Hyster 60xm starting problems

[alphonso]

Recently acquired forklift that needed lots of attention. Hyster H60XM. Perkins diesel engine. Virtually nothing about the engine in the Hyster manuals I have.

Instrument cluster was disintegrating. Steering column covers broken into multiple pieces, some pieces missing. Previous owner had been using a remote starter button to start and pulling the fuel solenoid connector apart to stop it.

Replaced the cluster and covers. Starts and stops with key.

Decided to change water separator filter. Took forever to find priming lever underneath accumulated crud and get injector pump primed.. Ran just fine for a few days.

Then....... start up cold and after a few minutes of idling to warm it up, it would either die(restart, no problem) or almost die.

Latest behavior, start, do whatever, shut off. Will not restart.

Fuses not blown. Fuel solenoid doesn't click .

Three wires to solenoid: red 12vdc, white and black wires seem to be connected internally. 026 ohms between red and white/black wires.

New solenoid. Plunger is spring loaded to extend when un-powered. I assume that the injector pump pushes the plunger in and when powered the plunger is forced extended to open up the fuel passage.

Hooking solenoid to power on the bench, I get no response. +12vdc to red terminal, white terminal to minus of power supply, black terminal open/to minus/to ground. None of the combinations get any response from solenoid.

Checked voltage at connector on machine: red to ground=12.5 vdc, Red to black terminal=12.5 vdc, red to white terminal =0vdc.

Do not have wiring diagrams nor have I found any for this machine with Perkins engine.

Got any ideas why new solenoid doesn't seem to function before I try to install it? A real PITA to install. Took over an hour to get the old one out.

 

[Garwood]

My Skidsteer uses the same shutdown solenoid on it's Yanmar engine.

They don't usually act directly on the fuel. Shutdown solenoids generally force the fuel rack to a position that completely shuts fuel off to the pumping elements.

One wire will be ground. One wire will be pull and one wire is hold.

The pull wire needs a lot of current to work. Just touching it to a wire won't work. It's like trying to test a starter motor- Without plenty of current you won't get anything to happen.

The hold wire will not pull the solenoid in, but if you push it in by hand it will stay in.

These solenoids are often driven off the starter wiring on the engine and therefore have diodes inside them to prevent the solenoid power from backfeeding the starter. So polarity matters.

The pull wire is meant for very short durations. These solenoids usually fail wehn somebody changes the fuel filter then cranks and cranks the engine for 20 minutes to run the lift pump and get fuel to the injectors.

Engine dying after fuel filter change suggests an air leak somewhere. The air leak on the small engines is often the O-ring packing in the fuel shutoff valve that you turn off when you change the fuel filter so all the fuel doesn't dump on the ground. Atleast it's a good place to start.

 

[alphonso]

That makes some sense. The pull wire is the red 12v wire? Hold wire is the white wire?

There is no fuel shut valve on this critter.

And, yes, they have cranked and cranked without getting it to start.

One of the morons disconnected the fuel line from the fuel pump to the separator/filter to see if the pump was working.

Oh, yeah, forgot to mention that when first working on this thing, I noticed the radiator was really low, so I started pouring water in. HHmmm, level is not coming up. Then noticed the floor is all wet under the machine. Behind the water separator/filter there is a big round hole in the block where a freeze plug is supposed to be. How long had they been running this thing without water?? After a lot of pain and discomfort, I got an expanding plug in place. Somewhat surprised that the block and head seem to be intact. Forklift has run some fifteen hours over several days before the latest behavior started. Haven't lost any coolant or gotten white smoke in that time.

 

[Spruewell]

That thing sounds like a total basket case. The previous owner did you no favors. I would be checking everything before I went any further. Change the oil in the engine, transmission, rear end etc. inspect the old oil for metallic particles and other contaminates. Clean everything so you can spot leaks. Make sure all the hydraulic lines are in good shape (no cracks or rub marks) and properly secured. Inspect all the linkage and cylinder mounts.

 

[alphonso]

I had nothing to do with acquisition of this POS. I have gone over all the rest of it and nothing seems amiss other than a clear plastic hose from the tank to fuel pump. Changing that out today.

FWIW the engine is a Series 700 Perkins.

 

[alphonso]

Well, it's running. Wonder what the next fuck up will be.

 

[TeachMePlease]

Well, it's running. Wonder what the next fuck up will be.

Probably me.