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Complete service repair manual with Electrical Wiring Diagrams for Hyster F001 (H1.6-1.8FT, H2.0FTS Europe & H30-35FT, H40FTS) Forklift Trucks, with all the shop information to maintain, diagnose, repair, and rebuild like professional mechanics.
Hyster F001 (H1.6-1.8FT, H2.0FTS Europe & H30-35FT, H40FTS) workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
Hyster F001 (H1.6-1.8FT, H2.0FTS Europe & H30-35FT, H40FTS) Service Manual.pdf
Total Pages: 2,690 + 2,815 pages
File Format: PDF
Language: English
F001 (H1.6-1.8FT, H2.0FTS Europe)/9000SRM1112_DTC 110-6 chg DTC 110-16.pdf
F001 (H1.6-1.8FT, H2.0FTS Europe)/9000SRM1112_Operational Checkout.pdf
F001 (H1.6-1.8FT, H2.0FTS Europe)/9000SRM1112_Speed Sensor Direction or Direction Check Logical Failure.pdf
F001 (H1.6-1.8FT, H2.0FTS Europe)/9000SRM1112_TOSS_TISS Sensor 1 & 2 No Output.pdf
F001 (H1.6-1.8FT, H2.0FTS Europe)/9000SRM1112_TSP MLM Data Error.pdf.pdf
F001 (H1.6-1.8FT, H2.0FTS Europe)/9000SRM1112_UPDATE CUMMINS QSB 3.3L FAULT CODES DTC 627-12.pdf
F001 (H1.6-1.8FT, H2.0FTS Europe)/910442-8000SRM0231-(12-2004)-UK-EN.pdf
F001 (H1.6-1.8FT, H2.0FTS Europe)/1579259-9000SRM1112-(07-2008)-UK-EN.pdf
F001 (H1.6-1.8FT, H2.0FTS Europe)/1580502-0100SRM1120-(01-2007)-UK-EN.pdf
F001 (H1.6-1.8FT, H2.0FTS Europe)/1580504-0600SRM1122-(12-2006)-UK-EN.pdf
F001 (H1.6-1.8FT, H2.0FTS Europe)/1580505-0700SRM1123-(04-2008)-UK-EN.pdf
F001 (H1.6-1.8FT, H2.0FTS Europe)/1580507-0900SRM1125-(05-2005)-UK-EN.pdf
F001 (H1.6-1.8FT, H2.0FTS Europe)/1580510-1300SRM1129-(07-2008)-UK-EN.pdf
F001 (H1.6-1.8FT, H2.0FTS Europe)/1580512-1600SRM1133-(07-2008)-UK-EN.pdf
F001 (H1.6-1.8FT, H2.0FTS Europe)/1580513-1800SRM1135-(10-2006)-UK-EN.pdf
F001 (H1.6-1.8FT, H2.0FTS Europe)/1580514-1900SRM1136-(07-2008)-UK-EN.pdf
F001 (H1.6-1.8FT, H2.0FTS Europe)/1580515-2000SRM1137-(07-2008)-UK-EN.pdf
F001 (H1.6-1.8FT, H2.0FTS Europe)/1580516-2100SRM1139-(07-2008)-UK-EN.pdf
F001 (H1.6-1.8FT, H2.0FTS Europe)/1580517-2200SRM1128-(08-2008)-UK-EN.pdf
F001 (H1.6-1.8FT, H2.0FTS Europe)/1580518-2200SRM1130-(08-2008)-UK-EN.pdf
F001 (H1.6-1.8FT, H2.0FTS Europe)/1580519-2200SRM1131-(08-2008)-UK-EN.pdf
F001 (H1.6-1.8FT, H2.0FTS Europe)/1580520-2200SRM1142-(09-2008)-UK-EN.pdf
F001 (H1.6-1.8FT, H2.0FTS Europe)/1580521-2200SRM1143-(05-2005)-UK-EN.pdf
F001 (H1.6-1.8FT, H2.0FTS Europe)/1580524-4000SRM1148-(11-2008)-UK-EN.pdf
F001 (H1.6-1.8FT, H2.0FTS Europe)/1580528-8000SRM1134-(07-2008)-UK-EN.pdf
F001 (H1.6-1.8FT, H2.0FTS Europe)/1598588-0600SRM1205-(03-2007)-UK-EN.pdf
F001 (H1.6-1.8FT, H2.0FTS Europe)/1598589-1400SRM1206-(11-2008)-UK-EN.pdf
F001 (H1.6-1.8FT, H2.0FTS Europe)/1598591-8000SRM1208-(06-2007)-UK-EN.pdf
F001 (H1.6-1.8FT, H2.0FTS Europe)/1602994-8000SRM1207-(07-2008)-UK-EN.pdf
F001 (H1.6-1.8FT, H2.0FTS Europe)/1673866-0100SRM1290-(07-2008)-UK-EN.pdf
F001 (H1.6-1.8FT, H2.0FTS Europe)/1698613-8000SRM1387-(07-2008)-UK-EN.pdf
F001 (H30-35FT, H40FTS)/9000SRM1112_DTC 110-6 chg DTC 110-16.pdf
F001 (H30-35FT, H40FTS)/9000SRM1112_Operational Checkout.pdf
F001 (H30-35FT, H40FTS)/9000SRM1112_Speed Sensor Direction or Direction Check Logical Failure.pdf
F001 (H30-35FT, H40FTS)/9000SRM1112_TOSS_TISS Sensor 1 & 2 No Output.pdf
F001 (H30-35FT, H40FTS)/9000SRM1112_TSP MLM Data Error.pdf.pdf
F001 (H30-35FT, H40FTS)/9000SRM1112_UPDATE CUMMINS QSB 3.3L FAULT CODES DTC 627-12.pdf
F001 (H30-35FT, H40FTS)/910442-8000SRM0231-(12-2004)-US-EN.pdf
F001 (H30-35FT, H40FTS)/1579259-9000SRM1112-(07-2008)-US-EN.pdf
F001 (H30-35FT, H40FTS)/1580502-0100SRM1120-(01-2007)-US-EN.pdf
F001 (H30-35FT, H40FTS)/1580504-0600SRM1122-(12-2006)-US-EN.pdf
F001 (H30-35FT, H40FTS)/1580505-0700SRM1123-(04-2008)-US-EN.pdf
F001 (H30-35FT, H40FTS)/1580507-0900SRM1125-(05-2005)-US-EN.pdf
F001 (H30-35FT, H40FTS)/1580509-0900SRM1127-(05-2005)-US-EN.pdf
F001 (H30-35FT, H40FTS)/1580510-1300SRM1129-(07-2008)-US-EN.pdf
F001 (H30-35FT, H40FTS)/1580512-1600SRM1133-(07-2008)-US-EN.pdf
F001 (H30-35FT, H40FTS)/1580513-1800SRM1135-(10-2006)-US-EN.pdf
F001 (H30-35FT, H40FTS)/1580514-1900SRM1136-(07-2008)-US-EN.pdf
F001 (H30-35FT, H40FTS)/1580515-2000SRM1137-(07-2008)-US-EN.pdf
F001 (H30-35FT, H40FTS)/1580516-2100SRM1139-(07-2008)-US-EN.pdf
F001 (H30-35FT, H40FTS)/1580517-2200SRM1128-(08-2008)-US-EN.pdf
F001 (H30-35FT, H40FTS)/1580518-2200SRM1130-(08-2008)-US-EN.pdf
F001 (H30-35FT, H40FTS)/1580519-2200SRM1131-(08-2008)-US-EN.pdf
F001 (H30-35FT, H40FTS)/1580520-2200SRM1142-(09-2008)-US-EN.pdf
F001 (H30-35FT, H40FTS)/1580521-2200SRM1143-(05-2005)-US-EN.pdf
F001 (H30-35FT, H40FTS)/1580524-4000SRM1148-(11-2008)-US-EN.pdf
F001 (H30-35FT, H40FTS)/1580528-8000SRM1134-(07-2008)-US-EN.pdf
F001 (H30-35FT, H40FTS)/1598588-0600SRM1205-(03-2007)-US-EN.pdf
F001 (H30-35FT, H40FTS)/1598589-1400SRM1206-(11-2008)-US-EN.pdf
F001 (H30-35FT, H40FTS)/1598590-8000SRM1207-(07-2008)-US-EN.pdf
F001 (H30-35FT, H40FTS)/1598591-8000SRM1208-(06-2007)-US-EN.pdf
F001 (H30-35FT, H40FTS)/1653957-0900SRM1325-(12-2006)-US-EN.pdf
F001 (H30-35FT, H40FTS)/1653958-0900SRM1326-(03-2007)-US-EN.pdf
F001 (H30-35FT, H40FTS)/1653959-2200SRM1327-(03-2007)-US-EN.pdf
F001 (H30-35FT, H40FTS)/1673866-0100SRM1290-(07-2008)-US-EN.pdf
F001 (H30-35FT, H40FTS)/1698613-8000SRM1387-(07-2008)-US-EN.pdf
F001 (H1.6-1.8FT, H2.0FTS Europe)…2
1579259-9000SRM1112-(07-2008)-UK-EN…4
toc…4
Diagnostic Troubleshooting Manual…4
Safety Precautions TROUBLESHOOTING PROCEDURES…5
How To Use This Troubleshooting Manual…7
General Instructions and Safety Information…7
How to Use Diagnostic Troubleshooting Manual…7
General Instructions…8
Operational Diagnostic Procedures…10
Operational Checkout Procedures…12
DTC Check…13
Horn Circuit Check…13
Light Circuit Check…13
Windshield Washer Wiper Check (If equipped)…13
Heater Check (If equipped)…14
Dome Light Check (If equipped)…14
Circulating (Accessory) Fan Check (If equipped)…15
Indicator Light Power Check…16
Operator Presence System Check…17
Engine Malfunction Indicator Check…17
Cold Start Check (Cummins and Yanmar)…17
Brake Pedal Check…18
Backup Alarm Check (If equipped)…18
Armrest Hydraulic Interlock Check (If equipped and with original…18
Engine Cover Latch Sensor Check (If equipped)…19
Brake and Inching Pedal Check…19
Park Brake Sensor Check…19
Park Brake Check…20
Engine Speed Check (All Cummins, Yanmar, and Mazda Engines Excep…20
Engine Power Check…21
Transmission Clutch Check…21
Transmission Check…22
Transmission Speed Selection Check (If equipped)…22
Brake and Axle Drag Check…22
Hydraulic Pump Flow Check…23
Priority Flow Divider Valve Check…24
Steering Relief Valve Low Pressure Check…24
Steering Relief Valve High Pressure Check…25
Control Valve Load Check Valve (Manual Valve)…25
Lift E-Valve Check…25
Lift Check (E-Valve)…25
Tilt Function Counterbalance Check…26
Lift Drift Check…26
Tilt Function Drift Check…27
Mast Cushion Check (All Except 2-Stage Mast)…27
Lift/Tilt Mast Adjustment Check…27
Tilt Racking Check…28
Chain and Header Hose Adjustment Check…28
Mast Mounting Check…29
Mast Channel Check…29
Carriage Adjustment Check…30
Chain Sheave Check…30
Carriage Adjustment Check (Standard and Integral Side Shift)…30
Engine…32
Engine Basics…38
General Terminology…38
Combustion Theory…38
Engine Components – Cylinder Block…39
Camshaft and Timing Set…40
Cylinder Head Assembly…40
Valve Train Assembly…40
Air Cleaner/Filter…40
Carburetion…40
Electronic Fuel Injection (EFI)…40
Positive Crankcase Ventilation (PCV)…41
Engine Electrical…41
Introduction…41
Battery Construction…41
Conventional Standard Battery…42
Maintenance-Free Battery…42
Battery Charging…42
Battery Fast Charging…43
Battery Slow Charging…43
Starting System Principles of Operation…43
Starting System Components – Ignition Switch…44
Starting System Components – Starter Solenoid…44
Starting System Components – Flywheel and Ring Gear…44
Starting System Components – Starter Motor and Drive…44
Charging System – General…45
Charging System – Regulator…45
Charging System – Theory…45
Engine Fuel System/Exhaust and Emissions…46
Introduction…46
Gasoline System Components – Fuel Tank…46
Electronic Fuel Injector (EFI) – General Description…46
Port Fuel System Components – ECU…46
Port Fuel System Components – Fuel Pump/Filter…46
Port Fuel System Components – Fuel Rail…46
Port Fuel System Components – Pressure Regulator…46
Port Fuel System Components – Fuel Injectors…47
LPG Systems General Information…47
LPG Fuel Properties…47
LPG Fuel Tank…47
AISAN Closed-Loop System…48
Filter/Lockoff and Regulator…48
Carburetor…48
Start Mode…48
Idle Mode…49
Run Mode…49
Main Fuel Lockoff Solenoid…49
Injector Fuel Lockoff Solenoid…49
Oxygen (O 2 ) Sensor…49
Electronic Control Unit (ECU)…49
Catalytic Converter/Muffler…49
Engine Management…49
Introduction…49
Ignition and Timing – Conventional Spark…49
Components – Ignition Coil…50
Components – Distributor…50
Spark Timing…50
Components – Ignition Wires…50
Components – Spark Plugs…50
Faulty or Fouled Spark Plugs…51
Electric Controlled Governing System – Mazda LPG…51
Engine Identification…52
Cummins (Diesel) Engine…54
Description…54
Diesel Fuel System…55
Principle of Operation…55
Fuel Injection Pump and Governor…56
Description…56
Principles of Operation…57
Cummins Engine Control…58
Engine Speed (RPM) Sensor…59
Throttle Position Sensor…60
Electronic Throttle Actuator…61
Engine Oil Pressure Sensor…61
Coolant Temperature Sensor…61
Air Restriction Switch…62
Fuel Filter/Water Separator…62
Fuel Level Sensor (In Tank)…62
Engine Electrical System…63
Magnetic Valve (Engine Stop Solenoid)…63
Alternator…63
Grid Heater…63
Cold Start Timing Advance (Fuel Injection Pump)…63
Cummins QSB 3.3L (Diesel) Engine…64
Description…64
Diesel Fuel System…65
Electronics System…68
Engine Protection…69
Diagnostics…69
Grid Heater…69
Turbocharger and Charge Air Cooler…69
Cooling System…71
Crankcase Oil Separator…72
Lubrication System…73
Mazda Engine Overview…74
Description…74
Fuel System…74
Engine Controls Unit (ECU) and Emissions…74
Cooling System…74
Ignition System…74
Mazda (LPG) Engine Controls…75
LPG System (Aisan/E-Controls-Mechanical)…75
Description…75
Principles of Operation…76
Control System…79
Oxygen (O 2 ) Sensor…80
Fuel Tank…80
Regulator…81
Start Mode…82
Idle Mode…82
Run Mode…83
Resonator…83
Carburetor…83
Start Mode…83
Idle Mode…84
Run Mode…84
Governor…85
LPG System (E-Controls)…85
Description…85
Principles of Operation…86
Manifold Absolute Pressure Sensor…86
Throttle Position Sensor…86
Oxygen (O 2 ) Sensor…87
Engine Coolant Temperature Sensor…87
Intake Air Temperature Sensor…87
Engine Control Unit…87
Accelerator Pedal Position Sensor…87
Three-Way Catalytic Converter…87
Camshaft Position Sensor…87
Electric Controlled Governing System…88
Electronic Governor Sensor…89
Mazda (Gasoline) Engine Controls…90
Gasoline System…90
Description…90
Principles of Operation…91
Control System…93
Camshaft Position Sensor…94
Intake Air Temperature Sensor…95
Mass Air Flow Sensor…96
Throttle Position Sensor…97
Electronic Governor Sensor…98
Electronic Governing System…99
Manifold Absolute Pressure Sensor/Boost Sensor…99
Engine Coolant Temperature Sensor…100
Intake Air System…101
Throttle Body…101
Idle Air Control Valve…102
Fuel System…103
Fuel Injector…103
Pressure Regulator…104
Exhaust System…105
Heated Oxygen (O 2 ) Sensor…105
Three-Way Catalytic Converter…106
GM (LPG) Engine Controls…107
Engine Control System …107
Engine Control System Overview…108
Principles of Operation…108
Control System…109
GM/TGFI 2.4L (Four Cylinder) Control System Component Location…109
GM/TGFI 4.3L (Six Cylinder) Control System Component Location…110
GM/TGFI 2.4L (Four-Cylinder) LPG System…111
GM/TGFI 4.3L (Six-Cylinder) LPG System…113
Fuel Tank…115
Engine Control Unit…115
Electronic Throttle Body/Throttle Position Sensor…116
Manifold Absolute Pressure/Manifold Air Temperature Sensor…116
Propane Injectors…117
Engine Coolant Temperature Sensor…119
Oxygen (O 2 ) Sensor…119
Crankshaft Position Sensor (Engine Speed Sensor)…120
Oil Pressure Sensor…120
Power Latch Relay…120
GM 2.4L Camshaft Position Sensor…120
GM 4.3L Camshaft Position Sensor…121
Injector Driver Module…122
Vaporizer/Regulator…122
Accelerator Pedal Position Sensor…125
Three-Way Catalytic Converter…125
Ignition System…126
Ignition Coils…126
Distributorless Ignition System Module…126
Electronic Ignition Signals…127
Distributor Ignition (DI) System…127
Camshaft Position (CMP) Sensor…128
Ignition Coil and Ignition Control Module (ICM)…128
Secondary Ignition Components…128
GM (Gasoline) Engine Controls…129
Engine Control System…129
GM 2.4L (Four Cylinder) Engine Control System…129
GM 4.3L (Six Cylinder) Engine Control System…130
Engine Control System Overview…131
Principles of Operation…131
Control System…131
GM/TGFI 2.4L (Four Cylinder) Control System Component Location…131
GM/TGFI 4.3L (Six Cylinder) Control System Component Location…133
GM/TGFI 2.4L (Four-Cylinder) Gasoline System Components…134
GM/TGFI 4.3L (Six Cylinder) Gasoline System Components…136
Engine Control Unit…138
Electronic Throttle Body/Throttle Position Sensor…138
Manifold Absolute Pressure/Manifold Air Temperature Sensor …139
Fuel Injector…140
Engine Coolant Temperature Sensor…141
Oxygen (O 2 ) Sensor…142
Crankshaft Position Sensor (Engine Speed Sensor)…142
Oil Pressure Sensor…142
Power Latch Relay…142
Camshaft Position Sensor…143
Accelerator Pedal Position Sensor…144
Three-Way Catalytic Converter…145
Ignition System…145
Ignition Coils…145
Distributorless Ignition System Module…145
Electronic Ignition Signals…146
Yanmar (Diesel) Engine…147
Description…147
Diesel Fuel System…148
Principles of Operation…148
Fuel Injection Pump and Governor…149
Description…149
Principles of Operation…151
Timer…152
Feed Pump (Vane Type)…152
Regulating Valve…153
Injection Pump Plunger…154
Suction Process…155
Injection Process…155
End of Injection…156
Uniform Pressure Process…156
Reverse Rotation Prevention Mechanism…157
Fuel Injection Volume Adjustment Mechanism…157
Delivery Valve Assembly…157
Delivery Valve Holder with Damping Valve…158
All – Speed Governor…159
At Start of Engine…161
During Idle…162
At Full – Load Maximum Speed Control…163
At No-Load Maximum Speed Control…164
Full-Load Position Adjustment Mechanism…165
Structure and Operation of Timer…166
Standard Type Automatic Timer…166
Yanmar Engine Controls…167
Engine Speed (RPM) Sensor…168
Throttle Position Sensor…168
Electronic Throttle Actuator…169
Engine Oil Pressure Sensor…169
Coolant Temperature Sensor…170
Air Filter Restriction Switch…170
Fuel Filter/Water Separator and Strainer…171
Fuel Level Sensor…171
Engine Electrical System…171
Magnetic Valve (Engine Stop Solenoid)…171
Alternator…172
Glow Plugs…172
Cold Start Timing Advance (Fuel Injection Pump)…172
Cooling System – All Engines…173
Description…173
Radiator…173
Combination Cooler/Standard Radiator…174
Radiator Cap…174
Thermostat…174
Engine Coolant Pump…175
Fan…175
GM Engine Coolant Flow Diagram…175
Yanmar Diesel Engine Coolant Flow Diagram…176
Engine Does Not Crank…178
Engine Does Not Start/Engine is Hard to Start…181
Engine Idle Speed Incorrect…187
Engine Idle Speed is Unstable or Engine Stalls at Idle…190
Engine Cuts Out, Misses, Hesitates, Sags, or Stumbles…195
Engine Lack of Power…201
Engine Speed Surge Or Engine Speed Unstable…208
Engine Backfires…212
Engine Is Knocking or Pinging…215
Excessive Engine Vibrations…219
Abnormal Engine and Exhaust Noises…224
Fan or Alternator Bearing Noise…228
Abnormal Engine and Exhaust Smells…230
High Engine Fuel Consumption…232
Fuel Leaks…235
High Engine Oil Consumption…238
Engine Oil Leaks…240
Engine Oil is Discolored…245
Engine Coolant Leaks…247
Engine Coolant is Discolored…250
Engine Exhaust is Discolored…251
Engine Fails Emission Compliance Check…255
Alternator Light is Illuminated…259
Engine is Overheating…260
Air Intake Manifold Temperature too High (Cummins QSB 3.3L Only)…263
Air Intake Manifold Pressure (Boost) is Below Normal (Cummins QS…264
Engine Coolant Temperature is Low…265
Engine Oil Pressure is Low…266
Radiator Bubble Test…268
Engine Compression Test (GM and Mazda)…269
Engine Compression Test (Yanmar Diesel)…270
Engine Oil Pressure Test…271
Fuel System Pressure Test (Gasoline Engines Only)…273
Fuel Injection Nozzle Test (Yanmar Diesel)…275
Vacuum Leak…276
Vacuum Leak Detection…276
Vacuum Leak Repairs…276
Coolant System Test…277
Electrical System…278
Troubleshooting Guidelines and Procedures…292
Troubleshooting Guidelines…292
Troubleshooting Procedures…295
Troubleshooting Procedures, Identification…295
Troubleshooting Procedures, Location…295
Troubleshooting Procedures, Structure…295
Troubleshooting Procedures, Performance…296
Diagnostic Trouble Codes…297
Diagnostic Trouble Codes…297
Wiring Reference Data…311
Post 2007 Engine Connections…315
Cummins 4.5L…315
GM 2.4L (GAS/LPG)…316
GM 4.3L (GAS/LPG)…317
Mazda 2.0/2.2L (GAS/LPG)…318
Yanmar 2.6/3.3L…319
Harness Assembly Data…320
Electrical System…366
General Description…366
Description…367
Principles of Operation, Components…371
Principles Of Operation, System…379
100-2…386
100-2…386
100-3…386
523859-3…386
524223-3…386
524224-3…386
524225-3…386
524282-3…386
523958-3…386
523959-3…386
100-4…394
523859-4…394
523958-4…394
523959-4…394
524223-4…394
524224-4…394
524225-4…394
524282-4…394
524223-0…402
524224-0…402
524225-0…402
524229-0…402
524270-0…402
524276-0…402
524223-1…406
524224-1…406
524225-1…406
524229-1…406
524270-1…406
524276-1…406
110-3…410
110-3…410
110-5…410
177-3…410
522231-3…410
522555-3…410
522603-3…410
524235-3…410
110-4…418
110-4…418
177-4…418
522231-4…418
522555-4…418
522603-4…418
524235-4…418
110-2…426
110-2…426
110-10…429
522712-3…434
522713-3…434
522712-4…441
522713-4…441
51-2…448
51-7…448
91-2…456
91-2…456
522708-3…460
522710-3…460
522711-3…460
522714-3…460
522708-4…467
522710-4…467
522711-4…467
522714-4…467
515-0…474
523780-3…476
523860-3…476
524245-3…476
524275-3…476
523780-4…482
523860-4…482
524245-4…482
524275-4…482
677-3…487
2350-3…487
522754-3…487
522755-3…487
522764-3…487
522766-3…487
524230-3…487
SYMPTOMS WARNING…487
677-4…493
2350-4…493
522754-4…493
522755-4…493
522764-4…493
522766-4…493
524230-4…493
676-3…497
524195-3…497
524269-3…497
676-4…503
524195-4…503
524269-4…503
524269-7…509
524215-3…511
524215-6…511
524237-3…515
524238-3…515
524240-3…515
524237-4…520
524238-4…520
524240-4…520
879-3…525
880-3…525
881-3…525
882-3…525
522772-3…525
879-4…529
880-4…529
881-4…529
882-4…529
522772-4…529
168-0…533
168-3…533
521982-3…536
522760-3…536
522761-3…536
522762-3…536
522128-3…545
524251-0…545
524260-0…545
524260-3…545
524261-0…545
524261-3…545
168-1…554
168-4…554
521982-4…557
522760-4…557
522761-4…557
522761-6…557
522762-4…557
522128-4…564
524251-1…564
524260-1…564
524260-4…564
524261-1…564
524261-4…564
524260-2…574
524260-11…574
524261-2…574
524261-11…574
96-3…578
96-4…578
522810-4…582
524213-1…586
524213-3…586
524213-4…586
523920-3…589
523925-3…589
523930-3…589
523977-3…589
523978-3…589
523986-3…589
524284-3…589
524285-3…589
523920-4…595
523925-4…595
523930-4…595
523977-4…595
523978-4…595
523986-4…595
524284-4…595
524285-4…595
523920-6…600
523925-6…600
523930-6…600
523977-6…600
523978-6…600
523986-6…600
524284-6…600
524285-6…600
105-3…604
105-3…604
522570-3…604
105-4…609
105-4…609
522570-4…609
105-5…613
106-3…616
106-4…620
106-0…624
106-1…624
106-2…624
106-14…624
522739-3…627
522740-3…627
522739-5…632
522740-5…632
522739-6…636
522740-6…636
522735-2…640
522735-4…643
522735-5…646
522735-6…649
522630-2…653
522631-2…653
522632-2…653
522633-2…653
522635-3…653
522636-4…653
522637-3…653
522638-4…653
522606-10…657
522737-10…657
651-3…660
652-3…660
653-3…660
654-3…660
655-3…660
656-3…660
522599-3…660
522600-3…660
522601-3…660
522602-3…660
522721-3…660
522722-3…660
522723-3…660
522724-3…660
522725-3…660
522726-3…660
522599-3…660
522600-3…660
522601-3…660
522602-3…660
651-5…668
651-5…668
652-5…668
652-5…668
653-5…668
653-5…668
654-5…668
654-5…668
655-5…668
656-5…668
522721-5…668
522722-5…668
522723-5…668
522724-5…668
522725-5…668
522726-5…668
651-6…673
652-6…673
653-6…673
654-6…673
655-6…673
656-6…673
522599-4…673
522600-4…673
522601-4…673
522602-4…673
522721-6…673
522722-6…673
522723-6…673
522724-6…673
522725-6…673
522726-6…673
2000-9…681
2000-12…681
2000-12…681
2000-12…681
2000-12…681
2000-14…681
2003-12…681
2023-12…681
2039-2…681
2039-12…681
2235-12…681
2236-12…681
2238-12…681
521670-12…681
524258-2…681
522215-12…689
522215-14…689
524236-14…689
524262-12…689
524262-14…689
524263-1…689
524268-12…689
628-12…691
630-12…691
522690-2…691
522690-12…691
522691-2…691
522691-12…691
522692-2…691
522693-12…691
522694-12…691
522695-2…691
522696-2…691
522697-12…691
522698-2…691
522699-2…691
522700-2…691
190-2…693
190-2…693
190-7…693
522120-1…693
522585-2…693
522752-9…699
524249-2…703
524250-2…703
524264-2…703
524264-14…703
524265-2…703
524271-2…703
524225-14…703
628-12…708
630-12…708
2660-3…708
2660-4…708
2661-3…708
2661-4…708
2802-12…708
523510-12…708
523511-12…708
523515-3…708
523515-4…708
523519-3…708
523519-4…708
2802-12…710
628-12…710
630-12…710
523261-3…710
523261-4…710
523257-3…710
523257-4…710
523253-3…710
523253-4…710
523249-3…710
523249-4…710
522780-3…712
522781-3…712
522780-4…716
522781-4…716
522780-2…719
522781-2…719
111-1…722
524252-2…726
524253-14…728
524255-2…729
108-0…730
108-1…730
522655-0…733
522655-1…733
522660-0…733
522660-1…733
524212-2…737
524211-2…737
524210-2…737
524209-2…737
524208-2…737
524207-2…737
524206-2…737
524205-2…737
524204-2…737
524203-2…737
524202-2…737
524201-2…737
524200-2…737
524199-2…737
524198-2…737
524197-2…737
522800-13…739
522801-13…741
522130-0…742
522131-0…742
522132-0…742
522133-0…742
522134-0…742
522130-1…746
522131-1…746
522132-1…746
522133-1…746
522134-1…746
522130-3…751
522131-3…751
522132-3…751
522133-3…751
522134-3…751
522130-4…756
522131-4…756
522132-4…756
522133-4…756
522134-4…756
522135-0…760
522137-0…760
522138-0…760
522135-1…764
522137-1…764
522138-1…764
522135-3…768
522137-3…768
522138-3…768
522135-4…772
522137-4…772
522138-4…772
522155-2…776
522157-2…776
522122-0…783
522124-0…783
522125-0…783
522126-0…783
522127-0…783
522122-1…787
522124-1…787
522125-1…787
522126-1…787
522127-1…787
522122-6…791
522124-6…791
522125-6…791
522126-6…791
522127-6…791
522122-8…796
522124-8…796
522125-8…796
522126-8…796
522127-8…796
522129-3…800
522129-4…800
522197-0…802
522198-0…802
522199-0…802
522200-0…802
522201-0…802
522197-1…805
522198-1…805
522199-1…805
522200-1…805
522201-1…805
522197-6…806
522198-6…806
522199-6…806
522200-6…806
522201-6…806
522197-7…807
522198-7…807
522199-7…807
522200-7…807
522201-7…807
522197-8…808
522198-8…808
522199-8…808
522200-8…808
522201-8…808
522197-14…810
522198-14…810
522199-14…810
522200-14…810
522201-14…810
522197-27…811
522198-27…811
522199-27…811
522200-27…811
522201-27…811
2039-2…814
522540-3…817
522540-4…821
522604-3…826
522604-4…830
522604-5…834
522697-12…839
190-2…840
190-4…840
190-8…840
522752-2…840
522752-4…840
522752-5…846
522598-3…849
522598-4…853
522592-0…857
522592-1…859
522593-12…861
522594-12…865
522595-12…865
522596-12…865
522597-12…865
522614-7…868
522616-8…868
522617-5…868
524226-3…869
524226-4…871
524239…873
524241…873
524246…873
524267…873
524248…873
524746-2…876
Engine Continues to Run When Engine Cover is Raised…878
Engine Stops or Fails to Start…880
Electrical Functions Do Not Operate…882
Electrical Function Does Not Turn Off…887
Electro-Hydraulics Do Not Function With Armrest Down …893
Electro-Hydraulics Can Still Function With Armrest Raised…896
Vehicle Does Not Power On…899
Heater Fan Does Not Operate Properly…904
Heater Airflow Does Not Reach Desired Temperature…907
Heater Output Has Insufficient Airflow…908
Circulating (Accessory) Fan Inoperative…909
Dome Light Inoperative…912
Horn Failure…915
Drive Train…918
Mechanical Overview…922
Engine…922
Description…922
Torque Converter…922
Description…922
Stator…923
Turbine…923
Pump PTO…924
Chain Drive PTO…924
Spur Gear PTO…925
Transmission…926
Description…926
1.0-5.5 Ton Lift Truck Transmissions…929
Description…929
Single-Speed…929
Two-Speed…930
Clutch Pack…931
Power Flow…933
Single-Speed…933
Two-Speed…934
Transmission Hydraulic Schematic…936
Transmission Oil Flow…937
Control Valve Oil Flow…937
6.0-7.0 Ton Lift Truck Transmissions…939
