87 or higher, or if you hear
continuous spark knock while maintaining constant operating speeds, consult a dealer or
qualified technician.

Gasohol and Alcohol/Gasoline Fuels

Gasohol, a mixture of gasoline and ethanol (grain alcohol), is available in some areas.
PSI, GM Powertrain engines should operate satisfactorily on gasohol blends containing
no more than 10% ethanol by volume and having and anti-knock index of 87 or 89.
CAUTION: In some cases, methanol (wood alcohol) or other alcohol’s may be
added to gasoline. PSI GM Powertrain engines should operate satisfactorily on
blends containing up to 5% methanol by volume when cosolvents and other
necessary additives are used. DO NOT USE blends containing more than 5%
methanol by volume or blends that do not contain cosolvents and corrosion
inhibitors.

CAUTION: Discontinue use of any gasohol or alcohol/gasoline blend if fuel system

problems occur. Do not use such fuels unless they are UNLEADED.

Spark plugs
Always use the recommended spark plugs for your engine. Hotter or colder plugs, or
similar plugs that are not exact equivalents to the recommended plugs, can cause
permanent engine damage, reduce the engines useful life, and cause many other problems
such as hard starting, spark knock and run-on. Installing new spark plugs regularly is one
of the best ways to keep your engine at peak performance.
8
Power Loss at Higher Elevations

All engines will experience power loss when operated at elevations above sea level,
unless they are turbocharged or supercharged. Turbochargers and superchargers are
mechanical pumps that put extra air into the engine to make up for the lower air density
at higher elevations.

Carbureted Engines

Carbureted engines will loose power for two reasons. First, power is reduced 3.5% for
each 1000 feet it is operated above sea level due to the decreased air density. With less
dense air, the engine receives less oxygen to burn the fuel. The engine power is decreased
in direct proportion to the reduction of available oxygen. Second, the reduced oxygen
causes the fuel mixture to have too much fuel for the available oxygen. This is a rich
mixture (rich with fuel) and not only causes the engine to produce sooty black exhaust,
but causes additional loss of power and premature spark plug fouling. Engines that are
operated over 3000 feet of elevation, that exhibit black smoke or produce less than
optimum power should have the fuel system re-calibrated. For additional information on
optimizing your engine for higher elevations contact your dealer or Power Solutions, Inc.
at 800-551-2938.

Caution: Engines re-calibrated for high elevations will run lean at lower elevations. Lean
running can burn valves, will reduce valve and valve seat life and can cause engine
overheating. Failures caused by these problems are not covered by warranty.

Fuel Injected Engines

Fuel injected engines will loose 3.5% power for every 1000 feet the engine is operated
above sea level. All fuel injection systems installed by Power Solutions, Inc. are equipped
with a “manifold absolute pressure sensor” (MAP Sensor). The MAP sensor senses
barometric pressure and automatically corrects the fuel system calibration for changes in
altitude. This means the air/fuel mixture will always be optimized, regardless of elevation
(or barometric pressure), however, the engine will still loose 3.5% power for every 1000
feet increase in elevation.

9
 MAINTENANCE INSTRUCTIONS

Initial Start Up Maintenance

The initial start-up checks must be made before putting the engine into service. Please
refer to the Maintenance Schedule on page II and perform the initial start-up operations in
the sequence shown in column 1.

Routine Maintenance
Routine maintenance provides the best solution for making sure that the engine is ready
when you are. The following are some routine service points:

• Keep the fuel tank filled. A full tank of fuel reduces the possibility of
condensation forming in the fuel tank and moisture entering the fuel system
• Make frequent checks of the engine oil and coolant levels
• Repair any oil or coolant leaks immediately
• Check battery condition and cables frequently
• Keep the engine air filter clean
• Monitor engine coolant temperature
• Monitor engine oil pressure
• Check voltmeter and charging system

Scheduled Preventive Maintenance

Refer to the Maintenance Schedule on page II to ensure that all of the maintenance items
listed are checked and replaced as recommended at the hours shown.

Engine Oil Level Check

The engine oil level should be checked daily. It is recommended that the oil be checked
just before the engine is started for the first time for that day. The oil level should be
between the ‘Add’ and the ‘Full’ marks on the dipstick.

CAUTION: Do not operate the engine with the oil level below the bottom or ‘Add’
mark on the dipstick, or above the top or ‘Full’ mark on the dipstick.

Adding Engine Oil

It is normal to add some oil in the period of time between oil changes. The amount will
vary with the severity of operation. When adding or replacing engine oil, be sure the oil
meets or exceeds the recommended specification.

10
Changing Engine Oil and Filter
The engine oil and filter must be changed every 200 hours or every 3 months whichever
occurs first. Under normal operating conditions, you do not need to change them more
often if you use oil and filters of the recommended quality.

The oil and filter should be changed more often if the engine is operating in dusty or
extremely dirty areas, or during cold weather. No oil additives or break-in oil change is
required.

Engine Oil Quality

To achieve proper engine performance and durability, it is important that you use only
engine lubricating oils of the correct quality in your engine. Proper quality oils also
provide maximum efficiency for crankcase ventilation systems, which reduces pollution.

Important: use only engine oils displaying the American Petroleum Institute (API)
“Starburst” Certification Mark ‘FOR GASOLINE ENGINES’ on the container.

Gasoline engines that are converted for LPG or NG fuels MUST use oils labeled ‘FOR
GASOLINE ENGINES’. Do not use oils that are specifically formulated for Diesel
Engines only. CC or CD classification oils, even when labeled Heavy Duty or for
Natural Gas Engines, ARE NOT ACCEPTABLE.

Engine Oil Recommendation

Multi-viscosity oils are recommended. SAE 10W-30 is recommended for your engine
from 0 degrees F (-18 degrees C) or above. If ambient temperatures are consistently
below 0 degrees F, SAE 5W-30 oil can be used. Synthetic oils are not recommended for
industrial or stationary engines.

Oil Filter
The PSI GM Powertrain engines use an AC Delco oil filter as original equipment. An
equivalent oil filter must be used when servicing the engine (see Engine Specifications
for the recommended oil filter for your engine).

The filter protects your engine from harmful, abrasive, or sludgy particles without
blocking the flow of oil to vital engine parts.

To replace the filter, use a proper filter wrench to remove the filter.

Clean the filter mounting base and lightly coat the gasket surface of the new filter with
engine oil. Hand tighten the filter until the gasket contacts the base, then tighten another
½ turn. Fill the engine with the correct amount of oil, run the engine and check for oil
leaks at the drain plug and oil filter gasket. Tighten as necessary to stop any oil leakage
noted.

11
Engine Air Cleaner
The engine air cleaner filters air entering the engine intake system and acts as a silencer
and flame arrester when assembled to the intake system.

Air that contains dirt and grit produces an abrasive fuel mixture and can cause severe
damage to the cylinder walls and piston rings. Damage to the cylinder walls and piston
rings will cause high oil consumption and shorten engine life.

A restricted or dirty air cleaner will also cause a rich fuel mixture. Thus, it is extremely
important that the air cleaner be serviced properly at the recommended intervals.

CAUTION: Service the air cleaner more frequently under severe dusty or dirty
conditions.

Remove the primary air cleaner element from the air cleaner assembly and inspect the
element for foreign material restrictions or signs of excessive wear or damage. Replace
the element if necessary.

Remove all dust and foreign matter from the air cleaner housing.

Reinstall the air cleaner element. Reinstall the air cleaner cup, and securely fasten the
retaining clips.

Safety Element

If your engine is equipped with an air cleaner which utilizes a safety element, ensure that
the element is properly in place before installing the primary element.

Change the safety element annually.

Cooling System
Coolant Level

Check the coolant level of the radiator daily and only when the engine is cool. Generally
a good time to do this is just prior to starting the engine for the first time each day.

Maintain the coolant level at ¾ to 1½ inches below the filler neck seat of the radiator
when the coolant is cold. When ever coolant level checks are made inspect the condition
of the radiator cap rubber seal. Make sure it is clean and free of any dirt particles which
would keep it from seating on the filler neck seat. Rinse off with clean water if necessary.
Also make sure that the filler neck seat is free of any dirt particles.

12
WARNING
Never remove the radiator cap under any conditions while the engine is
operating. Failure to follow these instruction could result in damage to the
cooling system, engine, or cause personal injury. To avoid having scalding
hot coolant or steam blow out of the radiator, use extreme caution when
removing the radiator cap from a hot radiator. If possible, wait until the
engine has cooled, then wrap a thick cloth around the radiator cap and turn
slowly to the first stop. Step back while the pressure is released from the
cooling system. When all the pressure has been released, press down on the
cap and remove it slowly.

DO NOT add coolant to any engine that has become overheated until the
engine cools. Adding coolant to an extremely hot engine can result in a
cracked block or cylinder head.

Use only a permanent-type coolant when refilling or flushing the coolant system.
Recommended ethylene glycol mix 52/48 is normal up to a maximum of 60% glycol,
40% water.

Refer to the mixture chart on the container for additional antifreeze protection
information. DO NOT use alcohol or methanol antifreeze, or mix them with the specified
coolant.

Plain water may be used in an emergency (except in freezing temperatures), but replace it
with the specified coolant as quickly as possible to avoid damage to the system.

Radiator

Inspect the exterior of the radiator for obstructions. Remove all bugs, dirt or foreign
material with a soft brush or cloth. Use care to avoid damaging the core fins. If available,
use low pressure compressed air or a stream of water in the opposite direction of the
normal air flow.

Check all hoses and connections for leaks. If any of the hoses are cracked, frayed, or feel
spongy, they must be replaced.

Fan Belts
The water pump is usually belt driven. The same belt may also drive the fan and/or the
alternator. The drive belts should be properly adjusted at all times. A
loose belt can cause improper alternator, fan and water pump operation, in addition to
overheating.

13
Serpentine Belt

Some GM Powertrain engines utilize serpentine belts on the front of the engine. This
type of belt system incorporates a belt tensioning device which keeps the belt at the
proper tension.

This belt should be checked routinely for cracks or ‘checking’ on the groove side of the
belt. If cracks or ‘checking’ are apparent the belt must be changed.

