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Hyster C108 (E40-60XL) Service Manual – PDF DOWNLOAD
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Description
Hyster C108 (E40-60XL) Service Manual – PDF DOWNLOAD
DESCRIPTION:
Hyster C108 (E40-60XL) Service Manual – PDF DOWNLOAD
PART NO. 1580513
SAFETY PRECAUTIONS MAINTENANCE AND REPAIR :
• When lifting parts or assemblies,make sure all slings, chains, or cables are correctly fastened, and
that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity
to support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric
lift trucks. Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOWTO PUT THE LIFT
TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet
or exceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force
to remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the
unit needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are
flammable. Be sure to follow the necessary safety precautions when handling these fuels and
when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from
the area. Make sure the area is well ventilated.
TABLE OF CONTENTS:
Hyster C108 (E40-60XL) Service Manual – PDF DOWNLOAD
Brakes (1).................................................................................. 1 toc..................................................................................... 1 Brake System........................................................................ 1 Safety Precautions Maintenance and Repair........................................... 2 General............................................................................. 5 Dry Brake System................................................................ 5 Wet Brake System................................................................ 5 Service Brakes Repair (Dry Brake)................................................... 6 Remove and Disassemble.......................................................... 6 Clean........................................................................... 12 Inspect......................................................................... 13 Assemble and Install............................................................ 14 Adjust.......................................................................... 20 Inching Overlap Adjustment...................................................... 20 Parking Brake Repair................................................................ 21 Remove and Disassemble.......................................................... 21 Assemble and Install............................................................ 24 Adjust.......................................................................... 24 Master Cylinder Repair.............................................................. 25 Remove (Dry Brake).............................................................. 25 Disassemble (Dry Brake)......................................................... 25 Clean and Inspect (Dry Brake)................................................... 25 Assemble (Dry Brake)............................................................ 25 Bench Bleed Master Cylinder (Dry Brake)......................................... 25 Install and Adjust (Dry Brake).................................................. 28 Remove (Wet Brake).............................................................. 28 Disassemble (Wet Brake)......................................................... 28 Clean and Inspect (Wet Brake)................................................... 29 Assemble (Wet Brake)............................................................ 30 Install and Adjust (Wet Brake).................................................. 31 Service Brakes Adjustment (Dry Brake)............................................... 31 Brake System Air Removal............................................................ 32 Using Pressure Bleed System..................................................... 32 Using Brake Pedal Pressure...................................................... 32 Brake Pedal Adjustment.............................................................. 33 Free Pedal Adjustment............................................................... 34 Torque Specifications............................................................... 35 Brakes...................................................................................... 39 toc..................................................................................... 39 Brake System........................................................................ 39 Safety Precautions Maintenance and Repair........................................... 40 General............................................................................. 43 Dry Brake System................................................................ 43 Wet Brake System................................................................ 43 Service Brakes Repair (Dry Brake)................................................... 44 Remove and Disassemble.......................................................... 44 Clean........................................................................... 50 Inspect......................................................................... 51 Assemble and Install............................................................ 52 Adjust.......................................................................... 58 Inching Overlap Adjustment...................................................... 58 Parking Brake Repair................................................................ 59 Remove and Disassemble.......................................................... 59 Assemble and Install............................................................ 62 Adjust.......................................................................... 62 Master Cylinder Repair.............................................................. 63 Remove (Dry Brake).............................................................. 63 Disassemble (Dry Brake)......................................................... 63 Clean and Inspect (Dry Brake)................................................... 63 Assemble (Dry Brake)............................................................ 63 Bench Bleed Master Cylinder (Dry Brake)......................................... 63 Install and Adjust (Dry Brake).................................................. 66 Remove (Wet Brake).............................................................. 66 Disassemble (Wet Brake)......................................................... 66 Clean and Inspect (Wet Brake)................................................... 67 Assemble (Wet Brake)............................................................ 68 Install and Adjust (Wet Brake).................................................. 69 Service Brakes Adjustment (Dry Brake)............................................... 69 Brake System Air Removal............................................................ 70 Using Pressure Bleed System..................................................... 70 Using Brake Pedal Pressure...................................................... 70 Brake Pedal Adjustment.............................................................. 71 Free Pedal Adjustment............................................................... 72 Torque Specifications............................................................... 73 Calibration (1)............................................................................. 77 toc..................................................................................... 77 Calibration Procedures.............................................................. 77 Safety Precautions Maintenance and Repair........................................... 78 Description......................................................................... 83 Proc_Cal_001: Service Password Entry................................................ 86 When to Perform................................................................. 86 Why Perform..................................................................... 86 How to Perform.................................................................. 86 Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed..................... 88 When to Perform................................................................. 88 Calibration Order............................................................... 88 Why Perform..................................................................... 88 How to Perform.................................................................. 88 Proc_Cal_003: Save and Exit......................................................... 90 When to Perform................................................................. 90 Why Perform..................................................................... 90 How to Perform.................................................................. 90 Proc_Cal_004: Lift Valve Output Threshold........................................... 92 When to Perform................................................................. 92 Calibration Order............................................................... 92 Why Perform..................................................................... 92 How to Perform.................................................................. 92 Proc_Cal_005: Lower Valve Output Threshold.......................................... 96 When to Perform................................................................. 96 Calibration Order............................................................... 96 Why Perform..................................................................... 96 How to Perform.................................................................. 96 Proc_Cal_006: Tilt Back Valve Output Threshold...................................... 98 When to Perform................................................................. 98 Calibration Order............................................................... 98 Why Perform..................................................................... 98 How to Perform.................................................................. 98 Proc_Cal_007: Tilt Forward Valve Output Threshold................................... 102 When to Perform................................................................. 102 Calibration Order............................................................... 102 Why Perform..................................................................... 102 How to Perform.................................................................. 102 Proc_Cal_008: Aux 1 Dir A Valve Output Threshold.................................... 106 When to Perform................................................................. 106 Calibration Order............................................................... 106 Why Perform..................................................................... 106 How to Perform.................................................................. 106 Proc_Cal_009: Aux 1 Dir B Valve Output Threshold.................................... 108 When to Perform................................................................. 108 Calibration Order............................................................... 108 Why Perform..................................................................... 109 How to Perform.................................................................. 109 Proc_Cal_010: Aux 2 Dir A Valve Output Threshold.................................... 112 When to Perform................................................................. 112 Calibration Order............................................................... 112 Why Perform..................................................................... 112 How to Perform.................................................................. 112 Proc_Cal_011: Aux 2 Dir B Valve Output Threshold.................................... 114 When to Perform................................................................. 114 Calibration Order............................................................... 114 Why Perform..................................................................... 114 How to Perform.................................................................. 115 Proc_Cal_012: Aux 3 Dir A Valve Output Threshold.................................... 118 When to Perform................................................................. 118 Calibration Order............................................................... 118 Why Perform..................................................................... 118 How to Perform.................................................................. 118 Proc_Cal_013: Aux 3 Dir B Valve Output Threshold.................................... 120 When to Perform................................................................. 120 Calibration Order............................................................... 120 Why Perform..................................................................... 120 How to Perform.................................................................. 121 Proc_Cal_014: Load Weight Zero Point................................................ 124 When to Perform................................................................. 124 Calibration Order............................................................... 124 Why Perform..................................................................... 124 How to Perform.................................................................. 124 Proc_Cal_015: Loaded Weight Calibration............................................. 126 When to Perform................................................................. 126 Calibration Order............................................................... 126 Why Perform..................................................................... 126 How to Perform.................................................................. 126 Proc_Cal_016: Transmission Valve Calibration........................................ 128 Applicable System/Option........................................................ 128 When to Perform................................................................. 128 Calibration Order............................................................... 128 Why Perform..................................................................... 129 How to Perform.................................................................. 129 Proc_Cal_016A: Transmission Valve Calibration-Electronic Extende.................... 130 Applicable System/Option........................................................ 130 When to Perform................................................................. 130 Calibration Order............................................................... 130 Why Perform..................................................................... 130 How to Perform.................................................................. 131 Proc_Cal_016B: Trans. Valve Calibration-Electronic and Electroni.................... 132 Applicable System/Option........................................................ 132 When to Perform................................................................. 132 Calibration Order............................................................... 132 Why Perform..................................................................... 132 How to Perform.................................................................. 133 Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment......................... 134 Required Tools.................................................................. 134 When to Perform................................................................. 134 Calibration Order............................................................... 134 Why Perform..................................................................... 134 How to Perform.................................................................. 135 Proc_Cal_025: Hydraulic Valve Pressure Gage Installation............................ 136 When to Perform................................................................. 136 Why Perform..................................................................... 136 How to Perform.................................................................. 136 Proc_Cal_026: Travel Speed Calibration.............................................. 138 When to Perform................................................................. 138 Calibration Order............................................................... 138 Why Perform..................................................................... 138 How to Perform.................................................................. 138 tables.................................................................................. 77 Table 1. Calibration Procedures..................................................... 83 Table 2. How to Read Calibration Procedure.......................................... 85 Table 3. Proc_Cal_001: Service Password Entry....................................... 87 Table 4. Proc_Cal_002: Hydraulic Valve Calibration Warm Up and A.................... 88 Table 5. Proc_Cal_003: Save and Exit................................................ 91 Table 6. Proc_Cal_004: Lift Valve Output Threshold.................................. 93 Table 7. Proc_Cal_005: Lower Valve Output Threshold................................. 96 Table 8. Proc_Cal_006: Tilt Back Valve Output Threshold............................. 99 Table 9. Proc_Cal_007: Tilt Forward Valve Output Threshold.......................... 103 Table 10. Proc_Cal_008: Aux 1 Dir A Valve Output Threshold.......................... 106 Table 11. Proc_Cal_009: Aux 1 Dir B Valve Output Threshold.......................... 109 Table 12. Proc_Cal_010: Aux 2 Dir A Valve Output Threshold.......................... 112 Table 13. Proc_Cal_011: Aux 2 Dir B Valve Output Threshold.......................... 115 Table 14. Proc_Cal_012: Aux 3 Dir A Valve Output Threshold.......................... 118 Table 15. Proc_Cal_013: Aux 3 Dir B Valve Output Threshold.......................... 121 Table 16. Proc_Cal_014: Load Weight Zero Point...................................... 124 Table 17. Proc_Cal_015: Loaded Weight Calibration................................... 126 Table 18. Proc_Cal_016: Transmission Valve Calibration.............................. 129 Table 19. Proc_Cal_016A: Transmission Valve Calibration............................. 131 Table 20. Proc_Cal_016B: Transmission Valve Calibration............................. 133 Table 21. Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjus.................... 135 Table 22. Proc_Cal_025: Hydraulic Valve Pressure Gage Installati.................... 137 Table 23. Proc_Cal_026: Travel Speed Calibration.................................... 138 Calibration................................................................................. 143 toc..................................................................................... 143 Calibration Procedures.............................................................. 143 Safety Precautions Maintenance and Repair........................................... 144 Description......................................................................... 149 Proc_Cal_001: Service Password Entry................................................ 152 When to Perform................................................................. 152 Why Perform..................................................................... 152 How to Perform.................................................................. 152 Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed..................... 154 When to Perform................................................................. 154 Calibration Order............................................................... 154 Why Perform..................................................................... 154 How to Perform.................................................................. 154 Proc_Cal_003: Save and Exit......................................................... 156 When to Perform................................................................. 156 Why Perform..................................................................... 156 How to Perform.................................................................. 156 Proc_Cal_004: Lift Valve Output Threshold........................................... 158 When to Perform................................................................. 158 Calibration Order............................................................... 158 Why Perform..................................................................... 158 How to Perform.................................................................. 158 Proc_Cal_005: Lower Valve Output Threshold.......................................... 162 When to Perform................................................................. 162 Calibration Order............................................................... 162 Why Perform..................................................................... 162 How to Perform.................................................................. 162 Proc_Cal_006: Tilt Back Valve Output Threshold...................................... 164 When to Perform................................................................. 164 Calibration Order............................................................... 164 Why Perform..................................................................... 164 How to Perform.................................................................. 164 Proc_Cal_007: Tilt Forward Valve Output Threshold................................... 168 When to Perform................................................................. 168 Calibration Order............................................................... 168 Why Perform..................................................................... 168 How to Perform.................................................................. 168 Proc_Cal_008: Aux 1 Dir A Valve Output Threshold.................................... 172 When to Perform................................................................. 172 Calibration Order............................................................... 172 Why Perform..................................................................... 172 How to Perform.................................................................. 172 Proc_Cal_009: Aux 1 Dir B Valve Output Threshold.................................... 174 When to Perform................................................................. 174 Calibration Order............................................................... 174 Why Perform..................................................................... 175 How to Perform.................................................................. 175 Proc_Cal_010: Aux 2 Dir A Valve Output Threshold.................................... 178 When to Perform................................................................. 178 Calibration Order............................................................... 178 Why Perform..................................................................... 178 How to Perform.................................................................. 178 Proc_Cal_011: Aux 2 Dir B Valve Output Threshold.................................... 180 When to Perform................................................................. 180 Calibration Order............................................................... 180 Why Perform..................................................................... 180 How to Perform.................................................................. 181 Proc_Cal_012: Aux 3 Dir A Valve Output Threshold.................................... 184 When to Perform................................................................. 184 Calibration Order............................................................... 184 Why Perform..................................................................... 184 How to Perform.................................................................. 184 Proc_Cal_013: Aux 3 Dir B Valve Output Threshold.................................... 186 When to Perform................................................................. 186 Calibration Order............................................................... 186 Why Perform..................................................................... 186 How to Perform.................................................................. 187 Proc_Cal_014: Load Weight Zero Point................................................ 190 When to Perform................................................................. 190 Calibration Order............................................................... 190 Why Perform..................................................................... 190 How to Perform.................................................................. 190 Proc_Cal_015: Loaded Weight Calibration............................................. 192 When to Perform................................................................. 192 Calibration Order............................................................... 192 Why Perform..................................................................... 192 How to Perform.................................................................. 192 Proc_Cal_016: Transmission Valve Calibration........................................ 194 Applicable System/Option........................................................ 194 When to Perform................................................................. 194 Calibration Order............................................................... 194 Why Perform..................................................................... 195 How to Perform.................................................................. 195 Proc_Cal_016A: Transmission Valve Calibration-Electronic Extende.................... 196 Applicable System/Option........................................................ 196 When to Perform................................................................. 196 Calibration Order............................................................... 196 Why Perform..................................................................... 196 How to Perform.................................................................. 197 Proc_Cal_016B: Trans. Valve Calibration-Electronic and Electroni.................... 198 Applicable System/Option........................................................ 198 When to Perform................................................................. 198 Calibration Order............................................................... 198 Why Perform..................................................................... 198 How to Perform.................................................................. 199 Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment......................... 200 Required Tools.................................................................. 200 When to Perform................................................................. 200 Calibration Order............................................................... 200 Why Perform..................................................................... 200 How to Perform.................................................................. 201 Proc_Cal_025: Hydraulic Valve Pressure Gage Installation............................ 202 When to Perform................................................................. 202 Why Perform..................................................................... 202 How to Perform.................................................................. 202 Proc_Cal_026: Travel Speed Calibration.............................................. 204 When to Perform................................................................. 204 Calibration Order............................................................... 204 Why Perform..................................................................... 204 How to Perform.................................................................. 204 tables.................................................................................. 143 Table 1. Calibration Procedures..................................................... 149 Table 2. How to Read Calibration Procedure.......................................... 151 Table 3. Proc_Cal_001: Service Password Entry....................................... 153 Table 4. Proc_Cal_002: Hydraulic Valve Calibration Warm Up and A.................... 154 Table 5. Proc_Cal_003: Save and Exit................................................ 157 Table 6. Proc_Cal_004: Lift Valve Output Threshold.................................. 159 Table 7. Proc_Cal_005: Lower Valve Output Threshold................................. 162 Table 8. Proc_Cal_006: Tilt Back Valve Output Threshold............................. 165 Table 9. Proc_Cal_007: Tilt Forward Valve Output Threshold.......................... 169 Table 10. Proc_Cal_008: Aux 1 Dir A Valve Output Threshold.......................... 172 Table 11. Proc_Cal_009: Aux 1 Dir B Valve Output Threshold.......................... 175 Table 12. Proc_Cal_010: Aux 2 Dir A Valve Output Threshold.......................... 178 Table 13. Proc_Cal_011: Aux 2 Dir B Valve Output Threshold.......................... 181 Table 14. Proc_Cal_012: Aux 3 Dir A Valve Output Threshold.......................... 184 Table 15. Proc_Cal_013: Aux 3 Dir B Valve Output Threshold.......................... 187 Table 16. Proc_Cal_014: Load Weight Zero Point...................................... 190 Table 17. Proc_Cal_015: Loaded Weight Calibration................................... 192 Table 18. Proc_Cal_016: Transmission Valve Calibration.............................. 195 Table 19. Proc_Cal_016A: Transmission Valve Calibration............................. 197 Table 20. Proc_Cal_016B: Transmission Valve Calibration............................. 199 Table 21. Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjus.................... 201 Table 22. Proc_Cal_025: Hydraulic Valve Pressure Gage Installati.................... 203 Table 23. Proc_Cal_026: Travel Speed Calibration.................................... 204 Control Valve (1)........................................................................... 209 toc..................................................................................... 209 Main Control Valve.................................................................. 209 Safety Precautions Maintenance and Repair........................................... 210 General............................................................................. 215 Electro-Hydraulic Main Control Valve................................................ 216 Description..................................................................... 216 Remove.......................................................................... 222 Electro-Hydraulic Control Valve Sections........................................ 227 General..................................................................... 227 Outlet Control Valve Section................................................ 227 Remove.................................................................. 227 Disassemble............................................................. 228 Clean................................................................... 230 Inspect................................................................. 230 Assemble................................................................ 230 Install................................................................. 231 Auxiliary Control Valve Sections............................................ 231 Remove.................................................................. 231 Disassemble............................................................. 236 Clean................................................................... 237 Inspect................................................................. 237 Assemble................................................................ 238 Install................................................................. 239 Tilt Control Valve Section.................................................. 240 Remove.................................................................. 240 Disassemble............................................................. 240 Clean................................................................... 244 Inspect................................................................. 244 Assemble................................................................ 245 Install................................................................. 245 Lift/Lower Control Valve Section............................................ 246 Remove.................................................................. 246 Disassemble............................................................. 246 Clean................................................................... 253 Inspect................................................................. 253 Assemble................................................................ 253 Install................................................................. 255 Mid-Inlet Section........................................................... 255 Remove.................................................................. 255 Clean................................................................... 255 Inspect................................................................. 255 Install................................................................. 255 Install......................................................................... 256 Electro Hydraulic Poppet Valve (EHPV) Pilot Pin Adjustment...................... 260 Lift Pilot Pin.............................................................. 260 Lower Pilot Pin............................................................. 262 Abnormal/Erroneous EHPV Adjustment.......................................... 264 Manual Main Control Valve........................................................... 264 Description..................................................................... 264 Remove.......................................................................... 268 OPS Solenoid Assembly........................................................... 275 General..................................................................... 275 Remove...................................................................... 275 Clean and Inspect........................................................... 277 Install..................................................................... 277 Manual Control Valve Sections................................................... 278 General..................................................................... 278 Outlet Control Valve Section................................................ 278 Remove.................................................................. 278 Disassemble............................................................. 278 Clean................................................................... 281 Inspect................................................................. 281 Assemble................................................................ 281 Install................................................................. 282 Auxiliary Control Valve Sections............................................ 282 Remove.................................................................. 282 Disassemble............................................................. 285 Clean................................................................... 285 Inspect................................................................. 285 Assemble................................................................ 285 Install................................................................. 286 Lift/Tilt Control Valve Section............................................. 286 Remove.................................................................. 286 Disassemble............................................................. 286 Clean................................................................... 291 Inspect................................................................. 291 Assemble................................................................ 291 Install................................................................. 293 Mid-Inlet Section........................................................... 293 Remove.................................................................. 293 Clean................................................................... 293 Inspect................................................................. 293 Install................................................................. 294 Install......................................................................... 294 Pressure Relief Valve Check and Adjustment.......................................... 300 Primary Relief Valve............................................................ 300 Secondary Relief Valve.......................................................... 302 Steering Control Unit Repair........................................................ 307 Steering Control Unit, Remove................................................... 307 Steering Control Unit, Disassemble.............................................. 310 Steering Control Unit, Clean.................................................... 310 Steering Control Unit, Inspect.................................................. 310 Steering Control Unit, Assemble................................................. 312 Relief Valve, Disassemble....................................................... 312 Relief Valve, Clean............................................................. 313 Relief Valve, Inspect........................................................... 313 Relief Valve, Assemble.......................................................... 313 Steering Control Unit, Install.................................................. 313 tables.................................................................................. 209 Table 1. Relief Valve Settings...................................................... 301 Table 2. Steering Relief Pressures.................................................. 314 Control Valve............................................................................... 317 toc..................................................................................... 317 Main Control Valve.................................................................. 317 Safety Precautions Maintenance and Repair........................................... 318 General............................................................................. 323 Electro-Hydraulic Main Control Valve................................................ 324 Description..................................................................... 324 Remove.......................................................................... 330 Electro-Hydraulic Control Valve Sections........................................ 335 General..................................................................... 335 Outlet Control Valve Section................................................ 335 Remove.................................................................. 335 Disassemble............................................................. 336 Clean................................................................... 338 Inspect................................................................. 338 Assemble................................................................ 338 Install................................................................. 339 Auxiliary Control Valve Sections............................................ 339 Remove.................................................................. 339 Disassemble............................................................. 344 Clean................................................................... 345 Inspect................................................................. 345 Assemble................................................................ 346 Install................................................................. 347 Tilt Control Valve Section.................................................. 348 Remove.................................................................. 348 Disassemble............................................................. 348 Clean................................................................... 352 Inspect................................................................. 352 Assemble................................................................ 353 Install................................................................. 353 Lift/Lower Control Valve Section............................................ 354 Remove.................................................................. 354 Disassemble............................................................. 354 Clean................................................................... 361 Inspect................................................................. 361 Assemble................................................................ 361 Install................................................................. 363 Mid-Inlet Section........................................................... 363 Remove.................................................................. 363 Clean................................................................... 363 Inspect................................................................. 363 Install................................................................. 363 Install......................................................................... 364 Electro Hydraulic Poppet Valve (EHPV) Pilot Pin Adjustment...................... 368 Lift Pilot Pin.............................................................. 368 Lower Pilot Pin............................................................. 370 Abnormal/Erroneous EHPV Adjustment.......................................... 372 Manual Main Control Valve........................................................... 372 Description..................................................................... 372 Remove.......................................................................... 376 OPS Solenoid Assembly........................................................... 383 General..................................................................... 383 Remove...................................................................... 383 Clean and Inspect........................................................... 385 Install..................................................................... 385 Manual Control Valve Sections................................................... 386 General..................................................................... 386 Outlet Control Valve Section................................................ 386 Remove.................................................................. 386 Disassemble............................................................. 386 Clean................................................................... 389 Inspect................................................................. 389 Assemble................................................................ 389 Install................................................................. 390 Auxiliary Control Valve Sections............................................ 390 Remove.................................................................. 390 Disassemble............................................................. 393 Clean................................................................... 393 Inspect................................................................. 393 Assemble................................................................ 393 Install................................................................. 394 Lift/Tilt Control Valve Section............................................. 394 Remove.................................................................. 394 Disassemble............................................................. 394 Clean................................................................... 399 Inspect................................................................. 399 Assemble................................................................ 399 Install................................................................. 401 Mid-Inlet Section........................................................... 401 Remove.................................................................. 401 Clean................................................................... 401 Inspect................................................................. 401 Install................................................................. 402 Install......................................................................... 402 Pressure Relief Valve Check and Adjustment.......................................... 408 Primary Relief Valve............................................................ 408 Secondary Relief Valve.......................................................... 410 Steering Control Unit Repair........................................................ 415 Steering Control Unit, Remove................................................... 415 Steering Control Unit, Disassemble.............................................. 418 Steering Control Unit, Clean.................................................... 418 Steering Control Unit, Inspect.................................................. 418 Steering Control Unit, Assemble................................................. 420 Relief Valve, Disassemble....................................................... 420 Relief Valve, Clean............................................................. 421 Relief Valve, Inspect........................................................... 421 Relief Valve, Assemble.......................................................... 421 Steering Control Unit, Install.................................................. 421 tables.................................................................................. 317 Table 1. Relief Valve Settings...................................................... 409 Table 2. Steering Relief Pressures.................................................. 422 Cooling System (1).......................................................................... 425 toc..................................................................................... 425 Cooling System...................................................................... 425 Safety Precautions Maintenance and Repair........................................... 426 General............................................................................. 429 Cooling System Checks............................................................... 429 Exhaust Leaks Into Cooling System............................................... 429 Water Flow Restrictions in Radiator............................................. 429 Radiator Hoses.................................................................. 429 Water Pump...................................................................... 429 Flushing the Cooling System......................................................... 430 Cooling System, Clean........................................................... 430 Radiator Replacement................................................................ 431 Radiator, Remove for Lift Trucks Models S30FT, S35FT, S40FTS (E0................ 431 Radiator, Remove for Lift Truck Models S6.0FT, S7.0FT (S135FT, S................ 444 Radiator, Remove for Lift Truck Models H6.0FT, H7.0FT (H135FT, H................ 445 Radiator, Install for Lift Truck Models S30FT, S35FT, S40FTS (E0................ 448 Radiator, Install for Lift Truck Models S6.0FT, S7.0FT (S135FT, ................ 450 Radiator, Install for Lift Truck Models H6.0FT, H7.0FT (H135FT, ................ 453 Fan Assembly Replacement............................................................ 460 Fan Removal..................................................................... 460 Inspect......................................................................... 472 Fan Installation................................................................ 472 Cooling System.............................................................................. 477 toc..................................................................................... 477 Cooling System...................................................................... 477 Safety Precautions Maintenance and Repair........................................... 478 General............................................................................. 481 Cooling System Checks............................................................... 481 Exhaust Leaks Into Cooling System............................................... 481 Water Flow Restrictions in Radiator............................................. 481 Radiator Hoses.................................................................. 481 Water Pump...................................................................... 481 Flushing the Cooling System......................................................... 482 Cooling System, Clean........................................................... 482 Radiator Replacement................................................................ 483 Radiator, Remove for Lift Trucks Models S30FT, S35FT, S40FTS (E0................ 483 Radiator, Remove for Lift Truck Models S6.0FT, S7.0FT (S135FT, S................ 496 Radiator, Remove for Lift Truck Models H6.0FT, H7.0FT (H135FT, H................ 497 Radiator, Install for Lift Truck Models S30FT, S35FT, S40FTS (E0................ 500 Radiator, Install for Lift Truck Models S6.0FT, S7.0FT (S135FT, ................ 502 Radiator, Install for Lift Truck Models H6.0FT, H7.0FT (H135FT, ................ 505 Fan Assembly Replacement............................................................ 512 Fan Removal..................................................................... 512 Inspect......................................................................... 524 Fan Installation................................................................ 524 Diagrams (1)................................................................................ 529 toc..................................................................................... 529 Diagrams and Schematics............................................................. 529 Safety Precautions Maintenance and Repair........................................... 530 General Information About Diagrams and Schematics................................... 533 Symbol Definitions.............................................................. 534 Diagrams Manual Applications.................................................... 534 tables.................................................................................. 529 Table 1. Wire Colors................................................................ 533 Table 2. Symbol Definitions......................................................... 534 Table 3. 1-8 Ton Diagrams Manual Applications....................................... 534 Diagrams.................................................................................... 597 toc..................................................................................... 597 Diagrams and Schematics............................................................. 597 Safety Precautions Maintenance and Repair........................................... 598 General Information About Diagrams and Schematics................................... 601 Symbol Definitions.............................................................. 602 Diagrams Manual Applications.................................................... 602 tables.................................................................................. 597 Table 1. Wire Colors................................................................ 601 Table 2. Symbol Definitions......................................................... 602 Table 3. 1-8 Ton Diagrams Manual Applications....................................... 602 Drive Axle (1).............................................................................. 665 toc..................................................................................... 665 Drive Axle and Differential Assembly Repair......................................... 665 Safety Precautions Maintenance and Repair........................................... 666 General............................................................................. 669 Drive Axle Repair................................................................... 669 Remove and Disassemble.......................................................... 669 Clean and Inspect............................................................... 669 Assemble and Install............................................................ 671 Differential Repair................................................................. 673 Remove.......................................................................... 673 Differential Assembly From Center Section................................... 673 Drive Pinion, Pinion Gear, and Bearings From Center Section................. 677 Disassemble..................................................................... 681 Differential Assembly....................................................... 681 Drop Box Housing............................................................ 684 Center Section.............................................................. 685 Clean and Inspect............................................................... 687 Assemble........................................................................ 687 Center Section.............................................................. 687 Drop Box Housing............................................................ 690 Differential Assembly....................................................... 691 Install......................................................................... 695 Pinion Inner Shim Set, Adjust Thickness (Depth of Pinion)................... 695 Drive Pinion, Pinion Gear, and Bearings Into Center Section................. 697 Differential Assembly Into Center Section................................... 700 Ring Gear Backlash, Adjust.................................................. 705 Ring Gear, Runout Check..................................................... 707 Gear Set, Tooth Contact Pattern Check....................................... 707 Torque Specifications............................................................... 710 tables.................................................................................. 665 Table 1. Pinion Variation Numbers Examples.......................................... 696 Table 2. Ring and Pinion Tooth Contact Adjustment................................... 707 Table 3. Correct Tooth Contact...................................................... 708 Table 4. Incorrect Tooth Contact.................................................... 709 Drive Axle.................................................................................. 713 toc..................................................................................... 713 Drive Axle and Differential Assembly Repair......................................... 713 Safety Precautions Maintenance and Repair........................................... 714 General............................................................................. 717 Drive Axle Repair................................................................... 717 Remove and Disassemble.......................................................... 717 Clean and Inspect............................................................... 717 Assemble and Install............................................................ 719 Differential Repair................................................................. 721 Remove.......................................................................... 721 Differential Assembly From Center Section................................... 721 Drive Pinion, Pinion Gear, and Bearings From Center Section................. 725 Disassemble..................................................................... 729 Differential Assembly....................................................... 729 Drop Box Housing............................................................ 732 Center Section.............................................................. 733 Clean and Inspect............................................................... 735 Assemble........................................................................ 735 Center Section.............................................................. 735 Drop Box Housing............................................................ 738 Differential Assembly....................................................... 739 Install......................................................................... 743 Pinion Inner Shim Set, Adjust Thickness (Depth of Pinion)................... 743 Drive Pinion, Pinion Gear, and Bearings Into Center Section................. 745 Differential Assembly Into Center Section................................... 748 Ring Gear Backlash, Adjust.................................................. 753 Ring Gear, Runout Check..................................................... 755 Gear Set, Tooth Contact Pattern Check....................................... 755 Torque Specifications............................................................... 758 tables.................................................................................. 713 Table 1. Pinion Variation Numbers Examples.......................................... 744 Table 2. Ring and Pinion Tooth Contact Adjustment................................... 755 Table 3. Correct Tooth Contact...................................................... 756 Table 4. Incorrect Tooth Contact.................................................... 757 DTC (1)..................................................................................... 761 toc..................................................................................... 761 Diagnostic Troubleshooting Manual................................................... 761 Safety Precautions TROUBLESHOOTING PROCEDURES....................................... 762 How To Use This Troubleshooting Manual.............................................. 764 General Instructions and Safety Information..................................... 764 How to Use Diagnostic Troubleshooting Manual.................................... 764 General Instructions............................................................ 765 Operational Diagnostic Procedures................................................... 767 Operational Checkout Procedures................................................. 769 DTC Check................................................................... 770 Horn Circuit Check.......................................................... 770 Light Circuit Check......................................................... 770 Windshield Washer Wiper Check (If equipped)................................. 770 Heater Check (If equipped).................................................. 771 Dome Light Check (If equipped).............................................. 771 Circulating (Accessory) Fan Check (If equipped)............................. 772 Indicator Light Power Check................................................. 773 Engine Malfunction Indicator Check.......................................... 774 Cold Start Check (Cummins and Yanmar)....................................... 774 Brake Pedal Check 1-7 Ton Only.............................................. 775 Brake Check 8-9 Ton Only.................................................... 776 Backup Alarm Check (If equipped)............................................ 776 Operator Presence System Check.............................................. 776 Hydraulic Interlock Check................................................... 776 Armrest Hydraulic Interlock Check [If equipped and with original............ 778 Engine Cover Latch Sensor Check (If equipped)............................... 778 Brake and Inching Pedal Check............................................... 778 Park Brake Sensor Check..................................................... 778 Park Brake Check............................................................ 779 Engine Speed Check (All Cummins, Yanmar, and Mazda Engines Excep............ 779 Engine Power Check.......................................................... 780 Transmission Clutch Check................................................... 780 Transmission Check.......................................................... 781 Transmission Speed Selection Check (If equipped)............................ 781 Brake and Axle Drag Check................................................... 781 Hydraulic Pump Flow Check................................................... 782 Priority Flow Divider Valve Check........................................... 783 Steering Relief Valve Low Pressure Check.................................... 783 Steering Relief Valve High Pressure Check................................... 784 Control Valve Load Check Valve (Manual Valve)............................... 784 Lift E-Valve Check.............................................................. 784 Lift Check (E-Valve)........................................................ 784 Tilt Function Counterbalance Check.......................................... 785 Lift Drift Check............................................................ 785 Tilt Function Drift Check................................................... 786 Mast Cushion Check (All Except 2-Stage Mast)................................ 786 Lift/Tilt Mast Adjustment Check............................................. 787 Tilt Racking Check.......................................................... 787 Chain and Header Hose Adjustment Check...................................... 788 Mast Mounting Check......................................................... 788 Mast Channel Check.......................................................... 789 Carriage Adjustment Check................................................... 789 Chain Sheave Check.......................................................... 790 Carriage Adjustment Check (Standard and Integral Side Shift)................ 790 Engine.............................................................................. 791 Engine Basics................................................................... 799 General Terminology......................................................... 799 Combustion Theory........................................................... 799 Engine Components – Cylinder Block.......................................... 800 Camshaft and Timing Set..................................................... 801 Cylinder Head Assembly...................................................... 801 Valve Train Assembly........................................................ 801 Manifolds................................................................... 801 Air Cleaner/Filter.......................................................... 802 Carburetion................................................................. 802 Electronic Fuel Injection (EFI)............................................. 802 Positive Crankcase Ventilation (PCV)........................................ 802 Engine Electrical............................................................... 803 Introduction................................................................ 803 Battery Construction........................................................ 803 Conventional Standard Battery............................................... 803 Maintenance-Free Battery.................................................... 804 Battery Charging............................................................ 804 Battery Fast Charging....................................................... 804 Battery Slow Charging....................................................... 805 Starting System Principles of Operation..................................... 805 Starting System Components - Ignition Switch................................ 805 Starting System Components - Starter Solenoid............................... 805 Starting System Components - Flywheel and Ring Gear......................... 806 Starting System Components - Starter Motor and Drive........................ 806 Charging System - General................................................... 806 Charging System - Regulator................................................. 806 Charging System - Theory.................................................... 807 Engine Fuel System/Exhaust and Emissions........................................ 808 Introduction................................................................ 808 Gasoline System Components - Fuel Tank...................................... 808 Electronic Fuel Injector (EFI) - General Description........................ 808 Port Fuel System Components - ECU........................................... 808 Port Fuel System Components - Fuel Pump/Filter.............................. 808 Port Fuel System Components - Fuel Rail..................................... 808 Port Fuel System Components - Pressure Regulator............................ 808 Port Fuel System Components - Fuel Injectors................................ 808 LPG Systems General Information............................................. 809 LPG Fuel Properties......................................................... 809 LPG Fuel Tank............................................................... 809 PSI Closed-Loop System...................................................... 809 Electrical Fuel Lockoff Valve........................................... 810 Direct Electronic Pressure Regulator (DEPR)............................. 810 Air Fuel Mixer.......................................................... 810 Electronic Throttle Control Device (ETC)................................ 811 Three-Way Catalytic Converter........................................... 811 Engine Control Module (ECM)............................................. 811 Heated Exhaust Gas Oxygen Sensors (HEGO)................................ 812 TMAP Sensor............................................................. 812 Coolant Temperature Sensor€(ECT)........................................ 812 Oil Pressure Sender..................................................... 812 AISAN Closed-Loop System.................................................... 812 Filter/Lockoff and Regulator............................................ 812 Carburetor.............................................................. 