Description…939
Two-Speed…939
Three-Speed…939
Clutch Pack…941
Input Shaft and Range Clutches…941
Directional Clutches…941
Output Section…942
Power Flow…943
Two-Speed and Three-Speed…943
Transmission Hydraulic Schematic…947
Two-Speed…947
Three-Speed…948
Transmission Control System Overview…950
Transmission Control System…950
Transmission Control Software…953
Transmission Control Modes…953
Neutral…953
Gear Engagement Control…953
Basic Powershift Gear Engagement Mode…953
DuraMatch™ and Electronic Extended Features Gear Engagement Mo…953
Normal Forward or Reverse…953
Basic Powershift…953
DuraMatch™ and Electronic Extended Features Transmission…953
Auto-Shift…953
1st Gear Lock…954
Inching…954
Basic Powershift Inching Mode…954
DuraMatch™ Inching Mode…954
Electronic Extended Features Inching Mode…954
Inch/Brake Overlap Adjustment…954
Brake Wear Compensation…954
Auto Decel…955
Controlled Power Reversal…955
Basic Multi-Speed…955
Electronic Extended Features…955
Controlled Creep…955
Basic Powershift…955
DuraMatch™ and Electronic Extended Features…956
Controlled Roll Back…956
DuraMatch™ …956
Electronic Extended Features…956
Travel Speed Limit (Optional)…956
Extended Drawbar Pull ( Electronic Extended Features Multi-Speed…956
Auto-Speed Hydraulics ( Electronic Extended Features Transmissio…956
Throttle Response Management ( Electronic Extended Features Tran…957
Steady Travel Speed…957
Transmission Control Hardware…957
Control Valve and Sensors…957
Description…957
Principles of Operation…959
Transmission Proportional Valve…960
Description…960
Neutral…960
Proportional Control…960
MONOTROL® Pedal…961
Description…961
Principles of Operation…961
Directional Control Lever…961
Principles of Operation…961
Driveshaft, Differential, Drive Axle, and Brakes (Dry Brake Only…962
Driveshaft…962
Differential and Drive Axle…962
Brake System…964
Description…964
Service Brakes…964
Master Cylinder…964
Brake Position Sensor…965
Parking Brake…965
Driveshaft, Differential, Drive Axle, and Brakes (Wet Brake Only…965
Driveshaft…965
Differential…966
Brake System…968
Description…968
Service Brakes, 2.0-3.5 Ton Only…968
Service Brakes, 4.0-7.0 Ton…970
Brake Adjustment and Service…970
Parking Brake…970
Overheating Brakes (Dry Brake Axle Only)…974
Overheating Brakes (Wet Brake Axle Only)…976
Poor Brake Performance (Dry Brake Axle Only)…979
Poor Brake Performance (Wet Brake Axle Only)…982
Brakes Make Too Much Noise (Dry Brake Axle Only)…984
Brakes Pull To One Side (Dry Brake Axle Only)…985
Parking Brake Will Not Release…988
Parking Brake Will Not Hold Lift Truck (Dry Brake Axle Only)…989
Parking Brake Will Not Hold Lift Truck (Wet Brake Axle Only)…990
Abnormal Drive Axle Noise…991
Discolored Drive Axle Oil…994
Lift Truck Does Not Move (Drive Axle)…996
Abnormal Transmission Noise…999
Bubbles or Foaming In Transmission Dipstick Tube…1001
Inching Operation Is Not Smooth or Chatters…1003
Lift Truck Does Not Move In One or Both Directions (Transmission…1005
Loss of Power/Drivetrain Performance…1008
Transmission Is Too Hot…1011
Transmission Will Not Shift To Forward High Range…1014
Transmission Warmup Procedure…1016
Transmission Pressure Test…1016
Transmission Charge Pump Pressure Test…1018
Clutch Pack Pressure Test (Proportional Solenoid Valves)…1018
Torque Converter Pressure Test…1019
Lubrication Pressure Test…1019
Transmission Clutch Drag Test (1.0-5.5 Ton Trucks Only)…1020
Torque Converter Stall Test…1020
Hydraulic Systems…1024
Main Hydraulic System…1028
Description…1028
Principles of Operation…1031
Hydraulic Schematics…1032
Manual Control Valve Schematics…1032
Electro-Hydraulic Control Valve Schematics…1037
Manual Hydraulic Control Valve…1041
Description…1041
Principles of Operation…1043
Lift Section…1043
Lift Operation…1043
Lower Operation…1043
Tilt Section…1044
Tilt Backward…1044
Tilt Forward…1044
Auxiliary Section…1046
Anti-stall Feature…1047
Relief Valves…1047
Main Relief Valve…1047
Secondary Relief Valve…1047
Electro-Hydraulic Control Valve…1048
Description…1048
Principles of Operation…1049
Inlet Pressure Compensator/Unloader…1049
Lift/Lower EHPVs…1051
EHPV Operation…1052
Tilt and Auxiliary Spool Functions…1053
Tilt Forward Function…1055
Main Relief Valve …1056
Secondary Relief Valve…1056
Secondary Function Anti-stall Valve…1057
Emergency Lowering Valve…1058
Steering System…1058
Component Locations…1058
Description…1058
Steering Axle Assembly…1058
Steering Control Unit…1058
Steering Schematic…1060
Principles of Operation…1061
Steering Control Unit…1061
Actuation Functions With Armrest Up (E-Valve)…1062
Cycle Times Too Fast – Fast Actuation (E-Valve)…1063
Jump/Delay In Lift or Lower Activation After Moving Joystick or …1065
Jump/Delay In Secondary Function Actuation After Moving Joystick…1068
Jump/Delay In Tilt Forward Actuation (E-Valve)…1070
Forks Drop Slightly Before Lifting (E-Valve)…1072
Forks Lower Without Command (E-Valve)…1073
Forks Raise or Actuate Without Command (E-Valve)…1075
Forks Tilt Forward Without Command (E-Valve)…1077
Intermittent Activation (E-Valve) While Commanding Function…1079
Lift/Lower Function Maximum Speed Too Slow (E-Valve)…1081
Lift Function Will Not Move With Joystick or MLM Movement (E-Val…1084
Lift/Lower Continues To Move For Awhile After Joystick or MLM Is…1088
Lift/Lower/Secondary Function Suddenly Jumps In Middle of Stroke…1089
Lower Function Will Not Move With Joystick or MLM Movement (E-Va…1090
Poor Metering on Lift or Lower Functions (E-Valve)…1092
Secondary Function Continues to Move for Awhile After Joystick o…1095
Secondary Function Exhibits Slight Movement in Opposite Directio…1096
Secondary Function Maximum Speed Too Slow (E-Valve)…1097
Secondary Function or Tilt Back Moves Without Command (E-Valve)…1100
Secondary Function and Tilt Back Will Not Move With Joystick or …1102
Tilt Forward Function Continues to Move for Awhile When Joystick…1106
Tilt Forward Will Not Move Upon Joystick or MLM Movement (E-Valv…1107
Too Much Joystick or MLM Movement (Deadband) to Start Function M…1109
Wrong Actuation Operates or Actuation is Backward (E-Valve)…1110
Actuation Exhibits Slight Movement in Opposite Direction Before …1111
Auxiliary Function is Slow or Does Not Function (Manual Valve)…1112
Cycle Times Too Fast – Fast Actuation (Manual Valve)…1114
Function Continues to Activate After Returning to Neutral…1115
Lift Function Is Slow or Does Not Function (Manual Valve)…1116
Tilt Back Function Will Not Operate (Manual Valve)…1118
Tilt Forward Functions When Spool is Activated Forward With Engi…1119
Tilt Forward Will Not Function When Activated (Manual Valve)…1120
Abnormal Steer Axle Noise…1121
Abnormal Steering Wheel Vibration…1123
Back Lash/Kick Back in Steering Wheel…1124
No Steering (All Other Hydraulic Functions OK)…1126
Steering Is Slow or Difficult…1128
Steering Operation Is Not Smooth…1130
Steering Wheel End Lock Position Cannot Be Felt by Operator…1132
Steering Wheel Turns By Itself or Does Not Return To Neutral…1133
Steering Wheel Turns the Tires in the Wrong Direction…1134
Abnormal Hydraulic Noise and/or Vibration…1135
Abnormal Smell/Discoloration/Foaming of Oil…1138
Actuations Do Not Act Simultaneously…1139
Oil Leaking/Component Life Too Short…1140
Hydraulic Warmup Procedure…1144
Main Relief Valve Test and Adjustment…1145
Secondary Relief Valve Test and Adjustment…1147
Hydraulic Pump Flow Test…1149
Main Control Valve LS Leakage Test (E-Valve)…1151
Main Control Valve Unloader Margin Test…1152
Electro-Hydraulic Poppet Valve (EHPV) Leakage Test…1153
PPRV Pilot Pressure Test…1156
Steering Relief Pressure Test and Adjustment…1157
Steering Control Unit LS Pressure Test…1158
Lift Cylinder Leakage Test…1160
Tilt Cylinder Leakage Test…1161
Steering Cylinder Leakage Test…1162
Operators Station…1164
Operator Station General Description and Principles of Operation…1166
General Description and Location…1166
Display Switch Cluster (DSC)…1168
Detailed Description…1168
Control Inputs, Right Side…1169
Right Indicator and Warning Group…1171
LCD Display…1172
Left Indicator and Warning Group…1173
Control Inputs, Left Side (Cab Option Only)…1174
Transmission Control and Braking…1175
Description…1175
Vehicle System Manager (VSM)…1176
Display Switch Cluster…1176
Interlock and Switching Features…1176
MONOTROL® Directional Control…1176
Inch Brake/Service Brake Pedal…1176
Parking Brake…1177
Programming – Menus…1177
Menus…1177
Main Menu…1180
Save and Exit or Exit Without Saving…1180
Back One Level…1180
Hourmeters…1180
View Versions…1181
Passwords…1181
Diagnostics…1181
Setup Travel and Braking…1181
Setup Hydraulics…1181
Setup Display…1181
Setup General Items…1181
Calibrations…1181
Manual Hydraulic Control Levers…1182
General Description…1182
System Components…1182
Lift/Lower…1182
Tilt…1182
Auxiliary 1…1182
Auxiliary 2…1182
E-Hydraulic System Interface…1183
General Description…1183
System Components…1183
E-Hydraulic Control Input Device…1183
Joystick…1183
Lift/Lower…1184
Tilt…1184
Auxiliary 1…1184
Auxiliary 2…1184
Push Button…1184
Mini Lever Module (MLM)…1185
Lever 1…1185
Lever 2…1185
Lever 3…1186
Lever 4…1186
System Modes…1186
Hydraulic Interlock Mode…1186
Fault Mode…1186
Engine Off Mode…1186
Normal Operation…1186
Normal Operation Mode…1186
Lifting Control…1186
Lowering Control…1187
Tilt Control (Forward and Backward)…1187
Auxiliary Control…1187
Lighting Control…1187
Description…1187
Front Work Lights…1190
Front Marker Lights (if equipped)…1190
Front/Rear Turn Signal Lights…1190
Rear Tail/Marker Lights…1190
Rear Work Light…1190
Rear Backup Lights…1190
Rear Stop Lights…1190
Strobe Light(s)…1190
Spot Light (if equipped)…1190
Cab…1190
Description…1190
Component Descriptions…1192
Cab Heating System…1192
Lighting Control System…1192
Wiper/Washer System…1192
Cab Systems Operation…1193
Front End (Mast) and Chassis…1196
Front End, Mast…1198
Description…1198
Carriages…1198
Description…1198
Principles of Operation…1199
Integral Sideshift Carriage…1199
Mast Mounts…1201
Description…1201
Principles of Operation…1201
Two-Stage Limited Free-Lift (LFL) Mast…1203
Description…1203
Principles of Operation…1204
Two-Stage Full Free-Lift (FFL) Mast…1205
Description…1205
Principles of Operation…1206
Three-Stage Full Free-Lift (FFL) Mast…1207
Description…1207
Principles of Operation…1207
Four-Stage Full Free-Lift (FFL) Mast…1209
Description…1209
Principles of Operation…1210
Cylinder Cushion During Lifting Sequence…1212
Description…1212
Principles of Operation…1212
Cylinder Cushion During Lowering Sequence…1213
Description…1213
Principles of Operation…1213
Tilt and Sideshift Cylinders…1213
Description…1213
Tilt Cylinder…1213
Sideshift Cylinder…1213
Lowering Control Valves…1214
Description…1214
Principles of Operation…1214
Chassis…1216
Description…1216
Abnormal Channel Wear…1218
Abnormal Hose Wear…1220
Abnormal Mast Noise…1222
Body Panels Making Noise…1226
External Leakage From Free-Lift or Main Lift Cylinders…1227
FFL Mast Banging During Phasing…1228
High Tire Wear – Drive Axle…1230
High Tire Wear – Steer Axle…1232
Hoses Not Tracking Correctly…1234
Integral Sideshift Moving Too Fast…1235
Integral Sideshift Not Moving or Slow…1236
LP Tank Bracket Disengages…1239
LP Tank Rattles and Does Not Stay Latched…1240
Mast is Loose…1241
Mast Lift Chains Are Loose…1243
Mast or Carriage Binding…1244
Mast/Carriage Bounces or is Spongy…1246
Misphasing of Full Free-Lift Mast…1247
Overhead Guard Loose or Damaged…1249
Racking During Lift…1250
Racking During Tilt…1252
Truck Feels Unstable…1253
Truck Wanders, Does Not Track Straight or Steer Well…1255
Wheels Appear Tipped or Misaligned…1257
Wheels Spinning On Uneven Floors…1259
Wheel Studs Breaking…1260
Supplementary Data…1262
Abbreviations and Acronyms…1264
Special Tools List…1272
Fault Mode Indicator (FMI) Reference List…1278
TSP Reference Tables…1280
tables…4
Table 9020-10-1. IAT Ambient Temperature…95
Table 9020-40-1. Test Specifications…268
Table 9020-40-2. Test Specifications…269
Table 9020-40-3. Service Tools…269
Table 9020-40-4. Test Specifications…270
Table 9020-40-5. Service Tools…270
Table 9020-40-6. Test Specifications…271
Table 9020-40-7. Service Tools…272
Table 9020-40-8. Test Specifications – Mazda…273
Table 9020-40-9. Test Specifications – GM…273
Table 9020-40-10. Service Tools…273
Table 9020-40-11. Test Specifications…275
Table 9020-40-12. Service Tools…275
Table 9020-40-13. Test Specifications…277
Table 9020-40-14. Service Tools…277
Table 9030-03-1. Cummins QSB 3.3L Fault Codes…308
Table 9030-03-2. Circuit Group Identification…311
Table 9030-03-3. Hyster Wiring Color Codes…312
Table 9040-10-1. Two-Speed Transmission Clutch Pack Solenoid Val…948
Table 9040-10-2. Three-Speed Transmission Electronic Proportiona…949
Table 9040-10-3. Transmission Control Mode…951
Table 9040-40-1. Test Specifications…1016
Table 9040-40-2. Service Tools…1016
Table 9040-40-3. Service Tools…1016
Table 9040-40-4. Test Specifications…1018
Table 9040-40-5. Test Specifications…1018
Table 9040-40-6. Test Specifications…1019
Table 9040-40-7. Test Specifications…1019
Table 9040-40-8. Test Specifications…1020
Table 9040-40-9. Service Tools…1020
Table 9040-40-10. Stall Speeds…1021
Table 9050-10-1. Standby Pressure Table…1050
Table 9050-40-1. Test Specifications…1144
Table 9050-40-2. Service Tools…1144
Table 9050-40-3. Test Specifications…1145
Table 9050-40-4. Service Tools…1145
Table 9050-40-5. Test Specifications…1147
Table 9050-40-6. Service Tools…1147
Table 9050-40-7. Test Specifications…1149
Table 9050-40-8. Service Tools…1150
Table 9050-40-9. Test Specifications…1151
Table 9050-40-10. Test Specifications…1152
Table 9050-40-11. Service Tools…1152
Table 9050-40-12. Test Specifications…1153
Table 9050-40-13. Service Tools…1153
Table 9050-40-14. Test Specifications…1156
Table 9050-40-15. Service Tools…1156
Table 9050-40-16. Test Specifications…1157
Table 9050-40-17. Service Tools…1157
Table 9050-40-18. Test Specifications…1158
Table 9050-40-19. Service Tools…1159
Table 9050-40-20. Test Specifications…1160
Table 9050-40-21. Service Tools…1160
Table 9050-40-22. Test Specifications…1161
Table 9050-40-23. Service Tools…1161
Table 9050-40-24. Test Specifications…1162
Table 9050-40-25. Service Tools…1162
Table 9080-50-1. Abbreviations and Acronyms…1264
Table 9080-60-1. Special Tools…1272
Table 9080-70-1. FMI…1278
Table 9080-80-1. Resistor-Temperature Characteristics …1280
1580502-0100SRM1120-(01-2007)-UK-EN…1284
toc…1284
Frame…1284
Safety Precautions Maintenance and Repair…1285
General…1288
Description…1289
Hood, Seat, and Side Covers Replacement…1289
Remove…1289
Install…1294
LPG Tank and Bracket Replacement…1296
Remove…1296
LPG Tank…1296
LPG Bracket…1299
Install…1299
LPG Bracket…1299
LPG Tank…1300
Counterweight Replacement…1301
Remove…1301
Install…1302
Tow Pin, Remove and Install…1303
Overhead Guard Replacement…1303
Remove and Install…1303
LED Tail, Backup, and Brake Lights, Replace…1304
Operator Restraint System Replacement…1305
Description…1305
Automatic Locking Retractor (ALR)…1305
Emergency Locking Retractor (ELR)…1305
Engine Replacement…1306
Remove Engine Only…1306
Remove Engine and Transmission…1310
Install Engine Only…1310
Install Engine and Transmission…1311
Throttle Pedal and Cable Adjustment…1312
Mazda Gas/LPG Engines With Basic Power Shift Transmission and Ma…1312
Mazda Gasoline Engine With Electronic Transmission…1315
Throttle Pedal Stop Adjustment, Mazda 2007 Emission Compliant En…1316
Yanmar Diesel Engine With Basic Power Shift Transmission…1316
Yanmar Diesel Engine With Electronic Throttle…1316
Exhaust System Repair…1318
Lift Trucks With Counterweight Exhaust System…1318
Mazda and GM Gas and LPG Engines…1318
Remove and Disassemble…1318
Inspect…1318
Assemble and Install…1320
Yanmar Diesel Engine…1322
Remove and Disassemble…1322
Inspect…1322
Assemble and Install…1322
Lift Trucks With Overhead Exhaust System…1324
Yanmar Diesel Engine…1324
Remove and Disassemble…1324
Inspect…1324
Assemble and Install…1325
Mazda Gas and LPG Engines…1327
Remove and Disassemble…1327
Inspect…1327
Assemble and Install…1327
Cooling System…1331
Description…1331
Fuel and Hydraulic Tanks Repair…1331
Inspect…1331
Clean…1331
Steam Method of Cleaning…1331
Chemical Solution Method of Cleaning…1332
Additional Preparations for Repair…1332
Small Leaks, Repair…1333
Large Leaks, Repair…1333
Preparations for Use After Repair…1333
Safety Labels…1333
tables…1284
Table 1. Weight of Counterweights, Lift Truck Models S2.0-3.5FT …1302
Table 2. Weight of Counterweights, Lift Truck Models S30FT, S35F…1302
Table 3. Weight of Counterweights, Lift Truck Models H1.6FT, H1…1302
Table 4. Weight of Counterweights, Lift Truck Models H2.0-3.5FT …1302
1580504-0600SRM1122-(12-2006)-UK-EN…1338
toc…1338
Mazda Engine…1338
Safety Precautions Maintenance and Repair…1339
General…1342
Serial Number…1342
Engine Removal and Installation…1342
Cylinder Head, Camshaft, and Valve Mechanism Repair…1343
Remove…1343
Clean…1345
Inspect and Repair…1345
Cylinder Head…1345
Rocker Shaft Assembly…1345
Camshaft…1345
Valve Guides…1347
Valve Seats…1347
Valves…1347
Valve Springs…1348
Install…1348
Crankshaft and Main Bearings Repair…1352
Remove…1352
Inspect and Repair…1353
Crankshaft…1353
Main Bearings…1353
Install…1354
Pistons and Connecting Rods Repair…1355
Remove and Disassemble…1355
Clean…1355
Inspect and Repair…1355
Pistons…1355
Piston Rings…1355
Connecting Rods and Bearings…1356
Assemble and Install…1356
Cylinder Block Repair…1358
Oil Pump Repair…1358
Remove…1358
Disassemble…1360
Clean…1360
Inspect…1360
Assemble…1361
Install…1361
Cooling System Repair…1363
Thermostat…1363
Replace…1363
Fan Assembly…1363
Remove and Disassemble…1363
Assemble and Install…1363
Water Pump…1364
Remove…1364
Install…1365
Flywheel and Ring Gear Repair…1365
Remove…1365
Install…1365
Valve Adjustment…1366
Compression Pressure Check…1367
Engine Timing Adjustment…1368
Engine Specifications…1368
Engine Data…1368
Engine Speeds…1368
2007 Emission Compliant Engines…1368
All Engines Except 2007 Emission Compliant Engines…1369
Thermostat…1369
Cylinder Head…1369
Valve Mechanism…1369
Camshaft…1370
Crankshaft…1370
Connecting Rods…1371
Cylinder Block…1371
Pistons…1371
Oil Pump…1372
Torque Specifications…1372
tables…1338
Table 1. Pressure Specifications…1367
1580505-0700SRM1123-(04-2008)-UK-EN…1376
toc…1376
Cooling System…1376
Safety Precautions Maintenance and Repair…1377
General…1380
Cooling System Checks…1380
Exhaust Leaks Into Cooling System…1380
Water Flow Restrictions in Radiator…1380
Radiator Hoses…1380
Water Pump…1380
Flushing the Cooling System…1381
Cooling System, Clean…1381
Radiator Replacement…1382
Radiator, Remove for Lift Trucks Models S30FT, S35FT, S40FTS (E0…1382
Radiator, Remove for Lift Truck Models S6.0FT, S7.0FT (S135FT, S…1390
Radiator, Remove for Lift Truck Models H6.0FT, H7.0FT (H135FT, H…1391
Radiator, Install for Lift Truck Models S30FT, S35FT, S40FTS (E0…1393
Radiator, Install for Lift Truck Models S6.0FT, S7.0FT (S135FT, …1395
Radiator, Install for Lift Truck Models H6.0FT, H7.0FT (H135FT, …1397
Fan Assembly Replacement…1401
Fan Removal…1401
Inspect…1405
Fan Installation…1407
1580507-0900SRM1125-(05-2005)-UK-EN…1412
toc…1412
LPG Fuel System…1412
Safety Precautions Maintenance and Repair…1413
General…1416
Hoses Replacement…1416
LPG Tank Replacement…1416
Remove…1416
Install…1416
Fuel Filter…1418
Remove…1418
Clean and Inspect…1419
Install…1420
Relief Valve Replacement…1421
Remove and Install…1421
Carburetor Repair…1421
Remove…1421
Disassemble…1421
Clean…1423
Assemble…1423
Install…1423
Fuel Injector Repair…1424
Remove…1424
Clean and Inspect…1424
Install…1424
Governor Repair…1424
Remove…1424
Install…1424
Regulator Repair…1425
Remove…1425
Install…1426
Control System…1426
Engine Control Unit (ECU)…1426
Remove…1426
Install…1426
Engine Coolant Temperature (ECT) Sensor…1427
Remove…1427
Install…1427
Camshaft Position (CMP) Sensor…1427
Voltage Check…1427
Intake Air Temperature (IAT) Sensor…1428
Remove…1428
Install…1428
Manifold Absolute Pressure (MAP) Sensor…1429
Remove…1429
Install…1429
Oxygen Sensor…1429
Remove…1429
Install…1429
Throttle Position (TP) Sensor…1430
Remove…1430
Install…1430
1580510-1300SRM1129-(07-2008)-UK-EN…1434
toc…1434
Powershift Transmission…1434
Safety Precautions Maintenance and Repair…1435
General…1438
Serial Number…1438
Charge Pump Repair…1439
Remove…1439
Inspect…1439
Install…1439
Torque Converter Replace…1440
Remove…1440
Install…1444
Front Cover Housing and Chain Drive Repair…1450
Remove…1450
Clean…1457
Inspect…1457
Install…1457
Clutch Packs Repair…1463
Remove and Disassemble…1463
Transmission, Remove and Disassemble…1463
Clutch Assemblies, Remove and Disassemble…1474
Clean…1480
Inspect…1480
Assemble and Install…1481
Clutch Assemblies, Assemble and Install…1481
Transmission, Assemble and Install…1489
Control Valve Repair…1494
Remove and Disassemble…1494
Clean…1495
Inspect…1495
Assemble and Install…1497
MONOTROL® Pedal Repair…1498
Remove and Disassemble…1498
Assemble and Install…1501
Direction Control Lever…1502
Remove…1502
Install…1502
1580512-1600SRM1133-(07-2008)-UK-EN…1506
toc…1506
Steering Axle…1506
Safety Precautions Maintenance and Repair…1507
General…1510
Steering Axle Assembly Repair…1511
Remove…1511
Disassemble…1512
Clean…1512
Inspect…1512
Assemble…1519
Install…1524
Spindles, Bearings, and Tie Rods Repair…1525
Spindles and Bearings…1525
S2.0-3.5FT (S40-70FT, S55FTS) (F187), S4.0, 4.5, 5.5FT, S5.5FTS,…1525
Remove…1525
Disassemble…1526
Clean…1527
Inspect…1527
Assemble…1527
Install…1528
Spindles and Bearings…1531
S30FT, S35FT, S40FTS (E010), H1.6FT, H1.8FT, H2.0FTS (H30FT, H35…1531
Remove and Disassemble…1531
Assemble and Install…1531
Tie Rods…1532
S2.0-3.5FT (S40-70FT, S55FTS) (F187), and S4.0, 4.5, 5.5FT, S5.5…1532
Remove…1532
Install…1533
Tie Rods…1534
S30FT, S35FT, S40FTS (E010), H1.6FT, H1.8FT, H2.0FTS (H30FT, H35…1534
Remove…1534
Install…1534
Steering Cylinder Repair…1537
Remove and Disassemble…1537
Clean and Inspect…1538
Assemble and Install…1538
Torque Specifications…1539
1580513-1800SRM1135-(10-2006)-UK-EN…1544
toc…1544
Brake System…1544
Safety Precautions Maintenance and Repair…1545
General…1548
Dry Brake System…1548
Wet Brake System…1548
Service Brakes Repair (Dry Brake)…1549
Remove and Disassemble…1549
Clean…1554
Inspect…1555
Assemble and Install…1555
Adjust…1562
Parking Brake Repair…1563
Remove and Disassemble…1563
Assemble and Install…1563
Adjust…1566
Master Cylinder Repair…1566
Remove (Dry Brake)…1566
Disassemble (Dry Brake)…1567
Clean and Inspect (Dry Brake)…1569
Assemble (Dry Brake)…1569
Bench Bleed Master Cylinder (Dry Brake)…1569
Install and Adjust (Dry Brake)…1569
Remove (Wet Brake)…1570
Disassemble (Wet Brake)…1571
Clean and Inspect (Wet Brake)…1572
Assemble (Wet Brake)…1572
Install and Adjust (Wet Brake)…1572
Service Brakes Adjustment (Dry Brake)…1573
Brake System Air Removal…1574
Using Pressure Bleed System…1574
Using Brake Pedal Pressure…1574
Brake Pedal Adjustment…1575
Free Pedal Adjustment…1576
Torque Specifications…1577
1580514-1900SRM1136-(07-2008)-UK-EN…1580
toc…1580
Hydraulic Gear Pump…1580
Safety Precautions Maintenance and Repair…1581
General…1584
Single Gear Pump Assembly Repair…1584
Remove…1584
Disassemble…1585
Clean…1585
Inspect…1585
Assemble…1585
Install…1589
Tandem Gear Pump Assembly…1590
Remove…1590
Disassemble…1592
Clean…1594
Inspect…1594
Assemble…1594
Install…1595
Gear Pump Specifications…1595
Torque Specifications…1599
tables…1580
Table 1. Standard Gear Pump for Lift Truck Models S30FT, S35FT, …1595
Table 2. High Pressure Gear Pump for Lift Truck Models S30FT, S3…1596
Table 3. Standard Gear Pump for Lift Truck Models S4.0, 4.5, 5.5…1597
Table 4. High Pressure Gear Pump for Lift Truck Models S4.0, 4.5…1597
Table 5. Standard Gear Pump for Lift Truck Models S6.0FT, S7.0FT…1598
Table 6. High Pressure Gear Pump for Lift Truck Models S6.0FT, S…1598
1580515-2000SRM1137-(07-2008)-UK-EN…1602
toc…1602
Main Control Valve…1602
Safety Precautions Maintenance and Repair…1603
General…1608
Electro-Hydraulic Main Control Valve…1609
Description…1609
Remove…1612
Electro-Hydraulic Control Valve Sections…1616
General…1616
Outlet Control Valve Section…1616
Remove…1616
Disassemble…1616
Clean…1616
Inspect…1616
Assemble…1618
Install…1618