V-Type Belt

V-Type belts are generally tensioned by adjusting the alternator, or through a mechanical
belt tensioner. The belt is generally correctly tensioned when there is an ½ inch of
depression on the belt between the water pump and the crankshaft pulley.

Fuel Filter
Carbureted Engines

On carbureted engines, an in-line fuel filter is incorporated into the fuel supply line. It is
recommended that this filter be changed every 250 hours or every 6 months which ever
occurs first.

TBI Engines

On PSI Fuel Injection or Fuel Injection/Dual Fuel two fuel filters are used in the gasoline
fuel supply line to the engine TBI unit.

A coarse fuel filter is located in the supply line between the fuel tank and the electric fuel
pump. This filter protects the fuel pump from debris in the fuel tank.
This filter must be changed every 200 hours or every 6 months which ever occurs first.

A primary fuel filter is located between the fuel pump and the TBI unit on the engine.
This filter protects the injectors from microscopic particles in the fuel which can cause
plugging of the injectors. This filter MUST be changed every 500 hours or annually
which ever occurs first.

Zenith Z.E.E.M.S. TBI Fuel Injection requires an in-line fuel filter in the fuel supply line
from the fuel tank to the TBI unit, ahead of the electric fuel supply pump. This filter must
be changed every 200 hours or every 6 months which ever occurs first.

CAUTION: Failure to change the fuel system filters as recommended can result in
premature failure of the TBI fuel system components.

NOTE: Some original equipment manufacturers install their own fuel systems. Please
refer to the manufacturers manual if the gasoline fuel system is different than described
here.

14
WARNING
Use extreme care when changing the fuel filters on gasoline engines. Gasoline
is highly flammable and should not be exposed to open flame, sparks, or hot
engine components. Allow the engine to cool to ambient temperatures prior
to changing fuel filters.

Ignition Systems
Types of Ignition Systems

Three types of ignition systems are used on PSI GM Powertrain engines. Solid state
electronic distributor, solid state electronic distributor with ECU (Electronic Control
Unit) and distributor-less electronic ignition with ECU.

Please refer to the General Specification chart to determine the ignition system used on
your particular engine.

Ignition Timing

Proper adjustment of the ignition timing must be obtained to provide the optimum engine
power output and economy.

To properly adjust timing refer to the timing procedure section of this manual.

Spark Plugs

Spark plugs should be replaced at the recommended intervals described in the

Maintenance Schedule. Use only the recommended spark plug or an equivalent as
described in the General Specifications.

Spark plug gap, should be adjusted as recommended in the General Specifications.

When removing spark plugs, always note which cylinder each plug came out of. Look at
the porcelain around the center electrode of each plug. You can detect many engine
problems from the color and type of deposits that have built up on the white porcelain.
For example, if the deposits are a glossy brown, that cylinder is burning excess oil. If
the deposits are a very dark gray or sooty black color, your engine is running rich, and
you are burning excess fuel. The optimum color of the deposits on the porcelain is light
tan or light brown. This shows optimum fuel mixture and proper engine running
conditions. If the deposits are almost white, the engine may be running excessively lean.
Lean running is very detrimental to your engine life, and should be corrected
immediately.
If one or more cylinders are burning oil, the smoke from the engine will be a blue-gray
color. Most common causes are piston rings (worn out or not broken in) and valve stem
seals (cut, nicked, or worn out). If the engine is running rich the exhaust smoke will be a
sooty black color and it will smell like gasoline (on gasoline engines).

15
Storage
One to Six Months

If the engine or machine is to be placed in storage for a period of one to six months it is
recommended that the following steps be followed:

• Add ‘Stabil’ or equivalent fuel conditioner to the fuel tank as recommended

on the bottle. Run the engine for approximately 10 to 15 minutes to insure that
the treated fuel is completely through the fuel system.

• Fill the fuel tank with fuel

• Protect the air cleaner inlet from water entry

• Protect the exhaust outlet or muffler outlet from water entry

• Check the coolant protection and top off radiator

• Store indoors if possible

For Extended Periods

Follow the above recommended procedures, plus do the following:

• Drain the engine crankcase and refill with recommended oil

• Change the oil filter

• Disconnect and remove the battery

• Clean exterior surface of the engine

• If the engine is equipped with an automotive type clutch or PTO clutch,

make sure that the clutch is disengaged

Removing the Engine From Extended Storage

When removing the engine from extended storage:

• Install a fully charged battery

• Remove all protective coverings from the air inlet, air cleaner, exhaust,
and muffler openings

• Check the coolant level in the radiator and verify the protection level
of the coolant
16
Removing the Engine From Extended Storage (cont.)

• Start the engine and allow it to run at slow idle. Verify engine oil pressure

• Run the engine at idle until the coolant temperature approaches 120 degrees F
(49 degrees C)

• Run the engine a various speeds for approximately 15 minutes

• Shut the engine down, drain the oil, change the oil filter, and re-fill with
the recommended grade of oil

17
 GM Engine Timing Procedures
Carbureted, LPG an NG 3.0L, 4.3L, 5.7L, 7.4L PSI/GM Engines

PSI Timing Connector Part Number 33000036 MUST be used when checking and adjusting the
engine timing.
1. With the engine shut-off, plug the 33000036 Timing Connector into the distributor.
DO NOT connect the alligator clip to any positive or negative terminal. (Connecting
this wire to any battery terminal prior to starting the engine will cause the distributor
module to fail when starting the engine.)
2. Start the engine and run at slow idle. 800 to 1000 rpm.
3. Connect the alligator clip to a B+ terminal. (This connection cancels the programmed
timing advance from the distributor module. You will notice a change in engine
sound and rpm when making this connection.)
4. Connect an electronic timing light to the No.1 spark plug wire. (The front cylinder on
the 3.0L engine and the front cylinder on the left bank of the 4.3L, 5.7L and 7.4L
engines.)
5. Check and adjust the distributor as necessary viewing the timing mark on the
crankshaft pulley in relation to the pointer on the engine timing case. (On some
engines there may be a timing port in the flywheel housing also.)
6. Refer to the General Specifications chart in this manual, for the initial timing
specification for your engine and type of fuel being used.

PSI Fuel Injected and Dual Fuel engines

For engines equipped with this type of fuel system, the engine timing is controlled by the ECM
(Engine Control Module).

Checking the initial timing on engines equipped with PSI fuel injected and dual fuel engines
incorporating and ECM can only be accomplished when using a laptop computer or a hand
held diagnostic meter. It will be necessary to contact the OEM or PSI for the necessary
equipment and instructions for checking and adjusting the engine timing. (CAUTION:
Failure to follow the correct specified procedures when checking and adjusting the engine
timing, can cause severe damage to the engine.)

Zenith Z.E.E.M.S. Throttle Body Fuel Injected Engines

Engine timing for Zenith TBI fuel injected engines is checked and adjusted following the
procedures noted under Carbureted engines. Check the General Specifications chart for the
correct engine timing.

Generator Timing

PSI/GM engines operating on generators are timed at 1800 RPM. Timing procedures are
the same as for Carbureted engines. Check the General Specifications chart for the correct
engine timing for the type of fuel being used.

I
 Maintenance Schedule
Power Solutions, Inc.
GM Powertrain

1.6L, 3.0L, 4.3L, 5.7L, 7.4L, and 8.1L Engines

Initial
Start-Up Operation Daily Weekly Every Every Every Every Every As
Sequence 50 100 200 400 800 Req.
Checks hrs hrs hrs hrs hrs
1 Check Engine Oil Level x
2 Check Coolant Level x
3 Check for Fluid Leaks x
4 Governor, Mechanical (Check oil level)(2) x
Change Engine Oil & Filter (1) x
5 Battery, Check Charge & Fluid Level x
Inspect & Clean Radiator Exterior x
Clean Battery Cables x
6 Check Belts and Belt Tension x
Lubricate Throttle, Governor & Choke x
Linkage (Carbureted Engines Only)
Check & Adjust Idle Speed (Carbureted x
Engines Only)
Inspect and Clean Air Cleaner Element x
Replace Primary Air Cleaner Element (1) x
Replace Safety Air Cleaner Element x
Check Coolant Protection & Tighten Hose x
Clamps
Replace Engine Coolant (3) x
Replace Gasoline Fuel Filter (4) x
Replace LPG Filter – Zenith EFI (4) x
Replace PCV Valve (If Equipped) x
Check PCV Hoses, Tubes, and Fittings x
Replace Spark Plugs (3) x
Distributor Cap & Rotor (5) x
Secondary Ignition Wires x
Adjust Throttle & Governor (3) x
7 Check All Engine Bolts & Nuts for x
Tightness
(1) More frequent intervals may be required in dusty or dirty operating conditions.
(2) Mechanical governor (belt driven).
(3) To be performed at specified interval or annually, whichever occurs first.
(4) More frequent intervals may be required with dirt in the fuel system.
(5) Does not apply to engines with DIS ignition.