813 Start Mode.............................................................. 813 Idle Mode............................................................... 813 Run Mode................................................................ 813 Main Fuel Lockoff Solenoid.................................................. 814 Injector Fuel Lockoff Solenoid.............................................. 814 Oxygen (O 2 ) Sensor.................................................... 814 Electronic Control Unit (ECU)............................................... 814 Catalytic Converter/Muffler................................................. 814 Engine Management............................................................... 814 Introduction................................................................ 814 Ignition and Timing - Conventional Spark.................................... 814 Components - Ignition Coil.................................................. 814 Components - Distributor.................................................... 815 Spark Timing................................................................ 815 Components - Ignition Wires................................................. 815 Components - Spark Plugs.................................................... 815 Faulty or Fouled Spark Plugs................................................ 815 Electric Controlled Governing System - Mazda LPG............................ 816 ECONOMY MODE (ECO-eLo)...................................................... 816 Engine Identification........................................................... 816 Cummins (Diesel) Engine......................................................... 819 Description................................................................. 819 Diesel Fuel System.......................................................... 820 Principle of Operation.................................................. 820 Fuel Injection Pump and Governor............................................ 821 Description............................................................. 821 Principles of Operation................................................. 823 Cummins Engine Control...................................................... 823 Engine Speed (RPM) Sensor............................................... 824 Throttle Position Sensor................................................ 825 Electronic Throttle Actuator............................................ 826 Engine Oil Pressure Sensor.............................................. 826 Coolant Temperature Sensor.............................................. 827 Air Restriction Switch.................................................. 828 Fuel Filter/Water Separator............................................. 828 Fuel Level Sensor (In Tank)............................................. 828 Engine Electrical System.................................................... 829 Magnetic Valve (Engine Stop Solenoid)................................... 829 Alternator.............................................................. 829 Grid Heater............................................................. 829 Cold Start Timing Advance (Fuel Injection Pump)......................... 829 Cummins QSB 3.3L (Diesel) Engine................................................ 830 Description................................................................. 830 Diesel Fuel System.......................................................... 831 Electronics System.......................................................... 832 Engine Protection....................................................... 833 Diagnostics............................................................. 833 Grid Heater............................................................. 834 Turbocharger and Charge Air Cooler.......................................... 834 Cooling System.............................................................. 835 Crankcase Oil Separator..................................................... 836 Lubrication System.......................................................... 837 Mazda Engine Overview........................................................... 838 Description................................................................. 838 Fuel System................................................................. 838 Engine Controls Unit (ECU) and Emissions.................................... 838 Cooling System.............................................................. 838 Ignition System............................................................. 838 Mazda (LPG) Engine Controls..................................................... 839 LPG System (Aisan/E-Controls-Mechanical).................................... 839 Description............................................................. 839 Principles of Operation................................................. 840 Control System.......................................................... 842 Oxygen (O 2 ) Sensor.................................................... 843 Engine Coolant Temperature Sensor....................................... 843 Fuel Tank............................................................... 845 Regulator............................................................... 846 Start Mode.......................................................... 847 Idle Mode........................................................... 848 Run Mode............................................................ 848 Resonator............................................................... 848 Carburetor.............................................................. 849 Start Mode.......................................................... 849 Idle Mode........................................................... 849 Run Mode............................................................ 849 Governor................................................................ 850 LPG System (E-Controls)..................................................... 850 Description............................................................. 850 Principles of Operation................................................. 850 Manifold Absolute Pressure Sensor....................................... 850 Throttle Position Sensor................................................ 850 Oxygen (O 2 ) Sensor.................................................... 851 Engine Coolant Temperature Sensor....................................... 851 Intake Air Temperature Sensor........................................... 851 Engine Control Unit..................................................... 851 Accelerator Pedal Position Sensor....................................... 851 Three-Way Catalytic Converter........................................... 851 Camshaft Position Sensor................................................ 852 Electric Controlled Governing System.................................... 853 Electronic Governor Sensor.............................................. 853 Electronic Pressure Regulator........................................... 854 Mazda (Gasoline) Engine Controls................................................ 855 Gasoline System............................................................. 855 Description............................................................. 855 Principles of Operation (Lift Trucks Built Before January, 2007)........ 857 Principles of Operation (Lift Trucks Built After January, 2007)......... 859 Control System.............................................................. 862 Camshaft Position Sensor................................................ 864 Intake Air Temperature Sensor........................................... 865 Mass Air Flow Sensor, If Applicable..................................... 866 Electronic Throttle Assembly (ETA)...................................... 867 Throttle Position Sensor................................................ 867 Electrical Throttle Control System...................................... 868 Electronic Governor Sensor.............................................. 868 Electronic Governing System............................................. 870 Manifold Absolute Pressure Sensor/Boost Sensor.......................... 870 Engine Coolant Temperature Sensor (Lift Trucks Built Before Janu........ 871 Intake Air System........................................................... 873 Throttle Body (Lift Trucks Built Before January, 2007).................. 873 Intake Air Temperature Sensor (Lift Trucks Built After January, ........ 873 Idle Air Control Valve, If Applicable................................... 874 Fuel System................................................................. 875 Fuel Injector........................................................... 875 Pressure Regulator...................................................... 876 Exhaust System.............................................................. 877 Heated Oxygen (O 2 ) Sensor (Lift Trucks Built Before January, 2........ 877 Heated Exhaust Gas Oxygen (O 2 ) Sensor (Lift Trucks Built After........ 877 Three-Way Catalytic Converter........................................... 878 GM (LPG) Engine Controls........................................................ 879 Engine Control System ...................................................... 879 Engine Control System Overview.......................................... 880 Principles of Operation................................................. 880 Control System.............................................................. 881 GM/TGFI 2.4L (Four Cylinder) Control System Component Location.......... 881 GM/TGFI 4.3L (Six Cylinder) Control System Component Location........... 882 GM/TGFI 2.4L (Four-Cylinder) LPG System................................. 883 GM/TGFI 4.3L (Six-Cylinder) LPG System.................................. 886 Fuel Tank............................................................... 889 Engine Control Unit..................................................... 889 Electronic Throttle Body/Throttle Position Sensor....................... 890 Manifold Absolute Pressure/Manifold Air Temperature Sensor.............. 891 Propane Injectors....................................................... 892 Peak and Hold Drive Injector (Lift Trucks Built Before January, ........ 893 Saturated Drive Injector (Lift Trucks Built After January, 2010)........ 894 Engine Coolant Temperature Sensor....................................... 895 Oxygen (O 2 ) Sensor.................................................... 895 Crankshaft Position Sensor (Engine Speed Sensor)........................ 896 Oil Pressure Sensor..................................................... 896 Power Latch Relay....................................................... 896 GM 2.4L Camshaft Position Sensor........................................ 896 GM 4.3L Camshaft Position Sensor........................................ 897 Injector Driver Module.................................................. 898 Vaporizer/Regulator..................................................... 898 Accelerator Pedal Position Sensor....................................... 901 Three-Way Catalytic Converter........................................... 902 Ignition System............................................................. 902 Ignition Coils.......................................................... 902 Distributorless Ignition System Module.................................. 902 Electronic Ignition Signals............................................. 903 Distributor Ignition (DI) System........................................ 903 Camshaft Position (CMP) Sensor.......................................... 903 Ignition Coil and Ignition Control Module (ICM)......................... 904 Secondary Ignition Components........................................... 904 GM (5.7L V-8 LPG) Overview...................................................... 904 Description................................................................. 904 Fuel System................................................................. 904 Engine Controls Unit (ECU) and Emissions.................................... 904 Cooling System.............................................................. 904 Ignition System............................................................. 904 GM (Gasoline) Engine Controls................................................... 905 Engine Control System....................................................... 905 GM 2.4L (Four Cylinder) Engine Control System........................... 905 GM 4.3L (Six Cylinder) Engine Control System............................ 906 Engine Control System Overview.......................................... 907 Principles of Operation................................................. 907 Control System.............................................................. 908 GM/TGFI 2.4L (Four Cylinder) Control System Component Location.......... 908 GM/TGFI 4.3L (Six Cylinder) Control System Component Location........... 909 GM/TGFI 2.4L (Four-Cylinder) Gasoline System Components................. 910 GM/TGFI 4.3L (Six Cylinder) Gasoline System Components.................. 913 Engine Control Unit..................................................... 916 Electronic Throttle Body/Throttle Position Sensor....................... 916 Manifold Absolute Pressure/Manifold Air Temperature Sensor ............. 917 Fuel Injector........................................................... 918 Engine Coolant Temperature Sensor....................................... 919 Oxygen (O 2 ) Sensor.................................................... 920 Crankshaft Position Sensor (Engine Speed Sensor)........................ 920 Oil Pressure Sensor..................................................... 920 Power Latch Relay....................................................... 920 Camshaft Position Sensor................................................ 920 Accelerator Pedal Position Sensor....................................... 922 Three-Way Catalytic Converter........................................... 922 Ignition System............................................................. 922 Ignition Coils.......................................................... 922 Distributorless Ignition System Module.................................. 922 Electronic Ignition Signals............................................. 923 Yanmar (Diesel) Engine.......................................................... 924 Description................................................................. 924 Diesel Fuel System.......................................................... 925 Principles of Operation................................................. 925 Fuel Injection Pump and Governor............................................ 926 Description............................................................. 926 Principles of Operation................................................. 928 Timer................................................................... 929 Feed Pump (Vane Type)................................................... 929 Regulating Valve........................................................ 930 Injection Pump Plunger.................................................. 931 Suction Process..................................................... 932 Injection Process................................................... 932 End of Injection.................................................... 933 Uniform Pressure Process............................................ 933 Reverse Rotation Prevention Mechanism................................... 934 Fuel Injection Volume Adjustment Mechanism.............................. 934 Delivery Valve Assembly................................................. 934 Delivery Valve Holder with Damping Valve................................ 935 All - Speed Governor.................................................... 936 At Start of Engine...................................................... 938 During Idle............................................................. 939 At Full - Load Maximum Speed Control.................................... 940 At No-Load Maximum Speed Control........................................ 941 Full-Load Position Adjustment Mechanism................................. 942 Structure and Operation of Timer............................................ 943 Standard Type Automatic Timer........................................... 943 Yanmar Engine Controls...................................................... 944 Engine Speed (RPM) Sensor............................................... 945 Throttle Position Sensor................................................ 945 Electronic Throttle Actuator............................................ 946 Engine Oil Pressure Sensor.............................................. 946 Coolant Temperature Sensor.............................................. 947 Air Filter Restriction Switch........................................... 947 Fuel Filter/Water Separator and Strainer................................ 948 Fuel Level Sensor....................................................... 948 Engine Electrical System.................................................... 949 Magnetic Valve (Engine Stop Solenoid)................................... 949 Alternator.............................................................. 949 Glow Plugs.............................................................. 949 Cold Start Timing Advance (Fuel Injection Pump)......................... 949 Cooling System - All Engines.................................................... 950 Description................................................................. 950 Radiator.................................................................... 950 Combination Cooler/Standard Radiator.................................... 950 Radiator Cap................................................................ 951 Thermostat.................................................................. 951 Engine Coolant Pump......................................................... 952 Fan......................................................................... 952 GM Engine Coolant Flow Diagram.............................................. 952 Yanmar Diesel Engine Coolant Flow Diagram................................... 953 Engine Does Not Crank........................................................... 955 Engine Does Not Start/Engine is Hard to Start................................... 958 Engine Idle Speed Incorrect..................................................... 964 Engine Idle Speed is Unstable or Engine Stalls at Idle.......................... 967 Engine Cuts Out, Misses, Hesitates, Sags, or Stumbles........................... 973 Engine Lack of Power............................................................ 980 Engine Speed Surge Or Engine Speed Unstable..................................... 988 Engine Backfires................................................................ 993 Engine Is Knocking or Pinging................................................... 996 Excessive Engine Vibrations.....................................................1001 Abnormal Engine and Exhaust Noises..............................................1006 Fan or Alternator Bearing Noise.................................................1011 Abnormal Engine and Exhaust Smells..............................................1013 High Engine Fuel Consumption....................................................1015 Fuel Leaks......................................................................1019 High Engine Oil Consumption.....................................................1023 Engine Oil Leaks................................................................1025 Engine Oil is Discolored........................................................1030 Engine Coolant Leaks............................................................1032 Engine Coolant is Discolored....................................................1035 Engine Exhaust is Discolored....................................................1036 Engine Fails Emission Compliance Check..........................................1040 Alternator Light is Illuminated.................................................1044 Engine is Overheating...........................................................1045 Air Intake Manifold Temperature too High (Cummins QSB 3.3L Only)................1048 Air Intake Manifold Pressure (Boost) is Below Normal (Cummins QS................1049 Engine Coolant Temperature is Low...............................................1050 Engine Oil Pressure is Low......................................................1051 Radiator Bubble Test............................................................1053 Engine Compression Test (GM and Mazda)..........................................1054 Engine Compression Test (Yanmar Diesel).........................................1055 Engine Oil Pressure Test........................................................1056 Fuel System Pressure Test (Gasoline Engines Only)...............................1059 Fuel System Pressure Test (LPG ENGINES ONLY)....................................1061 Engine Description..........................................................1061 EPR Primary Pressure Test...................................................1062 EPR Secondary Pressure Test.................................................1063 Fuel Injection Nozzle Test (Yanmar Diesel)......................................1064 Vacuum Leak.....................................................................1065 Vacuum Leak Detection.......................................................1065 Vacuum Leak Repairs.........................................................1065 Coolant System Test.............................................................1066 Electrical System...................................................................1067 Troubleshooting Guidelines and Procedures.......................................1083 Troubleshooting Guidelines..................................................1083 Troubleshooting Procedures..................................................1086 Troubleshooting Procedures, Identification..............................1086 Troubleshooting Procedures, Location....................................1086 Troubleshooting Procedures, Structure...................................1086 Troubleshooting Procedures, Performance.................................1087 Diagnostic Trouble Codes........................................................1088 Diagnostic Trouble Codes....................................................1088 Wiring Reference Data...........................................................1102 Post 2007 Engine Connections....................................................1106 Cummins 4.5L................................................................1106 GM 2.4L (GAS/LPG)...........................................................1107 GM 4.3L (GAS/LPG)...........................................................1108 Mazda 2.0/2.2L (GAS/LPG)....................................................1109 Yanmar 2.6/3.3L.............................................................1110 Harness Assembly Data...........................................................1111 Electrical System...............................................................1159 General Description.........................................................1159 Description.................................................................1161 Principles of Operation, Components.........................................1165 Principles Of Operation, System.............................................1173 100-2...........................................................................1181 100-2...........................................................................1181 100-3...........................................................................1181 135-3...........................................................................1181 135-16..........................................................................1181 523859-3........................................................................1181 524223-3........................................................................1181 524224-3........................................................................1181 524225-3........................................................................1181 524282-3........................................................................1181 523958-3........................................................................1181 523959-3........................................................................1181 135-16..........................................................................1192 100-4...........................................................................1195 135-4...........................................................................1195 135-18..........................................................................1195 523859-4........................................................................1195 523958-4........................................................................1195 523959-4........................................................................1195 524223-4........................................................................1195 524224-4........................................................................1195 524225-4........................................................................1195 524282-4........................................................................1195 135-18..........................................................................1205 524223-0........................................................................1210 524224-0........................................................................1210 524225-0........................................................................1210 524229-0........................................................................1210 524270-0........................................................................1210 524276-0........................................................................1210 524223-1........................................................................1215 524224-1........................................................................1215 524225-1........................................................................1215 524229-1........................................................................1215 524270-1........................................................................1215 524276-1........................................................................1215 110-3...........................................................................1219 110-3...........................................................................1219 110-5...........................................................................1219 110-16..........................................................................1219 177-3...........................................................................1219 522231-3........................................................................1219 522555-3........................................................................1219 522603-3........................................................................1219 524010-3........................................................................1219 524235-3........................................................................1219 110-4...........................................................................1229 110-4...........................................................................1229 177-4...........................................................................1229 522231-4........................................................................1229 522555-4........................................................................1229 522603-4........................................................................1229 524010-4........................................................................1229 524235-4........................................................................1229 110-2...........................................................................1238 110-2...........................................................................1238 110-10..........................................................................1241 522565-2........................................................................1246 522712-3........................................................................1247 522713-3........................................................................1247 522712-4........................................................................1253 522713-4........................................................................1253 51-2............................................................................1259 51-7............................................................................1259 91-2............................................................................1268 91-2............................................................................1268 91-2............................................................................1268 91-2............................................................................1268 91-11...........................................................................1268 522708-3........................................................................1275 522710-3........................................................................1275 522711-3........................................................................1275 522714-3........................................................................1275 522708-4........................................................................1283 522710-4........................................................................1283 522711-4........................................................................1283 522714-4........................................................................1283 515-0...........................................................................1291 523780-3........................................................................1296 523860-3........................................................................1296 524245-3........................................................................1296 524275-3........................................................................1296 523780-4........................................................................1303 523860-4........................................................................1303 524245-4........................................................................1303 524275-4........................................................................1303 677-3...........................................................................1310 2350-3..........................................................................1310 522754-3........................................................................1310 522755-3........................................................................1310 522764-3........................................................................1310 522766-3........................................................................1310 524230-3........................................................................1310 SYMPTOMS WARNING................................................................1310 677-4...........................................................................1317 2350-4..........................................................................1317 522754-4........................................................................1317 522755-4........................................................................1317 522764-4........................................................................1317 522766-4........................................................................1317 524230-4........................................................................1317 676-3...........................................................................1322 524195-3........................................................................1322 524269-3........................................................................1322 676-4...........................................................................1328 524195-4........................................................................1328 524269-4........................................................................1328 524269-7........................................................................1334 524215-3........................................................................1337 524215-6........................................................................1337 524237-3........................................................................1341 524238-3........................................................................1341 524240-3........................................................................1341 524237-4........................................................................1346 524238-4........................................................................1346 524240-4........................................................................1346 879-3...........................................................................1352 880-3...........................................................................1352 881-3...........................................................................1352 882-3...........................................................................1352 522772-3........................................................................1352 879-4...........................................................................1356 880-4...........................................................................1356 881-4...........................................................................1356 882-4...........................................................................1356 522772-4........................................................................1356 168-0...........................................................................1360 168-3...........................................................................1360 521982-3........................................................................1364 522760-3........................................................................1364 522761-3........................................................................1364 522762-3........................................................................1364 1079-31.........................................................................1372 522128-3........................................................................1372 524251-0........................................................................1372 524260-0........................................................................1372 524260-3........................................................................1372 524261-0........................................................................1372 524261-3........................................................................1372 51-31...........................................................................1372 168-1...........................................................................1384 168-4...........................................................................1384 521982-4........................................................................1388 522760-4........................................................................1388 522761-4........................................................................1388 522761-6........................................................................1388 522762-4........................................................................1388 1079-31.........................................................................1396 522128-4........................................................................1396 524251-1........................................................................1396 524260-1........................................................................1396 524260-4........................................................................1396 524261-1........................................................................1396 524261-4........................................................................1396 51-31...........................................................................1396 524260-2........................................................................1407 524260-11.......................................................................1407 524261-2........................................................................1407 524261-11.......................................................................1407 96-3............................................................................1411 96-4............................................................................1411 522810-3........................................................................1415 522810-4........................................................................1420 524213-1........................................................................1424 524213-3........................................................................1424 524213-4........................................................................1424 523920-3........................................................................1428 523925-3........................................................................1428 523930-3........................................................................1428 523977-3........................................................................1428 523978-3........................................................................1428 523986-3........................................................................1428 524284-3........................................................................1428 524285-3........................................................................1428 523920-4........................................................................1434 523925-4........................................................................1434 523930-4........................................................................1434 523977-4........................................................................1434 523978-4........................................................................1434 523986-4........................................................................1434 524284-4........................................................................1434 524285-4........................................................................1434 523920-6........................................................................1439 523925-6........................................................................1439 523930-6........................................................................1439 523977-6........................................................................1439 523978-6........................................................................1439 523986-6........................................................................1439 524284-6........................................................................1439 524285-6........................................................................1439 105-3...........................................................................1444 105-3...........................................................................1444 105-16..........................................................................1444 522570-3........................................................................1444 105-4...........................................................................1451 105-4...........................................................................1451 522570-4........................................................................1451 105-5...........................................................................1456 106-3...........................................................................1459 106-4...........................................................................1464 106-0...........................................................................1469 106-1...........................................................................1469 106-2...........................................................................1469 106-14..........................................................................1469 522609-3........................................................................1472 522739-3........................................................................1472 522740-3........................................................................1472 522608-5........................................................................1477 522739-5........................................................................1477 522740-5........................................................................1477 522608-6........................................................................1482 522739-6........................................................................1482 522740-6........................................................................1482 522735-2........................................................................1487 522735-4........................................................................1490 522736-4........................................................................1490 522735-5........................................................................1494 522736-5........................................................................1494 522735-6........................................................................1498 522736-6........................................................................1498 522630-2........................................................................1503 522631-2........................................................................1503 522632-2........................................................................1503 522633-2........................................................................1503 522635-3........................................................................1503 522636-4........................................................................1503 522637-3........................................................................1503 522638-4........................................................................1503 522606-10.......................................................................1508 522737-10.......................................................................1508 522525-10.......................................................................1508 651-3...........................................................................1515 652-3...........................................................................1515 653-3...........................................................................1515 654-3...........................................................................1515 655-3...........................................................................1515 656-3...........................................................................1515 522599-3........................................................................1515 522600-3........................................................................1515 522601-3........................................................................1515 522602-3........................................................................1515 522721-3........................................................................1515 522722-3........................................................................1515 522723-3........................................................................1515 522724-3........................................................................1515 522725-3........................................................................1515 522726-3........................................................................1515 522599-3........................................................................1515 522600-3........................................................................1515 522601-3........................................................................1515 522602-3........................................................................1515 651-5...........................................................................1523 651-5...........................................................................1523 652-5...........................................................................1523 652-5...........................................................................1523 653-5...........................................................................1523 653-5...........................................................................1523 654-5...........................................................................1523 654-5...........................................................................1523 655-5...........................................................................1523 656-5...........................................................................1523 522721-5........................................................................1523 522722-5........................................................................1523 522723-5........................................................................1523 522724-5........................................................................1523 522725-5........................................................................1523 522726-5........................................................................1523 651-6...........................................................................1528 652-6...........................................................................1528 653-6...........................................................................1528 654-6...........................................................................1528 655-6...........................................................................1528 656-6...........................................................................1528 522599-4........................................................................1528 522600-4........................................................................1528 522601-4........................................................................1528 522602-4........................................................................1528 522721-6........................................................................1528 522722-6........................................................................1528 522723-6........................................................................1528 522724-6........................................................................1528 522725-6........................................................................1528 522726-6........................................................................1528 2000-9..........................................................................1536 2000-12.........................................................................1536 2000-12.........................................................................1536 2000-12.........................................................................1536 2000-12.........................................................................1536 2000-14.........................................................................1536 2003-12.........................................................................1536 2023-12.........................................................................1536 2039-2..........................................................................1536 2039-12.........................................................................1536 2235-12.........................................................................1536 2236-12.........................................................................1536 2238-12.........................................................................1536 521670-12.......................................................................1536 524258-2........................................................................1536 522215-12.......................................................................1547 522215-14.......................................................................1547 524236-14.......................................................................1547 524262-12.......................................................................1547 524262-14.......................................................................1547 524263-1........................................................................1547 524268-12.......................................................................1547 628-12..........................................................................1550 630-12..........................................................................1550 522690-2........................................................................1550 522690-12.......................................................................1550 522691-2........................................................................1550 522691-12.......................................................................1550 522692-2........................................................................1550 522693-12.......................................................................1550 522694-12.......................................................................1550 522695-2........................................................................1550 522696-2........................................................................1550 522697-12.......................................................................1550 522697-12.......................................................................1550 522698-2........................................................................1550 522699-2........................................................................1550 522700-2........................................................................1550 190-2...........................................................................1553 190-2...........................................................................1553 190-7...........................................................................1553 522120-1........................................................................1553 522585-2........................................................................1553 520800-7........................................................................1560 522752-8........................................................................1560 522752-9........................................................................1560 524250-14.......................................................................1565 524264-2........................................................................1565 524265-2........................................................................1565 524271-2........................................................................1565 524225-14.......................................................................1565 524264-14.......................................................................1570 628-12..........................................................................1573 630-12..........................................................................1573 2660-3..........................................................................1573 2660-4..........................................................................1573 2661-3..........................................................................1573 2661-4..........................................................................1573 2802-12.........................................................................1573 523510-12.......................................................................1573 523511-12.......................................................................1573 523515-3........................................................................1573 523515-4........................................................................1573 523519-3........................................................................1573 523519-4........................................................................1573 2802-12.........................................................................1576 628-12..........................................................................1576 523261-3........................................................................1576 523261-4........................................................................1576 523257-3........................................................................1576 523257-4........................................................................1576 523253-3........................................................................1576 523253-4........................................................................1576 523249-3........................................................................1576 523249-4........................................................................1576 630-12..........................................................................1576 523261-12.......................................................................1579 523257-12.......................................................................1579 523253-12.......................................................................1579 523249-12.......................................................................1579 522780-3........................................................................1581 522781-3........................................................................1581 522780-4........................................................................1585 522781-4........................................................................1585 522780-2........................................................................1588 522781-2........................................................................1588 111-1...........................................................................1591 524252-2........................................................................1596 524253-14.......................................................................1598 524255-2........................................................................1599 108-0...........................................................................1600 108-1...........................................................................1600 522655-0........................................................................1604 522655-1........................................................................1604 522660-0........................................................................1604 522660-1........................................................................1604 524212-2........................................................................1610 524211-2........................................................................1610 524210-2........................................................................1610 524209-2........................................................................1610 524208-2........................................................................1610 524207-2........................................................................1610 524206-2........................................................................1610 524205-2........................................................................1610 524204-2........................................................................1610 524203-2........................................................................1610 524202-2........................................................................1610 524201-2........................................................................1610 524200-2........................................................................1610 524199-2........................................................................1610 524198-2........................................................................1610 524197-2........................................................................1610 522800-13.......................................................................1612 522801-13.......................................................................1614 522130-0........................................................................1615 522131-0........................................................................1615 522132-0........................................................................1615 522133-0........................................................................1615 522134-0........................................................................1615 522130-1........................................................................1619 522131-1........................................................................1619 522132-1........................................................................1619 522133-1........................................................................1619 522134-1........................................................................1619 522130-3........................................................................1624 522131-3........................................................................1624 522132-3........................................................................1624 522133-3........................................................................1624 522134-3........................................................................1624 522130-4........................................................................1630 522131-4........................................................................1630 522132-4........................................................................1630 522133-4........................................................................1630 522134-4........................................................................1630 522135-0........................................................................1634 522137-0........................................................................1634 522138-0........................................................................1634 522135-1........................................................................1638 522137-1........................................................................1638 522138-1........................................................................1638 522135-3........................................................................1642 522137-3........................................................................1642 522138-3........................................................................1642 522135-4........................................................................1646 522137-4........................................................................1646 522138-4........................................................................1646 522155-2........................................................................1650 522157-2........................................................................1650 522122-0........................................................................1657 522124-0........................................................................1657 522125-0........................................................................1657 522126-0........................................................................1657 522127-0........................................................................1657 522122-1........................................................................1661 522124-1........................................................................1661 522125-1........................................................................1661 522126-1........................................................................1661 522127-1........................................................................1661 522122-6........................................................................1665 522124-6........................................................................1665 522125-6........................................................................1665 522126-6........................................................................1665 522127-6........................................................................1665 522122-8........................................................................1670 522124-8........................................................................1670 522125-8........................................................................1670 522126-8........................................................................1670 522127-8........................................................................1670 522129-3........................................................................1674 522129-4........................................................................1674 522197-0........................................................................1675 522198-0........................................................................1675 522199-0........................................................................1675 522200-0........................................................................1675 522201-0........................................................................1675 522197-1........................................................................1678 522198-1........................................................................1678 522199-1........................................................................1678 522200-1........................................................................1678 522201-1........................................................................1678 522197-6........................................................................1679 522198-6........................................................................1679 522199-6........................................................................1679 522200-6........................................................................1679 522201-6........................................................................1679 522197-7........................................................................1680 522198-7........................................................................1680 522199-7........................................................................1680 522200-7........................................................................1680 522201-7........................................................................1680 522197-8........................................................................1681 522198-8........................................................................1681 522199-8........................................................................1681 522200-8........................................................................1681 522201-8........................................................................1681 522197-14.......................................................................1683 522198-14.......................................................................1683 522199-14.......................................................................1683 522200-14.......................................................................1683 522201-14.......................................................................1683 522201-16.......................................................................1683 522197-27.......................................................................1684 522198-27.......................................................................1684 522199-27.......................................................................1684 522200-27.......................................................................1684 522201-27.......................................................................1684 2039-2..........................................................................1687 522540-3........................................................................1690 522540-4........................................................................1695 522604-3........................................................................1703 522604-4........................................................................1711 522604-5........................................................................1718 522697-12.......................................................................1727 190-2...........................................................................1728 190-4...........................................................................1728 190-8...........................................................................1728 522752-2........................................................................1728 522752-4........................................................................1728 522752-5........................................................................1737 522598-3........................................................................1740 522598-4........................................................................1745 522592-0........................................................................1751 522592-1........................................................................1754 522593-12.......................................................................1756 522594-12.......................................................................1760 522595-12.......................................................................1760 522596-12.......................................................................1760 522597-12.......................................................................1760 522614-7........................................................................1763 522616-8........................................................................1763 522617-5........................................................................1763 524266-31.......................................................................1764 524286-31.......................................................................1764 524226-3........................................................................1766 524227-3........................................................................1766 524192-3........................................................................1770 524219-3........................................................................1770 524220-3........................................................................1770 524221-3........................................................................1770 524222-3........................................................................1770 524226-4........................................................................1774 