Auxiliary Control Valve Sections…1618
Remove…1618
Disassemble…1620
Clean…1621
Inspect…1621
Assemble…1621
Install…1621
Tilt Control Valve Section…1622
Remove…1622
Disassemble…1622
Clean…1622
Inspect…1625
Assemble…1625
Install…1625
Lift/Lower Control Valve Section…1625
Remove…1625
Disassemble…1625
Clean…1628
Inspect…1628
Assemble…1628
Install…1629
Mid-Inlet Section…1629
Remove…1629
Clean…1630
Inspect…1630
Install…1630
Install…1630
Electro Hydraulic Poppet Valve (EHPV) Pilot Pin Adjustment…1634
Lift Pilot Pin…1634
Lower Pilot Pin…1636
Abnormal/Erroneous EHPV Adjustment…1638
Manual Main Control Valve…1638
Description…1638
Remove…1639
Manual Control Valve Sections…1644
General…1644
Outlet Control Valve Section…1644
Remove…1644
Disassemble…1644
Clean…1646
Inspect…1646
Assemble…1646
Install…1646
Auxiliary Control Valve Sections…1646
Remove…1646
Disassemble…1647
Clean…1647
Inspect…1647
Assemble…1647
Install…1649
Lift/Tilt Control Valve Section…1649
Remove…1649
Disassemble…1649
Clean…1652
Inspect…1652
Assemble…1652
Install…1653
Mid-Inlet Section…1653
Remove…1653
Clean…1654
Inspect…1654
Install…1654
Install…1654
Pressure Relief Valve Check and Adjustment…1658
Primary Relief Valve…1658
Secondary Relief Valve…1659
Steering Control Unit Repair…1662
Steering Control Unit, Remove…1662
Steering Control Unit, Disassemble…1665
Steering Control Unit, Clean…1665
Steering Control Unit, Inspect…1665
Steering Control Unit, Assemble…1667
Relief Valve, Disassemble…1667
Relief Valve, Clean…1668
Relief Valve, Inspect…1668
Relief Valve, Assemble…1668
Steering Control Unit, Install…1668
tables…1602
Table 1. Relief Valve Settings…1659
Table 2. Steering Relief Pressures…1669
1580516-2100SRM1139-(07-2008)-UK-EN…1672
toc…1672
Cylinder Repair…1672
Safety Precautions Maintenance and Repair…1673
General…1676
Description…1676
Safety Procedures When Working Near Mast…1677
Tilt Cylinder Repair…1679
Remove…1679
Disassemble…1679
Inspect…1680
Clean…1680
Assemble…1680
Install…1683
Tilt Cylinders, Adjust…1683
Tilt Cylinder Leak Check…1685
Torque Specifications…1686
Piston Rod Nut…1686
Gland…1686
Tilt Cylinder Mounting Capscrew…1687
Tilt Cylinder Rod End Capscrew…1687
Lift Cylinder Repair…1687
Main Lift Cylinders…1687
Remove…1687
Disassemble…1688
Clean…1689
Inspect…1689
Assemble…1689
Install…1690
Two-Stage FFL Left Side Main Lift Cylinder…1691
Disassemble…1691
Clean…1693
Inspect…1693
Assemble…1693
Install…1693
Free-Lift Cylinder…1693
Remove…1693
Disassemble…1696
Clean…1697
Inspect…1697
Assemble…1697
Install…1698
Torque Specifications…1698
Lift Cylinders Leak Check…1699
tables…1672
Table 1. Movement Rates (Maximum) for Tilt Cylinders…1686
1580517-2200SRM1128-(08-2008)-UK-EN…1702
toc…1702
Wire Harness Repair…1702
Safety Precautions Maintenance and Repair…1703
General…1708
Deutsch Crimping Tool…1708
How to Strip a Wire for Use With Deutsch Crimping Tool…1708
How to Crimp With the Deutsch Crimping Tool…1709
Calibration Test for the Deutsch Crimping Tool…1710
Deutsch Connectors…1712
DT, DTM, and DTP Series Connectors…1712
Connector Receptacle Replacement…1720
Connector Plug Replacement…1725
Connector Receptacle Pin Replacement…1731
Connector Plug Socket Replacement…1737
HD Series Connectors…1745
Connector Receptacle Replacement…1747
Connector Plug Replacement…1750
Connector Receptacle Pin Replacement…1753
Connector Plug Socket Replacement…1758
Sealing Plugs…1762
Metri-Pack Connectors…1764
Remove and Install…1764
Micro-Pack Connectors…1766
Weather-Pack Connectors…1767
Weather-Pack Terminal Repair…1767
AMPSEAL Crimping Tools…1768
AMP Hand Crimping Tool With Certi-Crimp…1768
Description…1768
Stripping Wire for Use With AMP Hand Crimping Tool…1769
Insulation Crimp Adjustment…1769
Maintenance and Inspection for AMP Hand Crimping Tool…1770
AMP Hand Crimping Tool…1770
Crimp Height Inspection…1770
How to Use AMP Hand Crimping Tool…1771
AMP Pro-Crimper II Tool…1771
Description…1771
Remove and Install Die Set and Locator Assembly…1772
Stripping Wire for Use With AMP PRO-CRIMPER II Tool…1773
Contact Support Adjustment…1773
Crimp Height Adjustment…1774
Maintenance and Inspection Procedures…1774
PRO-CRIMPER II Tool…1774
Crimp Height Inspection…1774
How to Use AMP PRO-CRIMPER II Tool…1775
AMPSEAL Connector Assemblies…1776
Description for Plug Connector Assembly…1776
Seal Plug…1776
Contact Crimping…1777
Contact Removal…1777
Contact Insertion…1779
Description for Plug Connector and Header Assembly…1781
Voltage Reading…1782
Seal Plug…1782
Contact Crimping…1783
Contact Removal…1785
Contact Insertion…1787
AMP Superseal 1.5 Crimping Tools…1789
Mini Mic Receptacle and Tab Contacts…1789
Description…1789
Crimping Conditions and Measurements…1789
Insertion of Rubber Seal on Cable…1791
Correction or Replacement of Parts…1792
AMP Hand Application Tool…1796
Description…1796
Maintenance and Inspection…1796
Crimp Height Inspection…1796
Crimp Height Adjustment…1797
How to Use AMP Hand Application Tool…1797
AMP Pro-Crimper II Tool…1798
Description…1798
Remove and Install Die Set and Locator Assembly…1798
Adjustments…1799
Contact Support…1799
Crimp Height…1799
Inspections and Maintenance…1801
Crimp Height Inspection…1801
Visual Inspection…1801
Maintenance…1801
How to Use Pro-Crimper II Tool…1801
AMP Superseal 1.5 Connector Assemblies…1802
Description…1802
Harness Assembly…1802
Positioning of anti-backout device…1803
Removal of Contacts…1805
Repair and Maintenance…1809
Panel Mount Option…1809
AMP Fastin-Faston Hand Tools…1809
Description – AMP Double Action Hand Tool…1809
Maintenance and Inspection Procedures…1811
Daily Maintenance…1811
Periodic Tool Inspection…1811
Lubrication…1811
Visual Inspection…1811
Crimp Height Inspection…1812
Certi-Crimp Ratchet Inspection…1812
How to Use AMP Double Action Hand Tool…1813
Description – AMP Extraction Tool…1814
Maintenance and Inspection…1814
How to Use AMP Extraction Tool…1815
AMP Fastin-Faston Receptacles and Housings…1816
Description…1816
Wire Repair…1822
Wire Splicing Requirements…1822
Deutsch Jiffy Splice…1823
Assemble…1823
Disassemble…1825
Del-City Crimp-Solder-Shrink Splice…1827
Twisted/Shielded Cable and Leads Repair…1828
Twisted/Shielded Cable Repair…1828
Twisted Leads Repair…1830
Special Tools…1831
tables…1702
Table 1. Wire Strip Length Specifications…1709
Table 2. Wire Size (AWG)…1770
Table 3. Crimp Height…1771
Table 4. Strip Length for PRO-CRIMPER II Tool…1773
Table 5. Crimp Measurement…1774
Table 6. Current Rating…1776
Table 7. Crimp Conditions…1784
Table 8. Wire Strip Lengths…1796
Table 9. Wire Strip Lengths…1797
Table 10. Crimp Height – Dimension …1801
Table 11. Wire Size and Crimp Height…1812
Table 12. Wire Strip Length…1813
Table 13. Wire Strip Length and Crimp Measurements…1818
Table 14. Crimp Pull-Out Test…1821
Table 15. Wire Strip Length Specifications…1822
Table 16. Wire Splice Size…1827
1580518-2200SRM1130-(08-2008)-UK-EN…1840
toc…1840
User Interface…1840
Safety Precautions Maintenance and Repair…1841
General…1844
Description…1844
Dash Display Menu Access…1844
Menu Navigation…1845
Standard Display…1845
Main Menu…1845
Passwords Menu…1846
Password Administration…1846
Add Password…1846
Delete Password…1847
Edit Password…1847
Other Password Functions…1848
Operator Passwords – Enable/Disable…1848
Password Time-Out Delay…1849
Passwords – Number Wrong to Disable…1849
Lockout Reset Password…1850
View Password Log…1850
View Versions…1851
VSM Versions…1851
Dash Display Versions…1852
Engine Controller Version…1853
Transmission (Xmsn) Controller Version…1854
Truck Serial Number…1855
Diagnostics…1856
View Fault Log…1856
Set Travel and Braking…1857
Speed Limit…1857
Acceleration Rate…1858
Auto-Deceleration Rate…1858
Set Power Reversal Rate…1859
Set Inching/Brake Overlap…1860
Setup Display Menu…1861
Set Operator Language…1861
Set Units…1862
Set Time Format (12/24 Hour)…1862
Set Daylight Saving Time…1863
Set Time…1865
Set Date Format…1865
Set Date…1865
Setup Hydraulics…1866
Return to Set Tilt Delay/On/Off…1866
Setup General Items…1867
Light Shutdown Time-Out…1867
Impact Sensor – Enable/Disable…1868
Impact Sensor – Soft Impact Settings…1869
Impact Sensor – Hard Impact Settings…1869
Adjust Impact Sensor Settings…1870
Initial Adjustment of Soft and Hard Impact Settings…1872
Readjustment of Soft and Hard Impact Settings…1873
Impact Sensor – Impact Alarm/Shutdown Reset…1873
Impact Sensor – Alarm Time Duration and Deactivation…1874
Impact Sensor – View Impact Event Log…1875
Operator Checklist…1876
Operator Checklist Off-On Mode…1876
Edit Operator Checklist…1876
Set Operator Checklist Expiration…1877
View Checklist Log…1877
Clear Operator Checklist Log…1878
Clear Operator Checklist Fault…1878
Calibrations…1879
Set Tilt Stop Point…1879
Calibrate Loaded Weight…1879
tables…1840
Table 1. Password Screen…1844
Table 2. Exit Options Menu…1845
Table 3. Add Password Menu…1846
Table 4. Delete Password Menu…1847
Table 5. Edit Password Menu…1848
Table 6. Operator Passwords Menu…1848
Table 7. Password Time-Out Delay Menu…1849
Table 8. Passwords – Number Wrong to Disable Menu…1849
Table 9. View Password Log Menu…1850
Table 10. View VSM Versions Menu…1851
Table 11. View Dash Display Versions Menu…1852
Table 12. View Engine Controller Versions Menu…1853
Table 13. View Transmission Controller Versions Menu…1854
Table 14. View Truck Serial Number Menu…1855
Table 15. View Fault Log…1856
Table 16. Speed Limit Menu…1857
Table 17. Acceleration Rate Menu…1858
Table 18. Auto-Decel Menu…1858
Table 19. Power Reversal Menu…1859
Table 20. Inch/Brake Overlap Menu…1860
Table 21. Set Language Menu…1861
Table 22. Set Units Menu…1862
Table 23. Set Time Format Menu…1862
Table 24. Set Daylight Saving Time Menu…1863
Table 25. Set Time Menu…1865
Table 26. Set Date Format Menu…1865
Table 27. Set Date Menu…1865
Table 28. Tilt Delay Menu…1866
Table 29. Light Time-Out Menu…1867
Table 30. Impact Sensor Enable/Disable…1868
Table 31. Soft Impact Settings Menu…1869
Table 32. Hard Impact Settings Menu…1870
Table 33. Impact Sensor Default Settings…1870
Table 34. Recommended Starting Values for Impact Sensor Settings…1872
Table 35. Shutdown Reset Menu…1873
Table 36. Alarm Duration Menu…1874
Table 37. View Event Log Menu…1875
Table 38. Checklist Off-On Mode Menu…1876
Table 39. Edit Checklist Menu…1876
Table 40. Checklist Expiration Menu…1877
Table 41. View Checklist Log Menu…1877
Table 42. Clear Checklist Log Menu…1878
Table 43. Clear Checklist Fault Menu…1878
Table 44. Tilt Stop Point Menu…1879
Table 45. Calibrate Loaded Weight…1879
1580519-2200SRM1131-(08-2008)-UK-EN…1882
toc…1882
User Interface…1882
Safety Precautions Maintenance and Repair…1883
General…1886
Description…1886
Dash Display Menu Access…1886
Menu Navigation…1887
Main Menu…1888
Passwords…1888
Adding Passwords…1889
Hourmeters…1890
View Versions…1891
VSM Versions…1891
Dash Display Versions…1892
Engine Controller Version…1893
Transmission (Xmsn) Controller Version…1894
Truck Serial Number…1895
Truck Configuration…1896
Diagnostics…1897
Clear Fault Log…1897
View Fault Log…1898
No-Run Data Display…1899
Engine Accelerator and Throttle Data Display…1900
Engine Speeds and Governor Data Display…1901
Engine Fuel and Emissions Data Display…1903
Engine General Data Display…1906
XMSN/Brake Data Display…1907
Hydraulic Data Display…1909
General Truck Data Display…1911
Set Travel and Braking…1913
Speed Limit…1913
Acceleration Rate…1914
Auto-Deceleration Rate…1914
Set Power Reversal Rate…1915
Set Inching/Brake Overlap…1916
Setup Hydraulics…1917
Lift Maximum Speed…1917
Lower Maximum Speed…1918
Tilt Maximum Speed…1918
Auxiliary Function One, Direction A, Maximum Speed…1920
Auxiliary Function One, Direction B, Maximum Speed…1920
Auxiliary Function Two, Direction A, Maximum Speed…1921
Auxiliary Function Two, Direction B, Maximum Speed…1921
Auxiliary Function Three, Direction A, Maximum Speed…1922
Auxiliary Function Three, Direction B, Maximum Speed…1922
Lift/Lower Ramp Rate…1923
Hydraulic Auxiliary Ramp Rate…1924
Return to Set Tilt Delay/On/Off…1925
Setup Display…1926
Set Service Language…1926
Setup General Items…1927
Motion Alarm Activation Type…1927
Light Shutdown Time-Out…1928
Restore Default Settings…1929
Restore Engine Controller Default Calibration…1929
Impact Sensor – Enable/Disable…1930
Impact Sensor – Soft Impact Settings…1931
Impact Sensor – Hard Impact Settings…1931
Adjust Impact Sensor Settings…1932
Initial Adjustment of Soft and Hard Impact Settings…1934
Readjustment of Soft and Hard Impact Settings…1935
Impact Sensor – Impact Alarm/Shutdown Reset…1935
Impact Sensor – Alarm Time Duration and Deactivation…1936
Impact Sensor – View Impact Event Log…1937
Calibrations…1938
Calibrate Transmission Valve…1940
Set Tilt Stop Point…1940
Calibrate Loaded Weight…1941
Calibrate Travel Speed Sensor…1941
Calibrate Mazda LP and Gas Accelerator Pedal…1942
tables…1882
Table 1. Password Screen…1886
Table 2. Exit Menu…1887
Table 3. Add Password Menu…1889
Table 4. Hourmeters Menu…1890
Table 5. View VSM Versions Menu…1891
Table 6. View Dash Display Versions Menu…1892
Table 7. View Engine Controller Versions Menu…1893
Table 8. View Transmission Controller Versions Menu…1894
Table 9. View Truck Serial Number Menu…1895
Table 10. View Truck Configuration Menu…1896
Table 11. Clear Fault Log…1897
Table 12. View Fault Log…1898
Table 13. No-Run Data Display…1899
Table 14. Engine Accelerator and Throttle Data Display…1900
Table 15. Engine Speeds and Governor Data Display…1902
Table 16. Engine Fuel and Emissions Data Display…1904
Table 17. Engine General Data Display…1906
Table 18. XMSN Brake Data Display…1907
Table 19. Hydraulic Data Display…1909
Table 20. General Truck Data Display…1911
Table 21. Speed Limit Menu…1913
Table 22. Acceleration Rate Menu…1914
Table 23. Auto-Decel Menu…1914
Table 24. Power Reversal Menu…1915
Table 25. Inch/Brake Overlap Menu…1916
Table 26. Lift Speed Menu…1917
Table 27. Lower Speed Menu…1918
Table 28. Tilt Speed Menu…1918
Table 29. Auxiliary Function Speed Menu…1920
Table 30. Auxiliary Function Speed Menu…1920
Table 31. Auxiliary Function Speed Menu…1921
Table 32. Auxiliary Function Speed Menu…1921
Table 33. Auxiliary Function Speed Menu…1922
Table 34. Auxiliary Function Speed Menu…1922
Table 35. Lift/Lower Ramp Rate Menu…1923
Table 36. Hydraulic Auxiliary Ramp Rate Menu…1924
Table 37. Tilt Delay Menu…1925
Table 38. Service Language Menu…1926
Table 39. Alarm Type Menu…1927
Table 40. Light Time-Out Menu…1928
Table 41. Restore Defaults Menu…1929
Table 42. Restore Settings Menu…1929
Table 43. Impact Sensor Enable/Disable…1930
Table 44. Soft Impact Settings Menu…1931
Table 45. Hard Impact Settings Menu…1932
Table 46. Impact Sensor Default Settings…1932
Table 47. Recommended Starting Values for Impact Sensor Settings…1934
Table 48. Shutdown Reset Menu…1935
Table 49. Alarm Duration Menu…1936
Table 50. View Event Log Menu…1937
Table 51. Calibrate Electro-Hydraulic Valve Menu…1939
Table 52. Calibrate Transmission Valve Menu…1940
Table 53. Tilt Stop Point Menu…1940
Table 54. Calibrate Loaded Weight…1941
Table 55. Travel Speed Menu…1941
Table 56. Travel Speed Menu…1942
1580520-2200SRM1142-(09-2008)-UK-EN…1946
toc…1946
Electrical System…1946
Safety Precautions Maintenance and Repair…1947
General…1956
Display Switch Cluster…1957
Remove…1957
Install…1959
Direction Control and Turn Signal Levers…1959
Remove…1959
Install…1959
Key Switch…1961
Remove…1961
Install…1961
Display Switch Cluster Panel Bezel and Overlay…1962
Remove…1962
Install…1962
Steering Column Repair…1962
Remove…1962
Disassemble…1962
Assemble…1962
Install…1963
Sensors and Switches…1965
General…1965
Dash and Kick Panel, Remove and Install…1965
Remove…1965
Install…1965
Accelerator Pedal Position Sensor…1967
Remove…1967
Install…1967
Brake Fluid Level Switch…1970
Remove…1970
Install…1970
Service Brake Pedal Position Sensor…1971
Remove…1971
Install…1971
Parking Brake Sensor…1972
Remove…1972
Install…1972
Service Brake Pressure Sensor…1973
Remove…1973
Install…1973
MONOTROL® Sensor Microswitch…1973
Remove…1973
Install…1975
Low Coolant Level Sensor…1975
Remove…1977
Install…1977
Fuel Level Sensor, Gas and Diesel Engines Only…1977
Remove…1977
Install…1977
Armrest Switch…1978
Remove…1978
Install…1978
Seat Sensor (Operator Presence System)…1980
Non-Suspension and Semi-Suspension Seats; All Lift truck Models …1980
Remove…1980
Install…1980
Non-Suspension Seats; Lift Truck Models H6.0FT, H7.0FT (H135FT, …1981
Remove…1981
Install…1981
Full Suspension Seats; All Lift Truck Models…1982
Remove…1982
Install…1982
Hood Shut Off Switch…1982
Remove…1982
Install…1982
Hydraulic Filter Pressure Switch…1986
Remove…1986
Install…1986
Transmission Speed Sensor…1986
Remove…1986
Install…1987
Transmission Pressure Sensors…1987
Remove…1987
Install…1987
Transmission Temperature Sensor…1987
Remove…1987
Install…1988
Engine Speed Sensor…1989
Remove…1989
Install…1989
Intermediate Speed Sensor…1989
Remove…1989
Install…1989
Return to Set Tilt (Tilt Angle) Sensor…1989
Lift Truck Models S30FT, S35FT, S40FTS (E010); H1.6FT, H1.8FT, H…1989
Remove…1989
Install…1990
Lift Truck Models S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024); …1990
Remove…1990
Install…1991
Rear Horn Button Switch…1991
Remove…1991
Install…1991
Impact Sensor…1992
All Lift Truck Models Except H6.0FT, H7.0FT (H135FT, H155FT) (H0…1992
Remove…1992
Install…1992
Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006)…1994
Remove…1994
Install…1995
Load Weight Sensor…1995
Remove…1995
Install…1996
Engine and Fuel Sensors – Mazda 2.0L and 2.2L Gas and LPG Engine…1996
Oxygen Sensor…1996
Remove…1996
Install…1996
Intake Air Temperature (IAT) Sensor…1997
Remove…1997
Install…1997
Manifold Absolute Pressure (MAP)/Boost Sensor…1997
Remove…1997
Install…1997
Throttle Position (TPS) Sensor…1998
Remove…1998
Install…1998
Engine and Fuel Sensors and Switches – Mazda 2.0L and 2.2L LPG E…1998
Oil Pressure Sensor…1998
Remove…1998
Install…1998
Low LPG Pressure Switch…1999
Remove…1999
Install…1999
Air Filter Restriction Switch…1999
Remove…1999
Install…2000
Engine Coolant Temperature (ECT) Sensor…2000
Remove…2000
Install…2000
Engine and Fuel Sensors and Switches- Mazda 2.0L and 2.2L Gas En…2000
Oil Pressure Sensor…2000
Remove…2000
Install…2000
Mass Air Flow (MAF) Sensor…2001
Remove…2001
Install…2001
Air Filter Restriction Switch…2001
Remove…2001
Install…2001
Engine Coolant Temperature (ECT) Sensor…2002
Remove…2002
Install…2002
Engine and Fuel Sensors and Switches – Mazda 2.0L and 2.2L Gas a…2002
Oil Pressure Sensor…2002
Remove…2002
Install…2002
Air Filter Restriction Switch…2003
Remove…2003
Install…2003
CAM Angle Sensor…2004
Voltage Check…2004
Oxygen Sensor…2005
Remove…2005
Install…2005
Engine and Fuel Sensors and Switches – Mazda 2.0L and 2.2L LPG E…2005
Engine Coolant Temperature (ECT) Sensor…2005
Remove…2005
Install…2006
Manifold Absolute Pressure (MAP) Sensor…2007
Remove…2007
Install…2007
Intake Air Temperature (IAT) Sensor…2007
Remove…2007
Install…2007
Fuel Temperature Sensor…2008
Remove…2008
Install…2008
Low LPG Pressure Switch…2009
Remove…2009
Install…2009
Engine and Fuel Sensors and Switches- Mazda 2.0L and 2.2L Gas En…2010
Intake Air Temperature (IAT) Sensor…2010
Remove…2010
Install…2010
Engine Coolant Temperature (ECT) Sensor…2011
Remove…2011
Install…2011
Manifold Absolute Pressure (MAP) Sensor…2012
Remove…2012
Install…2012
Engine and Fuel Sensors and Switches, GM 2.4L and 4.3L Gas and L…2013
Crankshaft Sensor…2013
Remove…2013
Install…2013
Camshaft Position (CMP) Sensor…2014
Remove…2014
Install…2014
Camshaft Position (CMP) Sensor Assembly…2015
Remove…2015
Install…2015
Oil Pressure Sensor…2015
Remove…2015
Install…2015
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) …2016
Remove…2016
Install…2016
Engine Coolant Temperature (ECT) Sensor…2017
Remove…2017
Install…2017
Air Flow Restriction Switch…2017
Remove…2017
Install…2018
Oxygen Sensor…2018
Remove…2018
Install…2021
Engine and Fuel Switches, GM 2.4L and GM 4.3L LPG Trucks Only…2022
Low LPG Pressure Switch…2022
Remove…2022
Install…2022
LPG Pressure Sensor, GM 4.3L Engine Only…2023
Remove…2023
Install…2023
Engine and Fuel Sensors and Switches, Yanmar Diesel Trucks…2023
Air Filter Restriction Switch…2023
Remove…2023
Install…2023
Oil Pressure Sensor…2023
Remove…2023
Install…2023
Engine Speed Sensor…2023
Remove…2023
Install…2023
Engine Coolant Temperature (ECT) Sensor…2025
Remove…2025
Install…2025
Throttle Position Sensor (TPS)…2025
Remove…2025
Install…2025
Fuel/Water Separator Sensor…2026
Remove…2026
Install…2026
Glow Plug Relay…2027
Remove…2027
Install…2029
Engine and Fuel Sensors and Switches, Cummins Diesel Engines…2029
Air Filter Restriction Switch…2029
Remove…2029
Install…2029
Oil Pressure Sensor…2031
Remove…2031
Install…2031
Engine Speed Sensor (Cummins 4.5L Only)…2031
Remove…2031
Install…2031
Engine Coolant Temperature (ECT) Sensor…2032
Remove…2032
Install…2032
Throttle Position Sensor (TPS) (Cummins 4.5L Only)…2032
Remove…2032
Install…2033
Fuel/Water Separator Sensor…2033
Remove…2033
Install…2033
Vehicle System Manager (VSM)…2034
General…2034
VSM Replacement…2034
Remove…2034
Install…2035
Programming a New VSM and/or Display Switch Cluster…2036
General…2036
PC Service Tool Software…2036
Data Transferring…2037
New or Used VSM…2037
New (Blank) Display Switch Cluster…2037
Used (Non-Blank) Display Switch Cluster…2037
Power Distribution Module (PDM) and Component Parts…2038
Remove…2038
PDM as a Unit…2038
Install…2041
PDM as a Unit…2041
Remove and Install…2041
PDM Component Parts…2041
Transmission Control Unit…2042
Remove S6.0FT, S7.0FT, (S135FT,S155FT) (D024, E024) and H6.0FT, …2042
Install S6.0FT, S7.0FT, (S135FT,S155FT) (D024, E024) and H6.0FT,…2043
Battery…2043
Remove…2043
Install…2043
Lights…2043
Work Lights (Front and Rear)…2043
Remove…2043
Install…2043
Strobe Light…2044
Remove…2044
Install…2045
LED Tail, Backup, and Brake Lights…2045
Remove…2045
Install…2045
Electronic-Hydraulic Controls…2047
General…2047
Mini-Lever Replacement…2047
Remove…2047
Clean and Inspect…2048
Install…2048
Push Button Switch Replacement…2049
Remove…2049
Install…2050
Test…2051
Mini-Levers…2051
Full Stroke Test…2051
Function Returns to Neutral Test…2051
Push Button Switch…2051
Mini-Lever Module (MLM)…2052
Remove…2052
Install…2052
tables…1946
Table 1. VSM and Display Switch Cluster Replacement…2038
1580521-2200SRM1143-(05-2005)-UK-EN…2056
toc…2056
Electrical System…2056
Safety Precautions Maintenance and Repair…2057
Ignition System…2060
General…2060
Ignition Timing Adjustment, Gasoline and LPG…2060
Spark Plugs Check…2060
Spark Plug Wires Check…2060
Distributor Repair…2063
Remove…2063
Disassemble…2064
Inspect…2064
Assemble…2065
Install…2065
Igniter…2066
Remove…2066
Test…2066
Install…2066
Camshaft Position (CMP) Sensor…2067
Voltage Check…2067
Ignition Coil Check…2068
Primary Coil Winding…2068
Secondary Coil Winding…2068
Starter Repair…2069
General…2069
Remove…2069
No-Load Test…2070
Magnetic Switch Test…2070
Pull-Out Test…2070
Holding Coil Test…2071
Return Test…2071
Pinion Movement Inspection…2071
Install…2071
Alternator Repair…2072
General…2072
Charging System Inspection…2072
Output Current Check…2073
No-Load Adjusted Voltage Check…2073
Remove…2074
Inspect…2074
Rectifier Check…2074
Install…2075
tables…2056
Table 1. Spark Plug Wire…2060
Table 2. Starter Specifications…2069
Table 3. Problem Diagnosis Chart…2070
Table 4. Specifications…2073
Table 5. Rectifier Check Table…2074
1580524-4000SRM1148-(11-2008)-UK-EN…2078
toc…2078
Mast Repairs…2078
Safety Precautions Maintenance and Repair…2079
General…2082
Safety Procedures When Working Near Mast…2082
Fork Repair…2084
Remove…2084
Install…2084
Checks…2085
Carriages Repair…2086
Standard Carriage…2086
Remove…2086
Repair…2087
Install…2087
Integral Sideshift Carriage…2087
Remove…2087
Clean and Inspect…2090
Repair…2091
Install…2092
Mast Repair…2092
Mast, Remove…2092
Two-Stage LFL and Two-Stage FFL Masts, Disassemble…2096
Clean and Inspect…2102
Three-Stage FFL Mast…2103
Disassemble…2103
Clean and Inspect…2107
Two-Stage LFL and Two-Stage FFL Mast, Assemble…2108
Three-Stage FFL Mast, Assemble…2109
Four-Stage FFL, Disassemble…2111
Clean and Inspect…2115
Four-Stage FFL, Assemble…2117
Mast, Install…2119
Header Hose Arrangement…2122
Two-Stage LFL…2122