Capacities
Engine 1.6L 3.0L 4.3L 5.7L 7.4L 8.1L
Oil Capacity Without Filter 3.4 qts. 4 qts. 4.5 qts. 5 qts. 8 qts. 8 qts.
Oil Capacity With Filter 3.7 qts. 4.5 qts. 5 qts. 5.5 qts. 9 qts. 9 qts.
Coolant Capacity Without Radiator 3.5 qts. 4 qts. 7.75 qts. 8.1 qts. 14.5 qts. 14.5 qts.
Coolant Capacity With Radiator 10 qts. 12 qts. 17 qts. 17.5 qts. 28 qts. 28.5 qts.
31 qt (Turbo)
Revised 12/27/01

II
 Power Solutions, Inc.
GM Powertrain Industrial Engines

Filter Chart
Engine 1.6L 3.0L 4.3L 5.7L 7.4L/7.4LT 8.1L
Oil Filter 94632619 P-25 or PF-47/PF-52 or PF-1218 PF-1218 or PF-454 or
Equivalent Equivalent Equivalent Equivalent Equivalent
Fuel Filter 32500020 32500020
(Carbureted) (101021) (101021)
Fuel Filter 32500111 32500111
(PSI TBI
Coarse)
Fuel Filter 32500058 32500058
(PSI TBI
Fine)
Fuel Filter Gasoline 32500292 32500292
Zenith C282-224
Z.E.E.M.S LPG
C282-5

Air Filter P822768 P8228889

Primary
(PSI Power
Unit)
Air Filter P822769 P829333
Safety
(PSI Power
Unit)
Revised 05/31/00

III
 Power Solutions, Inc.
GM Powertrain Industrial Engines

Fuel System Chart

Engine 1.6 L 3.0L 4.3L 5.7L 7.4L/T 8.1L
Zenith Carburetor (013448) Manual Choke x
Zenith Carburetor (015017) Electric Choke x
Zenith Carburetor (015052) used w/Dual Fuel System x x
Holley Carburetor (0-7448) Electric Choke x
Holley Carburetor(0-82010) Electric Choke x
Impco LPG Fuel System x x x x
Nolff LPG Fuel System x x x x x x
PSI Fuel Injection (Gasoline) x x x
PSI Fuel Injection/LPG Mixer (Dual Fuel) x x x
Impco Natural Gas Mixer x x x x
Nolff Natural Gas Mixer x x x x x x
Zenith Z.E.E.M.S Fuel Injection x x x

Governor Chart

Engine 1.6L 3.0L 4.3L 5.7L 7.4L/T 8.1L

Hoof Mechanical (Belt Driven)(No Longer Available) x
Hoof Velocity Governor x(NLA) x(NLA) x x
Aisan Velocity Governor x x
Barber Colman Electronic x x
Governors America x x x x
Barber Colman Power Flow, PSI ECU x x x x
Zenith Z.E.E.M.S. Fuel Injection Integral Integral Integral
Woodward x
Revised 06/05/01

IV
 GENERAL SPECIFICATIONS
Power Solutions, Inc.
GM Powertrain Industrial Engines
Engine 1.6L 3.0L 4.3L 5.7L 7.4L/7.4L Turbo 8.1L/8.1L Turbo
Type 1.6-2V 3.0L L4 4.3L V-6 5.7L V-8 GEN-1E 7.4L V-8 8.1L V-8
Displacement cc (c.i.d.) 1600 (98) 2966 (181) 4294 (262) 5735 (350) 7441 (454) 8127 (496)
Compression Ratio 9.4:1 9.2:1 9.4:1 9.4:1 8.9:1 9.1:1
Valve Configuration Overhead Cam Push Rod Actuated Push Rod Actuated Push Rod Actuated Push Rod Actuated Push Rod Actuated
Overhead Valve Overhead Valve Overhead Valve Overhead Canted Valve Overhead Valve
Valve Lifters Hydraulic Flat Follower Hydraulic Roller Hydraulic Roller Hydraulic Roller Hydraulic Roller
Bore x Stroke mm (inches) 79.0x81.5 (3.11x3.21) 101.60x91.44 (4.00x3.60) 101.60x88.39 (4.00x3.48) 101.60x88.39 (4.00x3.48) 107.95x101.60 (4.25x4.00) 107.95x111 (4.25x4.37)
Main Bearing Caps 2 Bolt 2 Bolt 2 Bolt 2 Bolt 4 Bolt 4 Bolt
Balance Method External External Internal Balance Shaft External External External
Intake Manifold TBI TBI, Carburetor, Mixer TBI, Carburetor, Mixer Mixer Mixer Mixer
Firing Order 1-3-4-2 1-3-4-2 1-6-5-4-3-2 1-8-4-3-6-5-7-2 1-8-4-3-6-5-7-2 1-8-7-2-6-5-4-3
Oil Capacity 3.4 qts. (3.2L) 4 qts. (3.8L) 4.5 qts. (4.3L) 4.5 qts. (4.3L) 8 qts. (7.6L) 8 qts. (7.6L)
With Oil Filter 3.7 qts. (3.5L) 5 qts. (4.7L) 5 qts. (4.7L) 5 qts. (4.7L) 9 qts. (8.5L) 9 qts (8.5L)
Oil Filter PF-25 or Equivalent PF-47/PF-52 or Equivalent PF-1218 or Equivalent PF-1218 or Equivalent PF-454 or Equivalent
Minimum Oil Pressure (Hot) 21 psi @ idle 6 psi @ 1000 rpm 6 psi @1000 rpm 6 psi @ 1000 rpm 6 psi @ 1000 rpm 5 psi @ 1000 rpm
18 psi @ 2000 rpm 18 psi @ 2000 rpm 18 psi @ 2000 rpm 18 psi @ 2000 rpm 15 psi @ 2000 rpm
Coolant Capacity (Engine) 3.5 qts. 4 qts. (3.78L) 7.75 qts. (7.3L) 8.1 qts (7.8L) 14.5 qts (13.7L) 14.5 qts (13.7L)
Coolant Capacity (W/PSI Rad) 10 qts 12 qts. (11.4L) 17 qts. (16L) 17.5 qts. (16.6L) 28 (26.5L) 28 qts (26.5L)
Fuel Type Gasoline, LPG Gasoline, LPG, NG Gasoline, LPG, NG LPG, NG LPG, NG LPG, NG
Engine Rotation (Flywheel End) CCW CCW CCW CCW CCW CCW
Ignition System Distributor-less Solid State Solid State Solid State Solid State Distributor-less
Electronic (ECU) Distributor Distributor Distributor Distributor Electronic ECU
Ignition Timing (Degrees BTDC)
Gasoline (Carb) 0 0 0 0
Gasoline (TBI) DIS 0 0 0 0 DIS
LPG No Adjustment 10 (4 Europe) 10 (4 Europe) 10 (4 Europe) 10 No Adjustment
NG 10 10 10 10
Dual Fuel 0 0 0 0
Ignition Timing (Degrees BTDC)
Generators 1800 RPM DIS
LPG No Adjustment 26 26 26 26 26
NG 36 36 36 36 30
Spark Plugs AC Delco 93206675 AC Delco R45TS AC Delco R42LTS AC Delco R42LTS AC Delco R42LTS AC Delco R42LTS
Spark Plug Gap

TBI .035 .035

LPG .8mm-.9mm .045 .035 .035 .035 .030/.025T
NG all all .035 .035 .035 .030/.025T
Dual Fuel .035 .035 .035 .030/.025T
Valve Clearance (Lash)
Intake No Adjustment ½ to 1 Turn Down From Net Lash 1 Turn Down From Net Lash Net Lash
Exhaust OHC Engine 0 Lash No Adjustment 0 Lash No Adjustment No Adjustment

Manufactured Brazil Toluca, Mexico Tonawanda, NY Toluca, Mexico Tonawanda, NY Tonawanda, NY

Revised 02/09/02
V
3.0L Engine Spark Plug Wire Routing
4.3L Engine Spark Plug Wire Routing
5.7L Engine Spark Plug Wire Routing
7.4L Engine Spark Plug Wire Routing
F300 ENGINE H04565-3-HOSEKIT

Hose Location Fitting #1 Fitting #2 Hose Length Hose Part # Hose Size Qty Hose ASM #
Shuttle Valve to Steer Pump H00828-1 H00829-1 27" H01372 #6 1 H04439-3
Control Valve to Tylt Lock Valve ( R ) H00830-1 H01660-1 16" H00956 #8 1 H04570-1
Control Valve to Tylt Lock Valve ( L ) H00830-1 H01660-1 19" H0956 #8 1 H03273-7
Lift Pump to Valve Pressure H00838-2 H00839-2 10" H00822 #20 1 H04567-7
Item Description Qty Built Item# Rev RPT? M Kit?
H03086 FEMALE 1/8 NPTF TO 1/8 NPTF UNION 1 _ 1
H05153 #6 SAE 45DEG FLARE TO 1/8-27 NPT PIPE 1 _ 1
H05154 STR CONN. #6 SAE 45DEG FEM TO #6 SA 1 _ 1
M01148 LPG FUEL LEVEL KIT 1 _ 0 1
M14659 JUMPER HARNESS LOW LP FKS-TITAN 1 _ 1
BOM Chec
k
Save Can Rpt View Part Next Prev
Parts Built First Last Quit
 Service Parts List
M06013-4 Hoist Transmission

M17547 Transmission Filter Element

Item Number Description Part Number Qty
1 Input Shaft Gear 25T *See Item 21 of Group ‐Turbine Shaft M07196 1
2 Rear Bearing Spacer * See Item 15 of Group ‐ Output Shaft M16037 1
3 Plug Fitting * See item 19 of Group ‐ Output Shaft M16038 1
Item Number Description Part Number Qty
1 NOT USED ON THIS MODEL
2 Pipe Plug M07254 1
3 Converter Housing & Tube Assembly M07204 1
(includes items 7‐15,19,24‐44)
7 Pressure & Lubrication Tube Sleeve M07205 1
8 Converter Housing Sleeve M07206 1
9 Washer M07207 1
10 Lock Washer M19514 1
11 Cap Screw M19515 1
12 Cap Screw M19515 1
13 Lock Washer M19514 1
14 Washer M07207 1
15 Converter Housing Sleeve M07206 1
16 Air Breather M04482 1
17 90 Degree Street Elbow Fitting M19516 1
18 Pipe Reducing Bushing M19517 1
19 Pressure & Lubrication Tube Sleeve M07205 3
20 Lock Washer M19518 4
21 Cap Screw M19519 4
22 Lock Washer M19518 4
23 Cap Screw M19520 4
24 Lock Washer M19514 1
25 Cap Screw M19521 1
26 O‐ring M07218 1
28 Suction Tube Assembly M07219 1
28A Suction Tube Clip M07220 2
29 Lock Washer M04748 2
30 Cap Screw M19522 1
31 Cap Screw M19515 1
32 Lock Washer M19514 1
33 Tube Clip M07225 1
34 Reverse Tube Assembly M07226 1
35 O‐ring M19523 1
36 Cap Screw M19521 1
37 Lock Washer M19514 1
38 Lube Tube Assembly M07229 1
39 Cap Screw M19515 1
40 Lock Washer M19514 1
41 Tube Clip M07225 1
42 3rd Speed Tube M07230 1
43 O‐ring M19523 1
44 Tube M07232 1
45 Cap Screw M19524 10
46 Lock Washer M19518 10
48 Dowel Pin M19525 2
49 Coverter Hsg To Trans Case Gasket M07235 1
50 Housing To Case Spacer M07237 1
NI Sensor Bushing M07238 1
NI Screw Type Plug M07263 1
NI O‐ring M07264 1
NI Shim Washer M07159 AR
NI Plug Fitting M07242 1
NI O‐ring M07243 2