524227-4........................................................................1774 524192-4........................................................................1777 524219-4........................................................................1777 524220-4........................................................................1777 524221-4........................................................................1777 524222-4........................................................................1777 524239..........................................................................1781 524241..........................................................................1781 524246..........................................................................1781 524267..........................................................................1781 524248..........................................................................1781 524746-2........................................................................1784 Engine Continues to Run When Engine Cover is Raised.............................1785 Engine Stops or Fails to Start..................................................1787 Electrical Functions Do Not Operate.............................................1789 Electrical Function Does Not Turn Off...........................................1796 Electro-Hydraulics Do Not Function With Armrest Down ...........................1803 Electro-Hydraulics Can Still Function With Armrest Raised.......................1806 Vehicle Does Not Power On.......................................................1810 Heater Fan Does Not Operate Properly............................................1817 Heater Airflow Does Not Reach Desired Temperature...............................1820 Heater Output Has Insufficient Airflow..........................................1821 Circulating (Accessory) Fan Inoperative.........................................1822 Dome Light Inoperative..........................................................1825 Horn Failure....................................................................1828 Horn Sounds Continuously........................................................1833 Drive Train.........................................................................1839 Mechanical Overview.............................................................1843 Engine..........................................................................1843 Description.................................................................1843 Torque Converter................................................................1843 Description.................................................................1843 Stator..................................................................1844 Turbine.................................................................1844 Pump PTO........................................................................1845 Cast Iron Transmission Chain Drive..........................................1845 Aluminum Transmission Gear Drive............................................1846 Aluminum Transmission Chain Drive...........................................1847 Spur Gear PTO...............................................................1848 Transmission....................................................................1849 Description.................................................................1849 1.0-5.5 Ton Lift Truck Transmissions........................................1852 Description.............................................................1852 Single-Speed........................................................1852 Two-Speed...........................................................1853 Clutch Pack.............................................................1853 Power Flow..............................................................1855 Single-Speed........................................................1855 Two-Speed...........................................................1856 Transmission Hydraulic Schematic........................................1858 Transmission Oil Flow...................................................1861 Control Valve Oil Flow..................................................1861 6.0-9.0 Ton Lift Truck Transmissions........................................1863 Description.............................................................1863 Two-Speed...........................................................1863 Three-Speed.........................................................1863 Clutch Pack.............................................................1865 Input Shaft and Range Clutches......................................1865 Directional Clutches................................................1865 Output Section......................................................1866 Power Flow..............................................................1866 Two-Speed and Three-Speed...........................................1866 Transmission Hydraulic Schematic........................................1870 Two-Speed...........................................................1870 Three-Speed.........................................................1872 Transmission Control System Overview............................................1873 Transmission Control System.................................................1873 Transmission Control Software...................................................1876 Transmission Control Modes..................................................1876 Neutral.................................................................1876 Gear Engagement Control.................................................1876 Basic Powershift Gear Engagement Mode...............................1876 DuraMatch™ and Extended Feature DuraMatch™ Plus Gear Engagemen......1876 Normal Forward or Reverse...............................................1876 Basic Powershift....................................................1876 DuraMatch™ and Extended Feature DuraMatch™ Plus Transmission........1876 Auto-Shift..............................................................1876 1st Gear Lock...........................................................1877 Inching.................................................................1877 Basic Powershift Inching Mode.......................................1877 DuraMatch™ Inching Mode.............................................1877 Extended Feature DuraMatch™ Plus Inching Mode.......................1877 Inch/Brake Overlap Adjustment...........................................1877 Brake Wear Compensation.................................................1877 Auto Decel..............................................................1878 Controlled Power Reversal...............................................1878 Basic Multi-Speed...................................................1878 Extended Feature DuraMatch™ Plus....................................1878 Controlled Creep........................................................1878 DuraMatch™ and DuraMatch™ Plus......................................1878 Controlled Roll Back....................................................1879 DuraMatch™ .........................................................1879 Electronic Extended Features........................................1879 Travel Speed Limit (Optional)...........................................1879 Extended Drawbar Pull ( Electronic Extended Features Multi-Speed........1879 Auto-Speed Hydraulics ( DuraMatch™ Plus Transmissions Only).............1879 Throttle Response Management ( Electronic Extended Features Tran....1880 Steady Travel Speed.................................................1880 Transmission Control Hardware...................................................1880 Control Valve and Sensors...................................................1880 Description.............................................................1880 Principles of Operation.................................................1882 Transmission Proportional Valve.............................................1883 Description.............................................................1883 Neutral.................................................................1883 Proportional Control....................................................1883 MONOTROL® Pedal.............................................................1884 Description.............................................................1884 Principles of Operation.................................................1884 Directional Control Lever...................................................1884 Principles of Operation.................................................1884 Driveshaft, Differential, Drive Axle, and Brakes (Dry Brake Only................1885 Driveshaft..................................................................1885 Differential and Drive Axle.................................................1885 Brake System................................................................1887 Description.............................................................1887 Service Brakes..........................................................1887 Master Cylinder.........................................................1888 Brake Position Sensor...................................................1888 Parking Brake...........................................................1888 Driveshaft, Differential, Drive Axle, and Brakes (Wet Brake Only................1888 Driveshaft..................................................................1888 Differential................................................................1889 Brake System................................................................1891 Description.............................................................1891 Service Brakes, 2.0-3.5 Ton Only........................................1892 Service Brakes, 4.0-9.0 Ton.............................................1893 Brake Adjustment and Service............................................1893 Parking Brake...........................................................1893 Overheating Brakes (Dry Brake Axle Only)........................................1897 Overheating Brakes (Wet Brake Axle Only)........................................1899 Poor Brake Performance (Dry Brake Axle Only)....................................1902 Poor Brake Performance (Wet Brake Axle Only)....................................1905 Brakes Make Too Much Noise (Dry Brake Axle Only)................................1907 Brakes Pull To One Side (Dry Brake Axle Only)...................................1908 Parking Brake Will Not Release..................................................1911 Parking Brake Will Not Hold Lift Truck (Dry Brake Axle Only)....................1912 Parking Brake Will Not Hold Lift Truck (Wet Brake Axle Only)....................1913 Abnormal Drive Axle Noise.......................................................1914 Discolored Drive Axle Oil.......................................................1918 Lift Truck Does Not Move (Drive Axle)...........................................1920 Abnormal Transmission Noise.....................................................1923 Bubbles or Foaming In Transmission Dipstick Tube................................1926 Inching Operation Is Not Smooth or Chatters.....................................1928 Lift Truck Does Not Move In One or Both Directions (Transmission................1930 Loss of Power/Drivetrain Performance............................................1934 Transmission Not Functioning Properly - No DTCs Generated.......................1938 Throttle Cable (Mazda Engine Only) is Out of Adjustment.........................1948 Transmission Is Too Hot.........................................................1950 Transmission Will Not Shift To Forward High Range...............................1953 Transmission Warm-up Procedure..................................................1955 Transmission Pressure Test......................................................1956 Transmission Charge Pump Pressure Test......................................1958 Clutch Pack Pressure Test (Proportional Solenoid Valves)....................1958 Torque Converter Pressure Test..............................................1959 Lubrication Pressure Test...................................................1959 Transmission Clutch Drag Test (1.0-5.5 Ton Trucks Only).........................1960 Torque Converter Stall Test.....................................................1961 Hydraulic Systems...................................................................1965 Main Hydraulic System...........................................................1969 Description.................................................................1969 Principles of Operation.....................................................1972 Hydraulic Schematics........................................................1973 Manual Control Valve Schematics.........................................1973 Electro-Hydraulic Control Valve Schematics..............................1976 Manual Hydraulic Control Valve..................................................1980 Description.................................................................1980 Principles of Operation.....................................................1982 Lift Section............................................................1982 Lift Operation......................................................1982 Lower Operation.....................................................1982 Tilt Section............................................................1983 Tilt Backward (1.0-9.0 Ton Lift Truck)..............................1983 Tilt Forward (1.0-5.5 Ton Lift Truck)...............................1983 Tilt Forward (6.0-7.0 Ton Lift Truck)...............................1984 Auxiliary Section.......................................................1984 Anti-Stall Feature......................................................1985 Relief Valves...........................................................1985 Main Relief Valve...................................................1985 Secondary Relief Valve..............................................1986 Emergency Lowering Valve................................................1986 Operator Presence Spool Lockout Mechanism...............................1986 Electro-Hydraulic Control Valve.................................................1987 Description.................................................................1987 Principles of Operation.....................................................1989 Inlet Pressure Compensator/Unloader.....................................1989 Lift/Lower EHPVs........................................................1991 EHPV Operation......................................................1991 Tilt and Auxiliary Spool Functions......................................1993 Tilt Forward (1.0-5.5 Ton Lift Truck)...............................1995 Tilt Forward (6.0-9.0 Ton Lift Truck)...............................1996 Main Relief Valve ......................................................1996 Secondary Relief Valve..................................................1997 Emergency Lowering Valve................................................1997 Anti-Stall Function.....................................................1997 Dual Stage Unloader.................................................1998 Steering System.................................................................1998 Component Locations.........................................................1998 Description.............................................................1998 Steering Axle Assembly..................................................1998 Steering Control Unit...................................................1998 Steering Schematic..........................................................2000 Principles of Operation.................................................2001 Steering Control Unit...................................................2001 Hydraulic System with Variable Displacement Pump................................2002 Description.................................................................2002 Principles of Operation.....................................................2004 Variable Displacement Pump..................................................2006 Description.............................................................2006 Operation...............................................................2008 Pressure Control........................................................2009 Flow Compensator........................................................2009 Electro-Hydraulic Control Valve.............................................2010 Description.............................................................2010 Operation...............................................................2011 Clipper Relief Valve....................................................2011 Emergency Lowering Valve................................................2011 Lift/Lower Section......................................................2012 Tilt and Auxiliary Sections.............................................2012 Tilt Forward Function with Counterbalance...............................2014 Secondary Relief Valve..................................................2015 Accumulator.............................................................2015 Steering Control Unit.......................................................2016 Description.............................................................2016 Operation...............................................................2017 When the engine is running and the steering wheel is not being t....2017 When the engine is running and the steering wheel is being turne....2018 Operational Check...........................................................2019 Abnormal Hydraulic Noise and/or Vibration.......................................2021 Abnormal Smell/Discoloration/Foaming of Oil.....................................2025 Abnormal Steer Axle Noise.......................................................2026 Abnormal Steering Wheel Vibration...............................................2028 Actuation Exhibits Slight Movement in Opposite Direction Before ................2029 Actuation Functions With Armrest Up (E-Valve)...................................2030 Actuations Do Not Act Simultaneously............................................2031 Auxiliary Function is Slow or Does Not Function (Manual Valve)..................2032 Back Lash/Kick Back in Steering Wheel...........................................2034 Cycle Times Too Fast - Fast Actuation...........................................2036 Cycle Times Too Fast - Fast Actuation (E-Valve).................................2038 Cycle Times Too Fast - Fast Actuation (Manual Valve)............................2039 Forks Drop Slightly Before Lifting (E-Valve)....................................2040 Forks Lower Without Command (E-Valve)...........................................2041 Forks Raise or Actuate Without Command (E-Valve)................................2043 Forks Tilt Forward Without Command (E-Valve)....................................2045 Intermittent Activation (E-Valve) While Commanding Function.....................2047 Jump/Delay In Lift or Lower Activation After Moving Joystick or ................2049 Jump/Delay In Secondary Function Actuation After Moving Joystick................2051 Jump/Delay In Tilt Forward Actuation (E-Valve)..................................2053 Lift Function Is Slow or Does Not Function (Manual Valve).......................2055 Lift Function Will Not Move With Joystick or MLM Movement (E-Val................2057 Lift/Lower Continues To Move For Awhile After Joystick or MLM Is................2061 Lift/Lower Function Maximum Speed Too Slow (E-Valve)............................2062 Lift/Lower/Secondary Function Suddenly Jumps In Middle of Stroke................2065 Load Drops Slightly When Metering Lift Function (Manual Valve)..................2066 Lower Function Will Not Move With Joystick or MLM Movement (E-Va................2067 No Steering (All Other Hydraulic Functions OK)..................................2069 Oil Leaking/Component Life Too Short............................................2071 Poor Metering on Lift or Lower Functions (E-Valve)..............................2074 Secondary Function Continues to Move for Awhile After Joystick o................2077 Secondary Function Exhibits Slight Movement in Opposite Directio................2078 Secondary Function Maximum Speed Too Slow (E-Valve).............................2079 Secondary Function and Tilt Back Will Not Move With Joystick or ................2082 Secondary Function or Tilt Back Moves Without Command (E-Valve).................2086 Steering Is Slow or Difficult...................................................2088 Steering Operation Is Not Smooth................................................2090 Steering Wheel End Lock Position Cannot Be Felt by Operator.....................2092 Steering Wheel Turns By Itself or Does Not Return To Neutral....................2093 Steering Wheel Turns the Tires in the Wrong Direction...........................2094 Tilt Back Function Will Not Operate (Manual Valve)..............................2095 Tilt Forward Function Continues to Move for Awhile When Joystick................2096 Tilt Forward Functions When Spool is Activated Forward With Engi................2097 Tilt Forward Will Not Function When Activated (Manual Valve)....................2098 Tilt Forward Will Not Move Upon Joystick or MLM Movement (E-Valv................2099 Too Much Joystick or MLM Movement (Deadband) to Start Function M................2101 Wrong Actuation Operates or Actuation is Backward (E-Valve).....................2102 No Steering and No Hydraulic Functions..........................................2103 Steering and Hydraulic Functions are Slow.......................................2104 No Steering (All other hydraulic functions are okay)............................2105 Steering Effort is Too High (All other hydraulic functions are o................2106 Steer Cylinder Does Not Reach End Of Stroke (All other hydraulic................2108 Steering Wheel Turns By Itself (Self-Steering)..................................2109 No Hydraulic Functions (Lift, Tilt, and Aux)....................................2110 Hydraulic Functions are Slow (Lift, Tilt, and Aux)..............................2111 Hydraulic Valve Assembly Leaks..................................................2112 No Lift Function (Steering and All other hydraulic functions oka................2113 Lift Function Is Slow (All other hydraulic functions are okay)..................2115 Delay In Lift Activation........................................................2117 Jump In Lift Activation.........................................................2118 Forks Drop Slightly Before Lifting..............................................2119 Forks Raise Without Command.....................................................2120 Intermittent Activation While Commanding Function...............................2121 Poor Metering On Lift Function..................................................2122 Too Much MLM/Joystick Movement (Deadband).......................................2123 No Lower Function (Steering, lift, tilt, and Aux functions okay)................2124 Lower Functions Too Slow (All other hydraulic functions are okay................2126 Delay In Lowering Activation....................................................2128 Jump In Lower Activation........................................................2130 Forks Lower Without Command.....................................................2132 Too Much MLM/Joystick Movement (Deadband) To Start Function.....................2134 No Secondary Function (Tilt or Aux).............................................2135 Secondary Function (Tilt or Aux) Too Slow.......................................2137 Secondary Function (Tilt or Aux) Delay in Actuation.............................2139 Secondary Function (Tilt or Aux) Jump in Actuation..............................2140 Secondary Function (Tilt or Aux) Actuate Without Command........................2141 Hydraulic Warm-Up Procedure.....................................................2143 Electro-Hydraulic Poppet Valve (EHPV) Leakage Test..............................2145 Hydraulic Pump Flow Test........................................................2147 Lift Cylinder Leakage Test......................................................2150 Main Control Valve LS Leakage Test (E-Valve)....................................2151 Main Relief Valve Test and Adjustment...........................................2152 PPRV Pilot Pressure Test........................................................2154 Secondary Relief Valve Test and Adjustment......................................2155 Steering Control Unit LS Pressure Test..........................................2157 Steering Cylinder Leakage Test..................................................2158 Steering Relief Pressure Test and Adjustment....................................2160 Tilt Cylinder Leakage Test......................................................2161 Pressure Compensator Test and Adjustment........................................2163 Flow Compensator Margin Test and Adjustment.....................................2164 Steering Relief Pressure Test and Adjustment....................................2166 Steering Control Unit LS Pressure Test..........................................2168 PPRV Pilot Pressure Test........................................................2169 Steering Column Binding Test....................................................2170 SCU Bolts and Main Control Valve Tie-Rod Torque.................................2173 Operators Station...................................................................2175 Operator Station General Description and Principles of Operation................2177 General Description and Location............................................2177 Display Switch Cluster (DSC)....................................................2179 Detailed Description........................................................2179 Control Inputs, Right Side..................................................2180 Right Indicator and Warning Group...........................................2182 LCD Display.................................................................2183 Left Indicator and Warning Group............................................2184 Control Inputs, Left Side (Cab Option Only).................................2185 Transmission Control and Braking................................................2186 Description.................................................................2186 Vehicle System Manager (VSM)............................................2186 Display Switch Cluster..................................................2187 Interlock and Switching Features....................................2187 MONOTROL® Directional Control...........................................2187 Inch Brake/Service Brake Pedal..........................................2187 Parking Brake...........................................................2187 Programming - Menus.............................................................2188 Menus.......................................................................2188 Main Menu...............................................................2191 Save and Exit or Exit Without Saving....................................2191 Back One Level..........................................................2191 Hourmeters..............................................................2191 View Versions...........................................................2192 Passwords...............................................................2192 Diagnostics.............................................................2192 Setup Travel and Braking................................................2192 Setup Hydraulics........................................................2192 Setup Display...........................................................2192 Setup General Items.....................................................2192 Calibrations............................................................2192 Manual Hydraulic Control Levers.................................................2193 General Description.........................................................2193 System Components...........................................................2193 Lift/Lower..............................................................2193 Tilt....................................................................2193 Auxiliary 1.............................................................2193 Auxiliary 2.............................................................2193 E-Hydraulic System Interface....................................................2194 General Description.........................................................2194 System Components...........................................................2194 E-Hydraulic Control Input Device............................................2194 Joystick................................................................2194 Lift/Lower..........................................................2195 Tilt................................................................2195 Auxiliary 1.........................................................2195 Auxiliary 2.........................................................2195 Push Button.........................................................2195 Mini-Lever Module (MLM).................................................2196 Lever 1.............................................................2196 Lever 2.............................................................2196 Lever 3.............................................................2197 Lever 4.............................................................2197 System Modes................................................................2197 Hydraulic Interlock Mode................................................2197 Fault Mode..............................................................2197 Engine Off Mode.........................................................2197 Normal Operation............................................................2197 Normal Operation Mode...................................................2197 Lifting Control.........................................................2197 Lowering Control........................................................2198 Tilt Control (Forward and Backward).....................................2198 Auxiliary Control.......................................................2198 Lighting Control................................................................2198 Description.................................................................2198 Front Work Lights.......................................................2201 Front Marker Lights (if equipped).......................................2201 Front/Rear Turn Signal Lights...........................................2201 Rear Tail/Marker Lights.................................................2201 Rear Work Light.........................................................2201 Rear Backup Lights......................................................2201 Rear Stop Lights........................................................2201 Strobe Light(s).........................................................2201 Spot Light (if equipped)................................................2201 Cab.............................................................................2201 Description.................................................................2201 Component Descriptions......................................................2203 Cab Heating System......................................................2203 Lighting Control System.................................................2204 Wiper/Washer System.....................................................2204 Cab Systems Operation.......................................................2204 Front End (Mast) and Chassis........................................................2207 Front End, Mast.................................................................2209 Description.................................................................2209 Carriages.......................................................................2210 Description.................................................................2210 Principles of Operation.....................................................2210 Integral Sideshift Carriage.............................................2210 Mast Mounts.....................................................................2212 Description.................................................................2212 Principles of Operation.....................................................2212 Two-Stage Limited Free-Lift (LFL) Mast..........................................2214 Description.................................................................2214 Principles of Operation.....................................................2215 Two-Stage Full Free-Lift (FFL) Mast.............................................2216 Description.................................................................2216 Principles of Operation.....................................................2216 Three-Stage Full Free-Lift (FFL) Mast...........................................2218 Description.................................................................2218 Principles of Operation.....................................................2218 Four-Stage Full Free-Lift (FFL) Mast............................................2220 Description.................................................................2220 Principles of Operation.....................................................2221 Cylinder Cushion During Lifting Sequence........................................2223 Description.................................................................2223 Principles of Operation.....................................................2223 Cylinder Cushion During Lowering Sequence.......................................2224 Description.................................................................2224 Principles of Operation.....................................................2224 Tilt and Sideshift Cylinders....................................................2224 Description.................................................................2224 Tilt Cylinder...........................................................2224 Sideshift Cylinder......................................................2224 Lowering Control Valves.........................................................2225 Description.................................................................2225 Principles of Operation.....................................................2225 Chassis.........................................................................2227 Description.................................................................2227 Abnormal Channel Wear...........................................................2229 Abnormal Hose Wear..............................................................2231 Abnormal Mast Noise.............................................................2233 Body Panels Making Noise........................................................2237 External Leakage From Free-Lift or Main Lift Cylinders..........................2238 FFL Mast Banging During Phasing.................................................2239 High Tire Wear - Drive Axle.....................................................2241 High Tire Wear - Steer Axle.....................................................2243 Hoses Not Tracking Correctly....................................................2245 Integral Sideshift Moving Too Fast..............................................2246 Integral Sideshift Not Moving or Slow...........................................2247 LP Tank Bracket Disengages......................................................2251 LP Tank Rattles and Does Not Stay Latched.......................................2252 Mast is Loose...................................................................2253 Mast Lift Chains Are Loose......................................................2255 Mast or Carriage Binding........................................................2256 Mast/Carriage Bounces or is Spongy..............................................2258 Misphasing of Full Free-Lift Mast...............................................2259 Overhead Guard Loose or Damaged.................................................2261 Racking During Lift.............................................................2262 Racking During Tilt.............................................................2264 Truck Feels Unstable............................................................2265 Truck Wanders, Does Not Track Straight or Steer Well............................2267 Wheels Appear Tipped or Misaligned..............................................2269 Wheels Spinning On Uneven Floors................................................2271 Wheel Studs Breaking............................................................2272 Supplementary Data..................................................................2273 Abbreviations and Acronyms......................................................2275 Special Tools List..............................................................2283 Fault Mode Indicator (FMI) Reference List.......................................2289 TSP Reference Tables............................................................2291 tables.................................................................................. 761 Table 9020-10-1. Test Specifications................................................ 854 Table 9020-10-2. IAT Ambient Temperature............................................ 865 Table 9020-40-1. Test Specifications................................................1053 Table 9020-40-2. Test Specifications................................................1054 Table 9020-40-3. Service Tools......................................................1054 Table 9020-40-4. Test Specifications................................................1055 Table 9020-40-5. Service Tools......................................................1055 Table 9020-40-6. Test Specifications................................................1056 Table 9020-40-7. Service Tools......................................................1057 Table 9020-40-8. Test Specifications - Mazda........................................1059 Table 9020-40-9. Test Specifications - GM...........................................1059 Table 9020-40-10. Service Tools.....................................................1059 Table 9020-40-11. Test Specifications...............................................1061 Table 9020-40-12. Service Tools.....................................................1062 Table 9020-40-13. Test Specifications...............................................1064 Table 9020-40-14. Service Tools.....................................................1064 Table 9020-40-15. Test Specifications...............................................1066 Table 9020-40-16. Service Tools.....................................................1066 Table 9030-03-1. Cummins QSB 3.3L Fault Codes.......................................1099 Table 9030-03-2. Circuit Group Identification.......................................1103 Table 9030-03-3. Hyster Wiring Color Codes..........................................1104 Table 9040-10-1. Two-Speed Transmission Clutch Pack Solenoid Val....................1871 Table 9040-10-2. Three-Speed Transmission Electronic Proportiona....................1872 Table 9040-10-3. Transmission Control Mode..........................................1875 Table 9040-40-1. Test Specifications................................................1955 Table 9040-40-2. Service Tools......................................................1955 Table 9040-40-3. Service Tools......................................................1956 Table 9040-40-4. Test Specifications................................................1958 Table 9040-40-5. Test Specifications................................................1958 Table 9040-40-6. Test Specifications................................................1959 Table 9040-40-7. Test Specifications 1.0 - 9.0 Ton Truck............................1959 Table 9040-40-8. Test Specifications................................................1960 Table 9040-40-9. Service Tools......................................................1960 Table 9040-40-10. Stall Speeds......................................................1962 Table 9050-10-1. Standby Pressure...................................................1990 Table 9050-40-1. Test Specifications................................................2143 Table 9050-40-2. Service Tools......................................................2143 Table 9050-43-1. Test Specifications................................................2145 Table 9050-43-2. Service Tools......................................................2145 Table 9050-43-3. Test Specifications................................................2148 Table 9050-43-4. Service Tools......................................................2148 Table 9050-43-5. Test Specifications................................................2150 Table 9050-43-6. Service Tools......................................................2150 Table 9050-43-7. Test Specifications................................................2151 Table 9050-43-8. Test Specifications................................................2152 Table 9050-43-9. Service Tools......................................................2152 Table 9050-43-10. Test Specifications...............................................2154 Table 9050-43-11. Service Tools.....................................................2154 Table 9050-43-12. Test Specifications...............................................2155 Table 9050-43-13. Service Tools.....................................................2155 Table 9050-43-14. Test Specifications...............................................2157 Table 9050-43-15. Service Tools.....................................................2157 Table 9050-43-16. Test Specifications...............................................2158 Table 9050-43-17. Service Tools.....................................................2158 Table 9050-43-18. Test Specifications...............................................2160 Table 9050-43-19. Service Tools.....................................................2160 Table 9050-43-20. Test Specifications...............................................2161 Table 9050-43-21. Service Tools.....................................................2161 Table 9050-45-1. Test Specifications................................................2163 Table 9050-45-2. Service Tools......................................................2163 Table 9050-45-3. Test Specifications................................................2164 Table 9050-45-4. Service Tools......................................................2164 Table 9050-45-5. Test Specifications................................................2166 Table 9050-45-6. Service Tools......................................................2166 Table 9050-45-7. Test Specifications................................................2168 Table 9050-45-8. Service Tools......................................................2168 Table 9050-45-9. Test Specifications................................................2169 Table 9050-45-10. Service Tools.....................................................2169 Table 9050-45-11. Test Specifications...............................................2170 Table 9050-45-12. Service Tools.....................................................2170 Table 9050-45-13. Torque Specifications.............................................2173 Table 9050-45-14. Service Tools.....................................................2173 Table 9080-50-1. Abbreviations and Acronyms.........................................2275 Table 9080-60-1. Special Tools......................................................2283 Table 9080-70-1. FMI................................................................2289 Table 9080-80-1. Resistor-Temperature Characteristics ..............................2291 DTC.........................................................................................2295 toc.....................................................................................2295 Diagnostic Troubleshooting Manual...................................................2295 Safety Precautions TROUBLESHOOTING PROCEDURES.......................................2296 How To Use This Troubleshooting Manual..............................................2298 General Instructions and Safety Information.....................................2298 How to Use Diagnostic Troubleshooting Manual....................................2298 General Instructions............................................................2299 Operational Diagnostic Procedures...................................................2301 Operational Checkout Procedures.................................................2303 DTC Check...................................................................2304 Horn Circuit Check..........................................................2304 Light Circuit Check.........................................................2304 Windshield Washer Wiper Check (If equipped).................................2304 Heater Check (If equipped)..................................................2305 Dome Light Check (If equipped)..............................................2305 Circulating (Accessory) Fan Check (If equipped).............................2306 Indicator Light Power Check.................................................2307 Engine Malfunction Indicator Check..........................................2308 Cold Start Check (Cummins and Yanmar).......................................2308 Brake Pedal Check 1-7 Ton Only..............................................2309 Brake Check 8-9 Ton Only....................................................2310 Backup Alarm Check (If equipped)............................................2310 Operator Presence System Check..............................................2310 Hydraulic Interlock Check...................................................2310 Armrest Hydraulic Interlock Check [If equipped and with original............2312 Engine Cover Latch Sensor Check (If equipped)...............................2312 Brake and Inching Pedal Check...............................................2312 Park Brake Sensor Check.....................................................2312 Park Brake Check............................................................2313 Engine Speed Check (All Cummins, Yanmar, and Mazda Engines Excep............2313 Engine Power Check..........................................................2314 Transmission Clutch Check...................................................2314 Transmission Check..........................................................2315 Transmission Speed Selection Check (If equipped)............................2315 Brake and Axle Drag Check...................................................2315 Hydraulic Pump Flow Check...................................................2316 Priority Flow Divider Valve Check...........................................2317 Steering Relief Valve Low Pressure Check....................................2317 Steering Relief Valve High Pressure Check...................................2318 Control Valve Load Check Valve (Manual Valve)...............................2318 Lift E-Valve Check..............................................................2318 Lift Check (E-Valve)........................................................2318 Tilt Function Counterbalance Check..........................................2319 Lift Drift Check............................................................2319 Tilt Function Drift Check...................................................2320 Mast Cushion Check (All Except 2-Stage Mast)................................2320 Lift/Tilt Mast Adjustment Check.............................................2321 Tilt Racking Check..........................................................2321 Chain and Header Hose Adjustment Check......................................2322 Mast Mounting Check.........................................................2322 Mast Channel Check..........................................................2323 Carriage Adjustment Check...................................................2323 Chain Sheave Check..........................................................2324 Carriage Adjustment Check (Standard and Integral Side Shift)................2324 Engine..............................................................................2325 Engine Basics...................................................................2333 General Terminology.........................................................2333 Combustion Theory...........................................................2333 Engine Components – Cylinder Block..........................................2334 Camshaft and Timing Set.....................................................2335 Cylinder Head Assembly......................................................2335 Valve Train Assembly........................................................2335 Manifolds...................................................................2335 Air Cleaner/Filter..........................................................2336 Carburetion.................................................................2336 Electronic Fuel Injection (EFI).............................................2336 Positive Crankcase Ventilation (PCV)........................................2336 Engine Electrical...............................................................2337 Introduction................................................................2337 Battery Construction........................................................2337 Conventional Standard Battery...............................................2337 Maintenance-Free Battery....................................................2338 Battery Charging............................................................2338 Battery Fast Charging.......................................................2338 Battery Slow Charging.......................................................2339 Starting System Principles of Operation.....................................2339 Starting System Components - Ignition Switch................................2339 Starting System Components - Starter Solenoid...............................2339 Starting System Components - Flywheel and Ring Gear.........................2340 Starting System Components - Starter Motor and Drive........................2340 Charging System - General...................................................2340 Charging System - Regulator.................................................2340 Charging System - Theory....................................................2341 Engine Fuel System/Exhaust and Emissions........................................2342 Introduction................................................................2342 Gasoline System Components - Fuel Tank......................................2342 Electronic Fuel Injector (EFI) - General Description........................2342 Port Fuel System Components - ECU...........................................2342 Port Fuel System Components - Fuel Pump/Filter..............................2342 Port Fuel System Components - Fuel Rail.....................................2342 Port Fuel System Components - Pressure Regulator............................2342 Port Fuel System Components - Fuel Injectors................................2342 LPG Systems General Information.............................................2343 LPG Fuel Properties.........................................................2343 LPG Fuel Tank...............................................................2343 PSI Closed-Loop System......................................................2343 Electrical Fuel Lockoff Valve...........................................2344 Direct Electronic Pressure Regulator (DEPR).............................2344 Air Fuel Mixer..........................................................2344 Electronic Throttle Control Device (ETC)................................2345 Three-Way Catalytic Converter...........................................2345 Engine Control Module (ECM).............................................2345 Heated Exhaust Gas Oxygen Sensors (HEGO)................................2346 TMAP Sensor.............................................................2346 Coolant Temperature Sensor€(ECT)........................................2346 Oil Pressure Sender.....................................................2346 AISAN Closed-Loop System....................................................2346 Filter/Lockoff and Regulator............................................2346 Carburetor..............................................................2347 Start Mode..............................................................2347 Idle Mode...............................................................2347 Run Mode................................................................2347 Main Fuel Lockoff Solenoid..................................................2348 Injector Fuel Lockoff Solenoid..............................................2348 Oxygen (O 2 ) Sensor....................................................2348 Electronic Control Unit (ECU)...............................................2348 Catalytic Converter/Muffler.................................................2348 Engine Management...............................................................2348 Introduction................................................................2348 Ignition and Timing - Conventional Spark....................................2348 Components - Ignition Coil..................................................2348 Components - Distributor....................................................2349 Spark Timing................................................................2349 Components - Ignition Wires.................................................2349 Components - Spark Plugs....................................................2349 Faulty or Fouled Spark Plugs................................................2349 Electric Controlled Governing System - Mazda LPG............................2350 ECONOMY MODE (ECO-eLo)......................................................2350 Engine Identification...........................................................2350 Cummins (Diesel) Engine.........................................................2353 Description.................................................................2353 Diesel Fuel System..........................................................2354 Principle of Operation..................................................2354 Fuel Injection Pump and Governor............................................2355 Description.............................................................2355 Principles of Operation.................................................2357 Cummins Engine Control......................................................2357 Engine Speed (RPM) Sensor...............................................2358 Throttle Position Sensor................................................2359 Electronic Throttle Actuator............................................2360 Engine Oil Pressure Sensor..............................................2360 Coolant Temperature Sensor..............................................2361 Air Restriction Switch..................................................2362 Fuel Filter/Water Separator.............................................2362 Fuel Level Sensor (In Tank).............................................2362 Engine Electrical System....................................................2363 Magnetic Valve (Engine Stop Solenoid)...................................2363 Alternator..............................................................2363 Grid Heater.............................................................2363 Cold Start Timing Advance (Fuel Injection Pump).........................2363 Cummins QSB 3.3L (Diesel) Engine................................................2364 Description.................................................................2364 Diesel Fuel System..........................................................2365 Electronics System..........................................................2366 Engine Protection.......................................................2367 Diagnostics.............................................................2367 Grid Heater.............................................................2368 Turbocharger and Charge Air Cooler..........................................2368 Cooling System..............................................................2369 Crankcase Oil Separator.....................................................2370 Lubrication System..........................................................2371 Mazda Engine Overview...........................................................2372 Description.................................................................2372 Fuel System.................................................................2372 Engine Controls Unit (ECU) and Emissions....................................2372 Cooling System..............................................................2372 Ignition System.............................................................2372 Mazda (LPG) Engine Controls.....................................................2373 LPG System (Aisan/E-Controls-Mechanical)....................................2373 Description.............................................................2373 Principles of Operation.................................................2374 Control System..........................................................2376 Oxygen (O 2 ) Sensor....................................................2377 Engine Coolant Temperature Sensor.......................................2377 Fuel Tank...............................................................2379 Regulator...............................................................2380 Start Mode..........................................................2381 Idle Mode...........................................................2382 Run Mode............................................................2382 Resonator...............................................................2382 Carburetor..............................................................2383 Start Mode..........................................................2383 Idle Mode...........................................................2383 Run Mode............................................................2383 Governor................................................................2384 LPG System (E-Controls).....................................................2384 Description.............................................................2384 Principles of Operation.................................................2384 Manifold Absolute Pressure Sensor.......................................2384 Throttle Position Sensor................................................2384 Oxygen (O 2 ) Sensor....................................................2385 Engine Coolant Temperature Sensor.......................................2385 Intake Air Temperature Sensor...........................................2385 Engine Control Unit.....................................................2385 Accelerator Pedal Position Sensor.......................................2385 Three-Way Catalytic Converter...........................................2385 Camshaft Position Sensor................................................2386 Electric Controlled Governing System....................................2387 Electronic Governor Sensor..............................................2387 Electronic Pressure Regulator...........................................2388 Mazda (Gasoline) Engine Controls................................................2389 Gasoline System.............................................................2389 Description.............................................................2389 Principles of Operation (Lift Trucks Built Before January, 2007)........2391 Principles of Operation (Lift Trucks Built After January, 2007).........2393 Control System..............................................................2396 Camshaft Position Sensor................................................2398 Intake Air Temperature Sensor...........................................2399 Mass Air Flow Sensor, If Applicable.....................................2400 Electronic Throttle Assembly (ETA)......................................2401 Throttle Position Sensor................................................2401 Electrical Throttle Control System......................................2402 Electronic Governor Sensor..............................................2402 Electronic Governing System.............................................2404 Manifold Absolute Pressure Sensor/Boost Sensor..........................2404 Engine Coolant Temperature Sensor (Lift Trucks Built Before Janu........2405 Intake Air System...........................................................2407 Throttle Body (Lift Trucks Built Before January, 2007)..................2407 Intake Air Temperature Sensor (Lift Trucks Built After January, ........2407 Idle Air Control Valve, If Applicable...................................2408 Fuel System.................................................................2409 Fuel Injector...........................................................2409 Pressure Regulator......................................................2410 Exhaust System..............................................................2411 Heated Oxygen (O 2 ) Sensor (Lift Trucks Built Before January, 2........2411 Heated Exhaust Gas Oxygen (O 2 ) Sensor (Lift Trucks Built After........2411 Three-Way Catalytic Converter...........................................2412 GM (LPG) Engine Controls........................................................2413 Engine Control System ......................................................2413 Engine Control System Overview..........................................2414 Principles of Operation.................................................2414 Control System..............................................................2415 GM/TGFI 2.4L (Four Cylinder) Control System Component Location..........2415 GM/TGFI 4.3L (Six Cylinder) Control System Component Location...........2416 GM/TGFI 2.4L (Four-Cylinder) LPG System.................................2417 GM/TGFI 4.3L (Six-Cylinder) LPG System..................................2420 Fuel Tank...............................................................2423 Engine Control Unit.....................................................2423 Electronic Throttle Body/Throttle Position Sensor.......................2424 Manifold Absolute Pressure/Manifold Air Temperature Sensor..............2425 Propane Injectors.......................................................2426 Peak and Hold Drive Injector (Lift Trucks Built Before January, ........2427 Saturated Drive Injector (Lift Trucks Built After January, 2010)........2428 Engine Coolant Temperature Sensor.......................................2429 Oxygen (O 2 ) Sensor....................................................2429 Crankshaft Position Sensor (Engine Speed Sensor)........................2430 Oil Pressure Sensor.....................................................2430 Power Latch Relay.......................................................2430 GM 2.4L Camshaft Position Sensor........................................2430 GM 4.3L Camshaft Position Sensor........................................2431 Injector Driver Module..................................................2432 Vaporizer/Regulator.....................................................2432 Accelerator Pedal Position Sensor.......................................2435 Three-Way Catalytic Converter...........................................2436 Ignition System.............................................................2436 Ignition Coils..........................................................2436 Distributorless Ignition System Module..................................2436 Electronic Ignition Signals.............................................2437 Distributor Ignition (DI) System........................................2437 Camshaft Position (CMP) Sensor..........................................2437 Ignition Coil and Ignition Control Module (ICM).........................2438 Secondary Ignition Components...........................................2438 GM (5.7L V-8 LPG) Overview......................................................2438 Description.................................................................2438 Fuel System.................................................................2438 Engine Controls Unit (ECU) and Emissions....................................2438 Cooling System..............................................................2438 Ignition System.............................................................2438 GM (Gasoline) Engine Controls...................................................2439 Engine Control System.......................................................2439 GM 2.4L (Four Cylinder) Engine Control System...........................2439 GM 4.3L (Six Cylinder) Engine Control System............................2440 Engine Control System Overview..........................................2441 Principles of Operation.................................................2441 Control System..............................................................2442 GM/TGFI 2.4L (Four Cylinder) Control System Component Location..........2442 GM/TGFI 4.3L (Six Cylinder) Control System Component Location...........2443 GM/TGFI 2.4L (Four-Cylinder) Gasoline System Components.................2444 GM/TGFI 4.3L (Six Cylinder) Gasoline System Components..................2447 Engine Control Unit.....................................................2450 Electronic Throttle Body/Throttle Position Sensor.......................2450 Manifold Absolute Pressure/Manifold Air Temperature Sensor .............2451 Fuel Injector...........................................................2452 Engine Coolant Temperature Sensor.......................................2453 Oxygen (O 2 ) Sensor....................................................2454 Crankshaft Position Sensor (Engine Speed Sensor)........................2454 Oil Pressure Sensor.....................................................2454 Power Latch Relay.......................................................2454 Camshaft Position Sensor................................................2454 Accelerator Pedal Position Sensor.......................................2456 Three-Way Catalytic Converter...........................................2456 Ignition