Two-Stage FFL…2129
Three-Stage FFL…2141
Four-Stage FFL…2156
Adjustment…2164
Lift Chains Adjustment…2165
Carriage Adjustments…2167
Tilt Cylinders Adjustment…2167
Mast Adjustments…2171
Load Roller Adjustment…2171
Mast Side Kicking Adjustment…2173
tables…2078
Table 1. Fork Tip Alignment…2085
Table 2. Pneumatic Tire Trucks…2125
Table 3. Cushion Tire Trucks…2125
Table 4. Standard Two-Stage Hose Dimensions…2128
Table 5. Pneumatic Tire Trucks…2132
Table 6. Cushion Tire Trucks…2132
Table 7. Pneumatic Tire Trucks…2150
Table 8. Cushion Tire Trucks…2150
Table 9. Standard Three-Stage Hose Dimensions…2152
Table 10. Standard Four-Stage Hose Dimensions…2157
Table 11. Hook-Type Carriage Chain Adjustment…2165
Table 12. Pin-Type Carriage Chain Adjustment…2166
1580528-8000SRM1134-(07-2008)-UK-EN…2176
toc…2176
Calibration Procedures…2176
Safety Precautions Maintenance and Repair…2177
Description…2182
Proc_Cal_001: Service Password Entry…2185
When to Perform…2185
Why Perform…2185
How to Perform…2185
Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed…2187
When to Perform…2187
Calibration Order…2187
Why Perform…2187
How to Perform…2187
Proc_Cal_003: Save and Exit…2189
When to Perform…2189
Why Perform…2189
How to Perform…2189
Proc_Cal_004: Lift Valve Output Threshold…2191
When to Perform…2191
Calibration Order…2191
Why Perform…2191
How to Perform…2191
Proc_Cal_005: Lower Valve Output Threshold…2193
When to Perform…2193
Calibration Order…2193
Why Perform…2193
How to Perform…2193
Proc_Cal_006: Tilt Back Valve Output Threshold…2197
When to Perform…2197
Calibration Order…2197
Why Perform…2197
How to Perform…2197
Proc_Cal_007: Tilt Forward Valve Output Threshold…2199
When to Perform…2199
Calibration Order…2199
Why Perform…2199
How to Perform…2200
Proc_Cal_008: Aux 1 Dir A Valve Output Threshold…2203
When to Perform…2203
Calibration Order…2203
Why Perform…2203
How to Perform…2203
Proc_Cal_009: Aux 1 Dir B Valve Output Threshold…2205
When to Perform…2205
Calibration Order…2205
Why Perform…2205
How to Perform…2205
Proc_Cal_010: Aux 2 Dir A Valve Output Threshold…2209
When to Perform…2209
Calibration Order…2209
Why Perform…2209
How to Perform…2209
Proc_Cal_011: Aux 2 Dir B Valve Output Threshold…2211
When to Perform…2211
Calibration Order…2211
Why Perform…2211
How to Perform…2212
Proc_Cal_012: Aux 3 Dir A Valve Output Threshold…2215
When to Perform…2215
Calibration Order…2215
Why Perform…2215
How to Perform…2215
Proc_Cal_013: Aux 3 Dir B Valve Output Threshold…2217
When to Perform…2217
Calibration Order…2217
Why Perform…2217
How to Perform…2218
Proc_Cal_014: Load Weight Zero Point…2221
When to Perform…2221
Calibration Order…2221
Why Perform…2221
How to Perform…2221
Proc_Cal_015: Loaded Weight Calibration…2223
When to Perform…2223
Calibration Order…2223
Why Perform…2223
How to Perform…2223
Proc_Cal_016: Transmission Valve Calibration…2225
Applicable System/Option…2225
When to Perform…2225
Calibration Order…2225
Why Perform…2226
How to Perform…2226
Applicable System/Option…2227
When to Perform…2227
Calibration Order…2227
Why Perform…2227
How to Perform…2227
Proc_Cal_016A: Transmission Valve Calibration-Electronic Extende…2229
Applicable System/Option…2229
When to Perform…2229
Calibration Order…2229
Why Perform…2229
How to Perform…2229
Proc_Cal_016B: Trans. Valve Calibration-Electronic and Electroni…2231
Applicable System/Option…2231
When to Perform…2231
Calibration Order…2231
Why Perform…2231
How to Perform…2231
Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment…2233
Required Tools…2233
When to Perform…2233
Calibration Order…2233
Why Perform…2233
How to Perform…2233
Proc_Cal_025: Hydraulic Valve Pressure Gage Installation…2235
When to Perform…2235
Why Perform…2235
How to Perform…2235
Proc_Cal_026: Travel Speed Calibration…2237
When to Perform…2237
Calibration Order…2237
Why Perform…2237
How to Perform…2237
tables…2176
Table 1. Calibration Procedures…2182
Table 2. How to Read Calibration Procedure…2183
Table 3. Proc_Cal_001: Service Password Entry…2186
Table 4. Proc_Cal_002: Hydraulic Valve Calibration Warm Up and A…2187
Table 5. Proc_Cal_003: Save and Exit…2190
Table 6. Proc_Cal_004: Lift Valve Output Threshold…2191
Table 7. Proc_Cal_005: Lower Valve Output Threshold…2194
Table 8. Proc_Cal_006: Tilt Back Valve Output Threshold…2197
Table 9. Proc_Cal_007: Tilt Forward Valve Output Threshold…2200
Table 10. Proc_Cal_008: Aux 1 Dir A Valve Output Threshold…2203
Table 11. Proc_Cal_009: Aux 1 Dir B Valve Output Threshold…2206
Table 12. Proc_Cal_010: Aux 2 Dir A Valve Output Threshold…2209
Table 13. Proc_Cal_011: Aux 2 Dir B Valve Output Threshold…2212
Table 14. Proc_Cal_012: Aux 3 Dir A Valve Output Threshold…2215
Table 15. Proc_Cal_013: Aux 3 Dir B Valve Output Threshold…2218
Table 16. Proc_Cal_014: Load Weight Zero Point…2221
Table 17. Proc_Cal_015: Loaded Weight Calibration…2223
Table 18. Proc_Cal_016: Transmission Valve Calibration…2226
Table 19. Proc_Cal_016: Transmission Valve Calibration ( S6.0FT,…2228
Table 20. Proc_Cal_016A: Transmission Valve Calibration…2230
Table 21. Proc_Cal_016B: Transmission Valve Calibration…2232
Table 22. Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjus…2234
Table 23. Proc_Cal_025: Hydraulic Valve Pressure Gage Installati…2236
Table 24. Proc_Cal_026: Travel Speed Calibration…2237
1598588-0600SRM1205-(03-2007)-UK-EN…2242
toc…2242
Yanmar Diesel Engines…2242
Safety Precautions Maintenance and Repair…2243
General…2248
Engine Identification…2248
Major Engine Component Identification…2248
Location of Labels…2248
Engine Removal and Installation…2249
Cylinder Head Assembly Repair…2249
Glow Plugs…2251
Remove…2251
Install…2251
Valve Cover…2251
Remove…2251
Clean and Inspect…2251
Install…2252
Rocker Arm Assembly…2252
Remove…2252
Disassemble…2253
Clean and Inspect…2253
Push Rods…2253
Rocker Arm Assembly…2253
Assemble…2254
Install…2254
Valve Clearance Adjustments…2254
Cylinder Head Assembly…2256
Remove…2256
Disassemble…2259
Valves and Valve Springs, Remove…2259
Valve Guides, Remove…2260
Clean and Inspect…2260
Cylinder Head…2261
Valve Guides…2261
Valves…2261
Valve Sink…2261
Valve Seat…2262
Valve Springs…2262
Assemble…2263
Valve Guides, Install…2263
Valves and Valve Springs, Install…2263
Install…2264
Timing Gear Case and Timing Gears Repair…2265
Timing Gear Case Cover…2265
Remove…2265
Clean and Inspect…2266
Install…2266
Timing Gears…2267
Crankshaft Gear…2267
Remove…2267
Install…2267
Idler Gear…2267
Remove…2267
Inspect…2268
Install…2268
Camshaft Gear…2268
Remove…2268
Install…2269
Timing Gear Case…2269
Remove…2269
Clean and Inspect…2269
Install…2269
Drive Train, Camshaft, and Cylinder Block Repair…2270
Remove…2270
Disassemble…2270
Pistons and Connecting Rods…2270
Crankshaft…2271
Camshaft…2273
Clean and Inspect…2274
Cylinder Block…2274
Honing and Boring…2277
Pistons…2278
Piston Pin…2278
Connecting Rod…2279
Tappets…2279
Crankshaft…2279
Camshaft…2281
Camshaft Bushing…2281
Assemble…2281
Camshaft…2281
Crankshaft…2282
Pistons and Connecting Rods…2282
Install…2283
Lubrication System Repair…2284
Engine Oil and Oil Filter Change…2284
Oil Pan…2284
Remove…2284
Install…2285
Oil Suction Tube…2285
Remove…2285
Clean…2285
Install…2286
Oil Pump…2286
Remove…2286
Clean and Inspect…2286
Outer Rotor Outside Clearance…2287
Outer Rotor to Inner Rotor Tip Clearance…2287
Outer Rotor Side Clearance…2287
Rotor Shaft Clearance…2287
Install…2288
Fuel System Repair…2288
Fuel Injectors…2288
Remove…2288
Inspect…2289
Clean…2289
Test…2290
Install…2292
Electronic Throttle System…2292
Remove…2292
Install…2295
Inspect…2296
Adjust…2296
Fuel Injection Pump…2296
Remove…2296
Clean and Inspect…2299
Install…2299
Check/Adjust Fuel Injection Timing…2300
Cooling System Repair…2302
V-Belt…2302
Remove…2302
Inspect…2302
Install…2302
Adjust…2302
Water Pump…2303
4TNE92-NMHA Engines…2303
Remove…2303
Install…2304
4TNE92-NMH and 4TNE98-NMH Engines…2305
Remove…2305
Install…2306
Thermostat…2307
Remove…2307
Inspect…2307
Install…2308
Flywheel and Flywheel Housing…2309
Flywheel…2309
Remove…2309
Install…2309
Flywheel Housing…2310
Remove…2310
Install…2310
Electrical Equipment Repair…2311
Alternator…2311
Remove…2311
Bench Test…2313
Regulate Voltage Check…2313
No Load Test…2315
Output Test…2315
Install…2315
Starter…2315
Remove…2317
No Load Test…2317
Install…2317
Engine Specifications…2318
Engine Data…2318
Engine Tuning…2321
Cylinder Head…2322
Intake/Exhaust Valve and Guide…2322
Valve Spring…2323
Rocker Arm and Shaft…2323
Push Rod…2323
Gear Train and Camshaft…2323
Camshaft…2323
Idle Gear Shaft and Bushing…2324
Backlash of Each Gear…2324
Cylinder Block…2325
Crankshaft…2325
Thrust Bearing…2325
Piston…2325
Piston Ring…2326
Connecting Rod…2326
Rod Small End…2327
Tappet…2327
Oil Pump…2327
Engine Oil Pressure…2327
Outer Rotor Outside Clearance…2327
Outer Rotor Side Clearance…2327
Outer Rotor to Inner Rotor Tip Clearance…2327
Rotor Shaft Clearance…2328
Standard Torque Specifications…2328
Standard Torque Chart…2328
Special Torque Specifications…2329
Special Tools…2330
tables…2242
Table 1. Cylinder Measurement Worksheet…2276
Table 2. Fuel Injector Spray Patterns…2291
Table 3. V-Belt Deflection Table…2302
Table 4. Alternator Specifications…2311
Table 5. Starter Specifications…2316
Table 6. No Load Test Specifications…2317
Table 7. 4TNE92-NMH Engine…2318
Table 8. 4TNE92-NMHA Engine…2319
Table 9. 4TNE98-NMH Engine…2320
1598589-1400SRM1206-(11-2008)-UK-EN…2338
toc…2338
Drive Axle and Differential Assembly Repair…2338
Safety Precautions Maintenance and Repair…2339
General…2342
Drive Axle Repair…2342
Remove and Disassemble…2342
Clean and Inspect…2344
Assemble and Install…2344
Differential Repair…2347
Remove…2347
Differential Assembly From Center Section Assembly…2347
Drive Pinion, Pinion Gear, and Bearings From Center Section…2351
Disassemble…2356
Differential Assembly…2356
Drop Box Housing…2360
Center Section…2361
Clean and Inspect…2363
Assemble…2363
Center Section…2363
Drop Box Housing…2366
Differential Assembly…2367
Install…2371
Pinion Inner Shim Set, Adjust Thickness (Depth of Pinion)…2371
Drive Pinion, Pinion Gear, and Bearings Into Center Section…2373
Differential Assembly Into Center Section…2376
Ring Gear Backlash, Adjust…2381
Ring Gear, Runout Check…2383
Gear Set, Tooth Contact Pattern Check…2383
Torque Specifications…2386
tables…2338
Table 1. Pinion Variation Numbers Examples…2372
Table 2. Ring and Pinion Tooth Contact Adjustment…2383
Table 3. Correct Tooth Contact…2384
Table 4. Incorrect Tooth Contact…2385
1598591-8000SRM1208-(06-2007)-UK-EN…2390
toc…2390
Capacities and Specifications…2390
Safety Precautions Maintenance and Repair…2391
Lift Truck Lifting Capacity…2394
Counterweight Weights…2394
Tire Sizes…2394
Capacities…2394
Electrical System…2397
Transmission Oil Pressures…2398
Hydraulic System Relief Pressures…2399
Steering System…2399
Stall Speeds (in RPM ±100 rpm)…2400
Mazda (Except 2007 Emission Compliant Engines)…2400
Mazda (2007 Emission Compliant Engines Only)…2400
Yanmar 2.6L…2400
Mast Speeds …2400
Tilt Angles…2401
Front End Equipment – Mast Creep…2402
Mast Creep…2402
Engine Specifications…2402
Torque Specifications…2404
Frame…2404
Mast…2404
Steering System, Cushion Tire Trucks…2404
Steering System, Pneumatic Tire Trucks…2404
Drive Axle…2404
Transmission…2405
Engine – Mazda 2.0L…2405
Engine – Yanmar 2.6L Diesel…2406
tables…2390
Table 1. Lift Truck Models S30FT, S35FT, S40FTS (E010) With Mazd…2400
Table 2. Lift Truck Models H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT…2401
Table 3. Lift Truck Models H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT…2401
Table 4. S30FT, S35FT, S40FTS (E010) Lift Truck Models…2401
Table 5. H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) (F001) L…2401
Table 6. S30FT, S35FT, S40FTS (E010) Lift Truck Models…2402
Table 7. H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) (F001) L…2402
1602994-8000SRM1207-(07-2008)-UK-EN…2410
toc…2410
Periodic Maintenance…2410
Safety Precautions Maintenance and Repair…2411
General…2416
Serial Number Data…2416
How to Move Disabled Lift Truck…2416
How to Tow Lift Truck…2416
How to Put Lift Truck on Blocks…2417
How to Raise Drive Tires…2417
How to Raise Steering Tires…2418
Maintenance Schedule…2418
Maintenance Procedures Every 8 Hours or Daily…2426
How to Make Checks With Engine Stopped…2426
Tires and Wheels…2426
Safety Labels…2426
Mast, Carriage, Lift Chains, Header Hoses, Attachment…2427
Operator Restraint System…2427
Emergency Locking Retractor (ELR)…2427
Hood and Seat Latches…2428
Engine Compartment…2428
Fuel, Oil, and Coolant Leaks, Check…2429
Hydraulic Hoses…2429
Coolant Hoses…2429
Steering Column Gas Cylinder…2429
Transmission…2429
Hydraulic System Oil…2429
Engine Oil…2430
Air Filter…2431
Forks…2431
Remove…2431
Inspect…2431
Install…2432
Adjust…2432
How to Make Checks With Engine Running…2433
Indicator Lights, Horn, Fuses, and Relays…2433
Service Brakes…2435
Brake Fluid Level…2435
Operation, Check…2436
Parking Brake…2436
Engine Oil Pressure…2436
Cooling System…2437
Steering System…2437
Control Levers and Pedals…2437
Lift System, Operate…2438
First Service After First 100 Hours of Operation…2438
Mazda Engine Oil Filter…2438
Yanmar Engine Oil Filter…2439
Hydraulic System…2439
Hydraulic Filter, Replace…2439
Transmission Oil Filter, Replace…2440
Maintenance Procedures Every 500 Hours or 6 Months…2441
Hydraulic System Oil…2441
Hydraulic Tank Breather…2441
Inspect…2441
Battery…2442
Engine Oil and Filter, Mazda and Yanmar Engines…2442
Drive Belt…2443
Mazda 2.0L Engines…2443
Fan and Alternator Drive Belt…2443
Yanmar Diesel Engine…2444
Fan and Alternator Drive Belt…2444
PCV Valve…2444
Clean Debris From Radiator Core…2445
Transmission Oil Level…2445
Forks…2445
Mast Lubrication…2446
Header Hose Checks…2448
Lift Chain Lubrication…2449
Tilt Cylinder Lubrication…2449
Master Brake Cylinder Rod End Pin Lubrication…2450
Manual Hydraulic Levers Lubrication…2450
Brake Fluid…2451
Drain Tar From LPG Regulator…2451
Tie Rod Lubrication …2451
Differential and Drive Axle Oil (Dry Brake)…2452
Maintenance Procedures Every 1000 Hours or 6 Months…2453
Valve Clearance, Check and Adjust…2453
Ignition System…2453
Mazda 2.0L Engines…2453
LPG Vapor Fuel Filter Replace, Mazda Engines …2453
Fuel Filter Replacement, Yanmar Engine…2453
Priming the Fuel System (Yanmar)…2455
Lift Chains Wear Check…2456
Lift Chain Lubrication…2456
Integral Sideshift Carriage, Check Bearings…2456
Steering Axle…2457
Control Levers and Pedals…2457
Maintenance Procedures Every 2000 Hours or Annually…2457
Hydraulic System…2457
Hydraulic Filter, Replace…2457
Hydraulic Tank Breather, Replace…2459
Air Filter…2459
PCV Valve…2460
Oxygen Sensor…2461
LPG Regulator Fuel Filter, Mazda Engines (Except 2007 Mazda Emis…2461
Remove and Replace…2461
Timing Belt…2461
Mazda Engines…2461
LPG Fuel Injector, Mazda Engines (Except 2007 Mazda Emission Com…2461
Fuel Injector, Yanmar Engines…2461
Forks…2462
Integral Sideshift Carriage…2462
Bearings, Replace…2462
Transmission Oil and Filter (Dry Brake), Replace…2462
Brake Fluid (Master Cylinder), Change…2463
Brake Fluid (Dry Brake), Remove…2464
Service Brakes (Dry Brake)…2464
Differential (Dry Brake)…2464
Valve Clearance, Check and Adjust for Cummins QSB 3.3L Diesel En…2465
Maintenance Procedures Every 4000 Hours or 2 Years…2466
Hydraulic Oil, Replace…2466
Cooling System…2467
Safety Procedures When Working Near Mast…2468
Hood Latch Check…2471
Lift Chain Adjustments…2472
Jump-Starting the Lift Truck…2473
Jump-Starting Using a Battery Charger…2473
Jump-Starting a Lift Truck Using Another Lift Truck…2473
Welding Repairs…2474
Overhead Guard Changes…2474
Wheel Repair…2475
General…2475
Pneumatic Tire With Tube, Repair…2475
Remove Wheels From Lift Truck…2475
Remove Tire From Wheel…2475
Remove Tire From Two-Piece Wheel…2476
Remove Tire From Three- and Four-Piece Wheels…2477
Install Wheel in Tire…2478
Install Two-Piece Wheel in Tire…2479
Install Three- or Four-Piece Wheel in Tire…2480
Add Air to Pneumatic Tires With Tube…2481
Wheels, Install…2481
Pneumatic Tubeless Tire, Repair…2481
Remove Wheels From Lift Truck…2481
Remove Tire From Wheel…2482
Install Tire on Wheel…2484
Add Air to Pneumatic Tubeless Tire…2486
Wheels, Install…2487
Solid Rubber Tires on Pneumatic Wheels, Change…2487
Remove Tire From Wheel…2487
Install Tire on Wheel…2489
Snap-On-Tire, Change…2491
Remove Snap-On-Tire, Solid Tire From Wheel…2491
Install Snap-On-Tire, Solid Tire on Wheel…2492
Adhesives and Sealants…2493
tables…2410
Table 1. Maintenance Schedule…2421
Table 2. V-Belt Deflection Table…2444
Table 3. Carriage Chain Adjustment, Forks Not Installed…2473
1673866-0100SRM1290-(07-2008)-UK-EN…2496
toc…2496
Operator's Cab…2496
Safety Precautions Maintenance and Repair…2497
General…2502
Cab Replacement…2503
Remove, for Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F001); H2…2503
Install, for Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F001); H2…2514
Remove, for Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (H…2515
Install, for Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (…2519
Door Assemblies…2520
Right Side Door Assembly, Lift Truck Models H1.6FT, H1.8FT, 2.0F…2520
Remove…2520
Disassemble…2525
Door Cover…2525
Heater Assembly…2527
Door Lock Assembly…2528
Windows…2529
Clean…2529
Inspect…2529
Assemble…2529
Windows…2529
Door Lock Assembly…2529
Heater Assembly…2530
Door Cover…2530
Install…2530
Left Side Door Assembly, Lift Truck Models H1.6FT, H1.8FT, 2.0FT…2530
Remove…2530
Disassemble…2530
Door Cover…2530
Door Lock Assembly…2532
Windows…2532
Clean…2532
Inspect…2532
Assemble…2532
Windows…2532
Door Lock Assembly…2532
Door Cover…2532
Install…2532
Right and Left Side Door Assemblies, Lift Truck Models H6.0FT, H…2533
Remove…2533
Disassemble…2533
Door Cover…2533
Door Lock Assembly…2535
Windows…2535
Clean…2535
Inspect…2535
Assemble…2536
Windows…2536
Door Lock Assembly…2536
Door Cover…2536
Install…2537
Window Wipers Replacement…2537
General…2537
Front Wiper Assembly and Motor…2537
Remove, Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F001) and H2.0…2537
Install, Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F001) and H2…2537
Remove, Lift Truck Models H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-5…2539
Install, Lift Truck Models H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-…2539
Rear Wiper Assembly and Motor…2541
Remove, Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F001)…2541
Install, Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F001)…2541
Remove, Lift Truck Models H2.0-3.5FT (H40-70FT) (L177)…2543
Install, Lift Truck Models H2.0-3.5FT (H40-70FT) (L177)…2543
Remove, Lift Truck Models H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-5…2546
Install, Lift Truck Models H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-…2546
Remove, Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (H006,…2548
Install, Lift Truck Models H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-…2548
Window Replacement…2550
General…2550
Remove Door Window, Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F0…2550
Install Door Windows, Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (…2551
Remove Door Window, Lift Truck Models H6.0FT, H7.0FT (H135FT, H1…2552
Install Door Window, Lift Truck Models H6.0FT, H7.0FT (H135FT, H…2553
Heater Replacement…2553
Remove, for Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (H…2553
Install, for Lift truck Models H6.0FT, H7.0FT (H135FT, H155FT) (…2556
Light Replacement…2557
Work Lights (Front and Rear)…2557
Remove…2557
Install…2557
Strobe Light…2559
Remove…2559
Install…2559
Turn, Stop, Tail, and Backup Light…2560
Remove…2560
Install…2560
Front Marker/Turn Signal Lights…2560
Remove…2560
Install…2560
Display Switches…2561
Electrical Schematics…2565
Optional Equipment…2568
Heavy Duty Pre-Cleaner…2568
Remove…2568
Clean…2569
Inspect…2569
Install…2569
Fan…2569
Remove…2569
Install…2569
Mirror…2569
Remove…2569
Install…2569
Label Replacement…2569
1698613-8000SRM1387-(07-2008)-UK-EN…2574
toc…2574
Diagrams and Schematics…2574
Safety Precautions Maintenance and Repair…2575
General Information About Diagrams and Schematics…2578
Symbol Definitions…2578
tables…2574
Table 1. Wire Colors…2578
Table 2. Symbol Definitions…2578
9000SRM1112_DTC 110-6 chg DTC 110-16…2640
9000SRM1112_Operational Checkout…2641
toc…0
Operational Diagnostic Procedures…0
Operational Checkout Procedures…2641
DTC Check…2642
Horn Circuit Check…2642
Light Circuit Check…2642
Windshield Washer Wiper Check (If equipped)…2642
Heater Check (If equipped)…2643
Dome Light Check (If equipped)…2643
Circulating (Accessory) Fan Check (If equipped)…2644
Indicator Light Power Check…2645
Engine Malfunction Indicator Check…2646
Cold Start Check (Cummins and Yanmar)…2646
Brake Pedal Check…2646
Backup Alarm Check (If equipped)…2647
Operator Presence System Check…2647
Hydraulic Interlock Check…2647
Armrest Hydraulic Interlock Check (If equipped and with original…2647
Engine Cover Latch Sensor Check (If equipped)…2648
Brake and Inching Pedal Check…2648
Park Brake Sensor Check…2648
Park Brake Check…2649
Engine Speed Check (All Cummins, Yanmar, and Mazda Engines Excep…2649
Engine Power Check…2650
Transmission Clutch Check…2650
Transmission Check…2651
Transmission Speed Selection Check (If equipped)…2651
Brake and Axle Drag Check…2651
Hydraulic Pump Flow Check…2652
Priority Flow Divider Valve Check…2653
Steering Relief Valve Low Pressure Check…2653
Steering Relief Valve High Pressure Check…2654
Control Valve Load Check Valve (Manual Valve)…2654
Lift E-Valve Check…2654
Lift Check (E-Valve)…2654
Tilt Function Counterbalance Check…2655
Lift Drift Check…2655
Tilt Function Drift Check…2656
Mast Cushion Check (All Except 2-Stage Mast)…2656
Lift/Tilt Mast Adjustment Check…2656
Tilt Racking Check…2657
Chain and Header Hose Adjustment Check…2657
Mast Mounting Check…2658
Mast Channel Check…2658
Carriage Adjustment Check…2659
Chain Sheave Check…2659
Carriage Adjustment Check (Standard and Integral Side Shift)…2659
9000SRM1112_Speed Sensor Direction or Direction Check Logical Failure…2660
toc…0
522155-2…2660
522157-2…2660
9000SRM1112_TOSS_TISS Sensor 1 & 2 No Output…2667
9000SRM1112_TSP MLM Data Error.pdf…2668
toc…0
Electrical System…0
2802-12…2668
628-12…2668
523261-3…2668
523261-4…2668
523257-3…2668
523257-4…2668
523253-3…2668
523253-4…2668
523249-3…2668
523249-4…2668
630-12…2668
9000SRM1112_UPDATE CUMMINS QSB 3.3L FAULT CODES DTC 627-12…2670
910442-8000SRM0231-(12-2004)-UK-EN…2671
toc…2671
Metric and Inch (SAE) Fasteners…2671
Safety Precautions Maintenance and Repair…2672
General…2675
Threaded Fasteners…2675
Nomenclature, Threads…2675
Strength Identification…2676
Cotter (Split) Pins…2676
Fastener Torque Tables…2681
Conversion Table…2683
tables…2671
Table 1. Bolts and Screws…2677
Table 2. Studs and Nuts…2678
Table 3. Torque Nuts…2679
Table 4. Torque Nuts With Nylon Insert…2680
Table 5. Torque Values for Metric Fasteners*…2681
Table 6. Torque Values for Inch Fasteners*…2682
Table 7. Conversion Table for Metric and English Units…2683
Table 8. Cotter Pin Dimensional Data…2684
Table 9. Cotter Pin Dimensional Data…2685
Table 10. Cotter Pin Dimensional Data…2686
Table 11. Cotter Pin Dimensional Data…2688
F001 (H30-35FT, H40FTS)…2693
1579259-9000SRM1112-(07-2008)-US-EN…2695
toc…2695
Diagnostic Troubleshooting Manual…2695
Safety Precautions TROUBLESHOOTING PROCEDURES…2696
How To Use This Troubleshooting Manual…2698
General Instructions and Safety Information…2698
How to Use Diagnostic Troubleshooting Manual…2698
General Instructions…2699
Operational Diagnostic Procedures…2701
Operational Checkout Procedures…2703
DTC Check…2704
Horn Circuit Check…2704
Light Circuit Check…2704
Windshield Washer Wiper Check (If equipped)…2704
Heater Check (If equipped)…2705
Dome Light Check (If equipped)…2705
Circulating (Accessory) Fan Check (If equipped)…2706
Indicator Light Power Check…2707
Operator Presence System Check…2708
Engine Malfunction Indicator Check…2708
Cold Start Check (Cummins and Yanmar)…2708
Brake Pedal Check…2709
Backup Alarm Check (If equipped)…2709
Armrest Hydraulic Interlock Check (If equipped and with original…2709
Engine Cover Latch Sensor Check (If equipped)…2710
Brake and Inching Pedal Check…2710