*NI ‐ NOT ILLUSTRATED
Item Number Description Part Number Qty
1 Transmission Case & Tube Assembly M19526 1
(includes items 2‐12)
2 Suction Tube Assembly M07253 1
3 O‐ring M07258 1
4 Suction Line Retainer Washer M19527 1
5 Cap Screw M19528 2
6 Low Clutch Pressure Tube M07245 1
7 Pressure & Lube Tube Sleeve M07205 2
8 Oil Baffle M07260 1
9 Oil Baffle M07261 1
10 Rivet M07259 4
11 Snap Ring M19529 1
12 Needle Bearing M19530 1
13 Dowel Pin M07247 2
14 O‐ring M16615 3
15 Pipe Plug M04464 2
16 Magnetic Plug M07249 1
17 Expansion Plug M07255 1
18 Pipe Plug M19531 1
19 Suction Screen Assembly M07251 1
20 Gasket M07252 1
21 Sensor Bushing M07238 1
22 Shim Washer M07159 AR
23 Screw Type Plug M07263 1
24 O‐ring M07264 1
Item Number Description Part Number Qty
1 Rear Cover M19534 1
2 Gasket M07266 1
3 Cap Screw M19532 21
4 Lock Washer M19518 23
5 Nut M19533 2
6 Stud M07273 2
7 Plug M07270 2
Item Number Description Part Number Qty
1 Turbine Shaft M19535 1
2 Ball Bearing M19536 1
3 Snap Ring M07280 1
4 Piston Ring M19537 1
5 Stator Support M19538 1
6 Cap Csrew M19539 6
7 Lock Washer M19540 6
8 Piston Ring M19541 1
9 Oil Baffle Seal (includes item 10) M19003 1
10 Oil Seal M18360 1
11 Oil Baffle Seal Ring M07283 1
12 Oil Baffle Retaining Ring M07285 1
13 Roller Bearing M19542 1
14 Snap Ring M19543 1
15 Piston Ring Expander Spring M19544 1
16 Turbine Spacer M19545 1
17 Snap Ring M04655 1
18 Snap Ring M19546 1
19 Impeller Hub Gear
(see pump drive group or specail part section)
20 Impeller Hub Gear Snapring
(see pump drive group or specail part section)
21 Turbine Shaft Gear
(see special part section)
Item Number Vendor Number Description Part Number Qty
1 4215833 Torque Converter 3016F M19547 1
2 4215348 Torque Converter Plug kit M19548 1
(includes items 3‐5)
3 4214943 Torque Converter Plug   M19549 1
4 4215353 Snap Ring M19550 1
5 4215354 O‐ring M19551 1
Item Number Description Part Number Qty
1 Drive Plate Kit (includes items 3‐5) M19522 1
3 Backing Ring M04552 1
4 Cap Screw M04747 2
5 Lock Washer M04748 6
Item Number Description Part Number Qty
1 O‐ring M19553 2
2 Cap Screw M19554 2
2A Spindle Screw Washer M07315 2
3 Pump Drive Gear 84T M07316 1
4 Pump Drive Bearing Support M07330 1
5 Ball Bearing M19555 1
6 Snap Ring M07319 1
7 Snap Ring M07195 1
8 Impleer Hub Gear 84T M07194 1
9 Idler Gear 101T M19002 1
10 Pump Drive Bearing Support M07321 1
11 Bearing M07322 1
12 Lock Washer M19540 2
13 Cap Screw M19556 2
14 Snap Ring M07325 1
15 O‐ring M19553 2
16 Cap Screw M19554 2
16A Spindle Screw Washer M07315 2
17 Pump Drive Gear 84T M07316 1
18 Pump Drive Bearing Support M07330 1
19 Ball Bearing M19555 1
20 Snap Ring M07319 1
Item Number Description Part Number Qty
1 Clutch Drive Gear 27T M07199 2
2 High Range Gear 60T M07198 1
3 Drive Low & 4th Gear 26T M19557 1
4 2nd Gear 22T M07201 1
Item Number Description Part Number Qty
1 Piston Ring M19566 3
2 Front Bearing Retaining Ring M07334 1
3 Rev & High Shaft Front Bearing End Plate M19558 1
4 Rev & High Shaft Front Bearing End Plate Ball M19559 1
5 Rev & High Shaft Front PL1306‐U12 Bearing M19560 1
6 Front Bearing Retaining Ring M07334 1
7 Clutch Drive Gear Bearing 208SF M07337 1
8 Clutch Drive Gear Brg Snap Ring M07338 1
9 Clutch Hub Oil Baffle Ring M07339 1
10 Backing Plate Snap Ring 6‐1/8 OD Exp X 1/8 M07340 1
11 Clutch Disc Backing Plate (High Clutch) M19567 1
12 Clutch Outer Disc (High Clutch) M07342 7
13 Clutch Inner Disc (High Clutch) M07351 7
14 Clutch Piston & Seals Assy (Includes 15 & 16) M18474 1
15 Outer Clutch Piston Seal M07345 1
16 Inner Clutch Piston Seal M07346 1
17 Clutch Piston Metering Seal M19561 1
18 Rev & 3rd Shaft, Hub, Drum & Plug Assy M19562 1
19 Clutch Inner Piston Seal M07346 1
20 Clutch Piston Outer Seal M19563 1
21 Clutch Piston & Seals Assy (Includes 19 & 20) M19564 1
22 Clutch Inner Disc (Rev Clutch) M07351 12
23 Clutch Outer Disc (Rev Clutch) M07342 12
24 Clutch Disc Backing Plate (Rev Clutch) M07353 1
25 Backing Plate Snap Ring 6‐1/8 OD Exp X 1/8 M07340 1
26 Spring Retainer M19565 1
27 Disc Spring Rev Clutch Assy M07355 1
29 Spring Retaining Snap Ring Retainer M07356 1
30 Spring Retainer Snap Ring M07357 1
31 Clutch Drive Gear Bearing 110KS M07358 1
32 Clutch Drive Gear Brg Snap Ring M07338 1
33 Spring Retainer Snap Ring M07357 1
34 Spring Retainer M07361 1
35 Piston Return Spring M07362 1
36 Spring Retainer M07363 1
37 Spring Retaining Snap Ring Retainer M07356 1
38 Spring Retainer Snap Ring M07357 1
39 High Gear Bearing 109KS M07365 1
40 High Range Gear Bearing Snap Ring M07366 1
42 High Gear Bearing Spacer M07368 1
43 High Range Gear Bearing Snap Ring M07366 1
44 High Gear Bearing 109KSG M07369 1
45 Rev & High Shaft Gear Bearing U1309‐J1 M19568 1
46 Gear Retainer Ring M07371 1
47 Low Cluth Drive Gear 1
(See Fwd & Rev Shaft Gear Group)
48 3rd Gear 1
(See Fwd & Rev Shaft Gear Group)
49 Clutch Drive Gear 1
(See Fwd & Rev Shaft Gear Group)
Item Number Description Part Number Qty
1 Ring Piston M19566 3
2 Front Bearing Retaining Ring M07334 1
3 Fwn & @nd Shaft Front Bearing End Plate M19558 1
4 Fwd & 2nd Shaft Brg end Plate Ret Ball M19559 1
5 Fwd & 2nd Shaft Bearing LP1308‐U128 M19560 1
6 Front Bearing Retaining Ring M07375 1
7 Front Bearing Retaining Ring M07334 1
8 Clutch Drive Gear Bearing 208SF M07337 1
9 Clutch Drive Gear Snap Ring M07338 1
10 Clutch Hub Oil Baffle Ring M07339 1
11 Clutch Drive Gear Snap Ring M07338 1
12 Clutch Drive Gear Bearing 110KS M07358 1
13 Spring Retainer Snap Ring M07357 1
14 Spring Retainer Snap Ring M07357 1
15 Spring Retaining Snap Ring Retainer M07356 1
17 Disc Spring Fwd Clutch Assy M07355 1
18 Spring Retainer M19565 1
20 Spring Retainer Snap Ring M07357 1
21 2nd Gear Locating Ring Retainer M19569 1
22 2nd Gear Locating Ring Ret 247544 Snap Ring M19570 1
23 Spring Retainer Snap Ring M07357 1
24 Spring Retaining Snap Ring Retainer M07356 1
25 Spring Retainer M07363 1
26 Piston Return Spring M07362 1
27 Spring Retainer M07361 1
28 Backing Plate Snap Ring 6‐1/8 OD EXP X 1/8 M07340 1
29 Clutch Disc Backing Plate 2nd Clutch M19567 1
30 Clutch Outer Disc 2nd Clutch M07342 7
31 Clutch Inner Disc 2nd Clutch M07351 7
32 Clutch Piston & Seal (includes items 33 & 34) M18474 1
33 Clutch Piston Outer Seal M07345 1
34 Clutch Piston Inner Seal M07346 1
35 Clutch Piston Metering Seal M19561 1
36 Fwd & 2nd Shaft, Hub, Drum & Plug Assy M19571 1
37 Clutch Piston Inner Seal M07346 1
38 Clutch Piston Outer Seal M19563 1
39 Clutch Piston & Seal (includes items 37 & 38) M19564 1
40 Clutch Outer Disc Fwd Clutch M07342 12
41 Clutch Inner Disc Fwd Clutch M07351 12
42 Clutch Disc Backing Plate Fwd Clutch M07353 1
43 Backing Plate Snap Ring 6‐1/8 OD EXP X 1/8 M07340 1
44 Forward Clutch Drive Gear 1
(See Forward & Reverse Shaft Gear)
45 2nd Gear (See Forward & Reverse Shaft Gear) 1
Item Number Description Part Number Qty
1 Low Shaft, Hub, Drum & Plug Assy M19572 1
(includes items 2‐6)
2 Low Hub & Drum Assy M19573 1
3 O‐ring M19574 1
4 Snap Ring M19575 1
5 Low Shaft 20T M19576 1
6 Low Shaft Lube Plug M07511 1
7 Clutch Piston Metering Seal M19561 1
8 Clutch Piston & Seals Assy (includes 9 & 10) M19577 1
9 Clutch Piston Inner Seal M07346 1
10 Clutch Piston Outer Seal M07345 1
11 Clutch Inner Dics M07534 9
12 Clutch Outer Dics M07342 9
13 Clutch Disc Backing Plate M07341 1
14 Snap Ring M07340 1
15 Wave Clutch Piston Return Spring M19432 1
16 Spring Retainer M19431 1
17 Bearing Washer M19578 1
18 Spring Retainer M07422 1
19 Snap Ring M07280 1
20 Snap Ring Retainer M19579 1
21 Hub Low Clutch Gear 54T M19580 1
22 Roller Bearing M19581 1
23 Piston Ring M19582 1
24 Bearing M04577 1
25 Taper Roller Bearing Cup M19583 1
26 Taper Roller Bearing Cone M19584 1
27 Low Shaft Bearing Cap M19585 1
28 Cap Screw M19586 5
29 Lock Washer M04748 5
30 Plug M07270 1
31 O‐ring M19587 1
32 O‐ring M19588 1
33 Bearing Cup M19589 1
34 Bearing Cone M19590 1
35 Bearing Cap Shim 0.004 M19591 AR
35A Bearing Cap Shim 0.007 M19592 AR
35B Bearing Cap Shim 0.010 M19593 AR
35C Bearing Cap Shim 0.020 M19594 AR
Item Number Description Part Number Qty
1 Retaining Ring M07334 1
2 Bearing M07436 1
3 Output Shaft M19595 1
4 Output Shaft Gear 42T M19596 1
5 Output Shaft Geat Spacer M16035 1
6 Bearing M14489 1
7 Ball M19597 1
8 Snap Ring M07442 1
10 Bearing Cap Gasket M14490 1
11 See Item 16
12 See Item 17
13 See Item 18
14 Oil Seal M19598 1
15 Speedo Drive Gear (See Specail Part Section)
16 Output Shaft Bearing Cap M19599 1
17 Lock Washer M19600 2
18 Cap Screw M19601 2
19 Speedo Tube Nut (see Special Part Section)
20 Speedo Drive Gear (See Specail Part Section)
21 Cap Screw M19602 2
22 Lock Washer M19600 2
Item Number Description Part Number Qty
Brake Assy (Includes 1‐8, 13 & 14) M12056 1
1 Cam Lever Nut M19603 1
2 Cam Lever Washer M19604 1
3 Operating Lever (includes 1 & 2) M12297 1
4 Plate M19605 1
5 Brake Act Camshaft M19606 1
6 Strut Assembly M19607 1
7 Brake Shoe Spring M19608 2
8 Brake Shoe & Lining Kit (includes 13 & 14) 1408358‐18 1
9 Brake Flange (see Front Sheet)
10 Brake Drum 1408358‐22 1
11 Lock Washer M14438 8
12 Flange Screw M15513 8
13 Brake Lining Kit (includes item 14) M19609 1
14 Rivet (part of item 13) M16477 24
15 Screw M19610 4
17 Output Flange (See Front Page)
Item Number Description Part Number Qty
1 Press Regulator Valve Assy M07468 1
4 Gasket M07464 1
5 O‐ring M16615 1
6 O‐ring M16616 1
7 O‐ring M04780 1
8 Valve Body To Pump Gasket M07470 1
9 Stud M07469 4
10 Nut M19611 4
11 Lock Washer M19518 4
Charge Pump Assy M16614 1
Item Number Description Part Number Qty
2 Roll Pin M07488 3
3 Oil Seal M18059 1
4 Spring M07481 1
5 Pressure Regulator Inner Spring M07482 1
6 Pressure Regulator Valve Piston M07483 1
7 O‐ring M19613 1
8 Valve Stop M07485 1
9 Roll Pin M07480 1
10 Safety Valve Seat M07474 1
11 Safety Valve Spacer M07475 1
12 Pressure Relief Valve Plunger M07476 1
13 Safety Valve Spring M04509 1
14 O‐ring M19614 1
15 Safety Valve Spring Stop M07479 1
16 Roll Pin M07480 1
17 Plug Fitting M07473 1
Item Number Description Part Number Qty
1 Charge Pump Assy M17246 1
2 Pump Cover M19615 1
3 Cap Screw M19616 4
4 Washer M19617 4
5 Pump To Filter Gasket M16613 1
6 Pipe Plug M04469 1
7 O‐ring Seal Plug (include item 8) M19618 1
8 O‐ring (part of item 7) 91F5/M17433 1
Item Number Description Part Number Qty
1 Gasket M07510 1
2 Cap Screw M19619 2
3 Lock Washer M04748 2
Item Number Description Part Number Qty
2 Plug Fitting M04487 7
3 Shuttle Valve M07495 1
4 Reset Spool M19621 1
5 Reset Spring M19622 1
6 Dowel Pin M19623 1
7 O‐ring seal Plug (include item 8) M19624 7
8 O‐ring (part of item 7) M04486 1
9 O‐ring Seal Plug (include item 10) M19625 1
10 O‐ring (part of item 10) M19626 1
11 Accumulator Spool M04727 1
12 Stop Accumulator Pin M19627 1
13 Inner spring M04717 1
14 Middle Spring M04798 1
15 Accumulator Outer Spring M04797 1