System.............................................................2456 Ignition Coils..........................................................2456 Distributorless Ignition System Module..................................2456 Electronic Ignition Signals.............................................2457 Yanmar (Diesel) Engine..........................................................2458 Description.................................................................2458 Diesel Fuel System..........................................................2459 Principles of Operation.................................................2459 Fuel Injection Pump and Governor............................................2460 Description.............................................................2460 Principles of Operation.................................................2462 Timer...................................................................2463 Feed Pump (Vane Type)...................................................2463 Regulating Valve........................................................2464 Injection Pump Plunger..................................................2465 Suction Process.....................................................2466 Injection Process...................................................2466 End of Injection....................................................2467 Uniform Pressure Process............................................2467 Reverse Rotation Prevention Mechanism...................................2468 Fuel Injection Volume Adjustment Mechanism..............................2468 Delivery Valve Assembly.................................................2468 Delivery Valve Holder with Damping Valve................................2469 All - Speed Governor....................................................2470 At Start of Engine......................................................2472 During Idle.............................................................2473 At Full - Load Maximum Speed Control....................................2474 At No-Load Maximum Speed Control........................................2475 Full-Load Position Adjustment Mechanism.................................2476 Structure and Operation of Timer............................................2477 Standard Type Automatic Timer...........................................2477 Yanmar Engine Controls......................................................2478 Engine Speed (RPM) Sensor...............................................2479 Throttle Position Sensor................................................2479 Electronic Throttle Actuator............................................2480 Engine Oil Pressure Sensor..............................................2480 Coolant Temperature Sensor..............................................2481 Air Filter Restriction Switch...........................................2481 Fuel Filter/Water Separator and Strainer................................2482 Fuel Level Sensor.......................................................2482 Engine Electrical System....................................................2483 Magnetic Valve (Engine Stop Solenoid)...................................2483 Alternator..............................................................2483 Glow Plugs..............................................................2483 Cold Start Timing Advance (Fuel Injection Pump).........................2483 Cooling System - All Engines....................................................2484 Description.................................................................2484 Radiator....................................................................2484 Combination Cooler/Standard Radiator....................................2484 Radiator Cap................................................................2485 Thermostat..................................................................2485 Engine Coolant Pump.........................................................2486 Fan.........................................................................2486 GM Engine Coolant Flow Diagram..............................................2486 Yanmar Diesel Engine Coolant Flow Diagram...................................2487 Engine Does Not Crank...........................................................2489 Engine Does Not Start/Engine is Hard to Start...................................2492 Engine Idle Speed Incorrect.....................................................2498 Engine Idle Speed is Unstable or Engine Stalls at Idle..........................2501 Engine Cuts Out, Misses, Hesitates, Sags, or Stumbles...........................2507 Engine Lack of Power............................................................2514 Engine Speed Surge Or Engine Speed Unstable.....................................2522 Engine Backfires................................................................2527 Engine Is Knocking or Pinging...................................................2530 Excessive Engine Vibrations.....................................................2535 Abnormal Engine and Exhaust Noises..............................................2540 Fan or Alternator Bearing Noise.................................................2545 Abnormal Engine and Exhaust Smells..............................................2547 High Engine Fuel Consumption....................................................2549 Fuel Leaks......................................................................2553 High Engine Oil Consumption.....................................................2557 Engine Oil Leaks................................................................2559 Engine Oil is Discolored........................................................2564 Engine Coolant Leaks............................................................2566 Engine Coolant is Discolored....................................................2569 Engine Exhaust is Discolored....................................................2570 Engine Fails Emission Compliance Check..........................................2574 Alternator Light is Illuminated.................................................2578 Engine is Overheating...........................................................2579 Air Intake Manifold Temperature too High (Cummins QSB 3.3L Only)................2582 Air Intake Manifold Pressure (Boost) is Below Normal (Cummins QS................2583 Engine Coolant Temperature is Low...............................................2584 Engine Oil Pressure is Low......................................................2585 Radiator Bubble Test............................................................2587 Engine Compression Test (GM and Mazda)..........................................2588 Engine Compression Test (Yanmar Diesel).........................................2589 Engine Oil Pressure Test........................................................2590 Fuel System Pressure Test (Gasoline Engines Only)...............................2593 Fuel System Pressure Test (LPG ENGINES ONLY)....................................2595 Engine Description..........................................................2595 EPR Primary Pressure Test...................................................2596 EPR Secondary Pressure Test.................................................2597 Fuel Injection Nozzle Test (Yanmar Diesel)......................................2598 Vacuum Leak.....................................................................2599 Vacuum Leak Detection.......................................................2599 Vacuum Leak Repairs.........................................................2599 Coolant System Test.............................................................2600 Electrical System...................................................................2601 Troubleshooting Guidelines and Procedures.......................................2617 Troubleshooting Guidelines..................................................2617 Troubleshooting Procedures..................................................2620 Troubleshooting Procedures, Identification..............................2620 Troubleshooting Procedures, Location....................................2620 Troubleshooting Procedures, Structure...................................2620 Troubleshooting Procedures, Performance.................................2621 Diagnostic Trouble Codes........................................................2622 Diagnostic Trouble Codes....................................................2622 Wiring Reference Data...........................................................2636 Post 2007 Engine Connections....................................................2640 Cummins 4.5L................................................................2640 GM 2.4L (GAS/LPG)...........................................................2641 GM 4.3L (GAS/LPG)...........................................................2642 Mazda 2.0/2.2L (GAS/LPG)....................................................2643 Yanmar 2.6/3.3L.............................................................2644 Harness Assembly Data...........................................................2645 Electrical System...............................................................2693 General Description.........................................................2693 Description.................................................................2695 Principles of Operation, Components.........................................2699 Principles Of Operation, System.............................................2707 100-2...........................................................................2715 100-2...........................................................................2715 100-3...........................................................................2715 135-3...........................................................................2715 135-16..........................................................................2715 523859-3........................................................................2715 524223-3........................................................................2715 524224-3........................................................................2715 524225-3........................................................................2715 524282-3........................................................................2715 523958-3........................................................................2715 523959-3........................................................................2715 135-16..........................................................................2726 100-4...........................................................................2729 135-4...........................................................................2729 135-18..........................................................................2729 523859-4........................................................................2729 523958-4........................................................................2729 523959-4........................................................................2729 524223-4........................................................................2729 524224-4........................................................................2729 524225-4........................................................................2729 524282-4........................................................................2729 135-18..........................................................................2739 524223-0........................................................................2744 524224-0........................................................................2744 524225-0........................................................................2744 524229-0........................................................................2744 524270-0........................................................................2744 524276-0........................................................................2744 524223-1........................................................................2749 524224-1........................................................................2749 524225-1........................................................................2749 524229-1........................................................................2749 524270-1........................................................................2749 524276-1........................................................................2749 110-3...........................................................................2753 110-3...........................................................................2753 110-5...........................................................................2753 110-16..........................................................................2753 177-3...........................................................................2753 522231-3........................................................................2753 522555-3........................................................................2753 522603-3........................................................................2753 524010-3........................................................................2753 524235-3........................................................................2753 110-4...........................................................................2763 110-4...........................................................................2763 177-4...........................................................................2763 522231-4........................................................................2763 522555-4........................................................................2763 522603-4........................................................................2763 524010-4........................................................................2763 524235-4........................................................................2763 110-2...........................................................................2772 110-2...........................................................................2772 110-10..........................................................................2775 522565-2........................................................................2780 522712-3........................................................................2781 522713-3........................................................................2781 522712-4........................................................................2787 522713-4........................................................................2787 51-2............................................................................2793 51-7............................................................................2793 91-2............................................................................2802 91-2............................................................................2802 91-2............................................................................2802 91-2............................................................................2802 91-11...........................................................................2802 522708-3........................................................................2809 522710-3........................................................................2809 522711-3........................................................................2809 522714-3........................................................................2809 522708-4........................................................................2817 522710-4........................................................................2817 522711-4........................................................................2817 522714-4........................................................................2817 515-0...........................................................................2825 523780-3........................................................................2830 523860-3........................................................................2830 524245-3........................................................................2830 524275-3........................................................................2830 523780-4........................................................................2837 523860-4........................................................................2837 524245-4........................................................................2837 524275-4........................................................................2837 677-3...........................................................................2844 2350-3..........................................................................2844 522754-3........................................................................2844 522755-3........................................................................2844 522764-3........................................................................2844 522766-3........................................................................2844 524230-3........................................................................2844 SYMPTOMS WARNING................................................................2844 677-4...........................................................................2851 2350-4..........................................................................2851 522754-4........................................................................2851 522755-4........................................................................2851 522764-4........................................................................2851 522766-4........................................................................2851 524230-4........................................................................2851 676-3...........................................................................2856 524195-3........................................................................2856 524269-3........................................................................2856 676-4...........................................................................2862 524195-4........................................................................2862 524269-4........................................................................2862 524269-7........................................................................2868 524215-3........................................................................2871 524215-6........................................................................2871 524237-3........................................................................2875 524238-3........................................................................2875 524240-3........................................................................2875 524237-4........................................................................2880 524238-4........................................................................2880 524240-4........................................................................2880 879-3...........................................................................2886 880-3...........................................................................2886 881-3...........................................................................2886 882-3...........................................................................2886 522772-3........................................................................2886 879-4...........................................................................2890 880-4...........................................................................2890 881-4...........................................................................2890 882-4...........................................................................2890 522772-4........................................................................2890 168-0...........................................................................2894 168-3...........................................................................2894 521982-3........................................................................2898 522760-3........................................................................2898 522761-3........................................................................2898 522762-3........................................................................2898 1079-31.........................................................................2906 522128-3........................................................................2906 524251-0........................................................................2906 524260-0........................................................................2906 524260-3........................................................................2906 524261-0........................................................................2906 524261-3........................................................................2906 51-31...........................................................................2906 168-1...........................................................................2918 168-4...........................................................................2918 521982-4........................................................................2922 522760-4........................................................................2922 522761-4........................................................................2922 522761-6........................................................................2922 522762-4........................................................................2922 1079-31.........................................................................2930 522128-4........................................................................2930 524251-1........................................................................2930 524260-1........................................................................2930 524260-4........................................................................2930 524261-1........................................................................2930 524261-4........................................................................2930 51-31...........................................................................2930 524260-2........................................................................2941 524260-11.......................................................................2941 524261-2........................................................................2941 524261-11.......................................................................2941 96-3............................................................................2945 96-4............................................................................2945 522810-3........................................................................2949 522810-4........................................................................2954 524213-1........................................................................2958 524213-3........................................................................2958 524213-4........................................................................2958 523920-3........................................................................2962 523925-3........................................................................2962 523930-3........................................................................2962 523977-3........................................................................2962 523978-3........................................................................2962 523986-3........................................................................2962 524284-3........................................................................2962 524285-3........................................................................2962 523920-4........................................................................2968 523925-4........................................................................2968 523930-4........................................................................2968 523977-4........................................................................2968 523978-4........................................................................2968 523986-4........................................................................2968 524284-4........................................................................2968 524285-4........................................................................2968 523920-6........................................................................2973 523925-6........................................................................2973 523930-6........................................................................2973 523977-6........................................................................2973 523978-6........................................................................2973 523986-6........................................................................2973 524284-6........................................................................2973 524285-6........................................................................2973 105-3...........................................................................2978 105-3...........................................................................2978 105-16..........................................................................2978 522570-3........................................................................2978 105-4...........................................................................2985 105-4...........................................................................2985 522570-4........................................................................2985 105-5...........................................................................2990 106-3...........................................................................2993 106-4...........................................................................2998 106-0...........................................................................3003 106-1...........................................................................3003 106-2...........................................................................3003 106-14..........................................................................3003 522609-3........................................................................3006 522739-3........................................................................3006 522740-3........................................................................3006 522608-5........................................................................3011 522739-5........................................................................3011 522740-5........................................................................3011 522608-6........................................................................3016 522739-6........................................................................3016 522740-6........................................................................3016 522735-2........................................................................3021 522735-4........................................................................3024 522736-4........................................................................3024 522735-5........................................................................3028 522736-5........................................................................3028 522735-6........................................................................3032 522736-6........................................................................3032 522630-2........................................................................3037 522631-2........................................................................3037 522632-2........................................................................3037 522633-2........................................................................3037 522635-3........................................................................3037 522636-4........................................................................3037 522637-3........................................................................3037 522638-4........................................................................3037 522606-10.......................................................................3042 522737-10.......................................................................3042 522525-10.......................................................................3042 651-3...........................................................................3049 652-3...........................................................................3049 653-3...........................................................................3049 654-3...........................................................................3049 655-3...........................................................................3049 656-3...........................................................................3049 522599-3........................................................................3049 522600-3........................................................................3049 522601-3........................................................................3049 522602-3........................................................................3049 522721-3........................................................................3049 522722-3........................................................................3049 522723-3........................................................................3049 522724-3........................................................................3049 522725-3........................................................................3049 522726-3........................................................................3049 522599-3........................................................................3049 522600-3........................................................................3049 522601-3........................................................................3049 522602-3........................................................................3049 651-5...........................................................................3057 651-5...........................................................................3057 652-5...........................................................................3057 652-5...........................................................................3057 653-5...........................................................................3057 653-5...........................................................................3057 654-5...........................................................................3057 654-5...........................................................................3057 655-5...........................................................................3057 656-5...........................................................................3057 522721-5........................................................................3057 522722-5........................................................................3057 522723-5........................................................................3057 522724-5........................................................................3057 522725-5........................................................................3057 522726-5........................................................................3057 651-6...........................................................................3062 652-6...........................................................................3062 653-6...........................................................................3062 654-6...........................................................................3062 655-6...........................................................................3062 656-6...........................................................................3062 522599-4........................................................................3062 522600-4........................................................................3062 522601-4........................................................................3062 522602-4........................................................................3062 522721-6........................................................................3062 522722-6........................................................................3062 522723-6........................................................................3062 522724-6........................................................................3062 522725-6........................................................................3062 522726-6........................................................................3062 2000-9..........................................................................3070 2000-12.........................................................................3070 2000-12.........................................................................3070 2000-12.........................................................................3070 2000-12.........................................................................3070 2000-14.........................................................................3070 2003-12.........................................................................3070 2023-12.........................................................................3070 2039-2..........................................................................3070 2039-12.........................................................................3070 2235-12.........................................................................3070 2236-12.........................................................................3070 2238-12.........................................................................3070 521670-12.......................................................................3070 524258-2........................................................................3070 522215-12.......................................................................3081 522215-14.......................................................................3081 524236-14.......................................................................3081 524262-12.......................................................................3081 524262-14.......................................................................3081 524263-1........................................................................3081 524268-12.......................................................................3081 628-12..........................................................................3084 630-12..........................................................................3084 522690-2........................................................................3084 522690-12.......................................................................3084 522691-2........................................................................3084 522691-12.......................................................................3084 522692-2........................................................................3084 522693-12.......................................................................3084 522694-12.......................................................................3084 522695-2........................................................................3084 522696-2........................................................................3084 522697-12.......................................................................3084 522697-12.......................................................................3084 522698-2........................................................................3084 522699-2........................................................................3084 522700-2........................................................................3084 190-2...........................................................................3087 190-2...........................................................................3087 190-7...........................................................................3087 522120-1........................................................................3087 522585-2........................................................................3087 520800-7........................................................................3094 522752-8........................................................................3094 522752-9........................................................................3094 524250-14.......................................................................3099 524264-2........................................................................3099 524265-2........................................................................3099 524271-2........................................................................3099 524225-14.......................................................................3099 524264-14.......................................................................3104 628-12..........................................................................3107 630-12..........................................................................3107 2660-3..........................................................................3107 2660-4..........................................................................3107 2661-3..........................................................................3107 2661-4..........................................................................3107 2802-12.........................................................................3107 523510-12.......................................................................3107 523511-12.......................................................................3107 523515-3........................................................................3107 523515-4........................................................................3107 523519-3........................................................................3107 523519-4........................................................................3107 2802-12.........................................................................3110 628-12..........................................................................3110 523261-3........................................................................3110 523261-4........................................................................3110 523257-3........................................................................3110 523257-4........................................................................3110 523253-3........................................................................3110 523253-4........................................................................3110 523249-3........................................................................3110 523249-4........................................................................3110 630-12..........................................................................3110 523261-12.......................................................................3113 523257-12.......................................................................3113 523253-12.......................................................................3113 523249-12.......................................................................3113 522780-3........................................................................3115 522781-3........................................................................3115 522780-4........................................................................3119 522781-4........................................................................3119 522780-2........................................................................3122 522781-2........................................................................3122 111-1...........................................................................3125 524252-2........................................................................3130 524253-14.......................................................................3132 524255-2........................................................................3133 108-0...........................................................................3134 108-1...........................................................................3134 522655-0........................................................................3138 522655-1........................................................................3138 522660-0........................................................................3138 522660-1........................................................................3138 524212-2........................................................................3144 524211-2........................................................................3144 524210-2........................................................................3144 524209-2........................................................................3144 524208-2........................................................................3144 524207-2........................................................................3144 524206-2........................................................................3144 524205-2........................................................................3144 524204-2........................................................................3144 524203-2........................................................................3144 524202-2........................................................................3144 524201-2........................................................................3144 524200-2........................................................................3144 524199-2........................................................................3144 524198-2........................................................................3144 524197-2........................................................................3144 522800-13.......................................................................3146 522801-13.......................................................................3148 522130-0........................................................................3149 522131-0........................................................................3149 522132-0........................................................................3149 522133-0........................................................................3149 522134-0........................................................................3149 522130-1........................................................................3153 522131-1........................................................................3153 522132-1........................................................................3153 522133-1........................................................................3153 522134-1........................................................................3153 522130-3........................................................................3158 522131-3........................................................................3158 522132-3........................................................................3158 522133-3........................................................................3158 522134-3........................................................................3158 522130-4........................................................................3164 522131-4........................................................................3164 522132-4........................................................................3164 522133-4........................................................................3164 522134-4........................................................................3164 522135-0........................................................................3168 522137-0........................................................................3168 522138-0........................................................................3168 522135-1........................................................................3172 522137-1........................................................................3172 522138-1........................................................................3172 522135-3........................................................................3176 522137-3........................................................................3176 522138-3........................................................................3176 522135-4........................................................................3180 522137-4........................................................................3180 522138-4........................................................................3180 522155-2........................................................................3184 522157-2........................................................................3184 522122-0........................................................................3191 522124-0........................................................................3191 522125-0........................................................................3191 522126-0........................................................................3191 522127-0........................................................................3191 522122-1........................................................................3195 522124-1........................................................................3195 522125-1........................................................................3195 522126-1........................................................................3195 522127-1........................................................................3195 522122-6........................................................................3199 522124-6........................................................................3199 522125-6........................................................................3199 522126-6........................................................................3199 522127-6........................................................................3199 522122-8........................................................................3204 522124-8........................................................................3204 522125-8........................................................................3204 522126-8........................................................................3204 522127-8........................................................................3204 522129-3........................................................................3208 522129-4........................................................................3208 522197-0........................................................................3209 522198-0........................................................................3209 522199-0........................................................................3209 522200-0........................................................................3209 522201-0........................................................................3209 522197-1........................................................................3212 522198-1........................................................................3212 522199-1........................................................................3212 522200-1........................................................................3212 522201-1........................................................................3212 522197-6........................................................................3213 522198-6........................................................................3213 522199-6........................................................................3213 522200-6........................................................................3213 522201-6........................................................................3213 522197-7........................................................................3214 522198-7........................................................................3214 522199-7........................................................................3214 522200-7........................................................................3214 522201-7........................................................................3214 522197-8........................................................................3215 522198-8........................................................................3215 522199-8........................................................................3215 522200-8........................................................................3215 522201-8........................................................................3215 522197-14.......................................................................3217 522198-14.......................................................................3217 522199-14.......................................................................3217 522200-14.......................................................................3217 522201-14.......................................................................3217 522201-16.......................................................................3217 522197-27.......................................................................3218 522198-27.......................................................................3218 522199-27.......................................................................3218 522200-27.......................................................................3218 522201-27.......................................................................3218 2039-2..........................................................................3221 522540-3........................................................................3224 522540-4........................................................................3229 522604-3........................................................................3237 522604-4........................................................................3245 522604-5........................................................................3252 522697-12.......................................................................3261 190-2...........................................................................3262 190-4...........................................................................3262 190-8...........................................................................3262 522752-2........................................................................3262 522752-4........................................................................3262 522752-5........................................................................3271 522598-3........................................................................3274 522598-4........................................................................3279 522592-0........................................................................3285 522592-1........................................................................3288 522593-12.......................................................................3290 522594-12.......................................................................3294 522595-12.......................................................................3294 522596-12.......................................................................3294 522597-12.......................................................................3294 522614-7........................................................................3297 522616-8........................................................................3297 522617-5........................................................................3297 524266-31.......................................................................3298 524286-31.......................................................................3298 524226-3........................................................................3300 524227-3........................................................................3300 524192-3........................................................................3304 524219-3........................................................................3304 524220-3........................................................................3304 524221-3........................................................................3304 524222-3........................................................................3304 524226-4........................................................................3308 524227-4........................................................................3308 524192-4........................................................................3311 524219-4........................................................................3311 524220-4........................................................................3311 524221-4........................................................................3311 524222-4........................................................................3311 524239..........................................................................3315 524241..........................................................................3315 524246..........................................................................3315 524267..........................................................................3315 524248..........................................................................3315 524746-2........................................................................3318 Engine Continues to Run When Engine Cover is Raised.............................3319 Engine Stops or Fails to Start..................................................3321 Electrical Functions Do Not Operate.............................................3323 Electrical Function Does Not Turn Off...........................................3330 Electro-Hydraulics Do Not Function With Armrest Down ...........................3337 Electro-Hydraulics Can Still Function With Armrest Raised.......................3340 Vehicle Does Not Power On.......................................................3344 Heater Fan Does Not Operate Properly............................................3351 Heater Airflow Does Not Reach Desired Temperature...............................3354 Heater Output Has Insufficient Airflow..........................................3355 Circulating (Accessory) Fan Inoperative.........................................3356 Dome Light Inoperative..........................................................3359 Horn Failure....................................................................3362 Horn Sounds Continuously........................................................3367 Drive Train.........................................................................3373 Mechanical Overview.............................................................3377 Engine..........................................................................3377 Description.................................................................3377 Torque Converter................................................................3377 Description.................................................................3377 Stator..................................................................3378 Turbine.................................................................3378 Pump PTO........................................................................3379 Cast Iron Transmission Chain Drive..........................................3379 Aluminum Transmission Gear Drive............................................3380 Aluminum Transmission Chain Drive...........................................3381 Spur Gear PTO...............................................................3382 Transmission....................................................................3383 Description.................................................................3383 1.0-5.5 Ton Lift Truck Transmissions........................................3386 Description.............................................................3386 Single-Speed........................................................3386 Two-Speed...........................................................3387 Clutch Pack.............................................................3387 Power Flow..............................................................3389 Single-Speed........................................................3389 Two-Speed...........................................................3390 Transmission Hydraulic Schematic........................................3392 Transmission Oil Flow...................................................3395 Control Valve Oil Flow..................................................3395 6.0-9.0 Ton Lift Truck Transmissions........................................3397 Description.............................................................3397 Two-Speed...........................................................3397 Three-Speed.........................................................3397 Clutch Pack.............................................................3399 Input Shaft and Range Clutches......................................3399 Directional Clutches................................................3399 Output Section......................................................3400 Power Flow..............................................................3400 Two-Speed and Three-Speed...........................................3400 Transmission Hydraulic Schematic........................................3404 Two-Speed...........................................................3404 Three-Speed.........................................................3406 Transmission Control System Overview............................................3407 Transmission Control System.................................................3407 Transmission Control Software...................................................3410 Transmission Control Modes..................................................3410 Neutral.................................................................3410 Gear Engagement Control.................................................3410 Basic Powershift Gear Engagement Mode...............................3410 DuraMatch™ and Extended Feature DuraMatch™ Plus Gear Engagemen......3410 Normal Forward or Reverse...............................................3410 Basic Powershift....................................................3410 DuraMatch™ and Extended Feature DuraMatch™ Plus Transmission........3410 Auto-Shift..............................................................3410 1st Gear Lock...........................................................3411 Inching.................................................................3411 Basic Powershift Inching Mode.......................................3411 DuraMatch™ Inching Mode.............................................3411 Extended Feature DuraMatch™ Plus Inching Mode.......................3411 Inch/Brake Overlap Adjustment...........................................3411 Brake Wear Compensation.................................................3411 Auto Decel..............................................................3412 Controlled Power Reversal...............................................3412 Basic Multi-Speed...................................................3412 Extended Feature DuraMatch™ Plus....................................3412 Controlled Creep........................................................3412 DuraMatch™ and DuraMatch™ Plus......................................3412 Controlled Roll Back....................................................3413 DuraMatch™ .........................................................3413 Electronic Extended Features........................................3413 Travel Speed Limit (Optional)...........................................3413 Extended Drawbar Pull ( Electronic Extended Features Multi-Speed........3413 Auto-Speed Hydraulics ( DuraMatch™ Plus Transmissions Only).............3413 Throttle Response Management ( Electronic Extended Features Tran....3414 Steady Travel Speed.................................................3414 Transmission Control Hardware...................................................3414 Control Valve and Sensors...................................................3414 Description.............................................................3414 Principles of Operation.................................................3416 Transmission Proportional Valve.............................................3417 Description.............................................................3417 Neutral.................................................................3417 Proportional Control....................................................3417 MONOTROL® Pedal.............................................................3418 Description.............................................................3418 Principles of Operation.................................................3418 Directional Control Lever...................................................3418 Principles of Operation.................................................3418 Driveshaft, Differential, Drive Axle, and Brakes (Dry Brake Only................3419 Driveshaft..................................................................3419 Differential and Drive Axle.................................................3419 Brake System................................................................3421 Description.............................................................3421 Service Brakes..........................................................3421 Master Cylinder.........................................................3422 Brake Position Sensor...................................................3422 Parking Brake...........................................................3422 Driveshaft, Differential, Drive Axle, and Brakes (Wet Brake Only................3422 Driveshaft..................................................................3422 Differential................................................................3423 Brake System................................................................3425 Description.............................................................3425 Service Brakes, 2.0-3.5 Ton Only........................................3426 Service Brakes, 4.0-9.0 Ton.............................................3427 Brake Adjustment and Service............................................3427 Parking Brake...........................................................3427 Overheating Brakes (Dry Brake Axle Only)........................................3431 Overheating Brakes (Wet Brake Axle Only)........................................3433 Poor Brake Performance (Dry Brake Axle Only)....................................3436 Poor Brake Performance (Wet Brake Axle Only)....................................3439 Brakes Make Too Much Noise (Dry Brake Axle Only)................................3441 Brakes Pull To One Side (Dry Brake Axle Only)...................................3442 Parking Brake Will Not Release..................................................3445 Parking Brake Will Not Hold Lift Truck (Dry Brake Axle Only)....................3446 Parking Brake Will Not Hold Lift Truck (Wet Brake Axle Only)....................3447 Abnormal Drive Axle Noise.......................................................3448 Discolored Drive Axle Oil.......................................................3452 Lift Truck Does Not Move (Drive Axle)...........................................3454 Abnormal Transmission Noise.....................................................3457 Bubbles or Foaming In Transmission Dipstick Tube................................3460 Inching Operation Is Not Smooth or Chatters.....................................3462 Lift Truck Does Not Move In One or Both Directions (Transmission................3464 Loss of Power/Drivetrain Performance............................................3468 Transmission Not Functioning Properly - No DTCs Generated.......................3472 Throttle Cable (Mazda Engine Only) is Out of Adjustment.........................3482 Transmission Is Too Hot.........................................................3484 Transmission Will Not Shift To Forward High Range...............................3487 Transmission Warm-up Procedure..................................................3489 Transmission Pressure Test......................................................3490 Transmission Charge Pump Pressure Test......................................3492 Clutch Pack Pressure Test (Proportional Solenoid Valves)....................3492 Torque Converter Pressure Test..............................................3493 Lubrication Pressure Test...................................................3493 Transmission Clutch Drag Test (1.0-5.5 Ton Trucks Only).........................3494 Torque Converter Stall Test.....................................................3495 Hydraulic Systems...................................................................3499 Main Hydraulic System...........................................................3503 Description.................................................................3503 Principles of Operation.....................................................3506 Hydraulic Schematics........................................................3507 Manual Control Valve Schematics.........................................3507 Electro-Hydraulic Control Valve Schematics..............................3510 Manual Hydraulic Control Valve..................................................3514 Description.................................................................3514 Principles of Operation.....................................................3516 Lift Section............................................................3516 Lift Operation......................................................3516 Lower Operation.....................................................3516 Tilt Section............................................................3517 Tilt Backward (1.0-9.0 Ton Lift Truck)..............................3517 Tilt Forward (1.0-5.5 Ton Lift Truck)...............................3517 Tilt Forward (6.0-7.0 Ton Lift Truck)...............................3518 Auxiliary Section.......................................................3518 Anti-Stall Feature......................................................3519 Relief