Park Brake Sensor Check…2710
Park Brake Check…2711
Engine Speed Check (All Cummins, Yanmar, and Mazda Engines Excep…2711
Engine Power Check…2712
Transmission Clutch Check…2712
Transmission Check…2713
Transmission Speed Selection Check (If equipped)…2713
Brake and Axle Drag Check…2713
Hydraulic Pump Flow Check…2714
Priority Flow Divider Valve Check…2715
Steering Relief Valve Low Pressure Check…2715
Steering Relief Valve High Pressure Check…2716
Control Valve Load Check Valve (Manual Valve)…2716
Lift E-Valve Check…2716
Lift Check (E-Valve)…2716
Tilt Function Counterbalance Check…2717
Lift Drift Check…2717
Tilt Function Drift Check…2718
Mast Cushion Check (All Except 2-Stage Mast)…2718
Lift/Tilt Mast Adjustment Check…2718
Tilt Racking Check…2719
Chain and Header Hose Adjustment Check…2719
Mast Mounting Check…2720
Mast Channel Check…2720
Carriage Adjustment Check…2721
Chain Sheave Check…2721
Carriage Adjustment Check (Standard and Integral Side Shift)…2721
Engine…2723
Engine Basics…2729
General Terminology…2729
Combustion Theory…2729
Engine Components – Cylinder Block…2730
Camshaft and Timing Set…2731
Cylinder Head Assembly…2731
Valve Train Assembly…2731
Air Cleaner/Filter…2731
Carburetion…2731
Electronic Fuel Injection (EFI)…2731
Positive Crankcase Ventilation (PCV)…2732
Engine Electrical…2732
Introduction…2732
Battery Construction…2732
Conventional Standard Battery…2733
Maintenance-Free Battery…2733
Battery Charging…2733
Battery Fast Charging…2734
Battery Slow Charging…2734
Starting System Principles of Operation…2734
Starting System Components – Ignition Switch…2735
Starting System Components – Starter Solenoid…2735
Starting System Components – Flywheel and Ring Gear…2735
Starting System Components – Starter Motor and Drive…2735
Charging System – General…2736
Charging System – Regulator…2736
Charging System – Theory…2736
Engine Fuel System/Exhaust and Emissions…2737
Introduction…2737
Gasoline System Components – Fuel Tank…2737
Electronic Fuel Injector (EFI) – General Description…2737
Port Fuel System Components – ECU…2737
Port Fuel System Components – Fuel Pump/Filter…2737
Port Fuel System Components – Fuel Rail…2737
Port Fuel System Components – Pressure Regulator…2737
Port Fuel System Components – Fuel Injectors…2738
LPG Systems General Information…2738
LPG Fuel Properties…2738
LPG Fuel Tank…2738
AISAN Closed-Loop System…2739
Filter/Lockoff and Regulator…2739
Carburetor…2739
Start Mode…2739
Idle Mode…2740
Run Mode…2740
Main Fuel Lockoff Solenoid…2740
Injector Fuel Lockoff Solenoid…2740
Oxygen (O 2 ) Sensor…2740
Electronic Control Unit (ECU)…2740
Catalytic Converter/Muffler…2740
Engine Management…2740
Introduction…2740
Ignition and Timing – Conventional Spark…2740
Components – Ignition Coil…2741
Components – Distributor…2741
Spark Timing…2741
Components – Ignition Wires…2741
Components – Spark Plugs…2741
Faulty or Fouled Spark Plugs…2742
Electric Controlled Governing System – Mazda LPG…2742
Engine Identification…2743
Cummins (Diesel) Engine…2745
Description…2745
Diesel Fuel System…2746
Principle of Operation…2746
Fuel Injection Pump and Governor…2747
Description…2747
Principles of Operation…2748
Cummins Engine Control…2749
Engine Speed (RPM) Sensor…2750
Throttle Position Sensor…2751
Electronic Throttle Actuator…2752
Engine Oil Pressure Sensor…2752
Coolant Temperature Sensor…2752
Air Restriction Switch…2753
Fuel Filter/Water Separator…2753
Fuel Level Sensor (In Tank)…2753
Engine Electrical System…2754
Magnetic Valve (Engine Stop Solenoid)…2754
Alternator…2754
Grid Heater…2754
Cold Start Timing Advance (Fuel Injection Pump)…2754
Cummins QSB 3.3L (Diesel) Engine…2755
Description…2755
Diesel Fuel System…2756
Electronics System…2759
Engine Protection…2760
Diagnostics…2760
Grid Heater…2760
Turbocharger and Charge Air Cooler…2760
Cooling System…2762
Crankcase Oil Separator…2763
Lubrication System…2764
Mazda Engine Overview…2765
Description…2765
Fuel System…2765
Engine Controls Unit (ECU) and Emissions…2765
Cooling System…2765
Ignition System…2765
Mazda (LPG) Engine Controls…2766
LPG System (Aisan/E-Controls-Mechanical)…2766
Description…2766
Principles of Operation…2767
Control System…2770
Oxygen (O 2 ) Sensor…2771
Fuel Tank…2771
Regulator…2772
Start Mode…2773
Idle Mode…2773
Run Mode…2774
Resonator…2774
Carburetor…2774
Start Mode…2774
Idle Mode…2775
Run Mode…2775
Governor…2776
LPG System (E-Controls)…2776
Description…2776
Principles of Operation…2777
Manifold Absolute Pressure Sensor…2777
Throttle Position Sensor…2777
Oxygen (O 2 ) Sensor…2778
Engine Coolant Temperature Sensor…2778
Intake Air Temperature Sensor…2778
Engine Control Unit…2778
Accelerator Pedal Position Sensor…2778
Three-Way Catalytic Converter…2778
Camshaft Position Sensor…2778
Electric Controlled Governing System…2779
Electronic Governor Sensor…2780
Mazda (Gasoline) Engine Controls…2781
Gasoline System…2781
Description…2781
Principles of Operation…2782
Control System…2784
Camshaft Position Sensor…2785
Intake Air Temperature Sensor…2786
Mass Air Flow Sensor…2787
Throttle Position Sensor…2788
Electronic Governor Sensor…2789
Electronic Governing System…2790
Manifold Absolute Pressure Sensor/Boost Sensor…2790
Engine Coolant Temperature Sensor…2791
Intake Air System…2792
Throttle Body…2792
Idle Air Control Valve…2793
Fuel System…2794
Fuel Injector…2794
Pressure Regulator…2795
Exhaust System…2796
Heated Oxygen (O 2 ) Sensor…2796
Three-Way Catalytic Converter…2797
GM (LPG) Engine Controls…2798
Engine Control System …2798
Engine Control System Overview…2799
Principles of Operation…2799
Control System…2800
GM/TGFI 2.4L (Four Cylinder) Control System Component Location…2800
GM/TGFI 4.3L (Six Cylinder) Control System Component Location…2801
GM/TGFI 2.4L (Four-Cylinder) LPG System…2802
GM/TGFI 4.3L (Six-Cylinder) LPG System…2804
Fuel Tank…2806
Engine Control Unit…2806
Electronic Throttle Body/Throttle Position Sensor…2807
Manifold Absolute Pressure/Manifold Air Temperature Sensor…2807
Propane Injectors…2808
Engine Coolant Temperature Sensor…2810
Oxygen (O 2 ) Sensor…2810
Crankshaft Position Sensor (Engine Speed Sensor)…2811
Oil Pressure Sensor…2811
Power Latch Relay…2811
GM 2.4L Camshaft Position Sensor…2811
GM 4.3L Camshaft Position Sensor…2812
Injector Driver Module…2813
Vaporizer/Regulator…2813
Accelerator Pedal Position Sensor…2816
Three-Way Catalytic Converter…2816
Ignition System…2817
Ignition Coils…2817
Distributorless Ignition System Module…2817
Electronic Ignition Signals…2818
Distributor Ignition (DI) System…2818
Camshaft Position (CMP) Sensor…2819
Ignition Coil and Ignition Control Module (ICM)…2819
Secondary Ignition Components…2819
GM (Gasoline) Engine Controls…2820
Engine Control System…2820
GM 2.4L (Four Cylinder) Engine Control System…2820
GM 4.3L (Six Cylinder) Engine Control System…2821
Engine Control System Overview…2822
Principles of Operation…2822
Control System…2822
GM/TGFI 2.4L (Four Cylinder) Control System Component Location…2822
GM/TGFI 4.3L (Six Cylinder) Control System Component Location…2824
GM/TGFI 2.4L (Four-Cylinder) Gasoline System Components…2825
GM/TGFI 4.3L (Six Cylinder) Gasoline System Components…2827
Engine Control Unit…2829
Electronic Throttle Body/Throttle Position Sensor…2829
Manifold Absolute Pressure/Manifold Air Temperature Sensor …2830
Fuel Injector…2831
Engine Coolant Temperature Sensor…2832
Oxygen (O 2 ) Sensor…2833
Crankshaft Position Sensor (Engine Speed Sensor)…2833
Oil Pressure Sensor…2833
Power Latch Relay…2833
Camshaft Position Sensor…2834
Accelerator Pedal Position Sensor…2835
Three-Way Catalytic Converter…2836
Ignition System…2836
Ignition Coils…2836
Distributorless Ignition System Module…2836
Electronic Ignition Signals…2837
Yanmar (Diesel) Engine…2838
Description…2838
Diesel Fuel System…2839
Principles of Operation…2839
Fuel Injection Pump and Governor…2840
Description…2840
Principles of Operation…2842
Timer…2843
Feed Pump (Vane Type)…2843
Regulating Valve…2844
Injection Pump Plunger…2845
Suction Process…2846
Injection Process…2846
End of Injection…2847
Uniform Pressure Process…2847
Reverse Rotation Prevention Mechanism…2848
Fuel Injection Volume Adjustment Mechanism…2848
Delivery Valve Assembly…2848
Delivery Valve Holder with Damping Valve…2849
All – Speed Governor…2850
At Start of Engine…2852
During Idle…2853
At Full – Load Maximum Speed Control…2854
At No-Load Maximum Speed Control…2855
Full-Load Position Adjustment Mechanism…2856
Structure and Operation of Timer…2857
Standard Type Automatic Timer…2857
Yanmar Engine Controls…2858
Engine Speed (RPM) Sensor…2859
Throttle Position Sensor…2859
Electronic Throttle Actuator…2860
Engine Oil Pressure Sensor…2860
Coolant Temperature Sensor…2861
Air Filter Restriction Switch…2861
Fuel Filter/Water Separator and Strainer…2862
Fuel Level Sensor…2862
Engine Electrical System…2862
Magnetic Valve (Engine Stop Solenoid)…2862
Alternator…2863
Glow Plugs…2863
Cold Start Timing Advance (Fuel Injection Pump)…2863
Cooling System – All Engines…2864
Description…2864
Radiator…2864
Combination Cooler/Standard Radiator…2865
Radiator Cap…2865
Thermostat…2865
Engine Coolant Pump…2866
Fan…2866
GM Engine Coolant Flow Diagram…2866
Yanmar Diesel Engine Coolant Flow Diagram…2867
Engine Does Not Crank…2869
Engine Does Not Start/Engine is Hard to Start…2872
Engine Idle Speed Incorrect…2878
Engine Idle Speed is Unstable or Engine Stalls at Idle…2881
Engine Cuts Out, Misses, Hesitates, Sags, or Stumbles…2886
Engine Lack of Power…2892
Engine Speed Surge Or Engine Speed Unstable…2899
Engine Backfires…2903
Engine Is Knocking or Pinging…2906
Excessive Engine Vibrations…2910
Abnormal Engine and Exhaust Noises…2915
Fan or Alternator Bearing Noise…2919
Abnormal Engine and Exhaust Smells…2921
High Engine Fuel Consumption…2923
Fuel Leaks…2926
High Engine Oil Consumption…2929
Engine Oil Leaks…2931
Engine Oil is Discolored…2936
Engine Coolant Leaks…2938
Engine Coolant is Discolored…2941
Engine Exhaust is Discolored…2942
Engine Fails Emission Compliance Check…2946
Alternator Light is Illuminated…2950
Engine is Overheating…2951
Air Intake Manifold Temperature too High (Cummins QSB 3.3L Only)…2954
Air Intake Manifold Pressure (Boost) is Below Normal (Cummins QS…2955
Engine Coolant Temperature is Low…2956
Engine Oil Pressure is Low…2957
Radiator Bubble Test…2959
Engine Compression Test (GM and Mazda)…2960
Engine Compression Test (Yanmar Diesel)…2961
Engine Oil Pressure Test…2962
Fuel System Pressure Test (Gasoline Engines Only)…2964
Fuel Injection Nozzle Test (Yanmar Diesel)…2966
Vacuum Leak…2967
Vacuum Leak Detection…2967
Vacuum Leak Repairs…2967
Coolant System Test…2968
Electrical System…2969
Troubleshooting Guidelines and Procedures…2983
Troubleshooting Guidelines…2983
Troubleshooting Procedures…2986
Troubleshooting Procedures, Identification…2986
Troubleshooting Procedures, Location…2986
Troubleshooting Procedures, Structure…2986
Troubleshooting Procedures, Performance…2987
Diagnostic Trouble Codes…2988
Diagnostic Trouble Codes…2988
Wiring Reference Data…3002
Post 2007 Engine Connections…3006
Cummins 4.5L…3006
GM 2.4L (GAS/LPG)…3007
GM 4.3L (GAS/LPG)…3008
Mazda 2.0/2.2L (GAS/LPG)…3009
Yanmar 2.6/3.3L…3010
Harness Assembly Data…3011
Electrical System…3057
General Description…3057
Description…3058
Principles of Operation, Components…3062
Principles Of Operation, System…3070
100-2…3077
100-2…3077
100-3…3077
523859-3…3077
524223-3…3077
524224-3…3077
524225-3…3077
524282-3…3077
523958-3…3077
523959-3…3077
100-4…3085
523859-4…3085
523958-4…3085
523959-4…3085
524223-4…3085
524224-4…3085
524225-4…3085
524282-4…3085
524223-0…3093
524224-0…3093
524225-0…3093
524229-0…3093
524270-0…3093
524276-0…3093
524223-1…3097
524224-1…3097
524225-1…3097
524229-1…3097
524270-1…3097
524276-1…3097
110-3…3101
110-3…3101
110-5…3101
177-3…3101
522231-3…3101
522555-3…3101
522603-3…3101
524235-3…3101
110-4…3109
110-4…3109
177-4…3109
522231-4…3109
522555-4…3109
522603-4…3109
524235-4…3109
110-2…3117
110-2…3117
110-10…3120
522712-3…3125
522713-3…3125
522712-4…3132
522713-4…3132
51-2…3139
51-7…3139
91-2…3147
91-2…3147
522708-3…3151
522710-3…3151
522711-3…3151
522714-3…3151
522708-4…3158
522710-4…3158
522711-4…3158
522714-4…3158
515-0…3165
523780-3…3167
523860-3…3167
524245-3…3167
524275-3…3167
523780-4…3173
523860-4…3173
524245-4…3173
524275-4…3173
677-3…3178
2350-3…3178
522754-3…3178
522755-3…3178
522764-3…3178
522766-3…3178
524230-3…3178
SYMPTOMS WARNING…3178
677-4…3184
2350-4…3184
522754-4…3184
522755-4…3184
522764-4…3184
522766-4…3184
524230-4…3184
676-3…3188
524195-3…3188
524269-3…3188
676-4…3194
524195-4…3194
524269-4…3194
524269-7…3200
524215-3…3202
524215-6…3202
524237-3…3206
524238-3…3206
524240-3…3206
524237-4…3211
524238-4…3211
524240-4…3211
879-3…3216
880-3…3216
881-3…3216
882-3…3216
522772-3…3216
879-4…3220
880-4…3220
881-4…3220
882-4…3220
522772-4…3220
168-0…3224
168-3…3224
521982-3…3227
522760-3…3227
522761-3…3227
522762-3…3227
522128-3…3236
524251-0…3236
524260-0…3236
524260-3…3236
524261-0…3236
524261-3…3236
168-1…3245
168-4…3245
521982-4…3248
522760-4…3248
522761-4…3248
522761-6…3248
522762-4…3248
522128-4…3255
524251-1…3255
524260-1…3255
524260-4…3255
524261-1…3255
524261-4…3255
524260-2…3265
524260-11…3265
524261-2…3265
524261-11…3265
96-3…3269
96-4…3269
522810-4…3273
524213-1…3277
524213-3…3277
524213-4…3277
523920-3…3280
523925-3…3280
523930-3…3280
523977-3…3280
523978-3…3280
523986-3…3280
524284-3…3280
524285-3…3280
523920-4…3286
523925-4…3286
523930-4…3286
523977-4…3286
523978-4…3286
523986-4…3286
524284-4…3286
524285-4…3286
523920-6…3291
523925-6…3291
523930-6…3291
523977-6…3291
523978-6…3291
523986-6…3291
524284-6…3291
524285-6…3291
105-3…3295
105-3…3295
522570-3…3295
105-4…3300
105-4…3300
522570-4…3300
105-5…3304
106-3…3307
106-4…3311
106-0…3315
106-1…3315
106-2…3315
106-14…3315
522739-3…3318
522740-3…3318
522739-5…3323
522740-5…3323
522739-6…3327
522740-6…3327
522735-2…3331
522735-4…3334
522735-5…3337
522735-6…3340
522630-2…3344
522631-2…3344
522632-2…3344
522633-2…3344
522635-3…3344
522636-4…3344
522637-3…3344
522638-4…3344
522606-10…3348
522737-10…3348
651-3…3351
652-3…3351
653-3…3351
654-3…3351
655-3…3351
656-3…3351
522599-3…3351
522600-3…3351
522601-3…3351
522602-3…3351
522721-3…3351
522722-3…3351
522723-3…3351
522724-3…3351
522725-3…3351
522726-3…3351
522599-3…3351
522600-3…3351
522601-3…3351
522602-3…3351
651-5…3359
651-5…3359
652-5…3359
652-5…3359
653-5…3359
653-5…3359
654-5…3359
654-5…3359
655-5…3359
656-5…3359
522721-5…3359
522722-5…3359
522723-5…3359
522724-5…3359
522725-5…3359
522726-5…3359
651-6…3364
652-6…3364
653-6…3364
654-6…3364
655-6…3364
656-6…3364
522599-4…3364
522600-4…3364
522601-4…3364
522602-4…3364
522721-6…3364
522722-6…3364
522723-6…3364
522724-6…3364
522725-6…3364
522726-6…3364
2000-9…3372
2000-12…3372
2000-12…3372
2000-12…3372
2000-12…3372
2000-14…3372
2003-12…3372
2023-12…3372
2039-2…3372
2039-12…3372
2235-12…3372
2236-12…3372
2238-12…3372
521670-12…3372
524258-2…3372
522215-12…3380
522215-14…3380
524236-14…3380
524262-12…3380
524262-14…3380
524263-1…3380
524268-12…3380
628-12…3382
630-12…3382
522690-2…3382
522690-12…3382
522691-2…3382
522691-12…3382
522692-2…3382
522693-12…3382
522694-12…3382
522695-2…3382
522696-2…3382
522697-12…3382
522698-2…3382
522699-2…3382
522700-2…3382
190-2…3384
190-2…3384
190-7…3384
522120-1…3384
522585-2…3384
522752-9…3390
524249-2…3394
524250-2…3394
524264-2…3394
524264-14…3394
524265-2…3394
524271-2…3394
524225-14…3394
628-12…3399
630-12…3399
2660-3…3399
2660-4…3399
2661-3…3399
2661-4…3399
2802-12…3399
523510-12…3399
523511-12…3399
523515-3…3399
523515-4…3399
523519-3…3399
523519-4…3399
2802-12…3401
628-12…3401
630-12…3401
523261-3…3401
523261-4…3401
523257-3…3401
523257-4…3401
523253-3…3401
523253-4…3401
523249-3…3401
523249-4…3401
522780-3…3403
522781-3…3403
522780-4…3407
522781-4…3407
522780-2…3410
522781-2…3410
111-1…3413
524252-2…3417
524253-14…3419
524255-2…3420
108-0…3421
108-1…3421
522655-0…3424
522655-1…3424
522660-0…3424
522660-1…3424
524212-2…3428
524211-2…3428
524210-2…3428
524209-2…3428
524208-2…3428
524207-2…3428
524206-2…3428
524205-2…3428
524204-2…3428
524203-2…3428
524202-2…3428
524201-2…3428
524200-2…3428
524199-2…3428
524198-2…3428
524197-2…3428
522800-13…3430
522801-13…3432
522130-0…3433
522131-0…3433
522132-0…3433
522133-0…3433
522134-0…3433
522130-1…3437
522131-1…3437
522132-1…3437
522133-1…3437
522134-1…3437
522130-3…3442
522131-3…3442
522132-3…3442
522133-3…3442
522134-3…3442
522130-4…3447
522131-4…3447
522132-4…3447
522133-4…3447
522134-4…3447
522135-0…3451
522137-0…3451
522138-0…3451
522135-1…3455
522137-1…3455
522138-1…3455
522135-3…3459
522137-3…3459
522138-3…3459
522135-4…3463
522137-4…3463
522138-4…3463
522155-2…3467
522157-2…3467
522122-0…3474
522124-0…3474
522125-0…3474
522126-0…3474
522127-0…3474
522122-1…3478
522124-1…3478
522125-1…3478
522126-1…3478
522127-1…3478
522122-6…3482
522124-6…3482
522125-6…3482
522126-6…3482
522127-6…3482
522122-8…3487
522124-8…3487
522125-8…3487
522126-8…3487
522127-8…3487
522129-3…3491
522129-4…3491
522197-0…3493
522198-0…3493
522199-0…3493
522200-0…3493
522201-0…3493
522197-1…3496
522198-1…3496
522199-1…3496
522200-1…3496
522201-1…3496
522197-6…3497
522198-6…3497
522199-6…3497
522200-6…3497
522201-6…3497
522197-7…3498
522198-7…3498
522199-7…3498
522200-7…3498
522201-7…3498
522197-8…3499
522198-8…3499
522199-8…3499
522200-8…3499
522201-8…3499
522197-14…3501
522198-14…3501
522199-14…3501
522200-14…3501
522201-14…3501
522197-27…3502
522198-27…3502
522199-27…3502
522200-27…3502
522201-27…3502
2039-2…3505
522540-3…3508
522540-4…3512
522604-3…3517
522604-4…3521
522604-5…3525
522697-12…3530
190-2…3531
190-4…3531
190-8…3531
522752-2…3531
522752-4…3531
522752-5…3537
522598-3…3540
522598-4…3544
522592-0…3548
522592-1…3550
522593-12…3552
522594-12…3556
522595-12…3556
522596-12…3556
522597-12…3556
522614-7…3559
522616-8…3559
522617-5…3559
524226-3…3560
524226-4…3562
524239…3564
524241…3564
524246…3564
524267…3564
524248…3564
524746-2…3567
Engine Continues to Run When Engine Cover is Raised…3569
Engine Stops or Fails to Start…3571
Electrical Functions Do Not Operate…3573
Electrical Function Does Not Turn Off…3578
Electro-Hydraulics Do Not Function With Armrest Down …3584
Electro-Hydraulics Can Still Function With Armrest Raised…3587
Vehicle Does Not Power On…3590
Heater Fan Does Not Operate Properly…3595
Heater Airflow Does Not Reach Desired Temperature…3598
Heater Output Has Insufficient Airflow…3599
Circulating (Accessory) Fan Inoperative…3600
Dome Light Inoperative…3603
Horn Failure…3606
Drive Train…3609
Mechanical Overview…3613
Engine…3613
Description…3613
Torque Converter…3613
Description…3613
Stator…3614
Turbine…3614
Pump PTO…3615
Chain Drive PTO…3615
Spur Gear PTO…3616
Transmission…3617
Description…3617
1.0-5.5 Ton Lift Truck Transmissions…3620
Description…3620
Single-Speed…3620
Two-Speed…3621
Clutch Pack…3622
Power Flow…3624
Single-Speed…3624
Two-Speed…3625
Transmission Hydraulic Schematic…3627
Transmission Oil Flow…3628
Control Valve Oil Flow…3628
6.0-7.0 Ton Lift Truck Transmissions…3630
Description…3630
Two-Speed…3630
Three-Speed…3630
Clutch Pack…3632
Input Shaft and Range Clutches…3632
Directional Clutches…3632
Output Section…3633
Power Flow…3634
Two-Speed and Three-Speed…3634
Transmission Hydraulic Schematic…3638
Two-Speed…3638
Three-Speed…3639
Transmission Control System Overview…3641
Transmission Control System…3641
Transmission Control Software…3644
Transmission Control Modes…3644
Neutral…3644
Gear Engagement Control…3644
Basic Powershift Gear Engagement Mode…3644
DuraMatch™ and Electronic Extended Features Gear Engagement Mo…3644
Normal Forward or Reverse…3644
Basic Powershift…3644
DuraMatch™ and Electronic Extended Features Transmission…3644
Auto-Shift…3644
1st Gear Lock…3645
Inching…3645
Basic Powershift Inching Mode…3645
DuraMatch™ Inching Mode…3645
Electronic Extended Features Inching Mode…3645
Inch/Brake Overlap Adjustment…3645
Brake Wear Compensation…3645
Auto Decel…3646
Controlled Power Reversal…3646
Basic Multi-Speed…3646
Electronic Extended Features…3646
Controlled Creep…3646
Basic Powershift…3646
DuraMatch™ and Electronic Extended Features…3647
Controlled Roll Back…3647
DuraMatch™ …3647
Electronic Extended Features…3647
Travel Speed Limit (Optional)…3647
Extended Drawbar Pull ( Electronic Extended Features Multi-Speed…3647
Auto-Speed Hydraulics ( Electronic Extended Features Transmissio…3647
Throttle Response Management ( Electronic Extended Features Tran…3648
Steady Travel Speed…3648
Transmission Control Hardware…3648
Control Valve and Sensors…3648
Description…3648
Principles of Operation…3650
Transmission Proportional Valve…3651
Description…3651
Neutral…3651
Proportional Control…3651
MONOTROL® Pedal…3652
Description…3652
Principles of Operation…3652
Directional Control Lever…3652
Principles of Operation…3652
Driveshaft, Differential, Drive Axle, and Brakes (Dry Brake Only…3653
Driveshaft…3653
Differential and Drive Axle…3653
Brake System…3655
Description…3655
Service Brakes…3655
Master Cylinder…3655
Brake Position Sensor…3656
Parking Brake…3656
Driveshaft, Differential, Drive Axle, and Brakes (Wet Brake Only…3656
Driveshaft…3656
Differential…3657
Brake System…3659
Description…3659
Service Brakes, 2.0-3.5 Ton Only…3659
Service Brakes, 4.0-7.0 Ton…3661
Brake Adjustment and Service…3661
Parking Brake…3661
Overheating Brakes (Dry Brake Axle Only)…3665
Overheating Brakes (Wet Brake Axle Only)…3667
Poor Brake Performance (Dry Brake Axle Only)…3670
Poor Brake Performance (Wet Brake Axle Only)…3673
Brakes Make Too Much Noise (Dry Brake Axle Only)…3675
Brakes Pull To One Side (Dry Brake Axle Only)…3676
Parking Brake Will Not Release…3679
Parking Brake Will Not Hold Lift Truck (Dry Brake Axle Only)…3680
Parking Brake Will Not Hold Lift Truck (Wet Brake Axle Only)…3681
Abnormal Drive Axle Noise…3682
Discolored Drive Axle Oil…3685
Lift Truck Does Not Move (Drive Axle)…3687
Abnormal Transmission Noise…3690
Bubbles or Foaming In Transmission Dipstick Tube…3692
Inching Operation Is Not Smooth or Chatters…3694
Lift Truck Does Not Move In One or Both Directions (Transmission…3696
Loss of Power/Drivetrain Performance…3699
Transmission Is Too Hot…3702
Transmission Will Not Shift To Forward High Range…3705
Transmission Warmup Procedure…3707
Transmission Pressure Test…3707
Transmission Charge Pump Pressure Test…3709
Clutch Pack Pressure Test (Proportional Solenoid Valves)…3709
Torque Converter Pressure Test…3710
Lubrication Pressure Test…3710
Transmission Clutch Drag Test (1.0-5.5 Ton Trucks Only)…3711
Torque Converter Stall Test…3711
Hydraulic Systems…3715
Main Hydraulic System…3719
Description…3719
Principles of Operation…3722
Hydraulic Schematics…3723
Manual Control Valve Schematics…3723
Electro-Hydraulic Control Valve Schematics…3728
Manual Hydraulic Control Valve…3732
Description…3732
Principles of Operation…3734
Lift Section…3734
Lift Operation…3734
Lower Operation…3734
Tilt Section…3735
Tilt Backward…3735
Tilt Forward…3735
Auxiliary Section…3737
Anti-stall Feature…3738
Relief Valves…3738
Main Relief Valve…3738
Secondary Relief Valve…3738
Electro-Hydraulic Control Valve…3739
Description…3739
Principles of Operation…3740
Inlet Pressure Compensator/Unloader…3740
Lift/Lower EHPVs…3742
EHPV Operation…3743
Tilt and Auxiliary Spool Functions…3744
Tilt Forward Function…3746
Main Relief Valve …3747
Secondary Relief Valve…3747
Secondary Function Anti-stall Valve…3748
Emergency Lowering Valve…3749
Steering System…3749
Component Locations…3749
Description…3749
Steering Axle Assembly…3749
Steering Control Unit…3749
Steering Schematic…3751
Principles of Operation…3752
Steering Control Unit…3752
Actuation Functions With Armrest Up (E-Valve)…3753
Cycle Times Too Fast – Fast Actuation (E-Valve)…3754
Jump/Delay In Lift or Lower Activation After Moving Joystick or …3756
Jump/Delay In Secondary Function Actuation After Moving Joystick…3759
Jump/Delay In Tilt Forward Actuation (E-Valve)…3761
Forks Drop Slightly Before Lifting (E-Valve)…3763
Forks Lower Without Command (E-Valve)…3764
Forks Raise or Actuate Without Command (E-Valve)…3766
Forks Tilt Forward Without Command (E-Valve)…3768
Intermittent Activation (E-Valve) While Commanding Function…3770