Control Valve Assy M06023 1
(order valve assy to service control cover)
Item Number Description Part Number Qty
1 Gasket M07531 1
2 Cap Screw M19619 7
3 Lock Washer M04748 7
Item Number Description Part Number Qty
Control Valve Housing Assy M07512 1
(order assy to service housing)
2 Low Shaft Lube Plug M07511 1
3 O‐ring seal Plug (include item 4) M19625 1
4 O‐ring (part of item 3) M19626 1
5 Regulator Spring Spool M07529 1
6 Regulator Spool M16205 1
12 Spool Type Solenoid Cartridge Assy M19325 4
(includes items 13‐21)
13 Cartridge Valve (buy assy to service)
14 O‐ring M07522 4
15 O‐ring M07521 4
16 O‐ring M07520 4
17 O‐ring M19628 4
18 O‐ring M07517 4
19 O‐ring M19629 4
20 Solenoid Nut M19630 4
21 Solenoid Coil (buy assy to service)
Plug M07270 1
Item Number Description Part Number Qty
1 7C Output Flange M12292 1
2 O‐ring M18249 1
3 Washer M18250 1
4 Idler Shaft Nut M13575 1
Item Number Description Part Number Qty
1 Permanent Pump Adapter Cover M19631 1
2 Permanent Pump Hole Cover Gasket M19632 1
3 Screw M19633 4
4 Lock Washer M19540 4
M07883 28x10x22 Rubber Tire x4

33322-6

M07886
H O U S IN G G R O U P
0310  M15761  AXLE HOUSING   1 

1470  M15762  AXLE HOUSING STUD, SHORT  8 

1470  M15763  AXLE HOUSING STUD, LONG  4 

1790  M15764  MAGNET        4 

2520  M05093  PLUG        1 

2830  M01176  BREATHER ASSEMBLY  1 

2890  M15765  WASHER, HARDENED  12 

2895  M01380  LOCK NUT  12 

  *CAPSCREWS – TORQUE 85‐115 FTLBS 

  *STUDS – TORQUE 75‐100 FTLBS 

 
H U B AND SHAFT GROUP
5985  M13515  AXLE SHAFT RH  1 

5986  M13516  AXLE SHAFT LH  1 

5999  N/A  SILASTIC 5699 GREY  2 

6010  M14050  SPINDLE  2 

6040  M01401  WASHER  28 

6045  63150562  CAPSCREW  28 

6060  M01361  WASHER  20 

6065  M01458  CAPSCREW  20 

6070  M04205  BRAKE DRUM  2 

6080  M01164  OIL DEFLECTOR  2 

6100  M11647  OIL SEAL ASSEMBLY  2 

6120  M00159  INNER BEARING CONE  2 

6160  M15757  HUB & CUP ASSY  2 

6163  M00158  INNER BEARING CUP  2 

6169  M00517  OUTER BEARING CUP  2 

6185  M01465  STUD  40 

6215  M00514  OUTER BEARING CONE  2 

6241  M14794  HUB PLANETARY RING GEAR  2 

6260  M14795  GEAR PLANETARY RING  2 

6330  M15758  NUT  2 

6350  M11118  CAPSCREW  2 

6365  M00855  THRUST WASHER  2 

6400  M14793  PLANETARY SUN GEAR  2 

6410  M15756  SNAP RING  2 

6440  N/A  SILASTIC GREY  2 

6480  M15752  PLANETARY SPIDER ASSEMBLY  2 

6530  M01391  THRUST BUTTON  6 

6540  M01393  THRUST BUTTON  2 

6550  M01396  THRUST WASHER ‐ INNER  6 

6560  M14796  SPUR GEAR  6 

6570  M01395  THRUST WASHER – OUTER  6 

6580  M01387  SHAFT‐PINION PLANETARY  6 

6590  M01388  O‐RING  6 

6600  M01392  SET SCREW  6 

6610  M01374  HARDENED WASHER  32 

6620  M01389  CAPSCREW  32 

6639  N/A  PERMATEX #51 BLACK  .20 

6640  M01376  PLUG‐FILL/MAGNETIC DRAIN  2   

   