Valves...........................................................3519 Main Relief Valve...................................................3519 Secondary Relief Valve..............................................3520 Emergency Lowering Valve................................................3520 Operator Presence Spool Lockout Mechanism...............................3520 Electro-Hydraulic Control Valve.................................................3521 Description.................................................................3521 Principles of Operation.....................................................3523 Inlet Pressure Compensator/Unloader.....................................3523 Lift/Lower EHPVs........................................................3525 EHPV Operation......................................................3525 Tilt and Auxiliary Spool Functions......................................3527 Tilt Forward (1.0-5.5 Ton Lift Truck)...............................3529 Tilt Forward (6.0-9.0 Ton Lift Truck)...............................3530 Main Relief Valve ......................................................3530 Secondary Relief Valve..................................................3531 Emergency Lowering Valve................................................3531 Anti-Stall Function.....................................................3531 Dual Stage Unloader.................................................3532 Steering System.................................................................3532 Component Locations.........................................................3532 Description.............................................................3532 Steering Axle Assembly..................................................3532 Steering Control Unit...................................................3532 Steering Schematic..........................................................3534 Principles of Operation.................................................3535 Steering Control Unit...................................................3535 Hydraulic System with Variable Displacement Pump................................3536 Description.................................................................3536 Principles of Operation.....................................................3538 Variable Displacement Pump..................................................3540 Description.............................................................3540 Operation...............................................................3542 Pressure Control........................................................3543 Flow Compensator........................................................3543 Electro-Hydraulic Control Valve.............................................3544 Description.............................................................3544 Operation...............................................................3545 Clipper Relief Valve....................................................3545 Emergency Lowering Valve................................................3545 Lift/Lower Section......................................................3546 Tilt and Auxiliary Sections.............................................3546 Tilt Forward Function with Counterbalance...............................3548 Secondary Relief Valve..................................................3549 Accumulator.............................................................3549 Steering Control Unit.......................................................3550 Description.............................................................3550 Operation...............................................................3551 When the engine is running and the steering wheel is not being t....3551 When the engine is running and the steering wheel is being turne....3552 Operational Check...........................................................3553 Abnormal Hydraulic Noise and/or Vibration.......................................3555 Abnormal Smell/Discoloration/Foaming of Oil.....................................3559 Abnormal Steer Axle Noise.......................................................3560 Abnormal Steering Wheel Vibration...............................................3562 Actuation Exhibits Slight Movement in Opposite Direction Before ................3563 Actuation Functions With Armrest Up (E-Valve)...................................3564 Actuations Do Not Act Simultaneously............................................3565 Auxiliary Function is Slow or Does Not Function (Manual Valve)..................3566 Back Lash/Kick Back in Steering Wheel...........................................3568 Cycle Times Too Fast - Fast Actuation...........................................3570 Cycle Times Too Fast - Fast Actuation (E-Valve).................................3572 Cycle Times Too Fast - Fast Actuation (Manual Valve)............................3573 Forks Drop Slightly Before Lifting (E-Valve)....................................3574 Forks Lower Without Command (E-Valve)...........................................3575 Forks Raise or Actuate Without Command (E-Valve)................................3577 Forks Tilt Forward Without Command (E-Valve)....................................3579 Intermittent Activation (E-Valve) While Commanding Function.....................3581 Jump/Delay In Lift or Lower Activation After Moving Joystick or ................3583 Jump/Delay In Secondary Function Actuation After Moving Joystick................3585 Jump/Delay In Tilt Forward Actuation (E-Valve)..................................3587 Lift Function Is Slow or Does Not Function (Manual Valve).......................3589 Lift Function Will Not Move With Joystick or MLM Movement (E-Val................3591 Lift/Lower Continues To Move For Awhile After Joystick or MLM Is................3595 Lift/Lower Function Maximum Speed Too Slow (E-Valve)............................3596 Lift/Lower/Secondary Function Suddenly Jumps In Middle of Stroke................3599 Load Drops Slightly When Metering Lift Function (Manual Valve)..................3600 Lower Function Will Not Move With Joystick or MLM Movement (E-Va................3601 No Steering (All Other Hydraulic Functions OK)..................................3603 Oil Leaking/Component Life Too Short............................................3605 Poor Metering on Lift or Lower Functions (E-Valve)..............................3608 Secondary Function Continues to Move for Awhile After Joystick o................3611 Secondary Function Exhibits Slight Movement in Opposite Directio................3612 Secondary Function Maximum Speed Too Slow (E-Valve).............................3613 Secondary Function and Tilt Back Will Not Move With Joystick or ................3616 Secondary Function or Tilt Back Moves Without Command (E-Valve).................3620 Steering Is Slow or Difficult...................................................3622 Steering Operation Is Not Smooth................................................3624 Steering Wheel End Lock Position Cannot Be Felt by Operator.....................3626 Steering Wheel Turns By Itself or Does Not Return To Neutral....................3627 Steering Wheel Turns the Tires in the Wrong Direction...........................3628 Tilt Back Function Will Not Operate (Manual Valve)..............................3629 Tilt Forward Function Continues to Move for Awhile When Joystick................3630 Tilt Forward Functions When Spool is Activated Forward With Engi................3631 Tilt Forward Will Not Function When Activated (Manual Valve)....................3632 Tilt Forward Will Not Move Upon Joystick or MLM Movement (E-Valv................3633 Too Much Joystick or MLM Movement (Deadband) to Start Function M................3635 Wrong Actuation Operates or Actuation is Backward (E-Valve).....................3636 No Steering and No Hydraulic Functions..........................................3637 Steering and Hydraulic Functions are Slow.......................................3638 No Steering (All other hydraulic functions are okay)............................3639 Steering Effort is Too High (All other hydraulic functions are o................3640 Steer Cylinder Does Not Reach End Of Stroke (All other hydraulic................3642 Steering Wheel Turns By Itself (Self-Steering)..................................3643 No Hydraulic Functions (Lift, Tilt, and Aux)....................................3644 Hydraulic Functions are Slow (Lift, Tilt, and Aux)..............................3645 Hydraulic Valve Assembly Leaks..................................................3646 No Lift Function (Steering and All other hydraulic functions oka................3647 Lift Function Is Slow (All other hydraulic functions are okay)..................3649 Delay In Lift Activation........................................................3651 Jump In Lift Activation.........................................................3652 Forks Drop Slightly Before Lifting..............................................3653 Forks Raise Without Command.....................................................3654 Intermittent Activation While Commanding Function...............................3655 Poor Metering On Lift Function..................................................3656 Too Much MLM/Joystick Movement (Deadband).......................................3657 No Lower Function (Steering, lift, tilt, and Aux functions okay)................3658 Lower Functions Too Slow (All other hydraulic functions are okay................3660 Delay In Lowering Activation....................................................3662 Jump In Lower Activation........................................................3664 Forks Lower Without Command.....................................................3666 Too Much MLM/Joystick Movement (Deadband) To Start Function.....................3668 No Secondary Function (Tilt or Aux).............................................3669 Secondary Function (Tilt or Aux) Too Slow.......................................3671 Secondary Function (Tilt or Aux) Delay in Actuation.............................3673 Secondary Function (Tilt or Aux) Jump in Actuation..............................3674 Secondary Function (Tilt or Aux) Actuate Without Command........................3675 Hydraulic Warm-Up Procedure.....................................................3677 Electro-Hydraulic Poppet Valve (EHPV) Leakage Test..............................3679 Hydraulic Pump Flow Test........................................................3681 Lift Cylinder Leakage Test......................................................3684 Main Control Valve LS Leakage Test (E-Valve)....................................3685 Main Relief Valve Test and Adjustment...........................................3686 PPRV Pilot Pressure Test........................................................3688 Secondary Relief Valve Test and Adjustment......................................3689 Steering Control Unit LS Pressure Test..........................................3691 Steering Cylinder Leakage Test..................................................3692 Steering Relief Pressure Test and Adjustment....................................3694 Tilt Cylinder Leakage Test......................................................3695 Pressure Compensator Test and Adjustment........................................3697 Flow Compensator Margin Test and Adjustment.....................................3698 Steering Relief Pressure Test and Adjustment....................................3700 Steering Control Unit LS Pressure Test..........................................3702 PPRV Pilot Pressure Test........................................................3703 Steering Column Binding Test....................................................3704 SCU Bolts and Main Control Valve Tie-Rod Torque.................................3707 Operators Station...................................................................3709 Operator Station General Description and Principles of Operation................3711 General Description and Location............................................3711 Display Switch Cluster (DSC)....................................................3713 Detailed Description........................................................3713 Control Inputs, Right Side..................................................3714 Right Indicator and Warning Group...........................................3716 LCD Display.................................................................3717 Left Indicator and Warning Group............................................3718 Control Inputs, Left Side (Cab Option Only).................................3719 Transmission Control and Braking................................................3720 Description.................................................................3720 Vehicle System Manager (VSM)............................................3720 Display Switch Cluster..................................................3721 Interlock and Switching Features....................................3721 MONOTROL® Directional Control...........................................3721 Inch Brake/Service Brake Pedal..........................................3721 Parking Brake...........................................................3721 Programming - Menus.............................................................3722 Menus.......................................................................3722 Main Menu...............................................................3725 Save and Exit or Exit Without Saving....................................3725 Back One Level..........................................................3725 Hourmeters..............................................................3725 View Versions...........................................................3726 Passwords...............................................................3726 Diagnostics.............................................................3726 Setup Travel and Braking................................................3726 Setup Hydraulics........................................................3726 Setup Display...........................................................3726 Setup General Items.....................................................3726 Calibrations............................................................3726 Manual Hydraulic Control Levers.................................................3727 General Description.........................................................3727 System Components...........................................................3727 Lift/Lower..............................................................3727 Tilt....................................................................3727 Auxiliary 1.............................................................3727 Auxiliary 2.............................................................3727 E-Hydraulic System Interface....................................................3728 General Description.........................................................3728 System Components...........................................................3728 E-Hydraulic Control Input Device............................................3728 Joystick................................................................3728 Lift/Lower..........................................................3729 Tilt................................................................3729 Auxiliary 1.........................................................3729 Auxiliary 2.........................................................3729 Push Button.........................................................3729 Mini-Lever Module (MLM).................................................3730 Lever 1.............................................................3730 Lever 2.............................................................3730 Lever 3.............................................................3731 Lever 4.............................................................3731 System Modes................................................................3731 Hydraulic Interlock Mode................................................3731 Fault Mode..............................................................3731 Engine Off Mode.........................................................3731 Normal Operation............................................................3731 Normal Operation Mode...................................................3731 Lifting Control.........................................................3731 Lowering Control........................................................3732 Tilt Control (Forward and Backward).....................................3732 Auxiliary Control.......................................................3732 Lighting Control................................................................3732 Description.................................................................3732 Front Work Lights.......................................................3735 Front Marker Lights (if equipped).......................................3735 Front/Rear Turn Signal Lights...........................................3735 Rear Tail/Marker Lights.................................................3735 Rear Work Light.........................................................3735 Rear Backup Lights......................................................3735 Rear Stop Lights........................................................3735 Strobe Light(s).........................................................3735 Spot Light (if equipped)................................................3735 Cab.............................................................................3735 Description.................................................................3735 Component Descriptions......................................................3737 Cab Heating System......................................................3737 Lighting Control System.................................................3738 Wiper/Washer System.....................................................3738 Cab Systems Operation.......................................................3738 Front End (Mast) and Chassis........................................................3741 Front End, Mast.................................................................3743 Description.................................................................3743 Carriages.......................................................................3744 Description.................................................................3744 Principles of Operation.....................................................3744 Integral Sideshift Carriage.............................................3744 Mast Mounts.....................................................................3746 Description.................................................................3746 Principles of Operation.....................................................3746 Two-Stage Limited Free-Lift (LFL) Mast..........................................3748 Description.................................................................3748 Principles of Operation.....................................................3749 Two-Stage Full Free-Lift (FFL) Mast.............................................3750 Description.................................................................3750 Principles of Operation.....................................................3750 Three-Stage Full Free-Lift (FFL) Mast...........................................3752 Description.................................................................3752 Principles of Operation.....................................................3752 Four-Stage Full Free-Lift (FFL) Mast............................................3754 Description.................................................................3754 Principles of Operation.....................................................3755 Cylinder Cushion During Lifting Sequence........................................3757 Description.................................................................3757 Principles of Operation.....................................................3757 Cylinder Cushion During Lowering Sequence.......................................3758 Description.................................................................3758 Principles of Operation.....................................................3758 Tilt and Sideshift Cylinders....................................................3758 Description.................................................................3758 Tilt Cylinder...........................................................3758 Sideshift Cylinder......................................................3758 Lowering Control Valves.........................................................3759 Description.................................................................3759 Principles of Operation.....................................................3759 Chassis.........................................................................3761 Description.................................................................3761 Abnormal Channel Wear...........................................................3763 Abnormal Hose Wear..............................................................3765 Abnormal Mast Noise.............................................................3767 Body Panels Making Noise........................................................3771 External Leakage From Free-Lift or Main Lift Cylinders..........................3772 FFL Mast Banging During Phasing.................................................3773 High Tire Wear - Drive Axle.....................................................3775 High Tire Wear - Steer Axle.....................................................3777 Hoses Not Tracking Correctly....................................................3779 Integral Sideshift Moving Too Fast..............................................3780 Integral Sideshift Not Moving or Slow...........................................3781 LP Tank Bracket Disengages......................................................3785 LP Tank Rattles and Does Not Stay Latched.......................................3786 Mast is Loose...................................................................3787 Mast Lift Chains Are Loose......................................................3789 Mast or Carriage Binding........................................................3790 Mast/Carriage Bounces or is Spongy..............................................3792 Misphasing of Full Free-Lift Mast...............................................3793 Overhead Guard Loose or Damaged.................................................3795 Racking During Lift.............................................................3796 Racking During Tilt.............................................................3798 Truck Feels Unstable............................................................3799 Truck Wanders, Does Not Track Straight or Steer Well............................3801 Wheels Appear Tipped or Misaligned..............................................3803 Wheels Spinning On Uneven Floors................................................3805 Wheel Studs Breaking............................................................3806 Supplementary Data..................................................................3807 Abbreviations and Acronyms......................................................3809 Special Tools List..............................................................3817 Fault Mode Indicator (FMI) Reference List.......................................3823 TSP Reference Tables............................................................3825 tables..................................................................................2295 Table 9020-10-1. Test Specifications................................................2388 Table 9020-10-2. IAT Ambient Temperature............................................2399 Table 9020-40-1. Test Specifications................................................2587 Table 9020-40-2. Test Specifications................................................2588 Table 9020-40-3. Service Tools......................................................2588 Table 9020-40-4. Test Specifications................................................2589 Table 9020-40-5. Service Tools......................................................2589 Table 9020-40-6. Test Specifications................................................2590 Table 9020-40-7. Service Tools......................................................2591 Table 9020-40-8. Test Specifications - Mazda........................................2593 Table 9020-40-9. Test Specifications - GM...........................................2593 Table 9020-40-10. Service Tools.....................................................2593 Table 9020-40-11. Test Specifications...............................................2595 Table 9020-40-12. Service Tools.....................................................2596 Table 9020-40-13. Test Specifications...............................................2598 Table 9020-40-14. Service Tools.....................................................2598 Table 9020-40-15. Test Specifications...............................................2600 Table 9020-40-16. Service Tools.....................................................2600 Table 9030-03-1. Cummins QSB 3.3L Fault Codes.......................................2633 Table 9030-03-2. Circuit Group Identification.......................................2637 Table 9030-03-3. Hyster Wiring Color Codes..........................................2638 Table 9040-10-1. Two-Speed Transmission Clutch Pack Solenoid Val....................3405 Table 9040-10-2. Three-Speed Transmission Electronic Proportiona....................3406 Table 9040-10-3. Transmission Control Mode..........................................3409 Table 9040-40-1. Test Specifications................................................3489 Table 9040-40-2. Service Tools......................................................3489 Table 9040-40-3. Service Tools......................................................3490 Table 9040-40-4. Test Specifications................................................3492 Table 9040-40-5. Test Specifications................................................3492 Table 9040-40-6. Test Specifications................................................3493 Table 9040-40-7. Test Specifications 1.0 - 9.0 Ton Truck............................3493 Table 9040-40-8. Test Specifications................................................3494 Table 9040-40-9. Service Tools......................................................3494 Table 9040-40-10. Stall Speeds......................................................3496 Table 9050-10-1. Standby Pressure...................................................3524 Table 9050-40-1. Test Specifications................................................3677 Table 9050-40-2. Service Tools......................................................3677 Table 9050-43-1. Test Specifications................................................3679 Table 9050-43-2. Service Tools......................................................3679 Table 9050-43-3. Test Specifications................................................3682 Table 9050-43-4. Service Tools......................................................3682 Table 9050-43-5. Test Specifications................................................3684 Table 9050-43-6. Service Tools......................................................3684 Table 9050-43-7. Test Specifications................................................3685 Table 9050-43-8. Test Specifications................................................3686 Table 9050-43-9. Service Tools......................................................3686 Table 9050-43-10. Test Specifications...............................................3688 Table 9050-43-11. Service Tools.....................................................3688 Table 9050-43-12. Test Specifications...............................................3689 Table 9050-43-13. Service Tools.....................................................3689 Table 9050-43-14. Test Specifications...............................................3691 Table 9050-43-15. Service Tools.....................................................3691 Table 9050-43-16. Test Specifications...............................................3692 Table 9050-43-17. Service Tools.....................................................3692 Table 9050-43-18. Test Specifications...............................................3694 Table 9050-43-19. Service Tools.....................................................3694 Table 9050-43-20. Test Specifications...............................................3695 Table 9050-43-21. Service Tools.....................................................3695 Table 9050-45-1. Test Specifications................................................3697 Table 9050-45-2. Service Tools......................................................3697 Table 9050-45-3. Test Specifications................................................3698 Table 9050-45-4. Service Tools......................................................3698 Table 9050-45-5. Test Specifications................................................3700 Table 9050-45-6. Service Tools......................................................3700 Table 9050-45-7. Test Specifications................................................3702 Table 9050-45-8. Service Tools......................................................3702 Table 9050-45-9. Test Specifications................................................3703 Table 9050-45-10. Service Tools.....................................................3703 Table 9050-45-11. Test Specifications...............................................3704 Table 9050-45-12. Service Tools.....................................................3704 Table 9050-45-13. Torque Specifications.............................................3707 Table 9050-45-14. Service Tools.....................................................3707 Table 9080-50-1. Abbreviations and Acronyms.........................................3809 Table 9080-60-1. Special Tools......................................................3817 Table 9080-70-1. FMI................................................................3823 Table 9080-80-1. Resistor-Temperature Characteristics ..............................3825 Elect. System (1)...........................................................................3829 toc.....................................................................................3829 Electrical System...................................................................3829 Safety Precautions Maintenance and Repair...........................................3830 General.............................................................................3837 Display Switch Cluster..............................................................3839 Remove..........................................................................3839 Install.........................................................................3841 Direction Control and Turn Signal Levers........................................3841 Remove......................................................................3841 Install.....................................................................3841 Key Switch......................................................................3843 Remove......................................................................3843 Install.....................................................................3843 Display Switch Cluster Panel Bezel and Overlay..................................3844 Remove......................................................................3844 Install.....................................................................3844 Steering Column Repair..............................................................3844 Remove..........................................................................3844 Disassemble.....................................................................3844 Assemble........................................................................3845 Install.........................................................................3845 Sensors and Switches................................................................3847 General.........................................................................3847 Dash and Kick Panel, Remove and Install.....................................3847 Remove..................................................................3847 Install.................................................................3847 Accelerator Pedal Position Sensor...............................................3849 Remove......................................................................3849 Install.....................................................................3850 Brake Fluid Level Switch........................................................3852 Remove......................................................................3852 Install.....................................................................3854 Service Brake Pedal Position Sensor.............................................3854 Remove......................................................................3854 Install.....................................................................3856 Parking Brake Sensor............................................................3857 Remove......................................................................3857 Install.....................................................................3858 Service Brake Pressure Sensor...................................................3858 Remove......................................................................3858 Install.....................................................................3859 Accumulator Pressure Switch For Lift Truck Models H8.0FT, H8.0FT................3860 Remove......................................................................3860 Install.....................................................................3860 MONOTROL® Sensor Microswitch....................................................3861 Remove......................................................................3861 Install.....................................................................3863 Low Coolant Level Sensor........................................................3864 Remove......................................................................3864 Install.....................................................................3866 Fuel Level Sensor, Gas and Diesel Engines Only..................................3867 Remove......................................................................3867 Install.....................................................................3867 Armrest Switch..................................................................3868 Remove......................................................................3868 Install.....................................................................3868 Seat Sensor (Operator Presence System)..........................................3870 Non-Suspension and Semi-Suspension Seats; All Lift truck Models ............3870 Remove..................................................................3870 Install.................................................................3870 Non-Suspension Seats; Lift Truck Models H6.0FT, H7.0FT (H135FT, ............3871 Remove..................................................................3871 Install.................................................................3871 Full Suspension Seats; All Lift Truck Models................................3872 Remove..................................................................3872 Install.................................................................3872 Hood Shut Off Switch............................................................3872 Remove......................................................................3872 Install.....................................................................3874 Remote Key Switch...............................................................3875 Remove......................................................................3875 Install.....................................................................3875 Hydraulic Filter Pressure Switch................................................3876 Remove......................................................................3876 Install.....................................................................3876 Transmission Speed Sensor.......................................................3878 Remove......................................................................3878 Install.....................................................................3881 Transmission Pressure Sensors...................................................3881 Remove......................................................................3881 Install.....................................................................3882 Transmission Temperature Sensor.................................................3883 Remove......................................................................3883 Install.....................................................................3885 Engine Speed Sensor.............................................................3886 Remove......................................................................3886 Install.....................................................................3886 Intermediate Speed Sensor.......................................................3886 Remove......................................................................3886 Install.....................................................................3886 Return to Set Tilt (Tilt Angle) Sensor..........................................3887 Lift Truck Models S30FT, S35FT, S40FTS (E010); H1.6FT, H1.8FT, H............3887 Remove..................................................................3887 Install.................................................................3887 Lift Truck Models S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024); ............3888 Remove..................................................................3888 Install.................................................................3889 Rear Horn Button Switch.........................................................3889 Remove......................................................................3889 Install.....................................................................3890 Impact Sensor...................................................................3890 All Lift Truck Models Except H6.0FT, H7.0FT (H135FT, H155FT) (H0............3890 Remove..................................................................3890 Install.................................................................3892 Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006) a............3892 Remove..................................................................3892 Install.................................................................3892 Load Weight Sensor..............................................................3894 Remove......................................................................3894 Install.....................................................................3894 Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equippe................3896 Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equippe................3896 Crankshaft Position (CKP) Sensor ...........................................3896 Camshaft Position (CMP) Sensor..............................................3896 Oil Pressure Sensor.........................................................3896 Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) ............3896 Engine Coolant Temperature (ECT) Sensor.....................................3896 Air Flow Restriction Switch.................................................3897 Remove for GM 2.4L Gas and LPG Trucks...................................3897 Install for GM 2.4L Gas and LPG Trucks..................................3897 Oxygen Sensor...............................................................3897 Remove..................................................................3897 Install.................................................................3900 Engine and Fuel Switches, GM 2.4L LPG Trucks Only...............................3901 Low LPG Pressure Switch.....................................................3901 Engine and Fuel Sensors and Switches, Yanmar Diesel Trucks......................3901 Air Filter Restriction Switch...............................................3901 Remove..................................................................3901 Install.................................................................3901 Oil Pressure Sensor.........................................................3901 Remove..................................................................3901 Install.................................................................3901 Engine Speed Sensor.........................................................3902 Remove..................................................................3902 Install.................................................................3902 Engine Coolant Temperature (ECT) Sensor.....................................3902 Remove..................................................................3902 Install.................................................................3902 Throttle Position Sensor (TPS)..............................................3904 Remove..................................................................3904 Install.................................................................3904 Fuel/Water Separator Sensor.................................................3905 Remove..................................................................3905 Install.................................................................3905 Glow Plug Relay.............................................................3906 Remove..................................................................3906 Install.................................................................3906 Engine and Fuel Sensors and Switches, Cummins Diesel Engines....................3908 Air Filter Restriction Switch...............................................3908 Remove..................................................................3908 Install.................................................................3908 Engine Oil Pressure Sensor..................................................3911 Remove..................................................................3911 Install.................................................................3911 Engine Speed Sensor.........................................................3911 Remove..................................................................3911 Install.................................................................3912 Engine Coolant Temperature (ECT) Sensor.....................................3912 Remove..................................................................3912 Install.................................................................3912 Throttle Position Sensor (TPS) (Cummins 4.5L Only)..........................3913 Remove..................................................................3913 Install.................................................................3913 Fuel/Water Separator Sensor.................................................3914 Remove..................................................................3914 Install.................................................................3914 Vehicle System Manager (VSM)........................................................3915 General.........................................................................3915 VSM Replacement.................................................................3915 Remove......................................................................3915 Install.....................................................................3915 Programming a New VSM and/or Display Switch Cluster.............................3917 General.....................................................................3917 PC Service Tool Software....................................................3917 Data Transferring...........................................................3917 New VSM.................................................................3917 New (Blank) Display Switch Cluster......................................3917 Used (Non-Blank) Display Switch Cluster.................................3918 Power Distribution Module (PDM) and Component Parts.................................3919 Remove..........................................................................3919 PDM as a Unit...............................................................3919 Install.........................................................................3922 PDM as a Unit...............................................................3922 Remove and Install..............................................................3922 PDM Component Parts.........................................................3922 Transmission Control Unit...........................................................3923 Remove..........................................................................3923 Install.........................................................................3923 Battery.............................................................................3924 Remove..........................................................................3924 Install.........................................................................3925 Lights..............................................................................3925 Work Lights (Front and Rear)....................................................3925 Remove......................................................................3925 Install.....................................................................3926 Strobe Light....................................................................3926 Remove......................................................................3926 Install.....................................................................3926 LED Tail, Backup, and Brake Lights..............................................3927 Remove......................................................................3927 Install.....................................................................3928 Front Marker/Turn Signal Lights.................................................3929 Replacing Whole Front Marker/Turn Signal Light Assembly.....................3929 Remove..................................................................3929 Install.................................................................3929 Replacing Just the Front Marker/Turn Signal Light LED Light Lens............3929 Remove..................................................................3929 Install.................................................................3929 Electronic-Hydraulic Controls - Generation 1........................................3930 E-Hydraulic Controls - Test.....................................................3930 Mini-Levers.................................................................3930 Full Stroke Test............................................................3930 Function Returns to Neutral Test............................................3930 Push Button Switch..........................................................3930 General.........................................................................3931 Mini-Lever Replacement..........................................................3931 Remove......................................................................3931 Clean and Inspect...........................................................3932 Install.....................................................................3932 Push Button Switch Replacement..................................................3933 Remove......................................................................3933 Install.....................................................................3934 Mini-Lever Module (MLM).........................................................3935 Remove......................................................................3935 Install.....................................................................3935 Joystick........................................................................3935 Remove and Disassemble......................................................3935 Inspect.....................................................................3936 Assemble and Install........................................................3936 Electronic-Hydraulic Controls - Generation 2........................................3936 General.........................................................................3936 Mini-levers, Remove and Install.................................................3937 Armrest Assembly................................................................3938 Remove......................................................................3938 Install.....................................................................3940 Horn Button.....................................................................3940 Remove......................................................................3940 Install.....................................................................3940 Direction Control Switch........................................................3941 Remove......................................................................3941 Install.....................................................................3941 Momentary Switches and Function Selection Button................................3941 Remove......................................................................3942 Install.....................................................................3942 Joystick........................................................................3944 Remove and Disassemble......................................................3944 Inspect.....................................................................3944 Assemble and Install........................................................3944 Joystick Armrest Slider Assembly................................................3944 Remove......................................................................3944 Install.....................................................................3944 tables..................................................................................3829 Table 1. VSM and Display Switch Cluster Replacement.................................3919 Elect. System...............................................................................3949 toc.....................................................................................3949 Electrical System...................................................................3949 Safety Precautions Maintenance and Repair...........................................3950 General.............................................................................3957 Display Switch Cluster..............................................................3959 Remove..........................................................................3959 Install.........................................................................3961 Direction Control and Turn Signal Levers........................................3961 Remove......................................................................3961 Install.....................................................................3961 Key Switch......................................................................3963 Remove......................................................................3963 Install.....................................................................3963 Display Switch Cluster Panel Bezel and Overlay..................................3964 Remove......................................................................3964 Install.....................................................................3964 Steering Column Repair..............................................................3964 Remove..........................................................................3964 Disassemble.....................................................................3964 Assemble........................................................................3965 Install.........................................................................3965 Sensors and Switches................................................................3967 General.........................................................................3967 Dash and Kick Panel, Remove and Install.....................................3967 Remove..................................................................3967 Install.................................................................3967 Accelerator Pedal Position Sensor...............................................3969 Remove......................................................................3969 Install.....................................................................3970 Brake Fluid Level Switch........................................................3972 Remove......................................................................3972 Install.....................................................................3974 Service Brake Pedal Position Sensor.............................................3974 Remove......................................................................3974 Install.....................................................................3976 Parking Brake Sensor............................................................3977 Remove......................................................................3977 Install.....................................................................3978 Service Brake Pressure Sensor...................................................3978 Remove......................................................................3978 Install.....................................................................3979 Accumulator Pressure Switch For Lift Truck Models H8.0FT, H8.0FT................3980 Remove......................................................................3980 Install.....................................................................3980 MONOTROL® Sensor Microswitch....................................................3981 Remove......................................................................3981 Install.....................................................................3983 Low Coolant Level Sensor........................................................3984 Remove......................................................................3984 Install.....................................................................3986 Fuel Level Sensor, Gas and Diesel Engines Only..................................3987 Remove......................................................................3987 Install.....................................................................3987 Armrest Switch..................................................................3988 Remove......................................................................3988 Install.....................................................................3988 Seat Sensor (Operator Presence System)..........................................3990 Non-Suspension and Semi-Suspension Seats; All Lift truck Models ............3990 Remove..................................................................3990 Install.................................................................3990 Non-Suspension Seats; Lift Truck Models H6.0FT, H7.0FT (H135FT, ............3991 Remove..................................................................3991 Install.................................................................3991 Full Suspension Seats; All Lift Truck Models................................3992 Remove..................................................................3992 Install.................................................................3992 Hood Shut Off Switch............................................................3992 Remove......................................................................3992 Install.....................................................................3994 Remote Key Switch...............................................................3995 Remove......................................................................3995 Install.....................................................................3995 Hydraulic Filter Pressure Switch................................................3996 Remove......................................................................3996 Install.....................................................................3996 Transmission Speed Sensor.......................................................3998 Remove......................................................................3998 Install.....................................................................4001 Transmission Pressure Sensors...................................................4001 Remove......................................................................4001 Install.....................................................................4002 Transmission Temperature Sensor.................................................4003 Remove......................................................................4003 Install.....................................................................4005 Engine Speed Sensor.............................................................4006 Remove......................................................................4006 Install.....................................................................4006 Intermediate Speed Sensor.......................................................4006 Remove......................................................................4006 Install.....................................................................4006 Return to Set Tilt (Tilt Angle) Sensor..........................................4007 Lift Truck Models S30FT, S35FT, S40FTS (E010); H1.6FT, H1.8FT, H............4007 Remove..................................................................4007 Install.................................................................4007 Lift Truck Models S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024); ............4008 Remove..................................................................4008 Install.................................................................4009 Rear Horn Button Switch.........................................................4009 Remove......................................................................4009 Install.....................................................................4010 Impact Sensor...................................................................4010 All Lift Truck Models Except H6.0FT, H7.0FT (H135FT, H155FT) (H0............4010 Remove..................................................................4010 Install.................................................................4012 Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006) a............4012 Remove..................................................................4012 Install.................................................................4012 Load Weight Sensor..............................................................4014 Remove......................................................................4014 Install.....................................................................4014 Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equippe................4016 Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equippe................4016 Crankshaft Position (CKP) Sensor ...........................................4016 Camshaft Position (CMP) Sensor..............................................4016 Oil Pressure Sensor.........................................................4016 Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) ............4016 Engine Coolant Temperature (ECT) Sensor.....................................4016 Air Flow Restriction Switch.................................................4017 Remove for GM 2.4L Gas and LPG Trucks...................................4017 Install for GM 2.4L Gas and LPG Trucks..................................4017 Oxygen Sensor...............................................................4017 Remove..................................................................4017 Install.................................................................4020 Engine and Fuel Switches, GM 2.4L LPG Trucks Only...............................4021 Low LPG Pressure Switch.....................................................4021 Engine and Fuel Sensors and Switches, Yanmar Diesel Trucks......................4021 Air Filter Restriction Switch...............................................4021 Remove..................................................................4021 Install.................................................................4021 Oil Pressure Sensor.........................................................4021 Remove..................................................................4021 Install.................................................................4021 Engine Speed Sensor.........................................................4022 Remove..................................................................4022 Install.................................................................4022 Engine Coolant Temperature (ECT) Sensor.....................................4022 Remove..................................................................4022 Install.................................................................4022 Throttle Position Sensor (TPS)..............................................4024 Remove..................................................................4024 Install.................................................................4024 Fuel/Water Separator Sensor.................................................4025 Remove..................................................................4025 Install.................................................................4025 Glow Plug Relay.............................................................4026 Remove..................................................................4026 Install.................................................................4026 Engine and Fuel Sensors and Switches, Cummins Diesel Engines....................4028 Air Filter Restriction Switch...............................................4028 Remove..................................................................4028 Install.................................................................4028 Engine Oil Pressure Sensor..................................................4031 Remove..................................................................4031 Install.................................................................4031 Engine Speed Sensor.........................................................4031 Remove..................................................................4031 Install.................................................................4032 Engine Coolant Temperature (ECT) Sensor.....................................4032 Remove..................................................................4032 Install.................................................................4032 Throttle Position Sensor (TPS) (Cummins 4.5L Only)..........................4033 Remove..................................................................4033 Install.................................................................4033 Fuel/Water Separator Sensor.................................................4034 Remove..................................................................4034 Install.................................................................4034 Vehicle System Manager (VSM)........................................................4035 General.........................................................................4035 VSM Replacement.................................................................4035 Remove......................................................................4035 Install.....................................................................4035 Programming a New VSM and/or Display Switch Cluster.............................4037 General.....................................................................4037 PC Service Tool Software....................................................4037 Data Transferring...........................................................4037 New VSM.................................................................4037 New (Blank) Display Switch Cluster......................................4037 Used (Non-Blank) Display Switch Cluster.................................4038 Power Distribution Module (PDM) and Component Parts.................................4039 Remove..........................................................................4039 PDM as a Unit...............................................................4039 Install.........................................................................4042 PDM as a Unit...............................................................4042 Remove and Install..............................................................4042 PDM Component Parts.........................................................4042 Transmission Control Unit...........................................................4043 Remove..........................................................................4043 Install.........................................................................4043 Battery.............................................................................4044 Remove..........................................................................4044 Install.........................................................................4045 Lights..............................................................................4045 Work Lights (Front and Rear)....................................................4045 Remove......................................................................4045 Install.....................................................................4046 Strobe Light....................................................................4046 Remove......................................................................4046 Install.....................................................................4046 LED Tail, Backup, and Brake Lights..............................................4047 Remove......................................................................4047 Install.....................................................................4048 Front Marker/Turn Signal Lights.................................................4049 Replacing Whole Front Marker/Turn Signal Light Assembly.....................4049 