Lift/Lower Function Maximum Speed Too Slow (E-Valve)…3772
Lift Function Will Not Move With Joystick or MLM Movement (E-Val…3775
Lift/Lower Continues To Move For Awhile After Joystick or MLM Is…3779
Lift/Lower/Secondary Function Suddenly Jumps In Middle of Stroke…3780
Lower Function Will Not Move With Joystick or MLM Movement (E-Va…3781
Poor Metering on Lift or Lower Functions (E-Valve)…3783
Secondary Function Continues to Move for Awhile After Joystick o…3786
Secondary Function Exhibits Slight Movement in Opposite Directio…3787
Secondary Function Maximum Speed Too Slow (E-Valve)…3788
Secondary Function or Tilt Back Moves Without Command (E-Valve)…3791
Secondary Function and Tilt Back Will Not Move With Joystick or …3793
Tilt Forward Function Continues to Move for Awhile When Joystick…3797
Tilt Forward Will Not Move Upon Joystick or MLM Movement (E-Valv…3798
Too Much Joystick or MLM Movement (Deadband) to Start Function M…3800
Wrong Actuation Operates or Actuation is Backward (E-Valve)…3801
Actuation Exhibits Slight Movement in Opposite Direction Before …3802
Auxiliary Function is Slow or Does Not Function (Manual Valve)…3803
Cycle Times Too Fast – Fast Actuation (Manual Valve)…3805
Function Continues to Activate After Returning to Neutral…3806
Lift Function Is Slow or Does Not Function (Manual Valve)…3807
Tilt Back Function Will Not Operate (Manual Valve)…3809
Tilt Forward Functions When Spool is Activated Forward With Engi…3810
Tilt Forward Will Not Function When Activated (Manual Valve)…3811
Abnormal Steer Axle Noise…3812
Abnormal Steering Wheel Vibration…3814
Back Lash/Kick Back in Steering Wheel…3815
No Steering (All Other Hydraulic Functions OK)…3817
Steering Is Slow or Difficult…3819
Steering Operation Is Not Smooth…3821
Steering Wheel End Lock Position Cannot Be Felt by Operator…3823
Steering Wheel Turns By Itself or Does Not Return To Neutral…3824
Steering Wheel Turns the Tires in the Wrong Direction…3825
Abnormal Hydraulic Noise and/or Vibration…3826
Abnormal Smell/Discoloration/Foaming of Oil…3829
Actuations Do Not Act Simultaneously…3830
Oil Leaking/Component Life Too Short…3831
Hydraulic Warmup Procedure…3835
Main Relief Valve Test and Adjustment…3836
Secondary Relief Valve Test and Adjustment…3838
Hydraulic Pump Flow Test…3840
Main Control Valve LS Leakage Test (E-Valve)…3842
Main Control Valve Unloader Margin Test…3843
Electro-Hydraulic Poppet Valve (EHPV) Leakage Test…3844
PPRV Pilot Pressure Test…3847
Steering Relief Pressure Test and Adjustment…3848
Steering Control Unit LS Pressure Test…3849
Lift Cylinder Leakage Test…3851
Tilt Cylinder Leakage Test…3852
Steering Cylinder Leakage Test…3853
Operators Station…3855
Operator Station General Description and Principles of Operation…3857
General Description and Location…3857
Display Switch Cluster (DSC)…3859
Detailed Description…3859
Control Inputs, Right Side…3860
Right Indicator and Warning Group…3862
LCD Display…3863
Left Indicator and Warning Group…3864
Control Inputs, Left Side (Cab Option Only)…3865
Transmission Control and Braking…3866
Description…3866
Vehicle System Manager (VSM)…3867
Display Switch Cluster…3867
Interlock and Switching Features…3867
MONOTROL® Directional Control…3867
Inch Brake/Service Brake Pedal…3867
Parking Brake…3868
Programming – Menus…3868
Menus…3868
Main Menu…3871
Save and Exit or Exit Without Saving…3871
Back One Level…3871
Hourmeters…3871
View Versions…3872
Passwords…3872
Diagnostics…3872
Setup Travel and Braking…3872
Setup Hydraulics…3872
Setup Display…3872
Setup General Items…3872
Calibrations…3872
Manual Hydraulic Control Levers…3873
General Description…3873
System Components…3873
Lift/Lower…3873
Tilt…3873
Auxiliary 1…3873
Auxiliary 2…3873
E-Hydraulic System Interface…3874
General Description…3874
System Components…3874
E-Hydraulic Control Input Device…3874
Joystick…3874
Lift/Lower…3875
Tilt…3875
Auxiliary 1…3875
Auxiliary 2…3875
Push Button…3875
Mini Lever Module (MLM)…3876
Lever 1…3876
Lever 2…3876
Lever 3…3877
Lever 4…3877
System Modes…3877
Hydraulic Interlock Mode…3877
Fault Mode…3877
Engine Off Mode…3877
Normal Operation…3877
Normal Operation Mode…3877
Lifting Control…3877
Lowering Control…3878
Tilt Control (Forward and Backward)…3878
Auxiliary Control…3878
Lighting Control…3878
Description…3878
Front Work Lights…3881
Front Marker Lights (if equipped)…3881
Front/Rear Turn Signal Lights…3881
Rear Tail/Marker Lights…3881
Rear Work Light…3881
Rear Backup Lights…3881
Rear Stop Lights…3881
Strobe Light(s)…3881
Spot Light (if equipped)…3881
Cab…3881
Description…3881
Component Descriptions…3883
Cab Heating System…3883
Lighting Control System…3883
Wiper/Washer System…3883
Cab Systems Operation…3884
Front End (Mast) and Chassis…3887
Front End, Mast…3889
Description…3889
Carriages…3889
Description…3889
Principles of Operation…3890
Integral Sideshift Carriage…3890
Mast Mounts…3892
Description…3892
Principles of Operation…3892
Two-Stage Limited Free-Lift (LFL) Mast…3894
Description…3894
Principles of Operation…3895
Two-Stage Full Free-Lift (FFL) Mast…3896
Description…3896
Principles of Operation…3897
Three-Stage Full Free-Lift (FFL) Mast…3898
Description…3898
Principles of Operation…3898
Four-Stage Full Free-Lift (FFL) Mast…3900
Description…3900
Principles of Operation…3901
Cylinder Cushion During Lifting Sequence…3903
Description…3903
Principles of Operation…3903
Cylinder Cushion During Lowering Sequence…3904
Description…3904
Principles of Operation…3904
Tilt and Sideshift Cylinders…3904
Description…3904
Tilt Cylinder…3904
Sideshift Cylinder…3904
Lowering Control Valves…3905
Description…3905
Principles of Operation…3905
Chassis…3907
Description…3907
Abnormal Channel Wear…3909
Abnormal Hose Wear…3911
Abnormal Mast Noise…3913
Body Panels Making Noise…3917
External Leakage From Free-Lift or Main Lift Cylinders…3918
FFL Mast Banging During Phasing…3919
High Tire Wear – Drive Axle…3921
High Tire Wear – Steer Axle…3923
Hoses Not Tracking Correctly…3925
Integral Sideshift Moving Too Fast…3926
Integral Sideshift Not Moving or Slow…3927
LP Tank Bracket Disengages…3930
LP Tank Rattles and Does Not Stay Latched…3931
Mast is Loose…3932
Mast Lift Chains Are Loose…3934
Mast or Carriage Binding…3935
Mast/Carriage Bounces or is Spongy…3937
Misphasing of Full Free-Lift Mast…3938
Overhead Guard Loose or Damaged…3940
Racking During Lift…3941
Racking During Tilt…3943
Truck Feels Unstable…3944
Truck Wanders, Does Not Track Straight or Steer Well…3946
Wheels Appear Tipped or Misaligned…3948
Wheels Spinning On Uneven Floors…3950
Wheel Studs Breaking…3951
Supplementary Data…3953
Abbreviations and Acronyms…3955
Special Tools List…3963
Fault Mode Indicator (FMI) Reference List…3969
TSP Reference Tables…3971
tables…2695
Table 9020-10-1. IAT Ambient Temperature…2786
Table 9020-40-1. Test Specifications…2959
Table 9020-40-2. Test Specifications…2960
Table 9020-40-3. Service Tools…2960
Table 9020-40-4. Test Specifications…2961
Table 9020-40-5. Service Tools…2961
Table 9020-40-6. Test Specifications…2962
Table 9020-40-7. Service Tools…2963
Table 9020-40-8. Test Specifications – Mazda…2964
Table 9020-40-9. Test Specifications – GM…2964
Table 9020-40-10. Service Tools…2964
Table 9020-40-11. Test Specifications…2966
Table 9020-40-12. Service Tools…2966
Table 9020-40-13. Test Specifications…2968
Table 9020-40-14. Service Tools…2968
Table 9030-03-1. Cummins QSB 3.3L Fault Codes…2999
Table 9030-03-2. Circuit Group Identification…3002
Table 9030-03-3. Hyster Wiring Color Codes…3003
Table 9040-10-1. Two-Speed Transmission Clutch Pack Solenoid Val…3639
Table 9040-10-2. Three-Speed Transmission Electronic Proportiona…3640
Table 9040-10-3. Transmission Control Mode…3642
Table 9040-40-1. Test Specifications…3707
Table 9040-40-2. Service Tools…3707
Table 9040-40-3. Service Tools…3707
Table 9040-40-4. Test Specifications…3709
Table 9040-40-5. Test Specifications…3709
Table 9040-40-6. Test Specifications…3710
Table 9040-40-7. Test Specifications…3710
Table 9040-40-8. Test Specifications…3711
Table 9040-40-9. Service Tools…3711
Table 9040-40-10. Stall Speeds…3712
Table 9050-10-1. Standby Pressure Table…3741
Table 9050-40-1. Test Specifications…3835
Table 9050-40-2. Service Tools…3835
Table 9050-40-3. Test Specifications…3836
Table 9050-40-4. Service Tools…3836
Table 9050-40-5. Test Specifications…3838
Table 9050-40-6. Service Tools…3838
Table 9050-40-7. Test Specifications…3840
Table 9050-40-8. Service Tools…3841
Table 9050-40-9. Test Specifications…3842
Table 9050-40-10. Test Specifications…3843
Table 9050-40-11. Service Tools…3843
Table 9050-40-12. Test Specifications…3844
Table 9050-40-13. Service Tools…3844
Table 9050-40-14. Test Specifications…3847
Table 9050-40-15. Service Tools…3847
Table 9050-40-16. Test Specifications…3848
Table 9050-40-17. Service Tools…3848
Table 9050-40-18. Test Specifications…3849
Table 9050-40-19. Service Tools…3850
Table 9050-40-20. Test Specifications…3851
Table 9050-40-21. Service Tools…3851
Table 9050-40-22. Test Specifications…3852
Table 9050-40-23. Service Tools…3852
Table 9050-40-24. Test Specifications…3853
Table 9050-40-25. Service Tools…3853
Table 9080-50-1. Abbreviations and Acronyms…3955
Table 9080-60-1. Special Tools…3963
Table 9080-70-1. FMI…3969
Table 9080-80-1. Resistor-Temperature Characteristics …3971
1580502-0100SRM1120-(01-2007)-US-EN…3975
toc…3975
Frame…3975
Safety Precautions Maintenance and Repair…3976
General…3979
Description…3980
Hood, Seat, and Side Covers Replacement…3980
Remove…3980
Install…3985
LPG Tank and Bracket Replacement…3987
Remove…3987
LPG Tank…3987
LPG Bracket…3990
Install…3990
LPG Bracket…3990
LPG Tank…3991
Counterweight Replacement…3992
Remove…3992
Install…3993
Tow Pin, Remove and Install…3994
Overhead Guard Replacement…3994
Remove and Install…3994
LED Tail, Backup, and Brake Lights, Replace…3995
Operator Restraint System Replacement…3996
Description…3996
Automatic Locking Retractor (ALR)…3996
Emergency Locking Retractor (ELR)…3996
Engine Replacement…3997
Remove Engine Only…3997
Remove Engine and Transmission…4001
Install Engine Only…4001
Install Engine and Transmission…4002
Throttle Pedal and Cable Adjustment…4003
Mazda Gas/LPG Engines With Basic Power Shift Transmission and Ma…4003
Mazda Gasoline Engine With Electronic Transmission…4006
Throttle Pedal Stop Adjustment, Mazda 2007 Emission Compliant En…4007
Yanmar Diesel Engine With Basic Power Shift Transmission…4007
Yanmar Diesel Engine With Electronic Throttle…4007
Exhaust System Repair…4009
Lift Trucks With Counterweight Exhaust System…4009
Mazda and GM Gas and LPG Engines…4009
Remove and Disassemble…4009
Inspect…4009
Assemble and Install…4011
Yanmar Diesel Engine…4013
Remove and Disassemble…4013
Inspect…4013
Assemble and Install…4013
Lift Trucks With Overhead Exhaust System…4015
Yanmar Diesel Engine…4015
Remove and Disassemble…4015
Inspect…4015
Assemble and Install…4016
Mazda Gas and LPG Engines…4018
Remove and Disassemble…4018
Inspect…4018
Assemble and Install…4018
Cooling System…4022
Description…4022
Fuel and Hydraulic Tanks Repair…4022
Inspect…4022
Clean…4022
Steam Method of Cleaning…4022
Chemical Solution Method of Cleaning…4023
Additional Preparations for Repair…4023
Small Leaks, Repair…4024
Large Leaks, Repair…4024
Preparations for Use After Repair…4024
Safety Labels…4024
tables…3975
Table 1. Weight of Counterweights, Lift Truck Models S2.0-3.5FT …3993
Table 2. Weight of Counterweights, Lift Truck Models S30FT, S35F…3993
Table 3. Weight of Counterweights, Lift Truck Models H1.6FT, H1…3993
Table 4. Weight of Counterweights, Lift Truck Models H2.0-3.5FT …3993
1580504-0600SRM1122-(12-2006)-US-EN…4029
toc…4029
Mazda Engine…4029
Safety Precautions Maintenance and Repair…4030
General…4033
Serial Number…4033
Engine Removal and Installation…4033
Cylinder Head, Camshaft, and Valve Mechanism Repair…4034
Remove…4034
Clean…4036
Inspect and Repair…4036
Cylinder Head…4036
Rocker Shaft Assembly…4036
Camshaft…4036
Valve Guides…4038
Valve Seats…4038
Valves…4038
Valve Springs…4039
Install…4039
Crankshaft and Main Bearings Repair…4043
Remove…4043
Inspect and Repair…4044
Crankshaft…4044
Main Bearings…4044
Install…4045
Pistons and Connecting Rods Repair…4046
Remove and Disassemble…4046
Clean…4046
Inspect and Repair…4046
Pistons…4046
Piston Rings…4046
Connecting Rods and Bearings…4047
Assemble and Install…4047
Cylinder Block Repair…4049
Oil Pump Repair…4049
Remove…4049
Disassemble…4051
Clean…4051
Inspect…4051
Assemble…4052
Install…4052
Cooling System Repair…4054
Thermostat…4054
Replace…4054
Fan Assembly…4054
Remove and Disassemble…4054
Assemble and Install…4054
Water Pump…4055
Remove…4055
Install…4056
Flywheel and Ring Gear Repair…4056
Remove…4056
Install…4056
Valve Adjustment…4057
Compression Pressure Check…4058
Engine Timing Adjustment…4059
Engine Specifications…4059
Engine Data…4059
Engine Speeds…4059
2007 Emission Compliant Engines…4059
All Engines Except 2007 Emission Compliant Engines…4060
Thermostat…4060
Cylinder Head…4060
Valve Mechanism…4060
Camshaft…4061
Crankshaft…4061
Connecting Rods…4062
Cylinder Block…4062
Pistons…4062
Oil Pump…4063
Torque Specifications…4063
tables…4029
Table 1. Pressure Specifications…4058
1580505-0700SRM1123-(04-2008)-US-EN…4067
toc…4067
Cooling System…4067
Safety Precautions Maintenance and Repair…4068
General…4071
Cooling System Checks…4071
Exhaust Leaks Into Cooling System…4071
Water Flow Restrictions in Radiator…4071
Radiator Hoses…4071
Water Pump…4071
Flushing the Cooling System…4072
Cooling System, Clean…4072
Radiator Replacement…4073
Radiator, Remove for Lift Trucks Models S30FT, S35FT, S40FTS (E0…4073
Radiator, Remove for Lift Truck Models S6.0FT, S7.0FT (S135FT, S…4081
Radiator, Remove for Lift Truck Models H6.0FT, H7.0FT (H135FT, H…4082
Radiator, Install for Lift Truck Models S30FT, S35FT, S40FTS (E0…4084
Radiator, Install for Lift Truck Models S6.0FT, S7.0FT (S135FT, …4086
Radiator, Install for Lift Truck Models H6.0FT, H7.0FT (H135FT, …4088
Fan Assembly Replacement…4092
Fan Removal…4092
Inspect…4096
Fan Installation…4098
1580507-0900SRM1125-(05-2005)-US-EN…4103
toc…4103
LPG Fuel System…4103
Safety Precautions Maintenance and Repair…4104
General…4107
Hoses Replacement…4107
LPG Tank Replacement…4107
Remove…4107
Install…4107
Fuel Filter…4109
Remove…4109
Clean and Inspect…4110
Install…4111
Relief Valve Replacement…4112
Remove and Install…4112
Carburetor Repair…4112
Remove…4112
Disassemble…4112
Clean…4114
Assemble…4114
Install…4114
Fuel Injector Repair…4115
Remove…4115
Clean and Inspect…4115
Install…4115
Governor Repair…4115
Remove…4115
Install…4115
Regulator Repair…4116
Remove…4116
Install…4117
Control System…4117
Engine Control Unit (ECU)…4117
Remove…4117
Install…4117
Engine Coolant Temperature (ECT) Sensor…4118
Remove…4118
Install…4118
Camshaft Position (CMP) Sensor…4118
Voltage Check…4118
Intake Air Temperature (IAT) Sensor…4119
Remove…4119
Install…4119
Manifold Absolute Pressure (MAP) Sensor…4120
Remove…4120
Install…4120
Oxygen Sensor…4120
Remove…4120
Install…4120
Throttle Position (TP) Sensor…4121
Remove…4121
Install…4121
1580509-0900SRM1127-(05-2005)-US-EN…4125
toc…4125
Gasoline Fuel System…4125
Safety Precautions Maintenance and Repair…4126
General…4129
Abbreviations…4129
Engine Tune-up…4129
Engine Tune-Up Preparation…4129
Idle Speed Adjustment…4129
Idle-Up Speed Check…4129
Intake-Air System…4131
Intake-Air System Manifold Vacuum Check…4131
Throttle Body…4132
Remove…4132
Install…4132
Electronic Governor…4132
Remove…4132
Install…4132
Intake-Air Control (IAC) Valve…4132
Remove…4132
Install…4134
Intake Manifold…4134
Remove…4134
Install…4134
Fuel System…4135
Before Repair Procedure…4135
Fuel Line Safety Procedure…4135
After Repair Procedure…4135
Fuel Hose, Install…4135
Fuel Leakage Check…4136
Fuel Line Pressure Check…4136
Fuel Injector…4137
Remove…4137
Install…4137
Pressure Regulator…4138
Remove…4138
Install…4139
Exhaust System…4140
Exhaust System, Inspect…4140
Three-Way Catalytic (TWC) Converter…4140
Remove and Install…4140
Exhaust Manifold…4140
Remove…4140
Install…4140
Positive Crankcase Ventilation (PCV) Valve…4142
Remove…4142
Inspect…4142
Install…4142
Control System…4142
Engine Control Unit (ECU)…4142
Remove…4142
Install…4144
Intake Air Temperature (IAT) Sensor…4145
Remove…4145
Install…4145
Mass Air Flow (MAF) Sensor…4145
Remove…4145
Install…4145
Throttle Position (TP) Sensor…4146
TP Sensor, Adjust…4146
Remove…4147
Install…4147
Engine Coolant Temperature (ECT) Sensor…4147
Remove…4147
Install…4148
Camshaft Position (CMP) Sensor…4148
Voltage Check…4148
Oxygen Sensor…4148
Remove…4148
Install…4148
Manifold Absolute Pressure (MAP)/Boost Sensor…4149
Remove…4149
Install…4149
Technical Data…4150
tables…4125
Table 1. PCV Valve Specifications…4142
Table 2. Closed Throttle Position Specifications…4147
Table 3. Gasoline Fuel Systems Technical Data…4150
1580510-1300SRM1129-(07-2008)-US-EN…4153
toc…4153
Powershift Transmission…4153
Safety Precautions Maintenance and Repair…4154
General…4157
Serial Number…4157
Charge Pump Repair…4158
Remove…4158
Inspect…4158
Install…4158
Torque Converter Replace…4159
Remove…4159
Install…4163
Front Cover Housing and Chain Drive Repair…4169
Remove…4169
Clean…4176
Inspect…4176
Install…4176
Clutch Packs Repair…4182
Remove and Disassemble…4182
Transmission, Remove and Disassemble…4182
Clutch Assemblies, Remove and Disassemble…4193
Clean…4199
Inspect…4199
Assemble and Install…4200
Clutch Assemblies, Assemble and Install…4200
Transmission, Assemble and Install…4208
Control Valve Repair…4213
Remove and Disassemble…4213
Clean…4214
Inspect…4214
Assemble and Install…4216
MONOTROL® Pedal Repair…4217
Remove and Disassemble…4217
Assemble and Install…4220
Direction Control Lever…4221
Remove…4221
Install…4221
1580512-1600SRM1133-(07-2008)-US-EN…4225
toc…4225
Steering Axle…4225
Safety Precautions Maintenance and Repair…4226
General…4229
Steering Axle Assembly Repair…4230
Remove…4230
Disassemble…4231
Clean…4231
Inspect…4231
Assemble…4238
Install…4243
Spindles, Bearings, and Tie Rods Repair…4244
Spindles and Bearings…4244
S2.0-3.5FT (S40-70FT, S55FTS) (F187), S4.0, 4.5, 5.5FT, S5.5FTS,…4244
Remove…4244
Disassemble…4245
Clean…4246
Inspect…4246
Assemble…4246
Install…4247
Spindles and Bearings…4250
S30FT, S35FT, S40FTS (E010), H1.6FT, H1.8FT, H2.0FTS (H30FT, H35…4250
Remove and Disassemble…4250
Assemble and Install…4250
Tie Rods…4251
S2.0-3.5FT (S40-70FT, S55FTS) (F187), and S4.0, 4.5, 5.5FT, S5.5…4251
Remove…4251
Install…4252
Tie Rods…4253
S30FT, S35FT, S40FTS (E010), H1.6FT, H1.8FT, H2.0FTS (H30FT, H35…4253
Remove…4253
Install…4253
Steering Cylinder Repair…4256
Remove and Disassemble…4256
Clean and Inspect…4257
Assemble and Install…4257
Torque Specifications…4258
1580513-1800SRM1135-(10-2006)-US-EN…4263
toc…4263
Brake System…4263
Safety Precautions Maintenance and Repair…4264
General…4267
Dry Brake System…4267
Wet Brake System…4267
Service Brakes Repair (Dry Brake)…4268
Remove and Disassemble…4268
Clean…4273
Inspect…4274
Assemble and Install…4274
Adjust…4281
Parking Brake Repair…4282
Remove and Disassemble…4282
Assemble and Install…4282
Adjust…4285
Master Cylinder Repair…4285
Remove (Dry Brake)…4285
Disassemble (Dry Brake)…4286
Clean and Inspect (Dry Brake)…4288
Assemble (Dry Brake)…4288
Bench Bleed Master Cylinder (Dry Brake)…4288
Install and Adjust (Dry Brake)…4288
Remove (Wet Brake)…4289
Disassemble (Wet Brake)…4290
Clean and Inspect (Wet Brake)…4291
Assemble (Wet Brake)…4291
Install and Adjust (Wet Brake)…4291
Service Brakes Adjustment (Dry Brake)…4292
Brake System Air Removal…4293
Using Pressure Bleed System…4293
Using Brake Pedal Pressure…4293
Brake Pedal Adjustment…4294
Free Pedal Adjustment…4295
Torque Specifications…4296
1580514-1900SRM1136-(07-2008)-US-EN…4299
toc…4299
Hydraulic Gear Pump…4299
Safety Precautions Maintenance and Repair…4300
General…4303
Single Gear Pump Assembly Repair…4303
Remove…4303
Disassemble…4304
Clean…4304
Inspect…4304
Assemble…4304
Install…4308
Tandem Gear Pump Assembly…4309
Remove…4309
Disassemble…4311
Clean…4313
Inspect…4313
Assemble…4313
Install…4314
Gear Pump Specifications…4314
Torque Specifications…4318
tables…4299
Table 1. Standard Gear Pump for Lift Truck Models S30FT, S35FT, …4314
Table 2. High Pressure Gear Pump for Lift Truck Models S30FT, S3…4315
Table 3. Standard Gear Pump for Lift Truck Models S4.0, 4.5, 5.5…4316
Table 4. High Pressure Gear Pump for Lift Truck Models S4.0, 4.5…4316
Table 5. Standard Gear Pump for Lift Truck Models S6.0FT, S7.0FT…4317
Table 6. High Pressure Gear Pump for Lift Truck Models S6.0FT, S…4317
1580515-2000SRM1137-(07-2008)-US-EN…4321
toc…4321
Main Control Valve…4321
Safety Precautions Maintenance and Repair…4322
General…4327
Electro-Hydraulic Main Control Valve…4328
Description…4328
Remove…4331
Electro-Hydraulic Control Valve Sections…4335
General…4335
Outlet Control Valve Section…4335
Remove…4335
Disassemble…4335
Clean…4335
Inspect…4335
Assemble…4337
Install…4337
Auxiliary Control Valve Sections…4337
Remove…4337
Disassemble…4339
Clean…4340
Inspect…4340
Assemble…4340
Install…4340
Tilt Control Valve Section…4341
Remove…4341
Disassemble…4341
Clean…4341
Inspect…4344
Assemble…4344
Install…4344
Lift/Lower Control Valve Section…4344
Remove…4344
Disassemble…4344
Clean…4347
Inspect…4347
Assemble…4347
Install…4348
Mid-Inlet Section…4348
Remove…4348
Clean…4349
Inspect…4349
Install…4349
Install…4349
Electro Hydraulic Poppet Valve (EHPV) Pilot Pin Adjustment…4353
Lift Pilot Pin…4353
Lower Pilot Pin…4355
Abnormal/Erroneous EHPV Adjustment…4357
Manual Main Control Valve…4357
Description…4357
Remove…4358
Manual Control Valve Sections…4363
General…4363
Outlet Control Valve Section…4363
Remove…4363
Disassemble…4363
Clean…4365
Inspect…4365
Assemble…4365
Install…4365
Auxiliary Control Valve Sections…4365
Remove…4365
Disassemble…4366
Clean…4366
Inspect…4366
Assemble…4366
Install…4368
Lift/Tilt Control Valve Section…4368
Remove…4368
Disassemble…4368
Clean…4371
Inspect…4371
Assemble…4371
Install…4372
Mid-Inlet Section…4372
Remove…4372
Clean…4373
Inspect…4373
Install…4373
Install…4373
Pressure Relief Valve Check and Adjustment…4377
Primary Relief Valve…4377
Secondary Relief Valve…4378
Steering Control Unit Repair…4381
Steering Control Unit, Remove…4381
Steering Control Unit, Disassemble…4384
Steering Control Unit, Clean…4384
Steering Control Unit, Inspect…4384
Steering Control Unit, Assemble…4386
Relief Valve, Disassemble…4386
Relief Valve, Clean…4387
Relief Valve, Inspect…4387
Relief Valve, Assemble…4387
Steering Control Unit, Install…4387
tables…4321
Table 1. Relief Valve Settings…4378
Table 2. Steering Relief Pressures…4388
1580516-2100SRM1139-(07-2008)-US-EN…4391
toc…4391
Cylinder Repair…4391
Safety Precautions Maintenance and Repair…4392
General…4395
Description…4395
Safety Procedures When Working Near Mast…4396
Tilt Cylinder Repair…4398
Remove…4398
Disassemble…4398
Inspect…4399
Clean…4399
Assemble…4399
Install…4402
Tilt Cylinders, Adjust…4402
Tilt Cylinder Leak Check…4404
Torque Specifications…4405
Piston Rod Nut…4405
Gland…4405
Tilt Cylinder Mounting Capscrew…4406
Tilt Cylinder Rod End Capscrew…4406
Lift Cylinder Repair…4406
Main Lift Cylinders…4406
Remove…4406
Disassemble…4407
Clean…4408
Inspect…4408
Assemble…4408
Install…4409
Two-Stage FFL Left Side Main Lift Cylinder…4410
Disassemble…4410
Clean…4412
Inspect…4412
Assemble…4412
Install…4412
Free-Lift Cylinder…4412
Remove…4412
Disassemble…4415
Clean…4416
Inspect…4416
Assemble…4416
Install…4417
Torque Specifications…4417
Lift Cylinders Leak Check…4418
tables…4391
Table 1. Movement Rates (Maximum) for Tilt Cylinders…4405
1580517-2200SRM1128-(08-2008)-US-EN…4421
toc…4421
Wire Harness Repair…4421
Safety Precautions Maintenance and Repair…4422
General…4427
Deutsch Crimping Tool…4427
How to Strip a Wire for Use With Deutsch Crimping Tool…4427
How to Crimp With the Deutsch Crimping Tool…4428
Calibration Test for the Deutsch Crimping Tool…4429
Deutsch Connectors…4431
DT, DTM, and DTP Series Connectors…4431
Connector Receptacle Replacement…4439
Connector Plug Replacement…4444
Connector Receptacle Pin Replacement…4450
Connector Plug Socket Replacement…4456
HD Series Connectors…4464
Connector Receptacle Replacement…4466