 
C A R R IE R & D IF F A S S Y
2900    M12698    CARRIER ASSEMBLY, COMPLETE  1 

2903    M15772    LOCK NUT  1 

2905    M00856    FLAT WASHER  1 

2915    M15767    YOKE DEFLECTOR ASSY  1 

2921    M01460    DEFLECTOR   1 

30200    M15768    CARRIER ASSY, DIFF STD  1 

30300    NSS    BEARING CAP ASSY  1 

30400    NSS    BEARING CAP ASSY  1 

30500    M15769    HARDENED WASHER  4 

30550    M15770    CAPSCREW  4 

31200    M15771    PROTECTOR  1 

32000    M15773    CAGE ASSY – PINION  1 

32050    M01339    INNER BEARING CUP  1 

32075    M01315    OUTER BEARING CUP  1 

32200    M01313    OIL SEAL ASSEMBLY  1 

32450    M01340    INNER BEARING CONE  1 

32455    N/A    GREASE  ‐ 

32475    M01317    SHIM KIT *INCL 32476‐32492  1 

32500    M01314    OUTER BEARING CONE  1 

34050    1324720‐107    ROLLER BEARING  1 

34100    M15780    SNAP RING  1 

34220    M15781    SHIM KIT *INCL 34222‐34228  1 

34255    M15782    FLAT WASHER  8 

34260    M15783    CAPSCREW  8 

34425    M12685    LH BEARING CONE  1 

34450    M15784    KIT  1 

34525    M01374    HARDENED WASHER  12 

34550    M15785    LOCK NUT  12 

34560    M12686    RH BEARING  1 

34900    NSS    BEVEL GEAR ASSY  1 

35200    M12697    CASE‐DIFF & NEST ASSY  1 

35400    NSS    CASE ASSY – DIFF  1 

36350    NSS    CASE DIFF, FLANGE HALF  1 

36400    NSS    CASE DIFF, PLAIN HALF  1 

36410    M01374    HARDENED WASHER  12 

36415    M15786    SPECIAL SCREW  12 

36420    M15787    KIT  1 

36425    M15790    THRUST WASHER  2 

36450    M12791    DIFF SIDE GEAR  2 

36475    M15792    DIFF SPIDER  1 

36500    M15793    DIFF PINION  4 

36525    M15794    THRUST WASHER  4 

36550    N/A    GREASE  ‐ 

36810    592077‐02    LH BEARING CUP  1 

36830    M12687    LH BEARING RING  1 

36840    M12684    RH BEARING CUP  1 

36870    M12683    RH BEARING RING  1 

37105    M15795    THRUST SCREW  1 

37106    N/A    #51 BLACK SLG COMPOUND  ‐ 

37115    M15796    JAM NUT  1 

BRAKE GROUP
8560  8000907  LH CAMSHAFT  1 

8563  8000908  RH CAMSHAFT  1 

8566  M00861  FLAT WASHER  2 

8567  M00923  BRAKE CAMSHAFT O‐RING  2 

8569  M01409  SPIDER ASSY – BRAKE  2 

8571  M00841  BRAKE CAMSHAFT BUSHING  1 

8572  NSS  BRAKE SPIDER  ‐ 

8573  M00670  BRAKE CAMSHAFT BUSHING  1 

8575  1364751‐28  BALL  2 

8576  M01404  BRAKE SHOE ANCHOR PIN  2 

8588  M00655  BRAKE SHOE SPRING  2 

8632  M01406  LINK  2 

8633  M01139  SNAP RING  4 

8654  M00675  LH SIDE SHOE AND LINING  2 

8654  M00674  RH SIDE SHOE AND LINING  2 

8691  N/A  SHIPPING PLUG  ‐ 

8711  8000909  FLAT WASHER  2 

8712  8000910  RETAINER  2 

59886  M11563  SCREW  2 

99930  N/A  SILASTIC RTV737  ‐ 

 
M07879 22x10x16 Poly Tire x2
1
 H04252 Control Valve Assembly 

3    4 5

 
2

1 

1.  H04806 Inlet Section 
AUXILIARY SECTIONS PLUGGED
2.  H04807 Outlet Section  
VALVE USED AS TWO SPOOL ON
3.  H04809 SS/FP/Aux Section  THIS TRUCK!
4.  H05082 Tilt Work Section 

5. H04808 Lift Section 

6. H04812 4‐Section Stud Kit 
H04954 Return filter element
 HOSEKIT, F-SERIES MAST c03097-1 C03097-1-HOSEKIT

HOSE LOCATION Fitting #1 Fitting #2 Hose Length Hose Part # Hose Size HOSE ASM # Qty
Lift Cyl to Hyd Tank Right H00827-1 H00826-1 135 H01390 #4 H04696-1 1
Lift Cyl to Hyd Tank Left H00827-1 H00826-1 129 H01390 #4 H04696 1
Manifold to Mast Bracket H00829-1 H00828-1 93.5 H01372 #6 H04697-3 2
Manifold to Mast Bracket H00829-1 H00828-1 86.5 H01372 #6 H04697-4 1
Mast Bracket to Apron (TRILINE) H00828-1 H00828-1 80 H04020 #6 H04507-4 1
Manifold to Cylinder H00835-1 H00834-1 9.5 H00957 #12 H04714 2
Manifold to Control Valve H00835-1 H00834-1 63 H00957 #12 H04714-1 1
 24615 APRON BUMPER BLOCK ASSEMBLY 

3  4 

1 

2 

Item Number      Description      Quantity 

1. 24615‐1      Apron Bumper             1 

2. 24615‐3      Apron Bumper Shoe           1   
3. F00217      ½” Lockwasher             4 
4. F00361      ½”‐20x1.25” HHCS           4    
HOSEKIT, F-SERIES APRON C02974 C02974-HOSEKIT APRON

HOSE LOCATION Fitting #1 Fitting #2 Hose Length Hose Part # Hose Size HOSE ASM # Qty

Bottom Cyl to Inner Mast Bracket H00828-1 H00828-1 51.5 H01372 6 H04691 1
Top Cyl to Inner Mast Bracket H00828-1 H00828-1 45 H01372 6 H04698-1 1
Inner Mast Bracket to Top Cyl H00828-1 H00828-1 25 H01372 6 H04698-2 1
Cylinder to Cylinder H00828-1 H00829-1 14 H01372 6 H04697-2 1
M13623 XS2 Expander Module x1
Item Description Qty Built Item# Rev RPT? M Kit? Cost PRI
W00063 FKS STEER COLUMN HARNESS (CR-11) 1 1 $225.00 #
W00059 FKS MAIN HARNESS LPG/DIESEL (CR-11) 1 _ 1 $247.80 #
W00060 FKS ENGINE HARNESS LPG (CR-11) 1 _ 1 $127.44 #
W00062 FKS OHG HARNESS (CR-11) 1 _ 1 $0.00 #
W00064 FKS ARMREST HARNESS (CR-11) 1 _ 1 $84.96 #
W00065 FKS ELECTRIC BOX HARNESS (CR-11) 1 _ 1 $0.00 #
W00094 FKS MAST HEAD LIGHT EXTENTION CR1 1 _ 1 $0.00 #

BOM Chec
Parts k
Save Can Rpt View Part Next Prev Assy
Built First Last Quit
Needs
 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16

PNK 18G PNK 18G

RED 14G SPARE 12
F9 10 A GRN/YEL 20G
A F5 15 A 7 A
GRN 14G SPARE PUR 16G 1.5 KOHM CAN XA2
SHEET 2 1W BLK 18G
F6 15 A 2
F10 15 A
BRN/WHT 14G SPARE RED 18G SHEET 2
11
BLU/WHT 14G PARK
F7 10 A A BRAKE
PUR/WHT 14G SPARE DISPLAY
F12 10 A CONN.C1 CAN ENG
C N/O
F8 10 A GRAY BLK 18G B
3
ENGINE
B RED 18G WHT/ORG 20G ENGINE CONN. B
KEY G J1939
16 PIN MALE CONN.
BAT SW RED 18G
PNK 14G 10 A
CHECK ENGINE M17651
F1 20 A 6 PIN M06458
MODEM
ACC ST IGN RED/GRN 14G 15-PIN CONN. 1
F
PUR 14G RED 18G 6 WHT 22G 5
GRN 22G
2 8
F11 5A 1
C POWER 9 BLK 22G
C
ORG/
RELAY RED/
BLK WHT
14G 14G BLK 22G
PROGRAMMING
CONNECTOR GRN 24G
7
USB WHT 24G
6

BLU/RED 20G
10

RED A RED 20G

D 8 D
2x RED/WHT 14G 2x ORG 14G BLACK
B BRN 20G
5
C
LIFT YELLOW WHT 20G
1
UP/DOWN

RED/BLK 18G
12

E E
ORG/
WHT
14G RED A RED 20G

BLACK
B
BRN 20G
F2 F3 F4 F15 F14 DISPLAY
F16 F13
TILT C
YELLOW YEL 20G CONN.C2
2

F 10 A 10 A 10 A
IN/OUT BLACK
F
10 A 10 A 10 A 10 A

NEUTRAL
GRY PNK/ YEL/ BRN YEL/ START
14G WHT BLK 14G WHT
14G 14G 14G

2&5
RED A RED 20G WARNING
FOOT
G BRAKE BLACK
B STROBE G
3 HEAD BRN 20G
SW LO
LIGHT C
+ 6
SW
SIDE SHIFT YELLOW GRY 20G
3
HORN HI
LEFT/RIGHT
REVERSE OPTIONAL
RELAY DRIVER
FAN
SWITCH

H H
WHT/ BLU BLK/ PNK/ WHT/ WHT/ YEL PNK/ RED/ RED/
BLK GRY/
RED 14G WHT WHT RED ORG 14G BLK GRN WHT
1/0G WHT A
14G 18G 14G 14G 14G 14G 20G RED RED 20G
14G 20G

BLACK
B BRN 20G
C
SPREAD YELLOW GRN 20G
4

IN/OUT
I I

11

SEAT
SWITCH NAME
BLK RED 18G BLU/YEL 20G
1/0G C N/O
FKS-SERIES 2012 MAIN CONTROLS
DESCRIPTION
J ELECTRICAL SCHEMATIC J
STOP REVERSE REVERSE HORN AIR RIDE DRIVER HEAD STROBE TAIL HYDRAULIC RED 18G AUTHOR CREATION DATE: 10/24/2012 7:25:21 AM
PUMP SHEET 2
OPTIONAL FAN