Remove..................................................................4049 Install.................................................................4049 Replacing Just the Front Marker/Turn Signal Light LED Light Lens............4049 Remove..................................................................4049 Install.................................................................4049 Electronic-Hydraulic Controls - Generation 1........................................4050 E-Hydraulic Controls - Test.....................................................4050 Mini-Levers.................................................................4050 Full Stroke Test............................................................4050 Function Returns to Neutral Test............................................4050 Push Button Switch..........................................................4050 General.........................................................................4051 Mini-Lever Replacement..........................................................4051 Remove......................................................................4051 Clean and Inspect...........................................................4052 Install.....................................................................4052 Push Button Switch Replacement..................................................4053 Remove......................................................................4053 Install.....................................................................4054 Mini-Lever Module (MLM).........................................................4055 Remove......................................................................4055 Install.....................................................................4055 Joystick........................................................................4055 Remove and Disassemble......................................................4055 Inspect.....................................................................4056 Assemble and Install........................................................4056 Electronic-Hydraulic Controls - Generation 2........................................4056 General.........................................................................4056 Mini-levers, Remove and Install.................................................4057 Armrest Assembly................................................................4058 Remove......................................................................4058 Install.....................................................................4060 Horn Button.....................................................................4060 Remove......................................................................4060 Install.....................................................................4060 Direction Control Switch........................................................4061 Remove......................................................................4061 Install.....................................................................4061 Momentary Switches and Function Selection Button................................4061 Remove......................................................................4062 Install.....................................................................4062 Joystick........................................................................4064 Remove and Disassemble......................................................4064 Inspect.....................................................................4064 Assemble and Install........................................................4064 Joystick Armrest Slider Assembly................................................4064 Remove......................................................................4064 Install.....................................................................4064 tables..................................................................................3949 Table 1. VSM and Display Switch Cluster Replacement.................................4039 Frame (1)...................................................................................4069 toc.....................................................................................4069 Frame...............................................................................4069 Safety Precautions Maintenance and Repair...........................................4070 General.............................................................................4073 Description.........................................................................4073 Hood, Seat, and Side Covers Replacement.............................................4074 Remove..........................................................................4074 Install.........................................................................4079 Steering Column.....................................................................4082 Description.....................................................................4082 Steering Column Repair..........................................................4082 Remove......................................................................4082 Disassemble.................................................................4083 Clean.......................................................................4085 Inspect.....................................................................4085 Assemble....................................................................4085 Install.....................................................................4085 Counterweight Replacement...........................................................4086 Remove..........................................................................4086 Install.........................................................................4088 Tow Pin, Remove and Install.....................................................4089 Overhead Guard Replacement..........................................................4089 Remove and Install..............................................................4089 LED Tail, Backup, and Brake Lights, Replace.....................................4090 Operator Restraint System Replacement...............................................4091 Description.....................................................................4091 Automatic Locking Retractor (ALR)...........................................4091 Emergency Locking Retractor (ELR)...........................................4091 Engine Replacement..................................................................4093 Remove..........................................................................4093 Install.........................................................................4098 Transmission Replacement............................................................4099 Remove Transmission with Iron Housing...........................................4099 Install Transmission with Iron Housing..........................................4101 Remove Transmission with Aluminum Housing.......................................4101 Install Transmission with Aluminum Housing......................................4106 Throttle Pedal and Cable Adjustment.................................................4109 Mazda Gas/LPG Engines With Basic Power Shift Transmission and El................4109 Mazda Gasoline Engine With Electronic Transmission..............................4111 Throttle Pedal Stop Adjustment..................................................4113 Yanmar Diesel Engine With Basic Power Shift Transmission........................4113 Yanmar Diesel Engine With Electronic Throttle...................................4113 Exhaust System Repair...............................................................4114 Lift Trucks With Counterweight Exhaust System...................................4114 Mazda Gas and LPG Engines...................................................4114 Remove and Disassemble..................................................4114 Inspect.................................................................4116 Assemble and Install....................................................4116 Yanmar Diesel Engine........................................................4116 Remove and Disassemble..................................................4116 Inspect.................................................................4117 Assemble and Install....................................................4117 Lift Trucks With Overhead Exhaust System........................................4119 Yanmar Diesel Engine........................................................4119 Remove and Disassemble..................................................4119 Inspect.................................................................4119 Assemble and Install....................................................4120 Mazda Gas and LPG Engines...................................................4122 Remove and Disassemble..................................................4122 Inspect.................................................................4122 Assemble and Install....................................................4122 Cooling System......................................................................4124 Description.....................................................................4124 Hydraulic Filter Assembly Repair....................................................4124 Remove..........................................................................4124 Clean and Inspect...............................................................4125 Install.........................................................................4125 Fuel and Hydraulic Tanks Repair.....................................................4126 Inspect.........................................................................4126 Clean...........................................................................4126 Steam Method of Cleaning....................................................4126 Chemical Solution Method of Cleaning........................................4127 Additional Preparations for Repair..............................................4127 Small Leaks, Repair.............................................................4127 Large Leaks, Repair.............................................................4127 Preparations for Use After Repair...............................................4128 Safety Labels.......................................................................4128 tables..................................................................................4069 Table 1. Weight of Counterweights, Lift Truck Models S2.0-3.5FT ....................4087 Table 2. Weight of Counterweights, Lift Truck Models S30FT, S35F....................4088 Table 3. Weight of Counterweights, Lift Truck Models H1.6FT, H1.....................4088 Table 4. Weight of Counterweights, Lift Truck Models H2.0-3.5FT ....................4088 Frame.......................................................................................4135 toc.....................................................................................4135 Frame...............................................................................4135 Safety Precautions Maintenance and Repair...........................................4136 General.............................................................................4139 Description.........................................................................4139 Hood, Seat, and Side Covers Replacement.............................................4140 Remove..........................................................................4140 Install.........................................................................4145 Steering Column.....................................................................4148 Description.....................................................................4148 Steering Column Repair..........................................................4148 Remove......................................................................4148 Disassemble.................................................................4149 Clean.......................................................................4151 Inspect.....................................................................4151 Assemble....................................................................4151 Install.....................................................................4151 Counterweight Replacement...........................................................4152 Remove..........................................................................4152 Install.........................................................................4154 Tow Pin, Remove and Install.....................................................4155 Overhead Guard Replacement..........................................................4155 Remove and Install..............................................................4155 LED Tail, Backup, and Brake Lights, Replace.....................................4156 Operator Restraint System Replacement...............................................4157 Description.....................................................................4157 Automatic Locking Retractor (ALR)...........................................4157 Emergency Locking Retractor (ELR)...........................................4157 Engine Replacement..................................................................4159 Remove..........................................................................4159 Install.........................................................................4164 Transmission Replacement............................................................4165 Remove Transmission with Iron Housing...........................................4165 Install Transmission with Iron Housing..........................................4167 Remove Transmission with Aluminum Housing.......................................4167 Install Transmission with Aluminum Housing......................................4172 Throttle Pedal and Cable Adjustment.................................................4175 Mazda Gas/LPG Engines With Basic Power Shift Transmission and El................4175 Mazda Gasoline Engine With Electronic Transmission..............................4177 Throttle Pedal Stop Adjustment..................................................4179 Yanmar Diesel Engine With Basic Power Shift Transmission........................4179 Yanmar Diesel Engine With Electronic Throttle...................................4179 Exhaust System Repair...............................................................4180 Lift Trucks With Counterweight Exhaust System...................................4180 Mazda Gas and LPG Engines...................................................4180 Remove and Disassemble..................................................4180 Inspect.................................................................4182 Assemble and Install....................................................4182 Yanmar Diesel Engine........................................................4182 Remove and Disassemble..................................................4182 Inspect.................................................................4183 Assemble and Install....................................................4183 Lift Trucks With Overhead Exhaust System........................................4185 Yanmar Diesel Engine........................................................4185 Remove and Disassemble..................................................4185 Inspect.................................................................4185 Assemble and Install....................................................4186 Mazda Gas and LPG Engines...................................................4188 Remove and Disassemble..................................................4188 Inspect.................................................................4188 Assemble and Install....................................................4188 Cooling System......................................................................4190 Description.....................................................................4190 Hydraulic Filter Assembly Repair....................................................4190 Remove..........................................................................4190 Clean and Inspect...............................................................4191 Install.........................................................................4191 Fuel and Hydraulic Tanks Repair.....................................................4192 Inspect.........................................................................4192 Clean...........................................................................4192 Steam Method of Cleaning....................................................4192 Chemical Solution Method of Cleaning........................................4193 Additional Preparations for Repair..............................................4193 Small Leaks, Repair.............................................................4193 Large Leaks, Repair.............................................................4193 Preparations for Use After Repair...............................................4194 Safety Labels.......................................................................4194 tables..................................................................................4135 Table 1. Weight of Counterweights, Lift Truck Models S2.0-3.5FT ....................4153 Table 2. Weight of Counterweights, Lift Truck Models S30FT, S35F....................4154 Table 3. Weight of Counterweights, Lift Truck Models H1.6FT, H1.....................4154 Table 4. Weight of Counterweights, Lift Truck Models H2.0-3.5FT ....................4154 GM Engine repair (1)........................................................................4201 toc.....................................................................................4201 GM Engine Repair....................................................................4201 Safety Precautions Maintenance and Repair...........................................4202 General.............................................................................4207 Engine Serial Number................................................................4207 Engine Removal and Installation.....................................................4209 Intake Manifold.....................................................................4209 Remove..........................................................................4209 Clean and Inspect...............................................................4210 Install.........................................................................4210 Exhaust Manifold....................................................................4211 Remove..........................................................................4211 Clean and Inspect...............................................................4211 Install.........................................................................4211 Camshaft and Cylinder Head Repair...................................................4212 Rocker Arm Cover................................................................4212 Remove......................................................................4212 Install.....................................................................4212 Camshaft Timing Pulley and/or Front Seal........................................4213 Remove......................................................................4213 Install.....................................................................4213 Camshaft Carrier and Cylinder Head..............................................4214 Remove......................................................................4214 Disassemble.................................................................4215 Camshaft Carrier........................................................4215 Cylinder Head...........................................................4216 Clean and Inspect...........................................................4217 Camshaft Carrier........................................................4217 Cylinder Head...........................................................4218 Valve and Valve Seat........................................................4220 Assemble....................................................................4220 Cylinder Head...........................................................4220 Camshaft Carrier........................................................4221 Install.....................................................................4221 Timing Belt.........................................................................4222 Timing Belt Front Cover.........................................................4222 Remove......................................................................4222 Install.....................................................................4223 Timing Belt and Timing Belt Tensioner...........................................4223 Remove......................................................................4223 Install.....................................................................4224 Timing Belt Rear Cover..........................................................4225 Remove......................................................................4225 Install.....................................................................4225 Lubrication System Repair...........................................................4226 Oil Pan.........................................................................4226 Remove......................................................................4226 Install.....................................................................4226 Oil Pump........................................................................4228 Remove......................................................................4228 Clean and Inspect...........................................................4229 Install.....................................................................4230 Piston and Piston Rod Assemblies Repair.............................................4231 Piston Rod Bearings, Replace....................................................4231 Piston and Piston Rod Assemblies................................................4233 Remove......................................................................4233 Disassemble.................................................................4233 Pistons, Clean and Inspect..................................................4234 Cylinder Bores, Inspect and Repair..........................................4235 Piston Rings, Inspect.......................................................4236 Assemble....................................................................4237 Install.....................................................................4237 Crankshaft and Main Bearings........................................................4238 Crankshaft Timing Pulley and/or Front Seal......................................4238 Remove......................................................................4238 Install.....................................................................4239 Crankshaft Rear Main Oil Seal...................................................4240 Remove......................................................................4240 Install.....................................................................4240 Crankshaft/RPM Sensor...........................................................4240 Remove......................................................................4240 Install.....................................................................4241 Crankshaft Reluctor Wheel.......................................................4241 Remove and Install..........................................................4241 Crankshaft and Main Bearings....................................................4241 Remove......................................................................4241 Inspect and Repair..........................................................4242 Bearing Selection...........................................................4243 Main Bearings and Journal Clearance, Check..................................4244 Install.....................................................................4245 Flywheel and Flywheel Housing.......................................................4246 Remove..........................................................................4246 Install.........................................................................4246 Cooling System Repair...............................................................4247 Serpentine Belt.................................................................4247 Remove......................................................................4247 Inspect.....................................................................4248 Install.....................................................................4248 Water Pump......................................................................4248 Remove......................................................................4248 Inspect.....................................................................4251 Install.....................................................................4251 Thermostat......................................................................4252 Remove......................................................................4252 Check.......................................................................4253 Install.....................................................................4253 Thermostat Housing..............................................................4254 Remove......................................................................4254 Clean and Inspect...........................................................4255 Install.....................................................................4255 Sensors and Switches................................................................4256 Crankshaft Position (CKP) Sensor................................................4256 Remove......................................................................4256 Install.....................................................................4256 Camshaft Position (CMP) Sensor..................................................4256 Remove for Lift Trucks Built Before January, 2010...........................4256 Assembly................................................................4256 Sensor Only.............................................................4257 Install for Lift Trucks Built Before January, 2010..........................4257 Assembly................................................................4257 Sensor Only.............................................................4258 Remove for Lift Trucks Built After January, 2010............................4258 Install for Lift Trucks Built After January, 2010...........................4259 Oil Pressure Sensor.............................................................4259 Remove......................................................................4259 Install.....................................................................4259 Ignition System.....................................................................4259 Spark Plug Wire Inspection......................................................4259 Spark Plug Wire Replacement.....................................................4259 Remove......................................................................4259 Install.....................................................................4260 Spark Plug Replacement..........................................................4260 Remove......................................................................4260 Install.....................................................................4261 Spark Plug Inspection...........................................................4261 Usage.......................................................................4261 Inspect.....................................................................4261 Visual Inspection...........................................................4263 Coil Pack.......................................................................4263 Remove......................................................................4263 Install.....................................................................4263 Alternator Repair...................................................................4264 Alternator......................................................................4264 Remove......................................................................4264 Install.....................................................................4264 Alternator Fuse, Replace........................................................4265 Starter Repair......................................................................4265 Remove..........................................................................4265 Install.........................................................................4265 Engine Specifications...............................................................4266 Engine Data.....................................................................4266 Cylinder Bore...................................................................4266 Piston..........................................................................4266 Piston Rings....................................................................4266 Wrist Pin.......................................................................4267 Crankshaft......................................................................4267 Piston Rod......................................................................4267 Camshaft and Camshaft Carrier...................................................4268 Valve System....................................................................4268 Cylinder Head Warpage...........................................................4269 Lubrication System..............................................................4269 Cooling System..................................................................4269 Torque Specifications...............................................................4269 Special Tools.......................................................................4271 GM Engine repair............................................................................4277 toc.....................................................................................4277 GM Engine Repair....................................................................4277 Safety Precautions Maintenance and Repair...........................................4278 General.............................................................................4283 Engine Serial Number................................................................4283 Engine Removal and Installation.....................................................4285 Intake Manifold.....................................................................4285 Remove..........................................................................4285 Clean and Inspect...............................................................4286 Install.........................................................................4286 Exhaust Manifold....................................................................4287 Remove..........................................................................4287 Clean and Inspect...............................................................4287 Install.........................................................................4287 Camshaft and Cylinder Head Repair...................................................4288 Rocker Arm Cover................................................................4288 Remove......................................................................4288 Install.....................................................................4288 Camshaft Timing Pulley and/or Front Seal........................................4289 Remove......................................................................4289 Install.....................................................................4289 Camshaft Carrier and Cylinder Head..............................................4290 Remove......................................................................4290 Disassemble.................................................................4291 Camshaft Carrier........................................................4291 Cylinder Head...........................................................4292 Clean and Inspect...........................................................4293 Camshaft Carrier........................................................4293 Cylinder Head...........................................................4294 Valve and Valve Seat........................................................4296 Assemble....................................................................4296 Cylinder Head...........................................................4296 Camshaft Carrier........................................................4297 Install.....................................................................4297 Timing Belt.........................................................................4298 Timing Belt Front Cover.........................................................4298 Remove......................................................................4298 Install.....................................................................4299 Timing Belt and Timing Belt Tensioner...........................................4299 Remove......................................................................4299 Install.....................................................................4300 Timing Belt Rear Cover..........................................................4301 Remove......................................................................4301 Install.....................................................................4301 Lubrication System Repair...........................................................4302 Oil Pan.........................................................................4302 Remove......................................................................4302 Install.....................................................................4302 Oil Pump........................................................................4304 Remove......................................................................4304 Clean and Inspect...........................................................4305 Install.....................................................................4306 Piston and Piston Rod Assemblies Repair.............................................4307 Piston Rod Bearings, Replace....................................................4307 Piston and Piston Rod Assemblies................................................4309 Remove......................................................................4309 Disassemble.................................................................4309 Pistons, Clean and Inspect..................................................4310 Cylinder Bores, Inspect and Repair..........................................4311 Piston Rings, Inspect.......................................................4312 Assemble....................................................................4313 Install.....................................................................4313 Crankshaft and Main Bearings........................................................4314 Crankshaft Timing Pulley and/or Front Seal......................................4314 Remove......................................................................4314 Install.....................................................................4315 Crankshaft Rear Main Oil Seal...................................................4316 Remove......................................................................4316 Install.....................................................................4316 Crankshaft/RPM Sensor...........................................................4316 Remove......................................................................4316 Install.....................................................................4317 Crankshaft Reluctor Wheel.......................................................4317 Remove and Install..........................................................4317 Crankshaft and Main Bearings....................................................4317 Remove......................................................................4317 Inspect and Repair..........................................................4318 Bearing Selection...........................................................4319 Main Bearings and Journal Clearance, Check..................................4320 Install.....................................................................4321 Flywheel and Flywheel Housing.......................................................4322 Remove..........................................................................4322 Install.........................................................................4322 Cooling System Repair...............................................................4323 Serpentine Belt.................................................................4323 Remove......................................................................4323 Inspect.....................................................................4324 Install.....................................................................4324 Water Pump......................................................................4324 Remove......................................................................4324 Inspect.....................................................................4327 Install.....................................................................4327 Thermostat......................................................................4328 Remove......................................................................4328 Check.......................................................................4329 Install.....................................................................4329 Thermostat Housing..............................................................4330 Remove......................................................................4330 Clean and Inspect...........................................................4331 Install.....................................................................4331 Sensors and Switches................................................................4332 Crankshaft Position (CKP) Sensor................................................4332 Remove......................................................................4332 Install.....................................................................4332 Camshaft Position (CMP) Sensor..................................................4332 Remove for Lift Trucks Built Before January, 2010...........................4332 Assembly................................................................4332 Sensor Only.............................................................4333 Install for Lift Trucks Built Before January, 2010..........................4333 Assembly................................................................4333 Sensor Only.............................................................4334 Remove for Lift Trucks Built After January, 2010............................4334 Install for Lift Trucks Built After January, 2010...........................4335 Oil Pressure Sensor.............................................................4335 Remove......................................................................4335 Install.....................................................................4335 Ignition System.....................................................................4335 Spark Plug Wire Inspection......................................................4335 Spark Plug Wire Replacement.....................................................4335 Remove......................................................................4335 Install.....................................................................4336 Spark Plug Replacement..........................................................4336 Remove......................................................................4336 Install.....................................................................4337 Spark Plug Inspection...........................................................4337 Usage.......................................................................4337 Inspect.....................................................................4337 Visual Inspection...........................................................4339 Coil Pack.......................................................................4339 Remove......................................................................4339 Install.....................................................................4339 Alternator Repair...................................................................4340 Alternator......................................................................4340 Remove......................................................................4340 Install.....................................................................4340 Alternator Fuse, Replace........................................................4341 Starter Repair......................................................................4341 Remove..........................................................................4341 Install.........................................................................4341 Engine Specifications...............................................................4342 Engine Data.....................................................................4342 Cylinder Bore...................................................................4342 Piston..........................................................................4342 Piston Rings....................................................................4342 Wrist Pin.......................................................................4343 Crankshaft......................................................................4343 Piston Rod......................................................................4343 Camshaft and Camshaft Carrier...................................................4344 Valve System....................................................................4344 Cylinder Head Warpage...........................................................4345 Lubrication System..............................................................4345 Cooling System..................................................................4345 Torque Specifications...............................................................4345 Special Tools.......................................................................4347 GM Gas Fuel System (1)......................................................................4353 toc.....................................................................................4353 Gasoline Fuel System................................................................4353 Safety Precautions Maintenance and Repair...........................................4354 General.............................................................................4357 Electronic Throttle Body Repair.....................................................4357 Electronic Throttle Body........................................................4357 Remove......................................................................4357 Install.....................................................................4357 Fuel System Repair..................................................................4358 Before Repair Procedure.........................................................4358 After Repair Procedure..........................................................4358 Fuel Leakage Check for Lift Trucks Built Before January, 2010...............4358 Fuel Leakage Check for Lift Trucks Built After January, 2010................4359 Fuel Line Pressure Check........................................................4360 Fuel Injectors..................................................................4361 Remove......................................................................4361 Install.....................................................................4364 Pressure Regulator..............................................................4364 Remove......................................................................4364 Install.....................................................................4364 Control System......................................................................4365 Electronic Control Unit (ECU)...................................................4365 Remove......................................................................4365 Install.....................................................................4366 Power Latch Relay...............................................................4366 Remove......................................................................4366 Install.....................................................................4367 Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) ................4367 Remove......................................................................4367 Install.....................................................................4367 Engine Coolant Temperature (ECT) Sensor.........................................4368 Remove......................................................................4368 Install.....................................................................4368 Oxygen Sensor...................................................................4368 Remove......................................................................4368 Install.....................................................................4369 Exhaust System Repair...............................................................4369 Remove and Disassemble..........................................................4369 Inspect.........................................................................4371 Assemble and Install............................................................4371 GM Gas Fuel System..........................................................................4375 toc.....................................................................................4375 Gasoline Fuel System................................................................4375 Safety Precautions Maintenance and Repair...........................................4376 General.............................................................................4379 Electronic Throttle Body Repair.....................................................4379 Electronic Throttle Body........................................................4379 Remove......................................................................4379 Install.....................................................................4379 Fuel System Repair..................................................................4380 Before Repair Procedure.........................................................4380 After Repair Procedure..........................................................4380 Fuel Leakage Check for Lift Trucks Built Before January, 2010...............4380 Fuel Leakage Check for Lift Trucks Built After January, 2010................4381 Fuel Line Pressure Check........................................................4382 Fuel Injectors..................................................................4383 Remove......................................................................4383 Install.....................................................................4386 Pressure Regulator..............................................................4386 Remove......................................................................4386 Install.....................................................................4386 Control System......................................................................4387 Electronic Control Unit (ECU)...................................................4387 Remove......................................................................4387 Install.....................................................................4388 Power Latch Relay...............................................................4388 Remove......................................................................4388 Install.....................................................................4389 Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) ................4389 Remove......................................................................4389 Install.....................................................................4389 Engine Coolant Temperature (ECT) Sensor.........................................4390 Remove......................................................................4390 Install.....................................................................4390 Oxygen Sensor...................................................................4390 Remove......................................................................4390 Install.....................................................................4391 Exhaust System Repair...............................................................4391 Remove and Disassemble..........................................................4391 Inspect.........................................................................4393 Assemble and Install............................................................4393 GM LPG System (1)...........................................................................4397 toc.....................................................................................4397 LPG Fuel System.....................................................................4397 Safety Precautions Maintenance and Repair...........................................4398 General.............................................................................4401 Hoses Replacement...................................................................4401 LPG Tank and Bracket Replacement....................................................4401 Remove LPG Tank.................................................................4401 Install LPG Tank................................................................4403 Remove LPG Bracket..............................................................4403 Install LPG Bracket.............................................................4405 Fuel Filter Unit Repair.............................................................4405 Fuel Filter Element.............................................................4405 Remove......................................................................4405 Clean/Inspect...............................................................4406 Install.....................................................................4406 Fuel Filter Housing.............................................................4406 Remove......................................................................4406 Disassemble.................................................................4406 Assemble....................................................................4407 Install.....................................................................4407 Electronic Throttle Body Repair.....................................................4408 Electronic Throttle Body........................................................4408 Remove......................................................................4408 Install.....................................................................4408 Electronic Throttle Body Adapter Plate..........................................4409 Remove......................................................................4409 Install.....................................................................4409 Fuel Injector Repair................................................................4409 Fuel Rail.......................................................................4409 Remove for Lift Trucks Built Before January, 2010...........................4409 Install for Lift Trucks Built Before January, 2010..........................4410 Remove for Lift Trucks Built After January, 2010............................4411 Install for Lift Trucks Built After January, 2010...........................4412 Fuel Injector for Lift Trucks Built Before January, 2010........................4412 Remove......................................................................4412 Clean.......................................................................4413 Install.....................................................................4413 Fuel Injector Adapters for Lift Trucks Built Before January, 201................4414 Remove......................................................................4414 Install.....................................................................4414 Fuel Injectors and Adapters for Lift Trucks Built After January,................4415 Remove......................................................................4415 Clean.......................................................................4415 Install.....................................................................4416 LPG Regulator Repair................................................................4416 LPG Regulator...................................................................4416 Remove......................................................................4416 Install.....................................................................4417 LPG Regulator Fuel Filter.......................................................4417 Remove......................................................................4417 Install.....................................................................4418 Lock-Off Solenoid and Cartridge.................................................4418 Remove......................................................................4418 Install.....................................................................4419 Control System......................................................................4419 Electronic Control Unit (ECU)...................................................4419 Remove......................................................................4419 Install.....................................................................4420 Fuel Pump Relay.................................................................4421 Remove......................................................................4421 Install.....................................................................4421 Injector Driver Module..........................................................4422 Remove......................................................................4422 Install.....................................................................4422 Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) ................4423 Remove......................................................................4423 Install.....................................................................4423 Engine Coolant Temperature (ECT) Sensor.........................................4423 Remove......................................................................4423 Install.....................................................................4423 Oxygen Sensor...................................................................4424 Remove......................................................................4424 Install.....................................................................4424 Low LPG Pressure Switch.........................................................4425 Remove......................................................................4425 Install.....................................................................4425 Exhaust System Repair...............................................................4426 Remove and Disassemble..........................................................4426 Inspect.........................................................................4426 Assemble and Install............................................................4426 GM LPG System...............................................................................4431 toc.....................................................................................4431 LPG Fuel System.....................................................................4431 Safety Precautions Maintenance and Repair...........................................4432 General.............................................................................4435 Hoses Replacement...................................................................4435 LPG Tank and Bracket Replacement....................................................4435 Remove LPG Tank.................................................................4435 Install LPG Tank................................................................4437 Remove LPG Bracket..............................................................4437 Install LPG Bracket.............................................................4439 Fuel Filter Unit Repair.............................................................4439 Fuel Filter Element.............................................................4439 Remove......................................................................4439 Clean/Inspect...............................................................4440 Install.....................................................................4440 Fuel Filter Housing.............................................................4440 Remove......................................................................4440 Disassemble.................................................................4440 Assemble....................................................................4441 Install.....................................................................4441 Electronic Throttle Body Repair.....................................................4442 Electronic Throttle Body........................................................4442 Remove......................................................................4442 Install.....................................................................4442 Electronic Throttle Body Adapter Plate..........................................4443 Remove......................................................................4443 Install.....................................................................4443 Fuel Injector Repair................................................................4443 Fuel Rail.......................................................................4443 Remove for Lift Trucks Built Before January, 2010...........................4443 Install for Lift Trucks Built Before January, 2010..........................4444 Remove for Lift Trucks Built After January, 2010............................4445 Install for Lift Trucks Built After January, 2010...........................4446 Fuel Injector for Lift Trucks Built Before January, 2010........................4446 Remove......................................................................4446 Clean.......................................................................4447 Install.....................................................................4447 Fuel Injector Adapters for Lift Trucks Built Before January, 201................4448 Remove......................................................................4448 Install.....................................................................4448 Fuel Injectors and Adapters for Lift Trucks Built After January,................4449 Remove......................................................................4449 Clean.......................................................................4449 Install.....................................................................4450 LPG Regulator Repair................................................................4450 LPG Regulator...................................................................4450 Remove......................................................................4450 Install.....................................................................4451 LPG Regulator Fuel Filter.......................................................4451 Remove......................................................................4451 Install.....................................................................4452 Lock-Off Solenoid and Cartridge.................................................4452 Remove......................................................................4452 Install.....................................................................4453 Control System......................................................................4453 Electronic Control Unit (ECU)...................................................4453 Remove......................................................................4453 Install.....................................................................4454 Fuel Pump Relay.................................................................4455 Remove......................................................................4455 Install.....................................................................4455 Injector Driver Module..........................................................4456 Remove......................................................................4456 Install.....................................................................4456 Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) ................4457 Remove......................................................................4457 Install.....................................................................4457 Engine Coolant Temperature (ECT) Sensor.........................................4457 Remove......................................................................4457 Install.....................................................................4457 Oxygen Sensor...................................................................4458 Remove......................................................................4458 Install.....................................................................4458 Low LPG Pressure Switch.........................................................4459 Remove......................................................................4459 Install.....................................................................4459 Exhaust System Repair...............................................................4460 Remove and Disassemble..........................................................4460 Inspect.........................................................................4460 Assemble and Install............................................................4460 Hyd. Pump (1)...............................................................................4465 toc.....................................................................................4465 Hydraulic Gear Pump.................................................................4465 Safety Precautions Maintenance and Repair...........................................4466 General.............................................................................4469 Hydraulic Gear Pump Assembly....................................................4469 Variable Displacement Pump Assembly.............................................4469 Single Gear Pump Assembly Repair....................................................4471 Remove..........................................................................4471 Disassemble.....................................................................4476 Clean...........................................................................4478 Inspect.........................................................................4478 Assemble........................................................................4478 Install.........................................................................4478 Tandem Gear Pump Assembly...........................................................4483 Remove..........................................................................4483 Disassemble.....................................................................4485 Clean...........................................................................4487 Inspect.........................................................................4487 Assemble........................................................................4487 Install.........................................................................4488 Gear Pump Specifications............................................................4488 Variable Displacement Pump Repair...................................................4492 Remove..........................................................................4492 Disassemble.....................................................................4499 Clean...........................................................................4501 Inspect.........................................................................4501 Assemble........................................................................4502 Install.........................................................................4502 Variable Displacement Pump Checks and Adjustments...................................4504 Margin Pressure Check...........................................................4504 Flow Compensator Adjustment.....................................................4505 Pressure Compensator Adjustment.................................................4506 Variable Displacement Pump Specifications...........................................4507 Torque Specifications...............................................................4508 Hydraulic Gear Pump.............................................................4508 Variable Displacement Pump......................................................4509 tables..................................................................................4465 Table 1. Hydraulic Gear Pumps for Lift Truck Models S30FT, S35FT....................4488 Table 2. Hydraulic Gear Pumps for Lift Truck Models S2.0-3.5FT (....................4489 Table 3. Hydraulic Gear Pumps for Lift Truck Model S4.0, 4.5, 5.....................4490 Table 4. Hydraulic Gear Pumps for Lift Truck Models H4.0FT5/FT6;....................4490 Table 5. Hydraulic Gear Pumps for Lift Truck Models S6.0FT, S7.0....................4491 Table 6. Hydraulic Gear Pumps for Lift Truck Model H8.0FT, H8.0F....................4491 Table 7. Margin Pressure............................................................4505 Table 8. Pressure Compensator Adjustment............................................4506 