Connector Plug Replacement…4469
Connector Receptacle Pin Replacement…4472
Connector Plug Socket Replacement…4477
Sealing Plugs…4481
Metri-Pack Connectors…4483
Remove and Install…4483
Micro-Pack Connectors…4485
Weather-Pack Connectors…4486
Weather-Pack Terminal Repair…4486
AMPSEAL Crimping Tools…4487
AMP Hand Crimping Tool With Certi-Crimp…4487
Description…4487
Stripping Wire for Use With AMP Hand Crimping Tool…4488
Insulation Crimp Adjustment…4488
Maintenance and Inspection for AMP Hand Crimping Tool…4489
AMP Hand Crimping Tool…4489
Crimp Height Inspection…4489
How to Use AMP Hand Crimping Tool…4490
AMP Pro-Crimper II Tool…4490
Description…4490
Remove and Install Die Set and Locator Assembly…4491
Stripping Wire for Use With AMP PRO-CRIMPER II Tool…4492
Contact Support Adjustment…4492
Crimp Height Adjustment…4493
Maintenance and Inspection Procedures…4493
PRO-CRIMPER II Tool…4493
Crimp Height Inspection…4493
How to Use AMP PRO-CRIMPER II Tool…4494
AMPSEAL Connector Assemblies…4495
Description for Plug Connector Assembly…4495
Seal Plug…4495
Contact Crimping…4496
Contact Removal…4496
Contact Insertion…4498
Description for Plug Connector and Header Assembly…4500
Voltage Reading…4501
Seal Plug…4501
Contact Crimping…4502
Contact Removal…4504
Contact Insertion…4506
AMP Superseal 1.5 Crimping Tools…4508
Mini Mic Receptacle and Tab Contacts…4508
Description…4508
Crimping Conditions and Measurements…4508
Insertion of Rubber Seal on Cable…4510
Correction or Replacement of Parts…4511
AMP Hand Application Tool…4515
Description…4515
Maintenance and Inspection…4515
Crimp Height Inspection…4515
Crimp Height Adjustment…4516
How to Use AMP Hand Application Tool…4516
AMP Pro-Crimper II Tool…4517
Description…4517
Remove and Install Die Set and Locator Assembly…4517
Adjustments…4518
Contact Support…4518
Crimp Height…4518
Inspections and Maintenance…4520
Crimp Height Inspection…4520
Visual Inspection…4520
Maintenance…4520
How to Use Pro-Crimper II Tool…4520
AMP Superseal 1.5 Connector Assemblies…4521
Description…4521
Harness Assembly…4521
Positioning of anti-backout device…4522
Removal of Contacts…4524
Repair and Maintenance…4528
Panel Mount Option…4528
AMP Fastin-Faston Hand Tools…4528
Description – AMP Double Action Hand Tool…4528
Maintenance and Inspection Procedures…4530
Daily Maintenance…4530
Periodic Tool Inspection…4530
Lubrication…4530
Visual Inspection…4530
Crimp Height Inspection…4531
Certi-Crimp Ratchet Inspection…4531
How to Use AMP Double Action Hand Tool…4532
Description – AMP Extraction Tool…4533
Maintenance and Inspection…4533
How to Use AMP Extraction Tool…4534
AMP Fastin-Faston Receptacles and Housings…4535
Description…4535
Wire Repair…4541
Wire Splicing Requirements…4541
Deutsch Jiffy Splice…4542
Assemble…4542
Disassemble…4544
Del-City Crimp-Solder-Shrink Splice…4546
Twisted/Shielded Cable and Leads Repair…4547
Twisted/Shielded Cable Repair…4547
Twisted Leads Repair…4549
Special Tools…4550
tables…4421
Table 1. Wire Strip Length Specifications…4428
Table 2. Wire Size (AWG)…4489
Table 3. Crimp Height…4490
Table 4. Strip Length for PRO-CRIMPER II Tool…4492
Table 5. Crimp Measurement…4493
Table 6. Current Rating…4495
Table 7. Crimp Conditions…4503
Table 8. Wire Strip Lengths…4515
Table 9. Wire Strip Lengths…4516
Table 10. Crimp Height – Dimension …4520
Table 11. Wire Size and Crimp Height…4531
Table 12. Wire Strip Length…4532
Table 13. Wire Strip Length and Crimp Measurements…4537
Table 14. Crimp Pull-Out Test…4540
Table 15. Wire Strip Length Specifications…4541
Table 16. Wire Splice Size…4546
1580518-2200SRM1130-(08-2008)-US-EN…4559
toc…4559
User Interface…4559
Safety Precautions Maintenance and Repair…4560
General…4563
Description…4563
Dash Display Menu Access…4563
Menu Navigation…4564
Standard Display…4564
Main Menu…4564
Passwords Menu…4565
Password Administration…4565
Add Password…4565
Delete Password…4566
Edit Password…4566
Other Password Functions…4567
Operator Passwords – Enable/Disable…4567
Password Time-Out Delay…4568
Passwords – Number Wrong to Disable…4568
Lockout Reset Password…4569
View Password Log…4569
View Versions…4570
VSM Versions…4570
Dash Display Versions…4571
Engine Controller Version…4572
Transmission (Xmsn) Controller Version…4573
Truck Serial Number…4574
Diagnostics…4575
View Fault Log…4575
Set Travel and Braking…4576
Speed Limit…4576
Acceleration Rate…4577
Auto-Deceleration Rate…4577
Set Power Reversal Rate…4578
Set Inching/Brake Overlap…4579
Setup Display Menu…4580
Set Operator Language…4580
Set Units…4581
Set Time Format (12/24 Hour)…4581
Set Daylight Saving Time…4582
Set Time…4584
Set Date Format…4584
Set Date…4584
Setup Hydraulics…4585
Return to Set Tilt Delay/On/Off…4585
Setup General Items…4586
Light Shutdown Time-Out…4586
Impact Sensor – Enable/Disable…4587
Impact Sensor – Soft Impact Settings…4588
Impact Sensor – Hard Impact Settings…4588
Adjust Impact Sensor Settings…4589
Initial Adjustment of Soft and Hard Impact Settings…4591
Readjustment of Soft and Hard Impact Settings…4592
Impact Sensor – Impact Alarm/Shutdown Reset…4592
Impact Sensor – Alarm Time Duration and Deactivation…4593
Impact Sensor – View Impact Event Log…4594
Operator Checklist…4595
Operator Checklist Off-On Mode…4595
Edit Operator Checklist…4595
Set Operator Checklist Expiration…4596
View Checklist Log…4596
Clear Operator Checklist Log…4597
Clear Operator Checklist Fault…4597
Calibrations…4598
Set Tilt Stop Point…4598
Calibrate Loaded Weight…4598
tables…4559
Table 1. Password Screen…4563
Table 2. Exit Options Menu…4564
Table 3. Add Password Menu…4565
Table 4. Delete Password Menu…4566
Table 5. Edit Password Menu…4567
Table 6. Operator Passwords Menu…4567
Table 7. Password Time-Out Delay Menu…4568
Table 8. Passwords – Number Wrong to Disable Menu…4568
Table 9. View Password Log Menu…4569
Table 10. View VSM Versions Menu…4570
Table 11. View Dash Display Versions Menu…4571
Table 12. View Engine Controller Versions Menu…4572
Table 13. View Transmission Controller Versions Menu…4573
Table 14. View Truck Serial Number Menu…4574
Table 15. View Fault Log…4575
Table 16. Speed Limit Menu…4576
Table 17. Acceleration Rate Menu…4577
Table 18. Auto-Decel Menu…4577
Table 19. Power Reversal Menu…4578
Table 20. Inch/Brake Overlap Menu…4579
Table 21. Set Language Menu…4580
Table 22. Set Units Menu…4581
Table 23. Set Time Format Menu…4581
Table 24. Set Daylight Saving Time Menu…4582
Table 25. Set Time Menu…4584
Table 26. Set Date Format Menu…4584
Table 27. Set Date Menu…4584
Table 28. Tilt Delay Menu…4585
Table 29. Light Time-Out Menu…4586
Table 30. Impact Sensor Enable/Disable…4587
Table 31. Soft Impact Settings Menu…4588
Table 32. Hard Impact Settings Menu…4589
Table 33. Impact Sensor Default Settings…4589
Table 34. Recommended Starting Values for Impact Sensor Settings…4591
Table 35. Shutdown Reset Menu…4592
Table 36. Alarm Duration Menu…4593
Table 37. View Event Log Menu…4594
Table 38. Checklist Off-On Mode Menu…4595
Table 39. Edit Checklist Menu…4595
Table 40. Checklist Expiration Menu…4596
Table 41. View Checklist Log Menu…4596
Table 42. Clear Checklist Log Menu…4597
Table 43. Clear Checklist Fault Menu…4597
Table 44. Tilt Stop Point Menu…4598
Table 45. Calibrate Loaded Weight…4598
1580519-2200SRM1131-(08-2008)-US-EN…4601
toc…4601
User Interface…4601
Safety Precautions Maintenance and Repair…4602
General…4605
Description…4605
Dash Display Menu Access…4605
Menu Navigation…4606
Main Menu…4607
Passwords…4607
Adding Passwords…4608
Hourmeters…4609
View Versions…4610
VSM Versions…4610
Dash Display Versions…4611
Engine Controller Version…4612
Transmission (Xmsn) Controller Version…4613
Truck Serial Number…4614
Truck Configuration…4615
Diagnostics…4616
Clear Fault Log…4616
View Fault Log…4617
No-Run Data Display…4618
Engine Accelerator and Throttle Data Display…4619
Engine Speeds and Governor Data Display…4620
Engine Fuel and Emissions Data Display…4622
Engine General Data Display…4625
XMSN/Brake Data Display…4626
Hydraulic Data Display…4628
General Truck Data Display…4630
Set Travel and Braking…4632
Speed Limit…4632
Acceleration Rate…4633
Auto-Deceleration Rate…4633
Set Power Reversal Rate…4634
Set Inching/Brake Overlap…4635
Setup Hydraulics…4636
Lift Maximum Speed…4636
Lower Maximum Speed…4637
Tilt Maximum Speed…4637
Auxiliary Function One, Direction A, Maximum Speed…4639
Auxiliary Function One, Direction B, Maximum Speed…4639
Auxiliary Function Two, Direction A, Maximum Speed…4640
Auxiliary Function Two, Direction B, Maximum Speed…4640
Auxiliary Function Three, Direction A, Maximum Speed…4641
Auxiliary Function Three, Direction B, Maximum Speed…4641
Lift/Lower Ramp Rate…4642
Hydraulic Auxiliary Ramp Rate…4643
Return to Set Tilt Delay/On/Off…4644
Setup Display…4645
Set Service Language…4645
Setup General Items…4646
Motion Alarm Activation Type…4646
Light Shutdown Time-Out…4647
Restore Default Settings…4648
Restore Engine Controller Default Calibration…4648
Impact Sensor – Enable/Disable…4649
Impact Sensor – Soft Impact Settings…4650
Impact Sensor – Hard Impact Settings…4650
Adjust Impact Sensor Settings…4651
Initial Adjustment of Soft and Hard Impact Settings…4653
Readjustment of Soft and Hard Impact Settings…4654
Impact Sensor – Impact Alarm/Shutdown Reset…4654
Impact Sensor – Alarm Time Duration and Deactivation…4655
Impact Sensor – View Impact Event Log…4656
Calibrations…4657
Calibrate Transmission Valve…4659
Set Tilt Stop Point…4659
Calibrate Loaded Weight…4660
Calibrate Travel Speed Sensor…4660
Calibrate Mazda LP and Gas Accelerator Pedal…4661
tables…4601
Table 1. Password Screen…4605
Table 2. Exit Menu…4606
Table 3. Add Password Menu…4608
Table 4. Hourmeters Menu…4609
Table 5. View VSM Versions Menu…4610
Table 6. View Dash Display Versions Menu…4611
Table 7. View Engine Controller Versions Menu…4612
Table 8. View Transmission Controller Versions Menu…4613
Table 9. View Truck Serial Number Menu…4614
Table 10. View Truck Configuration Menu…4615
Table 11. Clear Fault Log…4616
Table 12. View Fault Log…4617
Table 13. No-Run Data Display…4618
Table 14. Engine Accelerator and Throttle Data Display…4619
Table 15. Engine Speeds and Governor Data Display…4621
Table 16. Engine Fuel and Emissions Data Display…4623
Table 17. Engine General Data Display…4625
Table 18. XMSN Brake Data Display…4626
Table 19. Hydraulic Data Display…4628
Table 20. General Truck Data Display…4630
Table 21. Speed Limit Menu…4632
Table 22. Acceleration Rate Menu…4633
Table 23. Auto-Decel Menu…4633
Table 24. Power Reversal Menu…4634
Table 25. Inch/Brake Overlap Menu…4635
Table 26. Lift Speed Menu…4636
Table 27. Lower Speed Menu…4637
Table 28. Tilt Speed Menu…4637
Table 29. Auxiliary Function Speed Menu…4639
Table 30. Auxiliary Function Speed Menu…4639
Table 31. Auxiliary Function Speed Menu…4640
Table 32. Auxiliary Function Speed Menu…4640
Table 33. Auxiliary Function Speed Menu…4641
Table 34. Auxiliary Function Speed Menu…4641
Table 35. Lift/Lower Ramp Rate Menu…4642
Table 36. Hydraulic Auxiliary Ramp Rate Menu…4643
Table 37. Tilt Delay Menu…4644
Table 38. Service Language Menu…4645
Table 39. Alarm Type Menu…4646
Table 40. Light Time-Out Menu…4647
Table 41. Restore Defaults Menu…4648
Table 42. Restore Settings Menu…4648
Table 43. Impact Sensor Enable/Disable…4649
Table 44. Soft Impact Settings Menu…4650
Table 45. Hard Impact Settings Menu…4651
Table 46. Impact Sensor Default Settings…4651
Table 47. Recommended Starting Values for Impact Sensor Settings…4653
Table 48. Shutdown Reset Menu…4654
Table 49. Alarm Duration Menu…4655
Table 50. View Event Log Menu…4656
Table 51. Calibrate Electro-Hydraulic Valve Menu…4658
Table 52. Calibrate Transmission Valve Menu…4659
Table 53. Tilt Stop Point Menu…4659
Table 54. Calibrate Loaded Weight…4660
Table 55. Travel Speed Menu…4660
Table 56. Travel Speed Menu…4661
1580520-2200SRM1142-(09-2008)-US-EN…4665
toc…4665
Electrical System…4665
Safety Precautions Maintenance and Repair…4666
General…4675
Display Switch Cluster…4676
Remove…4676
Install…4678
Direction Control and Turn Signal Levers…4678
Remove…4678
Install…4678
Key Switch…4680
Remove…4680
Install…4680
Display Switch Cluster Panel Bezel and Overlay…4681
Remove…4681
Install…4681
Steering Column Repair…4681
Remove…4681
Disassemble…4681
Assemble…4681
Install…4682
Sensors and Switches…4684
General…4684
Dash and Kick Panel, Remove and Install…4684
Remove…4684
Install…4684
Accelerator Pedal Position Sensor…4686
Remove…4686
Install…4686
Brake Fluid Level Switch…4689
Remove…4689
Install…4689
Service Brake Pedal Position Sensor…4690
Remove…4690
Install…4690
Parking Brake Sensor…4691
Remove…4691
Install…4691
Service Brake Pressure Sensor…4692
Remove…4692
Install…4692
MONOTROL® Sensor Microswitch…4692
Remove…4692
Install…4694
Low Coolant Level Sensor…4694
Remove…4696
Install…4696
Fuel Level Sensor, Gas and Diesel Engines Only…4696
Remove…4696
Install…4696
Armrest Switch…4697
Remove…4697
Install…4697
Seat Sensor (Operator Presence System)…4699
Non-Suspension and Semi-Suspension Seats; All Lift truck Models …4699
Remove…4699
Install…4699
Non-Suspension Seats; Lift Truck Models H6.0FT, H7.0FT (H135FT, …4700
Remove…4700
Install…4700
Full Suspension Seats; All Lift Truck Models…4701
Remove…4701
Install…4701
Hood Shut Off Switch…4701
Remove…4701
Install…4701
Hydraulic Filter Pressure Switch…4705
Remove…4705
Install…4705
Transmission Speed Sensor…4705
Remove…4705
Install…4706
Transmission Pressure Sensors…4706
Remove…4706
Install…4706
Transmission Temperature Sensor…4706
Remove…4706
Install…4707
Engine Speed Sensor…4708
Remove…4708
Install…4708
Intermediate Speed Sensor…4708
Remove…4708
Install…4708
Return to Set Tilt (Tilt Angle) Sensor…4708
Lift Truck Models S30FT, S35FT, S40FTS (E010); H1.6FT, H1.8FT, H…4708
Remove…4708
Install…4709
Lift Truck Models S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024); …4709
Remove…4709
Install…4710
Rear Horn Button Switch…4710
Remove…4710
Install…4710
Impact Sensor…4711
All Lift Truck Models Except H6.0FT, H7.0FT (H135FT, H155FT) (H0…4711
Remove…4711
Install…4711
Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006)…4713
Remove…4713
Install…4714
Load Weight Sensor…4714
Remove…4714
Install…4715
Engine and Fuel Sensors – Mazda 2.0L and 2.2L Gas and LPG Engine…4715
Oxygen Sensor…4715
Remove…4715
Install…4715
Intake Air Temperature (IAT) Sensor…4716
Remove…4716
Install…4716
Manifold Absolute Pressure (MAP)/Boost Sensor…4716
Remove…4716
Install…4716
Throttle Position (TPS) Sensor…4717
Remove…4717
Install…4717
Engine and Fuel Sensors and Switches – Mazda 2.0L and 2.2L LPG E…4717
Oil Pressure Sensor…4717
Remove…4717
Install…4717
Low LPG Pressure Switch…4718
Remove…4718
Install…4718
Air Filter Restriction Switch…4718
Remove…4718
Install…4719
Engine Coolant Temperature (ECT) Sensor…4719
Remove…4719
Install…4719
Engine and Fuel Sensors and Switches- Mazda 2.0L and 2.2L Gas En…4719
Oil Pressure Sensor…4719
Remove…4719
Install…4719
Mass Air Flow (MAF) Sensor…4720
Remove…4720
Install…4720
Air Filter Restriction Switch…4720
Remove…4720
Install…4720
Engine Coolant Temperature (ECT) Sensor…4721
Remove…4721
Install…4721
Engine and Fuel Sensors and Switches – Mazda 2.0L and 2.2L Gas a…4721
Oil Pressure Sensor…4721
Remove…4721
Install…4721
Air Filter Restriction Switch…4722
Remove…4722
Install…4722
CAM Angle Sensor…4723
Voltage Check…4723
Oxygen Sensor…4724
Remove…4724
Install…4724
Engine and Fuel Sensors and Switches – Mazda 2.0L and 2.2L LPG E…4724
Engine Coolant Temperature (ECT) Sensor…4724
Remove…4724
Install…4725
Manifold Absolute Pressure (MAP) Sensor…4726
Remove…4726
Install…4726
Intake Air Temperature (IAT) Sensor…4726
Remove…4726
Install…4726
Fuel Temperature Sensor…4727
Remove…4727
Install…4727
Low LPG Pressure Switch…4728
Remove…4728
Install…4728
Engine and Fuel Sensors and Switches- Mazda 2.0L and 2.2L Gas En…4729
Intake Air Temperature (IAT) Sensor…4729
Remove…4729
Install…4729
Engine Coolant Temperature (ECT) Sensor…4730
Remove…4730
Install…4730
Manifold Absolute Pressure (MAP) Sensor…4731
Remove…4731
Install…4731
Engine and Fuel Sensors and Switches, GM 2.4L and 4.3L Gas and L…4732
Crankshaft Sensor…4732
Remove…4732
Install…4732
Camshaft Position (CMP) Sensor…4733
Remove…4733
Install…4733
Camshaft Position (CMP) Sensor Assembly…4734
Remove…4734
Install…4734
Oil Pressure Sensor…4734
Remove…4734
Install…4734
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) …4735
Remove…4735
Install…4735
Engine Coolant Temperature (ECT) Sensor…4736
Remove…4736
Install…4736
Air Flow Restriction Switch…4736
Remove…4736
Install…4737
Oxygen Sensor…4737
Remove…4737
Install…4740
Engine and Fuel Switches, GM 2.4L and GM 4.3L LPG Trucks Only…4741
Low LPG Pressure Switch…4741
Remove…4741
Install…4741
LPG Pressure Sensor, GM 4.3L Engine Only…4742
Remove…4742
Install…4742
Engine and Fuel Sensors and Switches, Yanmar Diesel Trucks…4742
Air Filter Restriction Switch…4742
Remove…4742
Install…4742
Oil Pressure Sensor…4742
Remove…4742
Install…4742
Engine Speed Sensor…4742
Remove…4742
Install…4742
Engine Coolant Temperature (ECT) Sensor…4744
Remove…4744
Install…4744
Throttle Position Sensor (TPS)…4744
Remove…4744
Install…4744
Fuel/Water Separator Sensor…4745
Remove…4745
Install…4745
Glow Plug Relay…4746
Remove…4746
Install…4748
Engine and Fuel Sensors and Switches, Cummins Diesel Engines…4748
Air Filter Restriction Switch…4748
Remove…4748
Install…4748
Oil Pressure Sensor…4750
Remove…4750
Install…4750
Engine Speed Sensor (Cummins 4.5L Only)…4750
Remove…4750
Install…4750
Engine Coolant Temperature (ECT) Sensor…4751
Remove…4751
Install…4751
Throttle Position Sensor (TPS) (Cummins 4.5L Only)…4751
Remove…4751
Install…4752
Fuel/Water Separator Sensor…4752
Remove…4752
Install…4752
Vehicle System Manager (VSM)…4753
General…4753
VSM Replacement…4753
Remove…4753
Install…4754
Programming a New VSM and/or Display Switch Cluster…4755
General…4755
PC Service Tool Software…4755
Data Transferring…4756
New or Used VSM…4756
New (Blank) Display Switch Cluster…4756
Used (Non-Blank) Display Switch Cluster…4756
Power Distribution Module (PDM) and Component Parts…4757
Remove…4757
PDM as a Unit…4757
Install…4760
PDM as a Unit…4760
Remove and Install…4760
PDM Component Parts…4760
Transmission Control Unit…4761
Remove S6.0FT, S7.0FT, (S135FT,S155FT) (D024, E024) and H6.0FT, …4761
Install S6.0FT, S7.0FT, (S135FT,S155FT) (D024, E024) and H6.0FT,…4762
Battery…4762
Remove…4762
Install…4762
Lights…4762
Work Lights (Front and Rear)…4762
Remove…4762
Install…4762
Strobe Light…4763
Remove…4763
Install…4764
LED Tail, Backup, and Brake Lights…4764
Remove…4764
Install…4764
Electronic-Hydraulic Controls…4766
General…4766
Mini-Lever Replacement…4766
Remove…4766
Clean and Inspect…4767
Install…4767
Push Button Switch Replacement…4768
Remove…4768
Install…4769
Test…4770
Mini-Levers…4770
Full Stroke Test…4770
Function Returns to Neutral Test…4770
Push Button Switch…4770
Mini-Lever Module (MLM)…4771
Remove…4771
Install…4771
tables…4665
Table 1. VSM and Display Switch Cluster Replacement…4757
1580521-2200SRM1143-(05-2005)-US-EN…4775
toc…4775
Electrical System…4775
Safety Precautions Maintenance and Repair…4776
Ignition System…4779
General…4779
Ignition Timing Adjustment, Gasoline and LPG…4779
Spark Plugs Check…4779
Spark Plug Wires Check…4779
Distributor Repair…4782
Remove…4782
Disassemble…4783
Inspect…4783
Assemble…4784
Install…4784
Igniter…4785
Remove…4785
Test…4785
Install…4785
Camshaft Position (CMP) Sensor…4786
Voltage Check…4786
Ignition Coil Check…4787
Primary Coil Winding…4787
Secondary Coil Winding…4787
Starter Repair…4788
General…4788
Remove…4788
No-Load Test…4789
Magnetic Switch Test…4789
Pull-Out Test…4789
Holding Coil Test…4790
Return Test…4790
Pinion Movement Inspection…4790
Install…4790
Alternator Repair…4791
General…4791
Charging System Inspection…4791
Output Current Check…4792
No-Load Adjusted Voltage Check…4792
Remove…4793
Inspect…4793
Rectifier Check…4793
Install…4794
tables…4775
Table 1. Spark Plug Wire…4779
Table 2. Starter Specifications…4788
Table 3. Problem Diagnosis Chart…4789
Table 4. Specifications…4792
Table 5. Rectifier Check Table…4793
1580524-4000SRM1148-(11-2008)-US-EN…4797
toc…4797
Mast Repairs…4797
Safety Precautions Maintenance and Repair…4798
General…4801
Safety Procedures When Working Near Mast…4801
Fork Repair…4803
Remove…4803
Install…4803
Checks…4804
Carriages Repair…4805
Standard Carriage…4805
Remove…4805
Repair…4806
Install…4806
Integral Sideshift Carriage…4806
Remove…4806
Clean and Inspect…4809
Repair…4810
Install…4811
Mast Repair…4811
Mast, Remove…4811
Two-Stage LFL and Two-Stage FFL Masts, Disassemble…4815
Clean and Inspect…4821
Three-Stage FFL Mast…4822
Disassemble…4822
Clean and Inspect…4826
Two-Stage LFL and Two-Stage FFL Mast, Assemble…4827
Three-Stage FFL Mast, Assemble…4828
Four-Stage FFL, Disassemble…4830
Clean and Inspect…4834
Four-Stage FFL, Assemble…4836
Mast, Install…4838
Header Hose Arrangement…4841
Two-Stage LFL…4841
Two-Stage FFL…4848
Three-Stage FFL…4860
Four-Stage FFL…4875
Adjustment…4883
Lift Chains Adjustment…4884
Carriage Adjustments…4886
Tilt Cylinders Adjustment…4886
Mast Adjustments…4890
Load Roller Adjustment…4890
Mast Side Kicking Adjustment…4892
tables…4797
Table 1. Fork Tip Alignment…4804
Table 2. Pneumatic Tire Trucks…4844
Table 3. Cushion Tire Trucks…4844
Table 4. Standard Two-Stage Hose Dimensions…4847
Table 5. Pneumatic Tire Trucks…4851
Table 6. Cushion Tire Trucks…4851
Table 7. Pneumatic Tire Trucks…4869
Table 8. Cushion Tire Trucks…4869
Table 9. Standard Three-Stage Hose Dimensions…4871
Table 10. Standard Four-Stage Hose Dimensions…4876
Table 11. Hook-Type Carriage Chain Adjustment…4884
Table 12. Pin-Type Carriage Chain Adjustment…4885
1580528-8000SRM1134-(07-2008)-US-EN…4895
toc…4895
Calibration Procedures…4895
Safety Precautions Maintenance and Repair…4896
Description…4901
Proc_Cal_001: Service Password Entry…4904
When to Perform…4904
Why Perform…4904
How to Perform…4904
Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed…4906
When to Perform…4906
Calibration Order…4906
Why Perform…4906
How to Perform…4906
Proc_Cal_003: Save and Exit…4908
When to Perform…4908
Why Perform…4908
How to Perform…4908
Proc_Cal_004: Lift Valve Output Threshold…4910
When to Perform…4910
Calibration Order…4910
Why Perform…4910
How to Perform…4910
Proc_Cal_005: Lower Valve Output Threshold…4912
When to Perform…4912
Calibration Order…4912
Why Perform…4912
How to Perform…4912
Proc_Cal_006: Tilt Back Valve Output Threshold…4916
When to Perform…4916
Calibration Order…4916
Why Perform…4916
How to Perform…4916
Proc_Cal_007: Tilt Forward Valve Output Threshold…4918
When to Perform…4918
Calibration Order…4918
Why Perform…4918
How to Perform…4919
Proc_Cal_008: Aux 1 Dir A Valve Output Threshold…4922
When to Perform…4922
Calibration Order…4922
Why Perform…4922
How to Perform…4922
Proc_Cal_009: Aux 1 Dir B Valve Output Threshold…4924
When to Perform…4924
Calibration Order…4924
Why Perform…4924
How to Perform…4924
Proc_Cal_010: Aux 2 Dir A Valve Output Threshold…4928
When to Perform…4928
Calibration Order…4928
Why Perform…4928
How to Perform…4928
Proc_Cal_011: Aux 2 Dir B Valve Output Threshold…4930
When to Perform…4930
Calibration Order…4930
Why Perform…4930
How to Perform…4931
Proc_Cal_012: Aux 3 Dir A Valve Output Threshold…4934
When to Perform…4934
Calibration Order…4934
Why Perform…4934
How to Perform…4934
Proc_Cal_013: Aux 3 Dir B Valve Output Threshold…4936
When to Perform…4936
Calibration Order…4936
Why Perform…4936
How to Perform…4937
Proc_Cal_014: Load Weight Zero Point…4940
When to Perform…4940
Calibration Order…4940
Why Perform…4940
How to Perform…4940
Proc_Cal_015: Loaded Weight Calibration…4942
When to Perform…4942
Calibration Order…4942
Why Perform…4942
How to Perform…4942
Proc_Cal_016: Transmission Valve Calibration…4944
Applicable System/Option…4944
When to Perform…4944
Calibration Order…4944
Why Perform…4945
How to Perform…4945
Applicable System/Option…4946
When to Perform…4946
Calibration Order…4946
Why Perform…4946
How to Perform…4946
Proc_Cal_016A: Transmission Valve Calibration-Electronic Extende…4948
Applicable System/Option…4948
When to Perform…4948
Calibration Order…4948
Why Perform…4948
How to Perform…4948