SHEET 1
LIGHTS ALARM LIGHTS SW SEAT LIGHTS LIGHT LIGHTS
PRESSURE MARCIN SZARA REVISION DATE:
POWER
RELIEF SEE SHEET 2
DISCONNECT
SWITCH
SEE SHEET 2
SOLENOID HOIST LIFTRUCK NUMBER:

01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16
 01 02 03 04 05 06 07 08 09 10

BLK 18G
TRANSMITION XA2 28
PUR 16G
SHEET 1
RED 18G SPEED SENSOR
A 2 WIRE SHIELDED MODULE BLK 16G A
CABLE 38
15
SHEET 1

BLK 18G
2
1 PUR 18G
PNK 20G
ADDRESS 1 CELLULAR
B 42
TAG 1
PRESSURE BLK 20G 14 MODEM
A 29
POWER
TRANSDUCER PNK/BLK 20G
C 39
RED 18G
26
SHEET 1 OF 2
PNK 20G BLK 18G
C 40

BLK 20G CAN MD3

B B B
ACCEL 27
A PNK/WHT 20G 24 R2
120 OHM
41
LIFT
GRY 18G
16

PUR 20G 2 GRY/BLK 18G

LOWER
GRY/WHT 18G
30

SHIFTER TILT
1 IN
YEL 18G
17
6
F3
C ORG/WHT 20G C
F2 10
F1
7 RED/WHT 20G 3
YEL/BLK 18G
N
R1 TILT
R2 5 GRN/WHT 20G
11 YEL/WHT 18G OUT
31
3
R3

FORKS
4 YEL/WHT 20G LEFT
13 GRN 18G
18
2 BLU/WHT 20G
12
GRN/BLK 18G
4
FORKS
GRN/WHT 18G RIGHT
32
NEUTRAL START RELAY
RED/WHT 20G FORKS
D SHEET 1 ORG 18G IN D
19

ORG/BLK 18G
5
FORKS
ORG/WHT 18G OUT
33

HYDRO
FILTER WHT/RED 20G REVERSE ALARM WHT/RED 20G
PUR 20G BRN/WHT 20G
21
36 SHEET 1
AIR
PUR 20G FILTER WHT/BLK 20G
34 FORWARD
E WHT/ORG 18G E
TRANS 8
PUR 20G FILTER GRY/WHT 20G
35

REVERSE
WHT/GRN 18G
RED/YEL 20G 9
20
TRANS
1 KOHM TEMP 1-ST SPEED
PUR 20G BLK 18G WHT/YEL 18G
22

2-ND SPEED
RED/GRN 20G 23 WHT/BLU 18G
25

1 KOHM
PUR 20G BLK 18G

FUEL NAME
LEVEL
FKS-SERIES HYDRO CONTROLS 2012
F (DIESEL) F
DESCRIPTION

ELECTRICAL SCHEMATIC
AUTHOR CREATION DATE: 10/24/2012 7:25:21 AM
RED 18G
LOW SHEET 1 REVISION DATE:
MARCIN SZARA

SHEET 2
FUEL
(LPG) LOW LPG NUMBER:
HOIST LIFTRUCK
01 02 03 04 05 06 07 08 09 10
 01 02 03 04 05 06 07 08 09 10

BOX TO ARMREST CONN.

23 PIN MALE ON BOX
A- WHT 22G (4 WIRE)
A ENGINE TO MAIN HARNESS B- GRN 22G (4 WIRE) A
C- BLK 22G (4 WIRE) MODEM
12 PIN CONN.MALE ON ENGINE
MODEM D- RED 18G CAN XA2
CONNECTOR
1- WHT/ORG 20G EP2
(OPT) E- BLK 18G CAN XA2
2- PNK 20G PTS XA2 F- RED 18G CAN ENG
3- PNK/BLK 20G PTS G- BLK 18G CAN ENG 5 1
4- PUR 20G AFS,HFS H- BLU/YEL 20G
5- RED/GRN 20G FLS J- BLU/RED 20G
6- BLK 20G PTS K- PNK 18G
7- GRN 14G N/A L- RED/BLK 18G 10
8- BLU/WHT 18G EP2 M- BLK 18G
B B
9- RED 14G N/A
10- RED/WHT 14G ST
11- RED/WHT 14G ST 15 11
12- RED/GRN 18G EP2,PRV

POWER RELAY 4 WIRE

CABLE

ENGINE TO BOX 31 PIN CONN. BLK GRN WHT

REVERSE RELAY
FEMALE ON ENGINE 22G 22G 22G
C C

1- RED(2 WIRE) 18G CAN ENG EP1

NEUTRAL START RELAY 2- BLK(2 WIRE) 18G CAN ENG EP1
3- RED(2 WIRE) 18G TSS TSS
4- BLK(2 WIRE) 18G TSS TSS
COLUMN TO MAIN HARNESS
5- WHT/BLK 20G AFS
8 PIN CONN.FEMALE ON COLUMN
6- GRY/WHT 20G TFS
7- RED/YEL 20G TTS 1- WHT/ORG 20G
8- RED/GRN 20G FLS 2- YEL/WHT 20G
BOX TO MAIN HARNESS 9- BRN/WHT 20G HFS 3- ORG/WHT 20G
D 23 PIN CONN. MALE ON BOX 10- WHT/YEL 18G TSV 4- GRN/WHT 20G D
11- WHT/ORG 18G TSV 5- BLU/WHT 20G
A- YEL/WHT 20G DPM
12- WHT/GRN 18G TSV 6- PUR 20G
B- PNK 20G ACC,ENG
13- WHT/BLU 18G TSV 7- RED/WHT 20G
C- PNK/WHT 20G ACC
14- YEL 18G TLTB 8- RED/GRN 20G
D- PNK/BLK 20G ENG
E- ORG/WHT 20G DPM 15- YEL/WHT 18G TLTF
F- GRN/WHT 20G DPM 16- YEL/BLK 18G TLTB,TLTF
G- BLU/WHT 20G DPM 17- ORG 18G FPC
18- ORG/WHT 18G FPO
COLUMN TO MAIN HARNESS
H- BLU/YEL 20G SH
19- ORG/BLK 18G FPC,FPO 8 PIN CONN.MALE ON COLUMN
J- BLU/RED 20G PBS
20- GRY 18G LFT 1- RED 18G
K- RED/WHT 20G DPM
E 21- GRY/WHT 18G LOW 2- PNK 14G E
L- BLK 20G ACC,ENG
22- GRY/BLK 18G LFT,LOW 3- ORG/WHT 14G
M- PNK 18G FBX
23- GRN 18G SSR 4- GRY 14G
N- RED/BLK 18G OHG
24- GRN/WHT 18G SSL 5- GRY/WHT 14G
O- PUR 16G FBX
25- GRN/BLK 18G SSR,SSL 6- PUR 14G
P- PNK/WHT 14G FBX
26- BLU 14G BUA 7- RED/BLK 14G
Q- ORG 14G FBX
27- RED/WHT 14G ST 8- BLK/WHT 14G
R- ORG 14G FBX
S- ORG/WHT 14G DPF 28- RED/WHT 14G ST
T- BLU 14G OHG 29-
U- RED/GRN 14G ENG 30- NAME

V- RED/BLK 14G DPF 31- FKS-SERIES 2012

F F
DESCRIPTION
W-
WIRING
X- BLK 14G GRD AUTHOR CREATION DATE: 10/24/2012 7:25:21 AM
MARCIN SZARA REVISION DATE:

HOIST LIFTRUCK NUMBER:

01 02 03 04 05 06 07 08 09 10
 01 02 03 04 05 06 07 08 09 10

A A

EFL LOW LPG

SPADE SPADE SHIFTER
RED 18G RED 18G M03060
WHT/ORG 20G RED/GRN 20G 1- PUR 20G
2- BLU/WHT 20G
B 10" 10" 3- B
4- YEL/WHT 20G
5- GRN/WHT 20G
COLUMN TO MAIN HARNESS 6- ORG/WHT 20G
8 PIN CONN.FEMALE ON COLUMN 7- RED/WHT 20G
8- PUR 20G
1- WHT/ORG 20G 10"
2- YEL/WHT 20G
8"
3- ORG/WHT 20G
4- GRN/WHT 20G
C C
5- BLU/WHT 20G
6- PUR 20G
7- RED/WHT 20G
8- RED/GRN 20G 0" 15" 7" 8" HS
SPADE
COLUMN TO MAIN HARNESS BLK/WHT 14G
8 PIN CONN.MALE ON COLUMN

1- RED 18G
D 2- PNK 14G 5" D
3- ORG/WHT 14G
4- GRY 14G
5- GRY/WHT 14G KS
6- PUR 14G RINGS #10
7- RED/BLK 14G
8- BLK/WHT 14G BAT-PNK 14G
IGN-PUR 14G
ACC-RED/BLK 14G
E E
ST- ORG/WHT 14G

NAME

FKS-SERIES 2012
F DESCRIPTION
F
STEER COLUMN
AUTHOR CREATION DATE: 10/24/2012 7:25:21 AM
MARCIN SZARA REVISION DATE:

HOIST LIFTRUCK NUMBER:

01 02 03 04 05 06 07 08 09 10
 01 02 03 04 05 06 07 08 09 10

EB
A A
M11873
M11146 A- YEL/WHT 20G DPM
B- PNK 20G ACC,ENG
F1- F8 RED/WHT 14Gx2 ENGx2 C- PNK/WHT 20G ACC
D- PNK/BLK 20G ENG
F9-F12 PUR 14G DPF
E- ORG/WHT 20G DPM
F13-F16 ORG 14Gx2 EBx2 F- GRN/WHT 20G DPM
G- BLU/WHT 20G DPM
H- BLU/YEL 20G SH
F2- GRY 14G DPF F1- PNK 14G DPF
J- BLU/RED 20G PBS
F4- YEL/BLK 14G HR F3- PNK/WHT 14G EB
K- RED/WHT 20G DPM
F6- GRN 14G ENG F5- RED 14G ENG
L- BLK 20G ACC,ENG
F8- PUR/WHT 14G EXC F7- BRN/WHT 14G EXC
M- PNK 18G FBX
F10- PUR 16G EB, PUR 20G DPM F9- PNK 18G EB,PBS
N- RED/BLK 18G OHG
B F12- BLU/WHT 14G ENG F11- RED 18G DPM,SH B
O- PUR 16G FBX
F14- YEL/WHT 14G LS F13- PNK/BLK 14G OHG
P- PNK/WHT 14G FBX
F16- PNK/WHT 18G ARS F15- BRN 18G FS
Q- ORG 14G FBX
R- ORG 14G FBX
FBX S- ORG/WHT 14G DPF
LS T- BLU 14G OHG