Table 9. Variable Displacement Pump for Lift Truck Models H2.0-3....................4507 Table 10. Variable Displacement Pump for Lift Truck Models H4.0F....................4507 Hyd. Pump...................................................................................4513 toc.....................................................................................4513 Hydraulic Gear Pump.................................................................4513 Safety Precautions Maintenance and Repair...........................................4514 General.............................................................................4517 Hydraulic Gear Pump Assembly....................................................4517 Variable Displacement Pump Assembly.............................................4517 Single Gear Pump Assembly Repair....................................................4519 Remove..........................................................................4519 Disassemble.....................................................................4524 Clean...........................................................................4526 Inspect.........................................................................4526 Assemble........................................................................4526 Install.........................................................................4526 Tandem Gear Pump Assembly...........................................................4531 Remove..........................................................................4531 Disassemble.....................................................................4533 Clean...........................................................................4535 Inspect.........................................................................4535 Assemble........................................................................4535 Install.........................................................................4536 Gear Pump Specifications............................................................4536 Variable Displacement Pump Repair...................................................4540 Remove..........................................................................4540 Disassemble.....................................................................4547 Clean...........................................................................4549 Inspect.........................................................................4549 Assemble........................................................................4550 Install.........................................................................4550 Variable Displacement Pump Checks and Adjustments...................................4552 Margin Pressure Check...........................................................4552 Flow Compensator Adjustment.....................................................4553 Pressure Compensator Adjustment.................................................4554 Variable Displacement Pump Specifications...........................................4555 Torque Specifications...............................................................4556 Hydraulic Gear Pump.............................................................4556 Variable Displacement Pump......................................................4557 tables..................................................................................4513 Table 1. Hydraulic Gear Pumps for Lift Truck Models S30FT, S35FT....................4536 Table 2. Hydraulic Gear Pumps for Lift Truck Models S2.0-3.5FT (....................4537 Table 3. Hydraulic Gear Pumps for Lift Truck Model S4.0, 4.5, 5.....................4538 Table 4. Hydraulic Gear Pumps for Lift Truck Models H4.0FT5/FT6;....................4538 Table 5. Hydraulic Gear Pumps for Lift Truck Models S6.0FT, S7.0....................4539 Table 6. Hydraulic Gear Pumps for Lift Truck Model H8.0FT, H8.0F....................4539 Table 7. Margin Pressure............................................................4553 Table 8. Pressure Compensator Adjustment............................................4554 Table 9. Variable Displacement Pump for Lift Truck Models H2.0-3....................4555 Table 10. Variable Displacement Pump for Lift Truck Models H4.0F....................4555 Mazda Elect. (1)............................................................................4561 toc.....................................................................................4561 Electrical System...................................................................4561 Safety Precautions Maintenance and Repair...........................................4562 Ignition System.....................................................................4565 General.........................................................................4565 Ignition Timing Adjustment, Gasoline and LPG....................................4565 Spark Plugs Check...............................................................4565 Spark Plug Wires Check..........................................................4565 Distributor Repair..................................................................4568 Remove..........................................................................4568 Disassemble.....................................................................4569 Inspect.........................................................................4569 Assemble........................................................................4570 Install.........................................................................4570 Igniter.........................................................................4571 Remove......................................................................4571 Test........................................................................4571 Install.....................................................................4571 Camshaft Position (CMP) Sensor..................................................4572 Voltage Check...............................................................4572 Ignition Coil Check.................................................................4573 Primary Coil Winding............................................................4573 Secondary Coil Winding..........................................................4573 Starter Repair......................................................................4574 General.........................................................................4574 Remove..........................................................................4574 No-Load Test....................................................................4575 Magnetic Switch Test............................................................4575 Pull-Out Test...............................................................4575 Holding Coil Test...........................................................4576 Return Test.................................................................4576 Pinion Movement Inspection..................................................4576 Install.........................................................................4576 Alternator Repair...................................................................4577 General.........................................................................4577 Charging System Inspection......................................................4577 Output Current Check............................................................4578 No-Load Adjusted Voltage Check..................................................4578 Remove..........................................................................4579 Inspect.........................................................................4579 Rectifier Check.............................................................4579 Install.........................................................................4580 tables..................................................................................4561 Table 1. Spark Plug Wire............................................................4565 Table 2. Starter Specifications.....................................................4574 Table 3. Problem Diagnosis Chart....................................................4575 Table 4. Specifications.............................................................4578 Table 5. Rectifier Check Table......................................................4579 Mazda Elect.................................................................................4583 toc.....................................................................................4583 Electrical System...................................................................4583 Safety Precautions Maintenance and Repair...........................................4584 Ignition System.....................................................................4587 General.........................................................................4587 Ignition Timing Adjustment, Gasoline and LPG....................................4587 Spark Plugs Check...............................................................4587 Spark Plug Wires Check..........................................................4587 Distributor Repair..................................................................4590 Remove..........................................................................4590 Disassemble.....................................................................4591 Inspect.........................................................................4591 Assemble........................................................................4592 Install.........................................................................4592 Igniter.........................................................................4593 Remove......................................................................4593 Test........................................................................4593 Install.....................................................................4593 Camshaft Position (CMP) Sensor..................................................4594 Voltage Check...............................................................4594 Ignition Coil Check.................................................................4595 Primary Coil Winding............................................................4595 Secondary Coil Winding..........................................................4595 Starter Repair......................................................................4596 General.........................................................................4596 Remove..........................................................................4596 No-Load Test....................................................................4597 Magnetic Switch Test............................................................4597 Pull-Out Test...............................................................4597 Holding Coil Test...........................................................4598 Return Test.................................................................4598 Pinion Movement Inspection..................................................4598 Install.........................................................................4598 Alternator Repair...................................................................4599 General.........................................................................4599 Charging System Inspection......................................................4599 Output Current Check............................................................4600 No-Load Adjusted Voltage Check..................................................4600 Remove..........................................................................4601 Inspect.........................................................................4601 Rectifier Check.............................................................4601 Install.........................................................................4602 tables..................................................................................4583 Table 1. Spark Plug Wire............................................................4587 Table 2. Starter Specifications.....................................................4596 Table 3. Problem Diagnosis Chart....................................................4597 Table 4. Specifications.............................................................4600 Table 5. Rectifier Check Table......................................................4601 Mazda Engine (1)............................................................................4605 toc.....................................................................................4605 Mazda Engine........................................................................4605 Safety Precautions Maintenance and Repair...........................................4606 General.............................................................................4609 Serial Number...................................................................4609 Engine Removal and Installation.....................................................4610 Cylinder Head, Camshaft, and Valve Mechanism Repair.................................4610 Remove..........................................................................4610 Clean...........................................................................4612 Inspect and Repair..............................................................4612 Cylinder Head...............................................................4612 Rocker Shaft Assembly.......................................................4612 Camshaft....................................................................4612 Valve Guides................................................................4614 Valve Seats.................................................................4614 Valves......................................................................4615 Valve Springs...............................................................4615 Install.........................................................................4615 Crankshaft and Main Bearings Repair.................................................4619 Remove..........................................................................4619 Inspect and Repair..............................................................4620 Crankshaft..................................................................4620 Main Bearings...............................................................4620 Install.........................................................................4621 Pistons and Connecting Rods Repair..................................................4622 Remove and Disassemble..........................................................4622 Clean...........................................................................4622 Inspect and Repair..............................................................4622 Pistons.....................................................................4622 Piston Rings................................................................4622 Connecting Rods and Bearings................................................4623 Assemble and Install............................................................4623 Cylinder Block Repair...............................................................4625 Oil Pump Repair.....................................................................4625 Remove..........................................................................4625 Disassemble.....................................................................4626 Clean...........................................................................4626 Inspect.........................................................................4627 Assemble........................................................................4628 Install.........................................................................4628 Cooling System Repair...............................................................4630 Thermostat......................................................................4630 Replace.....................................................................4630 Fan Assembly....................................................................4630 Remove and Disassemble......................................................4630 Assemble and Install........................................................4630 Water Pump......................................................................4631 Remove......................................................................4631 Install.....................................................................4632 Flywheel and Ring Gear Repair.......................................................4632 Remove..........................................................................4632 Install.........................................................................4632 Valve Adjustment....................................................................4633 Compression Pressure Check..........................................................4634 Engine Timing Adjustment............................................................4635 Engine Specifications...............................................................4635 Engine Data.....................................................................4635 Engine Speeds...................................................................4635 2007, and Later, Emission Compliant Engines.................................4635 All Engines Except 2007, and Later, Emission Compliant Engines..............4636 Thermostat......................................................................4636 Cylinder Head...................................................................4636 Valve Mechanism.................................................................4636 Camshaft........................................................................4637 Crankshaft......................................................................4637 Connecting Rods.................................................................4638 Cylinder Block..................................................................4638 Pistons.........................................................................4638 Oil Pump........................................................................4639 Torque Specifications...............................................................4639 tables..................................................................................4605 Table 1. Pressure Specifications....................................................4634 Mazda Engine................................................................................4643 toc.....................................................................................4643 Mazda Engine........................................................................4643 Safety Precautions Maintenance and Repair...........................................4644 General.............................................................................4647 Serial Number...................................................................4647 Engine Removal and Installation.....................................................4648 Cylinder Head, Camshaft, and Valve Mechanism Repair.................................4648 Remove..........................................................................4648 Clean...........................................................................4650 Inspect and Repair..............................................................4650 Cylinder Head...............................................................4650 Rocker Shaft Assembly.......................................................4650 Camshaft....................................................................4650 Valve Guides................................................................4652 Valve Seats.................................................................4652 Valves......................................................................4653 Valve Springs...............................................................4653 Install.........................................................................4653 Crankshaft and Main Bearings Repair.................................................4657 Remove..........................................................................4657 Inspect and Repair..............................................................4658 Crankshaft..................................................................4658 Main Bearings...............................................................4658 Install.........................................................................4659 Pistons and Connecting Rods Repair..................................................4660 Remove and Disassemble..........................................................4660 Clean...........................................................................4660 Inspect and Repair..............................................................4660 Pistons.....................................................................4660 Piston Rings................................................................4660 Connecting Rods and Bearings................................................4661 Assemble and Install............................................................4661 Cylinder Block Repair...............................................................4663 Oil Pump Repair.....................................................................4663 Remove..........................................................................4663 Disassemble.....................................................................4664 Clean...........................................................................4664 Inspect.........................................................................4665 Assemble........................................................................4666 Install.........................................................................4666 Cooling System Repair...............................................................4668 Thermostat......................................................................4668 Replace.....................................................................4668 Fan Assembly....................................................................4668 Remove and Disassemble......................................................4668 Assemble and Install........................................................4668 Water Pump......................................................................4669 Remove......................................................................4669 Install.....................................................................4670 Flywheel and Ring Gear Repair.......................................................4670 Remove..........................................................................4670 Install.........................................................................4670 Valve Adjustment....................................................................4671 Compression Pressure Check..........................................................4672 Engine Timing Adjustment............................................................4673 Engine Specifications...............................................................4673 Engine Data.....................................................................4673 Engine Speeds...................................................................4673 2007, and Later, Emission Compliant Engines.................................4673 All Engines Except 2007, and Later, Emission Compliant Engines..............4674 Thermostat......................................................................4674 Cylinder Head...................................................................4674 Valve Mechanism.................................................................4674 Camshaft........................................................................4675 Crankshaft......................................................................4675 Connecting Rods.................................................................4676 Cylinder Block..................................................................4676 Pistons.........................................................................4676 Oil Pump........................................................................4677 Torque Specifications...............................................................4677 tables..................................................................................4643 Table 1. Pressure Specifications....................................................4672 Mazda gas Fuel System (1)...................................................................4681 toc.....................................................................................4681 Gasoline Fuel System................................................................4681 Safety Precautions Maintenance and Repair...........................................4682 General.............................................................................4685 Abbreviations.......................................................................4685 Engine Tune-up......................................................................4685 Engine Tune-Up Preparation......................................................4685 Idle Speed Adjustment...........................................................4685 Idle-Up Speed Check.............................................................4685 Intake-Air System...................................................................4687 Intake-Air System Manifold Vacuum Check.........................................4687 Throttle Body...................................................................4688 Remove......................................................................4688 Install.....................................................................4688 Electronic Governor.............................................................4688 Remove......................................................................4688 Install.....................................................................4688 Intake-Air Control (IAC) Valve..................................................4688 Remove......................................................................4688 Install.....................................................................4690 Intake Manifold.................................................................4690 Remove......................................................................4690 Install.....................................................................4690 Fuel System.........................................................................4691 Before Repair Procedure.........................................................4691 Fuel Line Safety Procedure..................................................4691 After Repair Procedure..........................................................4691 Fuel Hose, Install..........................................................4691 Fuel Leakage Check..........................................................4692 Fuel Line Pressure Check........................................................4692 Fuel Injector...................................................................4693 Remove......................................................................4693 Install.....................................................................4693 Pressure Regulator..............................................................4694 Remove......................................................................4694 Install.....................................................................4695 Exhaust System......................................................................4696 Exhaust System, Inspect.........................................................4696 Three-Way Catalytic (TWC) Converter.............................................4696 Remove and Install..........................................................4696 Exhaust Manifold................................................................4696 Remove......................................................................4696 Install.....................................................................4696 Positive Crankcase Ventilation (PCV) Valve......................................4698 Remove......................................................................4698 Inspect.....................................................................4698 Install.....................................................................4698 Control System......................................................................4698 Engine Control Unit (ECU).......................................................4698 Remove......................................................................4698 Install.....................................................................4700 Intake Air Temperature (IAT) Sensor.............................................4701 Remove......................................................................4701 Install.....................................................................4701 Mass Air Flow (MAF) Sensor......................................................4701 Remove......................................................................4701 Install.....................................................................4701 Throttle Position (TP) Sensor...................................................4702 TP Sensor, Adjust...........................................................4702 Remove......................................................................4703 Install.....................................................................4703 Engine Coolant Temperature (ECT) Sensor.........................................4703 Remove......................................................................4703 Install.....................................................................4704 Camshaft Position (CMP) Sensor..................................................4704 Voltage Check...............................................................4704 Oxygen Sensor...................................................................4704 Remove......................................................................4704 Install.....................................................................4704 Manifold Absolute Pressure (MAP)/Boost Sensor...................................4705 Remove......................................................................4705 Install.....................................................................4705 Technical Data......................................................................4706 tables..................................................................................4681 Table 1. PCV Valve Specifications...................................................4698 Table 2. Closed Throttle Position Specifications....................................4703 Table 3. Gasoline Fuel Systems Technical Data.......................................4706 Mazda gas Fuel System.......................................................................4709 toc.....................................................................................4709 Gasoline Fuel System................................................................4709 Safety Precautions Maintenance and Repair...........................................4710 General.............................................................................4713 Abbreviations.......................................................................4713 Engine Tune-up......................................................................4713 Engine Tune-Up Preparation......................................................4713 Idle Speed Adjustment...........................................................4713 Idle-Up Speed Check.............................................................4713 Intake-Air System...................................................................4715 Intake-Air System Manifold Vacuum Check.........................................4715 Throttle Body...................................................................4716 Remove......................................................................4716 Install.....................................................................4716 Electronic Governor.............................................................4716 Remove......................................................................4716 Install.....................................................................4716 Intake-Air Control (IAC) Valve..................................................4716 Remove......................................................................4716 Install.....................................................................4718 Intake Manifold.................................................................4718 Remove......................................................................4718 Install.....................................................................4718 Fuel System.........................................................................4719 Before Repair Procedure.........................................................4719 Fuel Line Safety Procedure..................................................4719 After Repair Procedure..........................................................4719 Fuel Hose, Install..........................................................4719 Fuel Leakage Check..........................................................4720 Fuel Line Pressure Check........................................................4720 Fuel Injector...................................................................4721 Remove......................................................................4721 Install.....................................................................4721 Pressure Regulator..............................................................4722 Remove......................................................................4722 Install.....................................................................4723 Exhaust System......................................................................4724 Exhaust System, Inspect.........................................................4724 Three-Way Catalytic (TWC) Converter.............................................4724 Remove and Install..........................................................4724 Exhaust Manifold................................................................4724 Remove......................................................................4724 Install.....................................................................4724 Positive Crankcase Ventilation (PCV) Valve......................................4726 Remove......................................................................4726 Inspect.....................................................................4726 Install.....................................................................4726 Control System......................................................................4726 Engine Control Unit (ECU).......................................................4726 Remove......................................................................4726 Install.....................................................................4728 Intake Air Temperature (IAT) Sensor.............................................4729 Remove......................................................................4729 Install.....................................................................4729 Mass Air Flow (MAF) Sensor......................................................4729 Remove......................................................................4729 Install.....................................................................4729 Throttle Position (TP) Sensor...................................................4730 TP Sensor, Adjust...........................................................4730 Remove......................................................................4731 Install.....................................................................4731 Engine Coolant Temperature (ECT) Sensor.........................................4731 Remove......................................................................4731 Install.....................................................................4732 Camshaft Position (CMP) Sensor..................................................4732 Voltage Check...............................................................4732 Oxygen Sensor...................................................................4732 Remove......................................................................4732 Install.....................................................................4732 Manifold Absolute Pressure (MAP)/Boost Sensor...................................4733 Remove......................................................................4733 Install.....................................................................4733 Technical Data......................................................................4734 tables..................................................................................4709 Table 1. PCV Valve Specifications...................................................4726 Table 2. Closed Throttle Position Specifications....................................4731 Table 3. Gasoline Fuel Systems Technical Data.......................................4734 Mazda LPG Fuel System (1)...................................................................4737 toc.....................................................................................4737 LPG Fuel System.....................................................................4737 Safety Precautions Maintenance and Repair...........................................4738 General.............................................................................4741 Hoses Replacement...................................................................4741 LPG Tank Replacement................................................................4741 Remove..........................................................................4741 Install.........................................................................4741 Fuel Filter.........................................................................4743 Remove..........................................................................4743 Clean and Inspect...............................................................4744 Install.........................................................................4745 Relief Valve Replacement............................................................4746 Remove and Install..............................................................4746 Carburetor Repair...................................................................4746 Remove..........................................................................4746 Disassemble.....................................................................4746 Clean...........................................................................4748 Assemble........................................................................4748 Install.........................................................................4748 Fuel Injector Repair................................................................4749 Remove..........................................................................4749 Clean and Inspect...............................................................4749 Install.........................................................................4749 Governor Repair.....................................................................4749 Remove..........................................................................4749 Install.........................................................................4749 Regulator Repair....................................................................4750 Remove..........................................................................4750 Install.........................................................................4751 Control System......................................................................4751 Engine Control Unit (ECU).......................................................4751 Remove......................................................................4751 Install.....................................................................4751 Engine Coolant Temperature (ECT) Sensor.........................................4752 Remove......................................................................4752 Install.....................................................................4752 Camshaft Position (CMP) Sensor..................................................4752 Voltage Check...............................................................4752 Intake Air Temperature (IAT) Sensor.............................................4753 Remove......................................................................4753 Install.....................................................................4753 Manifold Absolute Pressure (MAP) Sensor.........................................4754 Remove......................................................................4754 Install.....................................................................4754 Oxygen Sensor...................................................................4754 Remove......................................................................4754 Install.....................................................................4754 Throttle Position (TP) Sensor...................................................4755 Remove......................................................................4755 Install.....................................................................4755 Mazda LPG Fuel System.......................................................................4759 toc.....................................................................................4759 LPG Fuel System.....................................................................4759 Safety Precautions Maintenance and Repair...........................................4760 General.............................................................................4763 Hoses Replacement...................................................................4763 LPG Tank Replacement................................................................4763 Remove..........................................................................4763 Install.........................................................................4763 Fuel Filter.........................................................................4765 Remove..........................................................................4765 Clean and Inspect...............................................................4766 Install.........................................................................4767 Relief Valve Replacement............................................................4768 Remove and Install..............................................................4768 Carburetor Repair...................................................................4768 Remove..........................................................................4768 Disassemble.....................................................................4768 Clean...........................................................................4770 Assemble........................................................................4770 Install.........................................................................4770 Fuel Injector Repair................................................................4771 Remove..........................................................................4771 Clean and Inspect...............................................................4771 Install.........................................................................4771 Governor Repair.....................................................................4771 Remove..........................................................................4771 Install.........................................................................4771 Regulator Repair....................................................................4772 Remove..........................................................................4772 Install.........................................................................4773 Control System......................................................................4773 Engine Control Unit (ECU).......................................................4773 Remove......................................................................4773 Install.....................................................................4773 Engine Coolant Temperature (ECT) Sensor.........................................4774 Remove......................................................................4774 Install.....................................................................4774 Camshaft Position (CMP) Sensor..................................................4774 Voltage Check...............................................................4774 Intake Air Temperature (IAT) Sensor.............................................4775 Remove......................................................................4775 Install.....................................................................4775 Manifold Absolute Pressure (MAP) Sensor.........................................4776 Remove......................................................................4776 Install.....................................................................4776 Oxygen Sensor...................................................................4776 Remove......................................................................4776 Install.....................................................................4776 Throttle Position (TP) Sensor...................................................4777 Remove......................................................................4777 Install.....................................................................4777 PM (1)......................................................................................4781 toc.....................................................................................4781 Periodic Maintenance................................................................4781 Safety Precautions Maintenance and Repair...........................................4782 General.............................................................................4787 Serial Number Data..............................................................4787 How to Move Disabled Lift Truck.................................................4787 How to Tow Lift Truck.......................................................4787 How to Put Lift Truck on Blocks.................................................4788 How to Raise Drive Tires....................................................4788 How to Raise Steering Tires.................................................4789 How to Clean a Lift Truck.......................................................4789 Maintenance Schedule................................................................4790 Maintenance Procedures Every 8 Hours or Daily.......................................4814 How to Make Checks With Engine Stopped..........................................4814 Tires and Wheels............................................................4814 Safety Labels...............................................................4815 Mast, Carriage, Lift Chains, Header Hoses, Attachment.......................4815 Operator Restraint System...................................................4816 Automatic Locking Retractor (ALR).......................................4816 Emergency Locking Retractor (ELR).......................................4816 Adjust Seat - Full Suspension...........................................4818 Adjust Seat - Internal Suspension.......................................4818 Hood and Seat Latches.......................................................4820 Engine Compartment..........................................................4820 Paper Application...........................................................4820 Fuel, Oil, and Coolant Leaks, Check.........................................4821 Hydraulic Hoses.............................................................4821 Coolant Hoses...............................................................4821 Steering Column Gas Cylinder................................................4821 Transmission................................................................4821 Hydraulic System Oil........................................................4821 Engine Oil..................................................................4822 Air Filter..................................................................4827 Forks.......................................................................4827 Remove..................................................................4827 Inspect.................................................................4827 Install.................................................................4828 Adjust..................................................................4828 How to Make Checks With Engine Running..........................................4829 Indicator Lights, Horn, Fuses, and Relays...................................4829 Service Brakes..............................................................4831 Brake Fluid Level.......................................................4831 Operation, Check........................................................4832 Parking Brake...............................................................4832 Engine Oil Pressure.........................................................4832 Cooling System..............................................................4833 Steering System.............................................................4834 Control Levers and Pedals...................................................4834 Lift System, Operate........................................................4834 First Service After First 100 Hours of Operation....................................4835 Mazda and GM Engine Oil and Oil Filter..........................................4835 Yanmar Engine Oil and Oil Filter................................................4836 Maintenance Procedures Every 250 Hours or 6 Months..................................4836 Mazda and GM Engine Oil and Oil Filter..........................................4836 Drive Belt......................................................................4837 Mazda 2.0L and 2.2L Engines.................................................4837 Fan and Alternator Drive Belt...........................................4837 GM 2.4L Engine..............................................................4837 Fan and Alternator Drive Belt...........................................4837 Drain Tar From LPG Regulator (Except 2007 Mazda Emission Complia................4838 Drain Tar From LPG Regulator (2007 Mazda Emission Compliant Engi................4839 Maintenance Procedures Every 500 Hours or 6 Months..................................4840 Hydraulic System Oil............................................................4840 Hydraulic Tank Breather.........................................................4840 Inspect.....................................................................4840 Battery.........................................................................4841 Yanmar Engine Oil and Oil Filter................................................4841 Drive Belt......................................................................4841 Yanmar Diesel Engine........................................................4841 Fan and Alternator Drive Belt...........................................4841 PCV Valve.......................................................................4842 Clean Debris From Radiator Core.................................................4842 Transmission Oil Level..........................................................4842 Wet Brake Planetary Housing Oil Level Check.....................................4844 Forks...........................................................................4845 Mast Lubrication................................................................4846 Header Hose Checks..............................................................4848 Lift Chain Lubrication..........................................................4849 Tilt Cylinder Lubrication.......................................................4849 Master Brake Cylinder Rod End Pin Lubrication...................................4850 Manual Hydraulic Levers Lubrication.............................................4850 Brake Fluid.....................................................................4851 Tie Rod Lubrication (H40-70FT)..................................................4852 Differential and Drive Axle Oil (Dry Brake).....................................4852 Maintenance Procedures Every 1000 Hours or 6 Months.................................4852 Valve Clearance, Check and Adjust...............................................4852 Ignition System.................................................................4853 GM 2.4L Engine..............................................................4853 Mazda 2.0L and 2.2L Engines.................................................4853 LPG Fuel Filter Element Replace, GM 2.4L Engine.................................4853 Remove......................................................................4853 Install.....................................................................4853 LPG Vapor Fuel Filter Replace, Mazda Engines (Except 2007 Mazda ................4854 LPG Fuel Filter Replace, Mazda 2007 Emission Compliant Engines O................4854 Remove......................................................................4854 Clean/Inspect...............................................................4855 Install.....................................................................4855 Gasoline Fuel Filter Replacement, Mazda 2007 Emission Compliant ................4855 Remove and Replace..........................................................4855 Fuel Filter Replacement, Yanmar Engine..........................................4856 Priming the Fuel System (Yanmar)................................................4857 Lift Chains Wear Check..........................................................4858 Lift Chain Lubrication..........................................................4858 Integral Sideshift Carriage, Check Bearings.....................................4859 Integral Sideshift Carriage, Check Lower Mounting Hooks.........................4859 Steering Axle...................................................................4860 Control Levers and Pedals.......................................................4860 Maintenance Procedures Every 2000 Hours or Annually.................................4861 Hydraulic System................................................................4861 Hydraulic Filter, Replace...................................................4861 Hydraulic Tank Breather, Replace............................................4862 Air Filter......................................................................4862 PCV Valve.......................................................................4864 Oxygen Sensor ..................................................................4864 LPG Regulator Fuel Filter, Mazda Engines (Except 2007 Mazda Emis................4865 Remove and Replace..........................................................4865 LPG Regulator Fuel Filter, GM Engines...........................................4866 Remove......................................................................4866 Install.....................................................................4866 Gasoline Fuel Filter............................................................4866 Remove and Replace..........................................................4866 Timing Belt.....................................................................4867 Mazda Engines...............................................................4867 GM 2.4L Engine..............................................................4867 LPG Fuel Injector, Mazda Engines (Except 2007 Mazda Emission Com................4867 Gasoline Fuel Injector, Mazda Engines...........................................4867 LPG Fuel Injector, GM Engines...................................................4867 Gasoline Fuel Injector, GM Engines..............................................4867 Fuel Injector, Yanmar Engines...................................................4867 Forks...........................................................................4868 Integral Sideshift Carriage.....................................................4868 Bearings, Replace...........................................................4868 Transmission Oil and Filter (Dry Brake), Replace................................4868 Iron Transmission Housing...................................................4868 Aluminum Transmission Housing...............................................4869 Remove..................................................................4869 Clean and Inspect.......................................................4870 Install.................................................................4870 Transmission Oil Change, Wet Brake Drive Axle...................................4871 Wet Brake Axle Center Section and Planetary Housing, Oil Change.................4873 Brake Fluid (Master Cylinder), Change...........................................4876 Brake Fluid (Dry Brake), Remove.................................................4878 Service Brakes (Dry Brake)......................................................4878 Differential (Dry Brake)........................................................4878 Valve Clearance, Check and Adjust for Cummins QSB 3.3L Diesel En................4879 Maintenance Procedures Every 4000 Hours or 2 Years..................................4880 Hydraulic Oil, Replace..........................................................4880 Cooling System..................................................................4881 Safety Procedures When Working Near Mast............................................4882 Hood Latch Check....................................................................4884 Lift Chain Adjustments..............................................................4886 Jump-Starting the Lift Truck........................................................4887 Jump-Starting Using a Battery Charger...........................................4887 Jump-Starting a Lift Truck Using Another Lift Truck.............................4887 Welding Repairs.....................................................................4888 Overhead Guard Changes..............................................................4888 Wheel and Tire Replacement..........................................................4888 General.........................................................................4888 Solid Rubber Tire, Change ( S Series)...........................................4888 Remove and Install Tire on Wheel............................................4889 Pneumatic Tire With Tube, Repair................................................4890 Remove Wheels From Lift Truck...............................................4890 Remove Tire From Wheel......................................................4890 Remove Tire From Two-Piece Wheel........................................4891 Remove Tire From Three- and Four-Piece Wheels...........................4892 Install Wheel in Tire.......................................................4893 Install Three-Piece or Four-Piece Wheel in Tire.........................4893 Install Tire on Two-Piece Wheel.........................................4894 Install Two-Piece Wheel in Tire.........................................4895 Add Air to Pneumatic Tires With Tube............................................4895 Install the Wheels..........................................................4896 Dual Drive Wheels, Install..................................................4896 Pneumatic Tubeless Tire, Repair.................................................4897 Remove Wheels From Lift Truck...............................................4897 Remove Tire From Wheel......................................................4897 Install Tire on Wheel.......................................................4899 Add Air to Pneumatic Tubeless Tire..........................................4902 Wheels, Install.............................................................4902 Solid Rubber Tires on Pneumatic Wheels, Change..................................4902 Remove Wheel From Tire......................................................4903 Install Tire on Wheel.......................................................4904 Adhesives and Sealants..............................................................4906 tables..................................................................................4781 Table 1. Maintenance Schedule.......................................................4805 Table 2. V-Belt Deflection Table....................................................4841 Table 3. Carriage Chain Adjustment, Forks Not Installed.............................4887 PM..........................................................................................4909 toc.....................................................................................4909 Periodic Maintenance................................................................4909 Safety Precautions Maintenance and Repair...........................................4910 General.............................................................................4915 Serial Number Data..............................................................4915 How to Move Disabled Lift Truck.................................................4915 How to Tow Lift Truck.......................................................4915 How to Put Lift Truck on Blocks.................................................4916 How to Raise Drive Tires....................................................4916 How to Raise Steering Tires.................................................4917 How to Clean a Lift Truck.......................................................4917 Maintenance Schedule................................................................4918 Maintenance Procedures Every 8 Hours or Daily.......................................4942 How to Make Checks With Engine Stopped..........................................4942 Tires and Wheels............................................................4942 Safety Labels...............................................................4943 Mast, Carriage, Lift Chains, Header Hoses, Attachment.......................4943 Operator Restraint System...................................................4944 Automatic Locking Retractor (ALR).......................................4944 Emergency Locking Retractor (ELR).......................................4944 Adjust Seat - Full Suspension...........................................4946 Adjust Seat - Internal Suspension.......................................4946 Hood and Seat Latches.......................................................4948 Engine Compartment..........................................................4948 Paper Application...........................................................4948 Fuel, Oil, and Coolant Leaks, Check.........................................4949 Hydraulic Hoses.............................................................4949 Coolant Hoses...............................................................4949 Steering Column Gas Cylinder................................................4949 Transmission................................................................4949 Hydraulic System Oil........................................................4949 Engine Oil..................................................................4950 Air Filter..................................................................4955 Forks.......................................................................4955 Remove..................................................................4955 Inspect.................................................................4955 Install.................................................................4956 Adjust..................................................................4956 How to Make Checks With Engine Running..........................................4957 Indicator Lights, Horn, Fuses, and Relays...................................4957 Service Brakes..............................................................4959 Brake Fluid Level.......................................................4959 Operation, Check........................................................4960 Parking Brake...............................................................4960 Engine Oil Pressure.........................................................4960 Cooling System..............................................................4961 Steering System.............................................................4962 Control Levers and Pedals...................................................4962 Lift System, Operate........................................................4962 First Service After First 100 Hours of Operation....................................4963 Mazda and GM Engine Oil and Oil Filter..........................................4963 Yanmar Engine Oil and Oil Filter................................................4964 Maintenance Procedures Every 250 Hours or 6 Months..................................4964 Mazda and GM Engine Oil and Oil Filter..........................................4964 Drive Belt......................................................................4965 Mazda 2.0L and 2.2L Engines.................................................4965 Fan and Alternator Drive Belt...........................................4965 GM 2.4L Engine..............................................................4965 Fan and Alternator Drive Belt...........................................4965 Drain Tar From LPG Regulator (Except 2007 Mazda Emission Complia................4966 Drain Tar From LPG Regulator (2007 Mazda Emission Compliant Engi................4967 Maintenance Procedures Every 500 Hours or 6 Months..................................4968 Hydraulic System Oil............................................................4968 Hydraulic Tank Breather.........................................................4968 Inspect.....................................................................4968 Battery.........................................................................4969 Yanmar Engine Oil and Oil