Proc_Cal_016B: Trans. Valve Calibration-Electronic and Electroni…4950
Applicable System/Option…4950
When to Perform…4950
Calibration Order…4950
Why Perform…4950
How to Perform…4950
Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment…4952
Required Tools…4952
When to Perform…4952
Calibration Order…4952
Why Perform…4952
How to Perform…4952
Proc_Cal_025: Hydraulic Valve Pressure Gage Installation…4954
When to Perform…4954
Why Perform…4954
How to Perform…4954
Proc_Cal_026: Travel Speed Calibration…4956
When to Perform…4956
Calibration Order…4956
Why Perform…4956
How to Perform…4956
tables…4895
Table 1. Calibration Procedures…4901
Table 2. How to Read Calibration Procedure…4902
Table 3. Proc_Cal_001: Service Password Entry…4905
Table 4. Proc_Cal_002: Hydraulic Valve Calibration Warm Up and A…4906
Table 5. Proc_Cal_003: Save and Exit…4909
Table 6. Proc_Cal_004: Lift Valve Output Threshold…4910
Table 7. Proc_Cal_005: Lower Valve Output Threshold…4913
Table 8. Proc_Cal_006: Tilt Back Valve Output Threshold…4916
Table 9. Proc_Cal_007: Tilt Forward Valve Output Threshold…4919
Table 10. Proc_Cal_008: Aux 1 Dir A Valve Output Threshold…4922
Table 11. Proc_Cal_009: Aux 1 Dir B Valve Output Threshold…4925
Table 12. Proc_Cal_010: Aux 2 Dir A Valve Output Threshold…4928
Table 13. Proc_Cal_011: Aux 2 Dir B Valve Output Threshold…4931
Table 14. Proc_Cal_012: Aux 3 Dir A Valve Output Threshold…4934
Table 15. Proc_Cal_013: Aux 3 Dir B Valve Output Threshold…4937
Table 16. Proc_Cal_014: Load Weight Zero Point…4940
Table 17. Proc_Cal_015: Loaded Weight Calibration…4942
Table 18. Proc_Cal_016: Transmission Valve Calibration…4945
Table 19. Proc_Cal_016: Transmission Valve Calibration ( S6.0FT,…4947
Table 20. Proc_Cal_016A: Transmission Valve Calibration…4949
Table 21. Proc_Cal_016B: Transmission Valve Calibration…4951
Table 22. Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjus…4953
Table 23. Proc_Cal_025: Hydraulic Valve Pressure Gage Installati…4955
Table 24. Proc_Cal_026: Travel Speed Calibration…4956
1598588-0600SRM1205-(03-2007)-US-EN…4961
toc…4961
Yanmar Diesel Engines…4961
Safety Precautions Maintenance and Repair…4962
General…4967
Engine Identification…4967
Major Engine Component Identification…4967
Location of Labels…4967
Engine Removal and Installation…4968
Cylinder Head Assembly Repair…4968
Glow Plugs…4970
Remove…4970
Install…4970
Valve Cover…4970
Remove…4970
Clean and Inspect…4970
Install…4971
Rocker Arm Assembly…4971
Remove…4971
Disassemble…4972
Clean and Inspect…4972
Push Rods…4972
Rocker Arm Assembly…4972
Assemble…4973
Install…4973
Valve Clearance Adjustments…4973
Cylinder Head Assembly…4975
Remove…4975
Disassemble…4978
Valves and Valve Springs, Remove…4978
Valve Guides, Remove…4979
Clean and Inspect…4979
Cylinder Head…4980
Valve Guides…4980
Valves…4980
Valve Sink…4980
Valve Seat…4981
Valve Springs…4981
Assemble…4982
Valve Guides, Install…4982
Valves and Valve Springs, Install…4982
Install…4983
Timing Gear Case and Timing Gears Repair…4984
Timing Gear Case Cover…4984
Remove…4984
Clean and Inspect…4985
Install…4985
Timing Gears…4986
Crankshaft Gear…4986
Remove…4986
Install…4986
Idler Gear…4986
Remove…4986
Inspect…4987
Install…4987
Camshaft Gear…4987
Remove…4987
Install…4988
Timing Gear Case…4988
Remove…4988
Clean and Inspect…4988
Install…4988
Drive Train, Camshaft, and Cylinder Block Repair…4989
Remove…4989
Disassemble…4989
Pistons and Connecting Rods…4989
Crankshaft…4990
Camshaft…4992
Clean and Inspect…4993
Cylinder Block…4993
Honing and Boring…4996
Pistons…4997
Piston Pin…4997
Connecting Rod…4998
Tappets…4998
Crankshaft…4998
Camshaft…5000
Camshaft Bushing…5000
Assemble…5000
Camshaft…5000
Crankshaft…5001
Pistons and Connecting Rods…5001
Install…5002
Lubrication System Repair…5003
Engine Oil and Oil Filter Change…5003
Oil Pan…5003
Remove…5003
Install…5004
Oil Suction Tube…5004
Remove…5004
Clean…5004
Install…5005
Oil Pump…5005
Remove…5005
Clean and Inspect…5005
Outer Rotor Outside Clearance…5006
Outer Rotor to Inner Rotor Tip Clearance…5006
Outer Rotor Side Clearance…5006
Rotor Shaft Clearance…5006
Install…5007
Fuel System Repair…5007
Fuel Injectors…5007
Remove…5007
Inspect…5008
Clean…5008
Test…5009
Install…5011
Electronic Throttle System…5011
Remove…5011
Install…5014
Inspect…5015
Adjust…5015
Fuel Injection Pump…5015
Remove…5015
Clean and Inspect…5018
Install…5018
Check/Adjust Fuel Injection Timing…5019
Cooling System Repair…5021
V-Belt…5021
Remove…5021
Inspect…5021
Install…5021
Adjust…5021
Water Pump…5022
4TNE92-NMHA Engines…5022
Remove…5022
Install…5023
4TNE92-NMH and 4TNE98-NMH Engines…5024
Remove…5024
Install…5025
Thermostat…5026
Remove…5026
Inspect…5026
Install…5027
Flywheel and Flywheel Housing…5028
Flywheel…5028
Remove…5028
Install…5028
Flywheel Housing…5029
Remove…5029
Install…5029
Electrical Equipment Repair…5030
Alternator…5030
Remove…5030
Bench Test…5032
Regulate Voltage Check…5032
No Load Test…5034
Output Test…5034
Install…5034
Starter…5034
Remove…5036
No Load Test…5036
Install…5036
Engine Specifications…5037
Engine Data…5037
Engine Tuning…5040
Cylinder Head…5041
Intake/Exhaust Valve and Guide…5041
Valve Spring…5042
Rocker Arm and Shaft…5042
Push Rod…5042
Gear Train and Camshaft…5042
Camshaft…5042
Idle Gear Shaft and Bushing…5043
Backlash of Each Gear…5043
Cylinder Block…5044
Crankshaft…5044
Thrust Bearing…5044
Piston…5044
Piston Ring…5045
Connecting Rod…5045
Rod Small End…5046
Tappet…5046
Oil Pump…5046
Engine Oil Pressure…5046
Outer Rotor Outside Clearance…5046
Outer Rotor Side Clearance…5046
Outer Rotor to Inner Rotor Tip Clearance…5046
Rotor Shaft Clearance…5047
Standard Torque Specifications…5047
Standard Torque Chart…5047
Special Torque Specifications…5048
Special Tools…5049
tables…4961
Table 1. Cylinder Measurement Worksheet…4995
Table 2. Fuel Injector Spray Patterns…5010
Table 3. V-Belt Deflection Table…5021
Table 4. Alternator Specifications…5030
Table 5. Starter Specifications…5035
Table 6. No Load Test Specifications…5036
Table 7. 4TNE92-NMH Engine…5037
Table 8. 4TNE92-NMHA Engine…5038
Table 9. 4TNE98-NMH Engine…5039
1598589-1400SRM1206-(11-2008)-US-EN…5057
toc…5057
Drive Axle and Differential Assembly Repair…5057
Safety Precautions Maintenance and Repair…5058
General…5061
Drive Axle Repair…5061
Remove and Disassemble…5061
Clean and Inspect…5063
Assemble and Install…5063
Differential Repair…5066
Remove…5066
Differential Assembly From Center Section Assembly…5066
Drive Pinion, Pinion Gear, and Bearings From Center Section…5070
Disassemble…5075
Differential Assembly…5075
Drop Box Housing…5079
Center Section…5080
Clean and Inspect…5082
Assemble…5082
Center Section…5082
Drop Box Housing…5085
Differential Assembly…5086
Install…5090
Pinion Inner Shim Set, Adjust Thickness (Depth of Pinion)…5090
Drive Pinion, Pinion Gear, and Bearings Into Center Section…5092
Differential Assembly Into Center Section…5095
Ring Gear Backlash, Adjust…5100
Ring Gear, Runout Check…5102
Gear Set, Tooth Contact Pattern Check…5102
Torque Specifications…5105
tables…5057
Table 1. Pinion Variation Numbers Examples…5091
Table 2. Ring and Pinion Tooth Contact Adjustment…5102
Table 3. Correct Tooth Contact…5103
Table 4. Incorrect Tooth Contact…5104
1598590-8000SRM1207-(07-2008)-US-EN…5109
toc…5109
Periodic Maintenance…5109
Safety Precautions Maintenance and Repair…5110
General…5115
Serial Number Data…5115
How to Move Disabled Lift Truck…5115
How to Tow Lift Truck…5115
How to Put Lift Truck on Blocks…5116
How to Raise Drive Tires…5116
How to Raise Steering Tires…5117
Maintenance Schedule…5117
Maintenance Procedures Every 8 Hours or Daily…5130
How to Make Checks With Engine Stopped…5130
Tires and Wheels…5130
Safety Labels…5130
Mast, Carriage, Lift Chains, Header Hoses, Attachment…5131
Operator Restraint System…5131
Emergency Locking Retractor (ELR)…5131
Hood and Seat Latches…5132
Engine Compartment…5132
Fuel, Oil, and Coolant Leaks, Check…5133
Hydraulic Hoses…5133
Coolant Hoses…5133
Steering Column Gas Cylinder…5133
Transmission…5133
Hydraulic System Oil…5133
Engine Oil…5134
Air Filter…5137
Forks…5137
Remove…5137
Inspect…5137
Install…5138
Adjust…5138
How to Make Checks With Engine Running…5139
Indicator Lights, Horn, Fuses, and Relays…5139
Service Brakes…5141
Brake Fluid Level…5141
Operation, Check…5142
Parking Brake…5142
Engine Oil Pressure…5142
Cooling System…5143
Steering System…5143
Control Levers and Pedals…5143
Lift System, Operate…5144
First Service After First 100 Hours of Operation…5144
Mazda Engine Oil Filter…5144
Yanmar Engine Oil Filter…5145
Hydraulic System…5145
Hydraulic Filter, Replace…5145
Transmission Oil Filter, Replace…5146
Maintenance Procedures Every 250 Hours or 6 months…5147
Mazda Engine Oil and Filter…5147
Drive Belt…5148
Mazda 2.0L Engines…5148
Fan and Alternator Drive Belt…5148
Drain Tar From LPG Regulator (Except 2007 Mazda Emission Complia…5148
Drain Tar From LPG Regulator (2007 Mazda Emission Compliant Engi…5149
Maintenance Procedures Every 500 Hours or 6 Months…5150
Hydraulic System Oil…5150
Hydraulic Tank Breather…5150
Inspect…5150
Battery…5151
Yanmar Engine Oil and Filter…5151
Drive Belt…5151
Yanmar Diesel Engine…5151
Fan and Alternator Drive Belt…5151
PCV Valve…5152
Clean Debris From Radiator Core…5152
Transmission Oil Level…5152
Forks…5153
Mast Lubrication…5153
Header Hose Checks…5156
Lift Chain Lubrication…5157
Tilt Cylinder Lubrication…5157
Master Brake Cylinder Rod End Pin Lubrication…5158
Manual Hydraulic Levers Lubrication…5158
Brake Fluid…5159
Tie Rod Lubrication…5159
Differential and Drive Axle Oil (Dry Brake)…5160
Maintenance Procedures Every 1000 Hours or 6 Months…5161
Valve Clearance, Check and Adjust…5161
Ignition System…5161
Mazda 2.0L Engines…5161
LPG Vapor Fuel Filter Replace, Mazda Engines (Except 2007 Mazda …5161
LPG Fuel Filter Replace, Mazda 2007 Emission Compliant Engines O…5162
Remove…5162
Clean/Inspect…5162
Install…5162
Gasoline Fuel Filter Replacement, Mazda 2007 Emission Compliant …5162
Remove and Replace…5162
Fuel Filter Replacement, Yanmar Engine…5163
Priming the Fuel System (Yanmar)…5164
Lift Chains Wear Check…5165
Lift Chain Lubrication…5166
Integral Sideshift Carriage, Check Bearings…5166
Steering Axle…5166
Control Levers and Pedals…5166
Maintenance Procedures Every 2000 Hours or Annually…5168
Hydraulic System…5168
Hydraulic Filter, Replace…5168
Hydraulic Tank Breather, Replace…5169
Air Filter…5169
PCV Valve…5171
Oxygen Sensor…5171
LPG Regulator Fuel Filter, Mazda Engines (Except 2007 Mazda Emis…5172
Remove and Replace…5172
Gasoline Fuel Filter…5172
Remove and Replace…5172
Timing Belt…5172
Mazda Engines…5172
LPG Fuel Injector, Mazda Engines (Except 2007 Mazda Emission Com…5172
Gasoline Fuel Injector, Mazda Engines…5172
Fuel Injector, Yanmar Engines…5173
Forks…5173
Integral Sideshift Carriage…5173
Bearings, Replace…5173
Transmission Oil and Filter (Dry Brake), Replace…5173
Brake Fluid (Master Cylinder), Change…5174
Brake Fluid (Dry Brake), Remove…5175
Service Brakes (Dry Brake)…5175
Differential (Dry Brake)…5175
Valve Clearance, Check and Adjust for Cummins QSB 3.3L Diesel En…5176
Maintenance Procedures Every 4000 Hours or 2 Years…5178
Hydraulic Oil, Replace…5178
Cooling System…5178
Safety Procedures When Working Near Mast…5179
Hood Latch Check…5182
Lift Chain Adjustments…5183
Jump-Starting the Lift Truck…5184
Jump-Starting Using a Battery Charger…5184
Jump-Starting a Lift Truck Using Another Lift Truck…5184
Welding Repairs…5185
Overhead Guard Changes…5185
Wheel Repair…5186
General…5186
How to Change Solid Rubber Tire (S Series)…5186
Remove and Install Tire on Wheel…5186
Pneumatic Tire With Tube, Repair…5187
Remove Wheels From Lift Truck…5187
Remove Tire From Wheel…5187
Remove Tire From Two-Piece Wheel…5188
Remove Tire From Three- and Four-Piece Wheels…5189
Install Wheel in Tire…5190
Install Two-Piece Wheel in Tire…5191
Install Three- or Four-Piece Wheel in Tire…5192
Add Air to Pneumatic Tires With Tube…5193
Wheels, Install…5193
Pneumatic Tubeless Tire, Repair…5193
Remove Wheels From Lift Truck…5193
Remove Tire From Wheel…5194
Install Tire on Wheel…5196
Add Air to Pneumatic Tubeless Tire…5198
Wheels, Install…5199
Solid Rubber Tires on Pneumatic Wheels, Change…5199
Remove Tire From Wheel…5199
Install Tire on Wheel…5201
Adhesives and Sealants…5203
tables…5109
Table 1. Maintenance Schedule…5123
Table 2. V-Belt Deflection Table…5151
Table 3. Carriage Chain Adjustment, Forks Not Installed…5184
1598591-8000SRM1208-(06-2007)-US-EN…5207
toc…5207
Capacities and Specifications…5207
Safety Precautions Maintenance and Repair…5208
Lift Truck Lifting Capacity…5211
Counterweight Weights…5211
Tire Sizes…5211
Capacities…5211
Electrical System…5214
Transmission Oil Pressures…5215
Hydraulic System Relief Pressures…5216
Steering System…5216
Stall Speeds (in RPM ±100 rpm)…5217
Mazda (Except 2007 Emission Compliant Engines)…5217
Mazda (2007 Emission Compliant Engines Only)…5217
Yanmar 2.6L…5217
Mast Speeds …5217
Tilt Angles…5218
Front End Equipment – Mast Creep…5219
Mast Creep…5219
Engine Specifications…5219
Torque Specifications…5221
Frame…5221
Mast…5221
Steering System, Cushion Tire Trucks…5221
Steering System, Pneumatic Tire Trucks…5221
Drive Axle…5221
Transmission…5222
Engine – Mazda 2.0L…5222
Engine – Yanmar 2.6L Diesel…5223
tables…5207
Table 1. Lift Truck Models S30FT, S35FT, S40FTS (E010) With Mazd…5217
Table 2. Lift Truck Models H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT…5218
Table 3. Lift Truck Models H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT…5218
Table 4. S30FT, S35FT, S40FTS (E010) Lift Truck Models…5218
Table 5. H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) (F001) L…5218
Table 6. S30FT, S35FT, S40FTS (E010) Lift Truck Models…5219
Table 7. H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) (F001) L…5219
1653957-0900SRM1325-(12-2006)-US-EN…5227
toc…5227
Gasoline Fuel System…5227
Safety Precautions Maintenance and Repair…5228
General…5231
Abbreviations…5231
Intake-Air System…5231
Intake-Air System Manifold Vacuum Check…5231
Throttle Body…5232
Remove…5233
Install…5233
Intake Manifold…5233
Remove…5233
Install…5234
Fuel System…5234
Before Repair Procedure…5234
Fuel Line Safety Procedure…5234
After Repair Procedure…5236
Fuel Hose, Install…5236
Fuel Leakage Check…5236
Fuel Line Pressure Check…5237
Fuel Injectors…5238
Remove…5238
Install…5238
Pressure Regulator…5240
Remove…5240
Install…5240
Exhaust System…5241
Exhaust System, Inspect…5241
Three-Way Catalytic (TWC) Converter…5241
Remove and Install…5241
Exhaust Manifold…5241
Remove…5241
Install…5241
Positive Crankcase Ventilation (PCV) Valve…5243
Remove…5243
Inspect…5243
Install…5243
Control System…5243
Engine Control Unit (ECU)…5243
Remove…5243
Install…5243
Intake Air Temperature (IAT) Sensor…5246
Remove…5246
Install…5246
Engine Coolant Temperature (ECT) Sensor…5247
Remove…5247
Install…5248
CAM Angle Sensor…5248
Voltage Check…5248
Manifold Absolute Pressure (MAP) Sensor…5249
Remove…5249
Install…5249
Oxygen Sensor…5250
Remove…5250
Install…5250
Technical Data…5251
tables…5227
Table 1. PCV Valve Specifications…5243
Table 2. Gasoline Fuel Systems Technical Data…5251
1653958-0900SRM1326-(03-2007)-US-EN…5255
toc…5255
LPG Fuel System…5255
Safety Precautions Maintenance and Repair…5256
General…5259
LPG Tank Replacement…5259
Remove…5259
Install…5261
Fuel Filter Unit Repair…5262
Fuel Filter Element…5262
Remove…5262
Clean/Inspect…5262
Install…5262
Fuel Filter Housing…5263
Remove…5263
Disassemble…5264
Assemble…5264
Install…5265
Electronic Throttle Body Repair…5265
Remove…5265
Install…5266
Electronic Pressure Regulator (EPR) Repair…5267
Remove…5267
Disassemble…5268
Assemble…5270
Install…5272
LPG Shutoff Valve Assembly…5273
Remove…5273
Install…5273
Fuel Mixer Repair…5275
Remove…5275
Install…5276
Control System…5278
Engine Control Unit (ECU)…5278
Remove…5278
Install…5279
Engine Coolant Temperature (ECT) Sensor…5280
Remove…5280
Install…5280
CAM Angle Sensor…5281
Voltage Check…5281
Manifold Absolute Pressure (MAP) Sensor…5282
Remove…5282
Install…5282
Intake Air Temperature (IAT) Sensor…5282
Remove…5282
Install…5282
Fuel Temperature Sensor…5283
Remove…5283
Install…5283
Oxygen Sensor…5284
Remove…5284
Install…5284
Exhaust System…5285
Exhaust System, Inspect…5285
Three-Way Catalytic (TWC) Converter…5285
Remove and Install…5285
Exhaust Manifold…5285
Remove…5285
Install…5285
Positive Crankcase Ventilation (PCV) Valve…5287
Remove…5287
Inspect…5287
Install…5287
tables…5255
Table 1. PCV Valve Specifications…5287
1653959-2200SRM1327-(03-2007)-US-EN…5291
toc…5291
Electrical System…5291
Safety Precautions Maintenance and Repair…5292
Ignition System…5295
General…5295
Ignition Timing Adjustment, Gasoline and LPG…5295
Spark Plugs Check…5298
Spark Plug Wires Check…5298
CAM Angle Sensor Repair…5298
Remove…5298
Install…5299
Coil Replacement…5300
Remove…5300
Inspect…5301
Install…5301
Starter Repair…5302
General…5302
Remove…5303
No-Load Test…5303
Magnetic Switch Test…5304
Pull-Out Test…5304
Holding Coil Test…5304
Return Test…5304
Pinion Movement Inspection…5304
Install…5305
Alternator Repair…5305
General…5305
Charging System Inspection…5306
Output Current Check…5306
No-Load Adjusted Voltage Check…5307
Remove…5307
Inspect…5307
Rectifier Check…5307
Install…5308
tables…5291
Table 1. Spark Plug Wires…5298
Table 2. Coil Inspection…5301
Table 3. Starter Specifications…5302
Table 4. Problem Diagnosis Chart…5303
Table 5. Specifications…5306
Table 6. Rectifier Check Table…5307
1673866-0100SRM1290-(07-2008)-US-EN…5311
toc…5311
Operator's Cab…5311
Safety Precautions Maintenance and Repair…5312
General…5317
Cab Replacement…5318
Remove, for Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F001); H2…5318
Install, for Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F001); H2…5329
Remove, for Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (H…5330
Install, for Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (…5334
Door Assemblies…5335
Right Side Door Assembly, Lift Truck Models H1.6FT, H1.8FT, 2.0F…5335
Remove…5335
Disassemble…5340
Door Cover…5340
Heater Assembly…5342
Door Lock Assembly…5343
Windows…5344
Clean…5344
Inspect…5344
Assemble…5344
Windows…5344
Door Lock Assembly…5344
Heater Assembly…5345
Door Cover…5345
Install…5345
Left Side Door Assembly, Lift Truck Models H1.6FT, H1.8FT, 2.0FT…5345
Remove…5345
Disassemble…5345
Door Cover…5345
Door Lock Assembly…5347
Windows…5347
Clean…5347
Inspect…5347
Assemble…5347
Windows…5347
Door Lock Assembly…5347
Door Cover…5347
Install…5347
Right and Left Side Door Assemblies, Lift Truck Models H6.0FT, H…5348
Remove…5348
Disassemble…5348
Door Cover…5348
Door Lock Assembly…5350
Windows…5350
Clean…5350
Inspect…5350
Assemble…5351
Windows…5351
Door Lock Assembly…5351
Door Cover…5351
Install…5352
Window Wipers Replacement…5352
General…5352
Front Wiper Assembly and Motor…5352
Remove, Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F001) and H2.0…5352
Install, Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F001) and H2…5352
Remove, Lift Truck Models H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-5…5354
Install, Lift Truck Models H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-…5354
Rear Wiper Assembly and Motor…5356
Remove, Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F001)…5356
Install, Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F001)…5356
Remove, Lift Truck Models H2.0-3.5FT (H40-70FT) (L177)…5358
Install, Lift Truck Models H2.0-3.5FT (H40-70FT) (L177)…5358
Remove, Lift Truck Models H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-5…5361
Install, Lift Truck Models H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-…5361
Remove, Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (H006,…5363
Install, Lift Truck Models H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-…5363
Window Replacement…5365
General…5365
Remove Door Window, Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F0…5365
Install Door Windows, Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (…5366
Remove Door Window, Lift Truck Models H6.0FT, H7.0FT (H135FT, H1…5367
Install Door Window, Lift Truck Models H6.0FT, H7.0FT (H135FT, H…5368
Heater Replacement…5368
Remove, for Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (H…5368
Install, for Lift truck Models H6.0FT, H7.0FT (H135FT, H155FT) (…5371
Light Replacement…5372
Work Lights (Front and Rear)…5372
Remove…5372
Install…5372
Strobe Light…5374
Remove…5374
Install…5374
Turn, Stop, Tail, and Backup Light…5375
Remove…5375
Install…5375
Front Marker/Turn Signal Lights…5375
Remove…5375
Install…5375
Display Switches…5376
Electrical Schematics…5380
Optional Equipment…5383
Heavy Duty Pre-Cleaner…5383
Remove…5383
Clean…5384
Inspect…5384
Install…5384
Fan…5384
Remove…5384
Install…5384
Mirror…5384
Remove…5384
Install…5384
Label Replacement…5384
1698613-8000SRM1387-(07-2008)-US-EN…5389
toc…5389
Diagrams and Schematics…5389
Safety Precautions Maintenance and Repair…5390
General Information About Diagrams and Schematics…5393
Symbol Definitions…5393
tables…5389
Table 1. Wire Colors…5393
Table 2. Symbol Definitions…5393
9000SRM1112_DTC 110-6 chg DTC 110-16…5455
9000SRM1112_Operational Checkout…5456
toc…0
Operational Diagnostic Procedures…0
Operational Checkout Procedures…5456
DTC Check…5457
Horn Circuit Check…5457
Light Circuit Check…5457
Windshield Washer Wiper Check (If equipped)…5457
Heater Check (If equipped)…5458
Dome Light Check (If equipped)…5458
Circulating (Accessory) Fan Check (If equipped)…5459
Indicator Light Power Check…5460
Engine Malfunction Indicator Check…5461
Cold Start Check (Cummins and Yanmar)…5461
Brake Pedal Check…5461
Backup Alarm Check (If equipped)…5462
Operator Presence System Check…5462
Hydraulic Interlock Check…5462
Armrest Hydraulic Interlock Check (If equipped and with original…5462
Engine Cover Latch Sensor Check (If equipped)…5463
Brake and Inching Pedal Check…5463
Park Brake Sensor Check…5463
Park Brake Check…5464
Engine Speed Check (All Cummins, Yanmar, and Mazda Engines Excep…5464
Engine Power Check…5465
Transmission Clutch Check…5465
Transmission Check…5466
Transmission Speed Selection Check (If equipped)…5466
Brake and Axle Drag Check…5466
Hydraulic Pump Flow Check…5467
Priority Flow Divider Valve Check…5468
Steering Relief Valve Low Pressure Check…5468
Steering Relief Valve High Pressure Check…5469
Control Valve Load Check Valve (Manual Valve)…5469
Lift E-Valve Check…5469
Lift Check (E-Valve)…5469
Tilt Function Counterbalance Check…5470
Lift Drift Check…5470
Tilt Function Drift Check…5471
Mast Cushion Check (All Except 2-Stage Mast)…5471
Lift/Tilt Mast Adjustment Check…5471
Tilt Racking Check…5472
Chain and Header Hose Adjustment Check…5472
Mast Mounting Check…5473
Mast Channel Check…5473
Carriage Adjustment Check…5474
Chain Sheave Check…5474
Carriage Adjustment Check (Standard and Integral Side Shift)…5474
9000SRM1112_Speed Sensor Direction or Direction Check Logical Failure…5475
toc…0
522155-2…5475
522157-2…5475
9000SRM1112_TOSS_TISS Sensor 1 & 2 No Output…5482
9000SRM1112_TSP MLM Data Error.pdf…5483
toc…0
Electrical System…0
2802-12…5483
628-12…5483
523261-3…5483
523261-4…5483
523257-3…5483
523257-4…5483
523253-3…5483
523253-4…5483
523249-3…5483
523249-4…5483
630-12…5483
9000SRM1112_UPDATE CUMMINS QSB 3.3L FAULT CODES DTC 627-12…5485
910442-8000SRM0231-(12-2004)-US-EN…5486
toc…5486
Metric and Inch (SAE) Fasteners…5486
Safety Precautions Maintenance and Repair…5487
General…5490
Threaded Fasteners…5490
Nomenclature, Threads…5490
Strength Identification…5491
Cotter (Split) Pins…5491
Fastener Torque Tables…5496
Conversion Table…5498
tables…5486
Table 1. Bolts and Screws…5492
Table 2. Studs and Nuts…5493
Table 3. Torque Nuts…5494
Table 4. Torque Nuts With Nylon Insert…5495
Table 5. Torque Values for Metric Fasteners*…5496
Table 6. Torque Values for Inch Fasteners*…5497
Table 7. Conversion Table for Metric and English Units…5498
Table 8. Cotter Pin Dimensional Data…5499
Table 9. Cotter Pin Dimensional Data…5500
Table 10. Cotter Pin Dimensional Data…5501
Table 11. Cotter Pin Dimensional Data…5503
Hyster Forklift Trucks F001 (H1.6-1.8FT, H2.0FTS Europe & H30-35FT, H40FTS) Repair Service Manuals
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