M04869 U- RED/GRN 14G ENG

5" V- RED/BLK 14G DPF
2- YEL/WHT 14G FBX
DPF DPM W- OHG
3- YEL 14G LT
7- BLK 18G GRD M03062 M05047
X- BLK 14G GRD
M03062
1- RED 18G FBX 1- GRY/WHT 14G DPF
FS 2- PNK 14G FBX 1- WHT/ORG 20G ENG 20" 2- BLU 14G EB
M04869 3- ORG/WHT 14G EB 2- YEL/WHT 20G EB
ACC
3- PNK/BLK 14G FBX
2- BRN 14G FBX 4- GRY 14G FBX 3- ORG/WHT 20G EB SH 4- WHT/ORG 14G FS
C HR 3- WHT/RED 14G OHG 5- GRY/WHT 14G OHG 4- GRN/WHT 20G EB
M05028 5- WHT/RED 14G FS
C
5- BRN 14G JUMP 6- PUR 14G FBX 5- BLU/WHT 20G EB M10203 6- BLK 14G GRD
M10153 6- WHT/ORG 14G OHG 7- RED/BLK 14G EB 6- PUR 20G FBX,ENG A- PNK/WHT 20G EB
GRD 1- RED 18G FBX 7- RED/BLK 18G EB
1- YEL/BLK 14G FBX 8- BLK/WHT 14G HR 7- RED/WHT 20G EB B- BLK 20G EB 8- BLK 18G GRD
7- BLK 18G GRD 2- BLU/YEL 20G EB
2- BLK/WHT 14G DPF 8- RED/GRN 20G ENG C- PNK 20G EB
M06522
10" 25" 10" 10" 22" 10" 7" 10"

10" PBS ARS

7"
M10153 M10153
5" 10"
1- PNK 18G FBX
1- PNK/WHT 18G FBX
2- BLU/RED 20G EB
D 2- BLK 18G GRD D
LT ENG
M00143 10" 0" M05042
YEL 14G LS
1- WHT/ORG 20G DPM
55" 15" 1" 10" 10" 36" 24" 3" 11" 25" 2- PNK 20G EB
3- PNK/BLK 20G EB
4- PUR 20G SH
5- RED/GRN 20G DPM
6- BLK 20G EB
7- GRN 14G FBX
8- BLU/WHT 14G FBX
9- RED 14G FBX
10- RED/WHT 14G FBX
E 11- RED/WHT 14G FBX E
12- RED/GRN 18G EB

NAME

F-SERIES POWER SOLUTIONS

F DESCRIPTION
F
MAIN HARNESS
AUTHOR CREATION DATE: 10/24/2012 7:25:22 AM
MARCIN SZARA REVISION DATE:

HOIST LIFTRUCK NUMBER:

01 02 03 04 05 06 07 08 09 10
 01 02 03 04 05 06 07 08 09 10

4" FPO A- ORG/WHT 18G ENG1

2" M05111 B- ORG/BLK 18G ENG1

4" SSL
A- GRN/WHT 18G ENG1
A
2" M05111 B- GRN/BLK 18G ENG1 A

4" TLTF A- YEL/WHT 18G ENG1

M05111 B- YEL/BLK 18G ENG1

2"

4" LOW
A- GRY/WHT 18G ENG1

M05111 B- GRY/BLK 18G ENG1

22"

ENG1
B M08842 B
4" LFT A- GRY 18G ENG1 1- RED(2 WIRE) 18G CAN ENG EP1

2" M05111 B- GRY/BLK 18G ENG1 2- BLK(2 WIRE) 18G CAN ENG EP1
TSV 3- RED(2 WIRE) 18G TSS TSS

M04937 4- BLK(2 WIRE) 18G TSS TSS

5- WHT/BLK 20G AFS
4" TLTB A- YEL 18G ENG1
A- WHT/ORG 18G ENG1 6- GRY/WHT 20G TFS
B- BLK 18G GRD 2" M05111 B- YEL/BLK 18G ENG1
7- RED/YEL 20G TTS
8- RED/GRN 20G FLS
M04937
4" SSR A- GRN 18G ENG1 9- BRN/WHT 20G HFS
A- WHT/GRN 18G ENG1 10- WHT/YEL 18G TSV
B- BLK 18G GRD 2" M05111 B- GRN/BLK 18G ENG1
11- WHT/ORG 18G TSV
12- WHT/GRN 18G TSV
M04937 13- WHT/BLU 18G TSV
4" FPC A- ORG 18G ENG1
C 14- YEL 18G TLTB C
A- WHT/YEL 18G ENG1
8" M05111 B- ORG/BLK 18G ENG1
15- YEL/WHT 18G TLTF
B- BLK 18G GRD
16- YEL/BLK 18G TLTB,TLTF
TSS M04937 AFS EP1 17- ORG 18G FPC

M10936 A- WHT/BLU 18G ENG1 M10117 M06458 GRD

18-
19-
ORG/WHT 18G
ORG/BLK 18G
FPO
FPC,FPO
1- RED(2 WIRE) 18G ENG1 B- BLK 18G GRD PUR 20G ENG2,TFS A- RED(2 WIRE) 18G ENG1 30" PTS A- BLK 20G ENG2
20- GRY 18G LFT
2- BLK(2 WIRE) 18G ENG1 WHT/BLK 20G ENG1 B- BLK(2 WIRE) 18G ENG1 M06522 M13350 B- PNK 20G ENG2
21- GRY/WHT 18G LOW
30" C- PNK/BLK 20G ENG2
22- GRY/BLK 18G LFT,LOW
12" 15" 70" 15" 12"
23- GRN 18G SSR
24- GRN/WHT 18G SSL
25- GRN/BLK 18G SSR,SSL

EP2 ST 26- BLU 14G BUA

M17651 FLS TFS PRV M03048

27-
28-
RED/WHT 14G
RED/WHT 14G
ST
ST
D
A- BLU/WHT 18G ENG2 60600452 M10153 M02017
RED/WHT
RED/WHT
14G
14G
ENG1
ENG1
29- D
30-
F- RED/GRN 18G ENG2 RED/GRN 20G ENG1,ENG2 1- PUR 20G AFS 1- RED/GRN 18G ENG2 RED/WHT 14G ENG2 31-
G- WHT/ORG 18G ENG2 BLK 20G GRD 2- GRY/WHT 20G ENG1 2- BLK 18G GRD RED/WHT 14G ENG2

30" 45" 15" 10" 40"

45"

15" 30"
TTS HFS
15" 10" ENG2
M10117 M04909
RED/YEL 20G ENG1 A- PUR 20G ENG2
B- BRN/WHT 20G ENG1
M05043
E BUA 1- WHT/ORG 20G EP2
E
2- PNK 20G PTS
6060011 3- PNK/BLK 20G PTS
140" 0"
2
1- BLU 14G ENG1 4- PUR 20G AFS,HFS
2- BLK 14G GRD 5- RED/GRN 20G FLS
1" 5" 3" 4" 3" 3" 3" 5" 5" 2" 42" 15" 6- BLK 20G PTS
7- GRN 14G N/A
8- BLU/WHT 18G EP2
9- RED 14G N/A
10- RED/WHT 14G ST
11- RED/WHT 14G ST
12- RED/GRN 18G EP2,PRV

NAME

F-SERIES POWER SOLUTIONS

F DESCRIPTION
F
ENGINE HARNESS
AUTHOR CREATION DATE: 10/24/2012 7:25:22 AM
MARCIN SZARA REVISION DATE:

HOIST LIFTRUCK NUMBER:

01 02 03 04 05 06 07 08 09 10
 01 02 03 04 05 06 07 08 09 10

BOX TO ARMREST CONN.

A
23 PIN MALE ON BOX PNK 18G
GRN/YEL 20G
12
A
7
1.5 KOHM CAN XA2
BLK 18G
A- WHT 22G (4 WIRE) PARK
1W 2
11
RED 18G SHEET 2

B- GRN 22G (4 WIRE) BRAKE

CAN ENG
C N/O DISPLAY BLK 18G
C- BLK 22G (4 WIRE)
3
CONN.C1 SHEET 3
10 RED 18G
GRAY
D- RED 18G CAN XA2
B E- BLK 18G CAN XA2 6
WHT 22G
1
5
B
GRN 22G 8
F- RED 18G CAN ENG
MODEM 2
1
15-PIN CONN.
9 BLK 22G

G- BLK 18G CAN ENG PROGRAMMING BLK 22G

GRN 24G
H- BLU/YEL 20G CONNECTOR
USB
WHT 24G
7
6

J- BLU/RED 20G RED A RED 20G

10

8
K- PNK 18G BLACK B BRN 20G
5
C YELLOW C WHT 20G C
LIFT
L- RED/BLK 18G UP/DOWN D
1

RED/BLK 18G
M- BLK 18G
E 12
F WARNING
STROBE

RED A RED 20G

B
BLACK BRN 20G DISPLAY
C
TILT YELLOW YEL 20G 2 CONN.C2
D BLACK
IN/OUT
D D
E

RED A RED 20G

BLACK B BRN 20G
SIDE SHIFT YELLOW C GRY 20G 3
LEFT/RIGHT D
E
E F E

RED A RED 20G

BLACK B BRN 20G
YELLOW C GRN 20G
SPREAD 4
IN/OUT

NAME

FKS-SERIES 2012
F F
DESCRIPTION
TO SEAT BLU/YEL 20G ARMREST WIRING
SWITCH 11
AUTHOR CREATION DATE: 10/24/2012 7:25:22 AM
MARCIN SZARA REVISION DATE:

HOIST LIFTRUCK NUMBER:

01 02 03 04 05 06 07 08 09 10