Filter................................................4969 Drive Belt......................................................................4969 Yanmar Diesel Engine........................................................4969 Fan and Alternator Drive Belt...........................................4969 PCV Valve.......................................................................4970 Clean Debris From Radiator Core.................................................4970 Transmission Oil Level..........................................................4970 Wet Brake Planetary Housing Oil Level Check.....................................4972 Forks...........................................................................4973 Mast Lubrication................................................................4974 Header Hose Checks..............................................................4976 Lift Chain Lubrication..........................................................4977 Tilt Cylinder Lubrication.......................................................4977 Master Brake Cylinder Rod End Pin Lubrication...................................4978 Manual Hydraulic Levers Lubrication.............................................4978 Brake Fluid.....................................................................4979 Tie Rod Lubrication (H40-70FT)..................................................4980 Differential and Drive Axle Oil (Dry Brake).....................................4980 Maintenance Procedures Every 1000 Hours or 6 Months.................................4980 Valve Clearance, Check and Adjust...............................................4980 Ignition System.................................................................4981 GM 2.4L Engine..............................................................4981 Mazda 2.0L and 2.2L Engines.................................................4981 LPG Fuel Filter Element Replace, GM 2.4L Engine.................................4981 Remove......................................................................4981 Install.....................................................................4981 LPG Vapor Fuel Filter Replace, Mazda Engines (Except 2007 Mazda ................4982 LPG Fuel Filter Replace, Mazda 2007 Emission Compliant Engines O................4982 Remove......................................................................4982 Clean/Inspect...............................................................4983 Install.....................................................................4983 Gasoline Fuel Filter Replacement, Mazda 2007 Emission Compliant ................4983 Remove and Replace..........................................................4983 Fuel Filter Replacement, Yanmar Engine..........................................4984 Priming the Fuel System (Yanmar)................................................4985 Lift Chains Wear Check..........................................................4986 Lift Chain Lubrication..........................................................4986 Integral Sideshift Carriage, Check Bearings.....................................4987 Integral Sideshift Carriage, Check Lower Mounting Hooks.........................4987 Steering Axle...................................................................4988 Control Levers and Pedals.......................................................4988 Maintenance Procedures Every 2000 Hours or Annually.................................4989 Hydraulic System................................................................4989 Hydraulic Filter, Replace...................................................4989 Hydraulic Tank Breather, Replace............................................4990 Air Filter......................................................................4990 PCV Valve.......................................................................4992 Oxygen Sensor ..................................................................4992 LPG Regulator Fuel Filter, Mazda Engines (Except 2007 Mazda Emis................4993 Remove and Replace..........................................................4993 LPG Regulator Fuel Filter, GM Engines...........................................4994 Remove......................................................................4994 Install.....................................................................4994 Gasoline Fuel Filter............................................................4994 Remove and Replace..........................................................4994 Timing Belt.....................................................................4995 Mazda Engines...............................................................4995 GM 2.4L Engine..............................................................4995 LPG Fuel Injector, Mazda Engines (Except 2007 Mazda Emission Com................4995 Gasoline Fuel Injector, Mazda Engines...........................................4995 LPG Fuel Injector, GM Engines...................................................4995 Gasoline Fuel Injector, GM Engines..............................................4995 Fuel Injector, Yanmar Engines...................................................4995 Forks...........................................................................4996 Integral Sideshift Carriage.....................................................4996 Bearings, Replace...........................................................4996 Transmission Oil and Filter (Dry Brake), Replace................................4996 Iron Transmission Housing...................................................4996 Aluminum Transmission Housing...............................................4997 Remove..................................................................4997 Clean and Inspect.......................................................4998 Install.................................................................4998 Transmission Oil Change, Wet Brake Drive Axle...................................4999 Wet Brake Axle Center Section and Planetary Housing, Oil Change.................5001 Brake Fluid (Master Cylinder), Change...........................................5004 Brake Fluid (Dry Brake), Remove.................................................5006 Service Brakes (Dry Brake)......................................................5006 Differential (Dry Brake)........................................................5006 Valve Clearance, Check and Adjust for Cummins QSB 3.3L Diesel En................5007 Maintenance Procedures Every 4000 Hours or 2 Years..................................5008 Hydraulic Oil, Replace..........................................................5008 Cooling System..................................................................5009 Safety Procedures When Working Near Mast............................................5010 Hood Latch Check....................................................................5012 Lift Chain Adjustments..............................................................5014 Jump-Starting the Lift Truck........................................................5015 Jump-Starting Using a Battery Charger...........................................5015 Jump-Starting a Lift Truck Using Another Lift Truck.............................5015 Welding Repairs.....................................................................5016 Overhead Guard Changes..............................................................5016 Wheel and Tire Replacement..........................................................5016 General.........................................................................5016 Solid Rubber Tire, Change ( S Series)...........................................5016 Remove and Install Tire on Wheel............................................5017 Pneumatic Tire With Tube, Repair................................................5018 Remove Wheels From Lift Truck...............................................5018 Remove Tire From Wheel......................................................5018 Remove Tire From Two-Piece Wheel........................................5019 Remove Tire From Three- and Four-Piece Wheels...........................5020 Install Wheel in Tire.......................................................5021 Install Three-Piece or Four-Piece Wheel in Tire.........................5021 Install Tire on Two-Piece Wheel.........................................5022 Install Two-Piece Wheel in Tire.........................................5023 Add Air to Pneumatic Tires With Tube............................................5023 Install the Wheels..........................................................5024 Dual Drive Wheels, Install..................................................5024 Pneumatic Tubeless Tire, Repair.................................................5025 Remove Wheels From Lift Truck...............................................5025 Remove Tire From Wheel......................................................5025 Install Tire on Wheel.......................................................5027 Add Air to Pneumatic Tubeless Tire..........................................5030 Wheels, Install.............................................................5030 Solid Rubber Tires on Pneumatic Wheels, Change..................................5030 Remove Wheel From Tire......................................................5031 Install Tire on Wheel.......................................................5032 Adhesives and Sealants..............................................................5034 tables..................................................................................4909 Table 1. Maintenance Schedule.......................................................4933 Table 2. V-Belt Deflection Table....................................................4969 Table 3. Carriage Chain Adjustment, Forks Not Installed.............................5015 Powershift Trans (1)........................................................................5037 toc.....................................................................................5037 Powershift Transmission.............................................................5037 Safety Precautions Maintenance and Repair...........................................5038 General.............................................................................5041 Serial Number...................................................................5041 Charge Pump Repair..................................................................5042 Remove..........................................................................5042 Inspect.........................................................................5042 Install.........................................................................5042 Torque Converter Replace............................................................5043 Remove..........................................................................5043 Install.........................................................................5050 Front Cover Housing and Chain Drive Repair..........................................5056 Remove..........................................................................5056 Clean...........................................................................5062 Inspect.........................................................................5062 Install.........................................................................5062 Clutch Packs Repair.................................................................5069 Remove and Disassemble..........................................................5069 Transmission, Remove and Disassemble........................................5069 Clutch Assemblies, Remove and Disassemble...................................5080 Clean...........................................................................5085 Inspect.........................................................................5085 Assemble and Install............................................................5086 Clutch Assemblies, Assemble and Install.....................................5086 Transmission, Assemble and Install..........................................5093 Control Valve Repair................................................................5099 Remove and Disassemble..........................................................5099 Clean...........................................................................5102 Inspect.........................................................................5102 Assemble and Install............................................................5102 MONOTROL® Pedal Repair..............................................................5104 Remove and Disassemble..........................................................5104 Assemble and Install............................................................5107 Direction Control Lever.............................................................5108 Remove..........................................................................5108 Install.........................................................................5108 Powershift Trans............................................................................5113 toc.....................................................................................5113 Powershift Transmission.............................................................5113 Safety Precautions Maintenance and Repair...........................................5114 General.............................................................................5117 Serial Number...................................................................5117 Charge Pump Repair..................................................................5118 Remove..........................................................................5118 Inspect.........................................................................5118 Install.........................................................................5118 Torque Converter Replace............................................................5119 Remove..........................................................................5119 Install.........................................................................5126 Front Cover Housing and Chain Drive Repair..........................................5132 Remove..........................................................................5132 Clean...........................................................................5138 Inspect.........................................................................5138 Install.........................................................................5138 Clutch Packs Repair.................................................................5145 Remove and Disassemble..........................................................5145 Transmission, Remove and Disassemble........................................5145 Clutch Assemblies, Remove and Disassemble...................................5156 Clean...........................................................................5161 Inspect.........................................................................5161 Assemble and Install............................................................5162 Clutch Assemblies, Assemble and Install.....................................5162 Transmission, Assemble and Install..........................................5169 Control Valve Repair................................................................5175 Remove and Disassemble..........................................................5175 Clean...........................................................................5178 Inspect.........................................................................5178 Assemble and Install............................................................5178 MONOTROL® Pedal Repair..............................................................5180 Remove and Disassemble..........................................................5180 Assemble and Install............................................................5183 Direction Control Lever.............................................................5184 Remove..........................................................................5184 Install.........................................................................5184 Single Speed Trans (1)......................................................................5189 toc.....................................................................................5189 Single Speed PowerShift.............................................................5189 Safety Precautions Maintenance and Repair...........................................5190 General.............................................................................5193 Serial Number...................................................................5193 Hydraulic Gear Pump.................................................................5194 Remove..........................................................................5194 Install.........................................................................5194 Charge Pump Repair..................................................................5195 Remove..........................................................................5195 Disassemble.....................................................................5196 Clean...........................................................................5196 Inspect.........................................................................5196 Assemble........................................................................5196 Install.........................................................................5196 Torque Converter Replacement........................................................5197 Remove..........................................................................5197 Clean and Inspect...............................................................5198 Install.........................................................................5198 Stator Support Assembly Repair......................................................5198 Remove..........................................................................5198 Disassemble.....................................................................5204 Clean...........................................................................5204 Inspect.........................................................................5205 Assemble........................................................................5206 Install.........................................................................5206 Clutch Packs Repair.................................................................5207 Remove..........................................................................5207 Engine, Torque Converter, and Transmission Assembly.........................5207 Transmission Components.....................................................5208 Disassemble.....................................................................5210 Transmission................................................................5210 Housings................................................................5210 Forward Clutch Pack.....................................................5213 Reverse Clutch Pack.....................................................5218 Clean...........................................................................5224 Inspect.........................................................................5224 Assemble........................................................................5225 Transmission................................................................5225 Reverse Clutch Pack.....................................................5225 Forward Clutch Pack.....................................................5232 Housings................................................................5239 Install.........................................................................5240 Transmission Components.....................................................5240 Engine, Torque Converter, and Transmission Assembly.........................5243 Inching Overlap Adjustment......................................................5243 Proportional and Solenoid Valves....................................................5244 Proportional Valves.............................................................5244 Remove......................................................................5244 Disassemble.................................................................5245 Clean and Inspect...........................................................5245 Assemble....................................................................5245 Install.....................................................................5245 Solenoid Valve..................................................................5245 Remove......................................................................5245 Disassemble.................................................................5245 Clean and Inspect...........................................................5245 Assemble....................................................................5246 Install.....................................................................5246 MONOTROL® Pedal Repair..............................................................5246 Remove and Disassembly..........................................................5246 Clean and Inspect...............................................................5247 Assemble and Install............................................................5249 Single Speed Trans..........................................................................5253 toc.....................................................................................5253 Single Speed PowerShift.............................................................5253 Safety Precautions Maintenance and Repair...........................................5254 General.............................................................................5257 Serial Number...................................................................5257 Hydraulic Gear Pump.................................................................5258 Remove..........................................................................5258 Install.........................................................................5258 Charge Pump Repair..................................................................5259 Remove..........................................................................5259 Disassemble.....................................................................5260 Clean...........................................................................5260 Inspect.........................................................................5260 Assemble........................................................................5260 Install.........................................................................5260 Torque Converter Replacement........................................................5261 Remove..........................................................................5261 Clean and Inspect...............................................................5262 Install.........................................................................5262 Stator Support Assembly Repair......................................................5262 Remove..........................................................................5262 Disassemble.....................................................................5268 Clean...........................................................................5268 Inspect.........................................................................5269 Assemble........................................................................5270 Install.........................................................................5270 Clutch Packs Repair.................................................................5271 Remove..........................................................................5271 Engine, Torque Converter, and Transmission Assembly.........................5271 Transmission Components.....................................................5272 Disassemble.....................................................................5274 Transmission................................................................5274 Housings................................................................5274 Forward Clutch Pack.....................................................5277 Reverse Clutch Pack.....................................................5282 Clean...........................................................................5288 Inspect.........................................................................5288 Assemble........................................................................5289 Transmission................................................................5289 Reverse Clutch Pack.....................................................5289 Forward Clutch Pack.....................................................5296 Housings................................................................5303 Install.........................................................................5304 Transmission Components.....................................................5304 Engine, Torque Converter, and Transmission Assembly.........................5307 Inching Overlap Adjustment......................................................5307 Proportional and Solenoid Valves....................................................5308 Proportional Valves.............................................................5308 Remove......................................................................5308 Disassemble.................................................................5309 Clean and Inspect...........................................................5309 Assemble....................................................................5309 Install.....................................................................5309 Solenoid Valve..................................................................5309 Remove......................................................................5309 Disassemble.................................................................5309 Clean and Inspect...........................................................5309 Assemble....................................................................5310 Install.....................................................................5310 MONOTROL® Pedal Repair..............................................................5310 Remove and Disassembly..........................................................5310 Clean and Inspect...............................................................5311 Assemble and Install............................................................5313 Specs (1)...................................................................................5317 toc.....................................................................................5317 Capacities and Specifications.......................................................5317 Safety Precautions Maintenance and Repair...........................................5318 Lift Truck Lifting Capacity.........................................................5321 Counterweight Weights...............................................................5321 Tire Sizes..........................................................................5321 Capacities..........................................................................5322 Electrical System...................................................................5326 Transmission Oil Pressures..........................................................5327 Hydraulic System Relief Pressures...................................................5330 Steering System.....................................................................5330 Stall Speeds (in RPM ±100 rpm)......................................................5331 Mazda 2.0L (Except 2007 Emission Compliant Engines).............................5331 Mazda 2.0L (2007 Emission Compliant Engines Only)...............................5331 Mazda 2.2L (Except 2007 Emission Compliant Engines).............................5331 Mazda 2.2L (2007 Emission Compliant Engines Only)...............................5332 GM 2.4L.........................................................................5332 Yanmar 2.6L.....................................................................5332 Yanmar 3.3L.....................................................................5332 Mast Speeds.........................................................................5333 Tilt Angles.........................................................................5336 Front End Equipment - Mast Creep....................................................5337 Mast Creep......................................................................5337 Engine Specifications...............................................................5338 Torque Specifications...............................................................5340 Frame...........................................................................5340 Mast............................................................................5340 Steering System, Cushioned Tire Trucks..........................................5340 Steering System, Pneumatic Tire Trucks..........................................5340 Drive Axle (Dry Brake)..........................................................5340 Drive Axle (Wet Brake)..........................................................5341 Transmission - Iron Housing.....................................................5341 Transmission - Aluminum Housing.................................................5342 Engine - Mazda 2.0L and 2.2L....................................................5342 Engine - GM 2.4L................................................................5343 Engine - Yanmar 2.6L and 3.3L Diesel............................................5344 tables..................................................................................5317 Table 1. Hydraulic Systems With Hydraulic Gear Pump.................................5330 Table 2. Hydraulic Systems With Variable Displacement Pump..........................5330 Table 3. Lift Truck Models S2.0-3.5FT (S40-70FT, S55FTS) (F187).....................5333 Table 4. Lift Truck Models H2.0-3.5FT (H40-70FT) (L177).............................5334 Table 5. S2.0-3.5FT (S40-70FT, S55FTS) (F187) Lift Truck Models.....................5336 Table 6. H2.0-3.5FT (H40-70FT) (L177) Lift Truck Models.............................5336 Table 7. S2.0-3.5FT (S40-70FT, S55FTS) (F187) Lift Truck Models.....................5337 Table 8. H2.0-3.5FT (H40-70FT) (L177) Lift Truck Models.............................5337 Specs.......................................................................................5349 toc.....................................................................................5349 Capacities and Specifications.......................................................5349 Safety Precautions Maintenance and Repair...........................................5350 Lift Truck Lifting Capacity.........................................................5353 Counterweight Weights...............................................................5353 Tire Sizes..........................................................................5353 Capacities..........................................................................5354 Electrical System...................................................................5358 Transmission Oil Pressures..........................................................5359 Hydraulic System Relief Pressures...................................................5362 Steering System.....................................................................5362 Stall Speeds (in RPM ±100 rpm)......................................................5363 Mazda 2.0L (Except 2007 Emission Compliant Engines).............................5363 Mazda 2.0L (2007 Emission Compliant Engines Only)...............................5363 Mazda 2.2L (Except 2007 Emission Compliant Engines).............................5363 Mazda 2.2L (2007 Emission Compliant Engines Only)...............................5364 GM 2.4L.........................................................................5364 Yanmar 2.6L.....................................................................5364 Yanmar 3.3L.....................................................................5364 Mast Speeds.........................................................................5365 Tilt Angles.........................................................................5368 Front End Equipment - Mast Creep....................................................5369 Mast Creep......................................................................5369 Engine Specifications...............................................................5370 Torque Specifications...............................................................5372 Frame...........................................................................5372 Mast............................................................................5372 Steering System, Cushioned Tire Trucks..........................................5372 Steering System, Pneumatic Tire Trucks..........................................5372 Drive Axle (Dry Brake)..........................................................5372 Drive Axle (Wet Brake)..........................................................5373 Transmission - Iron Housing.....................................................5373 Transmission - Aluminum Housing.................................................5374 Engine - Mazda 2.0L and 2.2L....................................................5374 Engine - GM 2.4L................................................................5375 Engine - Yanmar 2.6L and 3.3L Diesel............................................5376 tables..................................................................................5349 Table 1. Hydraulic Systems With Hydraulic Gear Pump.................................5362 Table 2. Hydraulic Systems With Variable Displacement Pump..........................5362 Table 3. Lift Truck Models S2.0-3.5FT (S40-70FT, S55FTS) (F187).....................5365 Table 4. Lift Truck Models H2.0-3.5FT (H40-70FT) (L177).............................5366 Table 5. S2.0-3.5FT (S40-70FT, S55FTS) (F187) Lift Truck Models.....................5368 Table 6. H2.0-3.5FT (H40-70FT) (L177) Lift Truck Models.............................5368 Table 7. S2.0-3.5FT (S40-70FT, S55FTS) (F187) Lift Truck Models.....................5369 Table 8. H2.0-3.5FT (H40-70FT) (L177) Lift Truck Models.............................5369 Steer Axle (1)..............................................................................5381 toc.....................................................................................5381 Steering Axle.......................................................................5381 Safety Precautions Maintenance and Repair...........................................5382 General.............................................................................5385 Steering Axle Assembly Repair.......................................................5387 Remove..........................................................................5387 Disassemble.....................................................................5388 Clean...........................................................................5395 Inspect.........................................................................5396 Assemble........................................................................5396 Install.........................................................................5401 Spindles, Bearings, and Tie Rods Repair.............................................5403 Spindles and Bearings...........................................................5403 S2.0-3.5FT (S40-70FT, S55FTS) (F187), S4.0, 4.5, 5.5FT, S5.5FTS,............5403 Remove..................................................................5403 Disassemble.............................................................5404 Clean...................................................................5405 Inspect.................................................................5405 Assemble................................................................5405 Install.................................................................5406 Spindles and Bearings...........................................................5409 S30FT, S35FT, S40FTS (E010), H1.6FT, H1.8FT, H2.0FTS (H30FT, H35............5409 Remove and Disassemble..................................................5409 Assemble and Install....................................................5410 Tie Rods........................................................................5411 S2.0-3.5FT (S40-70FT, S55FTS) (F187), and S4.0, 4.5, 5.5FT, S5.5............5411 Remove..................................................................5411 Install.................................................................5411 Tie Rods........................................................................5412 S30FT, S35FT, S40FTS (E010), H1.6FT, H1.8FT, H2.0FTS (H30FT, H35............5412 Remove..................................................................5412 Install.................................................................5414 Steering Cylinder Repair............................................................5416 Remove and Disassemble..........................................................5416 Clean and Inspect...............................................................5416 Assemble and Install............................................................5416 Torque Specifications...............................................................5417 Steer Axle..................................................................................5421 toc.....................................................................................5421 Steering Axle.......................................................................5421 Safety Precautions Maintenance and Repair...........................................5422 General.............................................................................5425 Steering Axle Assembly Repair.......................................................5427 Remove..........................................................................5427 Disassemble.....................................................................5428 Clean...........................................................................5435 Inspect.........................................................................5436 Assemble........................................................................5436 Install.........................................................................5441 Spindles, Bearings, and Tie Rods Repair.............................................5443 Spindles and Bearings...........................................................5443 S2.0-3.5FT (S40-70FT, S55FTS) (F187), S4.0, 4.5, 5.5FT, S5.5FTS,............5443 Remove..................................................................5443 Disassemble.............................................................5444 Clean...................................................................5445 Inspect.................................................................5445 Assemble................................................................5445 Install.................................................................5446 Spindles and Bearings...........................................................5449 S30FT, S35FT, S40FTS (E010), H1.6FT, H1.8FT, H2.0FTS (H30FT, H35............5449 Remove and Disassemble..................................................5449 Assemble and Install....................................................5450 Tie Rods........................................................................5451 S2.0-3.5FT (S40-70FT, S55FTS) (F187), and S4.0, 4.5, 5.5FT, S5.5............5451 Remove..................................................................5451 Install.................................................................5451 Tie Rods........................................................................5452 S30FT, S35FT, S40FTS (E010), H1.6FT, H1.8FT, H2.0FTS (H30FT, H35............5452 Remove..................................................................5452 Install.................................................................5454 Steering Cylinder Repair............................................................5456 Remove and Disassemble..........................................................5456 Clean and Inspect...............................................................5456 Assemble and Install............................................................5456 Torque Specifications...............................................................5457 User Int. Sup. (1)..........................................................................5461 toc.....................................................................................5461 User Interface......................................................................5461 Safety Precautions Maintenance and Repair...........................................5462 General.............................................................................5465 Description.....................................................................5465 Dash Display Menu Access........................................................5465 Menu Navigation.....................................................................5466 Standard Display................................................................5466 Main Menu...........................................................................5466 Passwords Menu......................................................................5467 Password Administration.............................................................5467 Add Password....................................................................5467 Delete Password.................................................................5468 Edit Password...................................................................5468 Other Password Functions............................................................5469 Operator Passwords - Enable/Disable.............................................5469 Password Time-Out Delay.........................................................5470 Passwords - Number Wrong to Disable.............................................5470 Lockout Reset Password..........................................................5471 View Password Log...............................................................5471 View Versions.......................................................................5472 VSM Versions....................................................................5472 Dash Display Versions...........................................................5473 Engine Controller Version.......................................................5474 Transmission (Xmsn) Controller Version..........................................5475 Truck Serial Number.............................................................5476 Diagnostics.........................................................................5477 View Fault Log..................................................................5477 Set Travel and Braking..............................................................5478 Speed Limit.....................................................................5478 Acceleration Rate...............................................................5479 Auto-Deceleration Rate..........................................................5479 Set Power Reversal Rate.........................................................5480 Set Inching/Brake Overlap.......................................................5481 Setup Display Menu..................................................................5482 Set Operator Language...........................................................5482 Set Units.......................................................................5483 Set Time Format (12/24 Hour)....................................................5483 Set Daylight Saving Time........................................................5484 Set Time........................................................................5486 Set Date Format.................................................................5486 Set Date........................................................................5487 Setup Hydraulics....................................................................5488 Return to Set Tilt Delay/On/Off.................................................5488 Setup General Items.................................................................5488 Light Shutdown Time-Out.........................................................5488 Impact Sensor - Enable/Disable..................................................5489 Impact Sensor - Soft Impact Settings............................................5490 Impact Sensor - Hard Impact Settings............................................5491 Adjust Impact Sensor Settings...................................................5492 Initial Adjustment of Soft and Hard Impact Settings.........................5494 Readjustment of Soft and Hard Impact Settings...............................5494 Impact Sensor - Impact Alarm/Shutdown Reset.....................................5494 Impact Sensor - Alarm Time Duration and Deactivation............................5495 Impact Sensor - View Impact Event Log...........................................5496 Economy Mode Indicator (ECO-eLo)................................................5497 Operator Checklist..................................................................5498 Operator Checklist Off-On Mode..................................................5498 Edit Operator Checklist.........................................................5498 Set Operator Checklist Expiration...............................................5499 View Checklist Log..............................................................5499 Clear Operator Checklist Log....................................................5500 Clear Operator Checklist Fault..................................................5500 Calibrations........................................................................5501 Set Tilt Stop Point.............................................................5501 Calibrate Loaded Weight.........................................................5501 tables..................................................................................5461 Table 1. Password Screen............................................................5465 Table 2. Exit Options Menu..........................................................5466 Table 3. Add Password Menu..........................................................5467 Table 4. Delete Password Menu.......................................................5468 Table 5. Edit Password Menu.........................................................5468 Table 6. Operator Passwords Menu....................................................5469 Table 7. Password Time-Out Delay Menu...............................................5470 Table 8. Passwords - Number Wrong to Disable Menu...................................5470 Table 9. View Password Log Menu.....................................................5471 Table 10. View VSM Versions Menu....................................................5472 Table 11. View Dash Display Versions Menu...........................................5473 Table 12. View Engine Controller Versions Menu......................................5474 Table 13. View Transmission Controller Versions Menu................................5475 Table 14. View Truck Serial Number Menu.............................................5476 Table 15. View Fault Log............................................................5477 Table 16. Speed Limit Menu..........................................................5478 Table 17. Acceleration Rate Menu....................................................5479 Table 18. Auto-Decel Menu...........................................................5479 Table 19. Power Reversal Menu.......................................................5480 Table 20. Inch/Brake Overlap Menu...................................................5481 Table 21. Set Language Menu.........................................................5482 Table 22. Set Units Menu............................................................5483 Table 23. Set Time Format Menu......................................................5483 Table 24. Set Daylight Saving Time Menu.............................................5484 Table 25. Set Time Menu.............................................................5486 Table 26. Set Date Format Menu......................................................5486 Table 27. Set Date Menu.............................................................5487 Table 28. Tilt Delay Menu...........................................................5488 Table 29. Light Time-Out Menu.......................................................5489 Table 30. Impact Sensor Enable/Disable..............................................5489 Table 31. Soft Impact Settings Menu.................................................5490 Table 32. Hard Impact Settings Menu.................................................5491 Table 33. Impact Sensor Default Settings............................................5492 Table 34. Recommended Starting Values for Impact Sensor Settings....................5492 Table 35. Shutdown Reset Menu.......................................................5494 Table 36. Alarm Duration Menu.......................................................5495 Table 37. View Event Log Menu.......................................................5496 Table 38. ECO-eLo Settings Menu.....................................................5497 Table 39. Checklist Off-On Mode Menu................................................5498 Table 40. Edit Checklist Menu.......................................................5498 Table 41. Checklist Expiration Menu.................................................5499 Table 42. View Checklist Log Menu...................................................5499 Table 43. Clear Checklist Log Menu..................................................5500 Table 44. Clear Checklist Fault Menu................................................5500 Table 45. Tilt Stop Point Menu......................................................5501 Table 46. Calibrate Loaded Weight...................................................5501 User Int. Sup...............................................................................5505 toc.....................................................................................5505 User Interface......................................................................5505 Safety Precautions Maintenance and Repair...........................................5506 General.............................................................................5509 Description.....................................................................5509 Dash Display Menu Access........................................................5509 Menu Navigation.....................................................................5510 Standard Display................................................................5510 Main Menu...........................................................................5510 Passwords Menu......................................................................5511 Password Administration.............................................................5511 Add Password....................................................................5511 Delete Password.................................................................5512 Edit Password...................................................................5512 Other Password Functions............................................................5513 Operator Passwords - Enable/Disable.............................................5513 Password Time-Out Delay.........................................................5514 Passwords - Number Wrong to Disable.............................................5514 Lockout Reset Password..........................................................5515 View Password Log...............................................................5515 View Versions.......................................................................5516 VSM Versions....................................................................5516 Dash Display Versions...........................................................5517 Engine Controller Version.......................................................5518 Transmission (Xmsn) Controller Version..........................................5519 Truck Serial Number.............................................................5520 Diagnostics.........................................................................5521 View Fault Log..................................................................5521 Set Travel and Braking..............................................................5522 Speed Limit.....................................................................5522 Acceleration Rate...............................................................5523 Auto-Deceleration Rate..........................................................5523 Set Power Reversal Rate.........................................................5524 Set Inching/Brake Overlap.......................................................5525 Setup Display Menu..................................................................5526 Set Operator Language...........................................................5526 Set Units.......................................................................5527 Set Time Format (12/24 Hour)....................................................5527 Set Daylight Saving Time........................................................5528 Set Time........................................................................5530 Set Date Format.................................................................5530 Set Date........................................................................5531 Setup Hydraulics....................................................................5532 Return to Set Tilt Delay/On/Off.................................................5532 Setup General Items.................................................................5532 Light Shutdown Time-Out.........................................................5532 Impact Sensor - Enable/Disable..................................................5533 Impact Sensor - Soft Impact Settings............................................5534 Impact Sensor - Hard Impact Settings............................................5535 Adjust Impact Sensor Settings...................................................5536 Initial Adjustment of Soft and Hard Impact Settings.........................5538 Readjustment of Soft and Hard Impact Settings...............................5538 Impact Sensor - Impact Alarm/Shutdown Reset.....................................5538 Impact Sensor - Alarm Time Duration and Deactivation............................5539 Impact Sensor - View Impact Event Log...........................................5540 Economy Mode Indicator (ECO-eLo)................................................5541 Operator Checklist..................................................................5542 Operator Checklist Off-On Mode..................................................5542 Edit Operator Checklist.........................................................5542 Set Operator Checklist Expiration...............................................5543 View Checklist Log..............................................................5543 Clear Operator Checklist Log....................................................5544 Clear Operator Checklist Fault..................................................5544 Calibrations........................................................................5545 Set Tilt Stop Point.............................................................5545 Calibrate Loaded Weight.........................................................5545 tables..................................................................................5505 Table 1. Password Screen............................................................5509 Table 2. Exit Options Menu..........................................................5510 Table 3. Add Password Menu..........................................................5511 Table 4. Delete Password Menu.......................................................5512 Table 5. Edit Password Menu.........................................................5512 Table 6. Operator Passwords Menu....................................................5513 Table 7. Password Time-Out Delay Menu...............................................5514 Table 8. Passwords - Number Wrong to Disable Menu...................................5514 Table 9. View Password Log Menu.....................................................5515 Table 10. View VSM Versions Menu....................................................5516 Table 11. View Dash Display Versions Menu...........................................5517 Table 12. View Engine Controller Versions Menu......................................5518 Table 13. View Transmission Controller Versions Menu................................5519 Table 14. View Truck Serial Number Menu.............................................5520 Table 15. View Fault Log............................................................5521 Table 16. Speed Limit Menu..........................................................5522 Table 17. Acceleration Rate Menu....................................................5523 Table 18. Auto-Decel Menu...........................................................5523 Table 19. Power Reversal Menu.......................................................5524 Table 20. Inch/Brake Overlap Menu...................................................5525 Table 21. Set Language Menu.........................................................5526 Table 22. Set Units Menu............................................................5527 Table 23. Set Time Format Menu......................................................5527 Table 24. Set Daylight Saving Time Menu.............................................5528 Table 25. Set Time Menu.............................................................5530 Table 26. Set Date Format Menu......................................................5530 Table 27. Set Date Menu.............................................................5531 Table 28. Tilt Delay Menu...........................................................5532 Table 29. Light Time-Out Menu.......................................................5533 Table 30. Impact Sensor Enable/Disable..............................................5533 Table 31. Soft Impact Settings Menu.................................................5534 Table 32. Hard Impact Settings Menu.................................................5535 Table 33. Impact Sensor Default Settings............................................5536 Table 34. Recommended Starting Values for Impact Sensor Settings....................5536 Table 35. Shutdown Reset Menu.......................................................5538 Table 36. Alarm Duration Menu.......................................................5539 Table 37. View Event Log Menu.......................................................5540 Table 38. ECO-eLo Settings Menu.....................................................5541 Table 39. Checklist Off-On Mode Menu................................................5542 Table 40. Edit Checklist Menu.......................................................5542 Table 41. Checklist Expiration Menu.................................................5543 Table 42. View Checklist Log Menu...................................................5543 Table 43. Clear Checklist Log Menu..................................................5544 Table 44. Clear Checklist Fault Menu................................................5544 Table 45. Tilt Stop Point Menu......................................................5545 Table 46. Calibrate Loaded Weight...................................................5545 User Int. Tech (1)..........................................................................5549 toc.....................................................................................5549 User Interface......................................................................5549 Safety Precautions Maintenance and Repair...........................................5550 General.............................................................................5553 Description.....................................................................5553 Dash Display Menu Access........................................................5553 Menu Navigation.....................................................................5554 Main Menu...........................................................................5555 Passwords...........................................................................5555 Adding Passwords................................................................5556 Hourmeters..........................................................................5557 View Versions.......................................................................5558 VSM Versions....................................................................5558 Dash Display Versions...........................................................5559 Engine Controller Version.......................................................5560 Transmission (Xmsn) Controller Version..........................................5561 Truck Serial Number.............................................................5562 Truck Configuration.............................................................5563 Diagnostics.........................................................................5564 Clear Fault Log.................................................................5564 View Fault Log..................................................................5565 No-Run Data Display.............................................................5566 Engine Accelerator and Throttle Data Display....................................5567 Engine Speeds and Governor Data Display.........................................5568 Engine Fuel and Emissions Data Display..........................................5569 Engine General Data Display.....................................................5571 XMSN/Brake Data Display.........................................................5572 Hydraulic Data Display..........................................................5574 General Truck Data Display......................................................5576 Set Travel and Braking..............................................................5578 Speed Limit.....................................................................5578 Acceleration Rate...............................................................5579 Auto-Deceleration Rate..........................................................5579 Set Power Reversal Rate.........................................................5580 Set Inching/Brake Overlap.......................................................5581 Setup Hydraulics....................................................................5582 Lift Maximum Speed..............................................................5582 Lower Maximum Speed.............................................................5583 Tilt Maximum Speed..............................................................5583 Auxiliary Function One, Direction A, Maximum Speed..............................5585 Auxiliary Function One, Direction B, Maximum Speed..............................5585 Auxiliary Function Two, Direction A, Maximum Speed..............................5586 Auxiliary Function Two, Direction B, Maximum Speed..............................5586 Auxiliary Function Three, Direction A, Maximum Speed............................5587 Auxiliary Function Three, Direction B, Maximum Speed............................5587 Lift/Lower Ramp Rate............................................................5588 Hydraulic Auxiliary Ramp Rate...................................................5589 Return to Set Tilt Delay/On/Off.................................................5590 Setup Display.......................................................................5591 Set Service Language............................................................5591 Setup General Items.................................................................5592 Motion Alarm Activation Type....................................................5592 Light Shutdown Time-Out.........................................................5593 Restore Default Settings........................................................5594 Restore Engine Controller Default Calibration...................................5594 Impact Sensor - Enable/Disable..................................................5595 Impact Sensor - Soft Impact Settings............................................5596 Impact Sensor - Hard Impact Settings............................................5597 Adjust Impact Sensor Settings...................................................5598 Initial Adjustment of Soft and Hard Impact Settings.........................5600 Readjustment of Soft and Hard Impact Settings...............................5600 Impact Sensor - Impact Alarm/Shutdown Reset.....................................5600 Impact Sensor - Alarm Time Duration and Deactivation............................5601 Impact Sensor - View Impact Event Log...........................................5602 Economy Mode Indicator (ECO-eLo)................................................5603 Calibrations........................................................................5604 Calibrate Transmission Valve....................................................5606 Set Tilt Stop Point.............................................................5606 Calibrate Loaded Weight.........................................................5606 Calibrate Travel Speed Sensor...................................................5607 Calibrate Mazda LP and Gas Accelerator Pedal....................................5607 tables..................................................................................5549 Table 1. Password Screen............................................................5553 Table 2. Exit Menu..................................................................5554 Table 3. Add Password Menu..........................................................5556 Table 4. Hourmeters Menu............................................................5557 Table 5. View VSM Versions Menu.....................................................5558 Table 6. View Dash Display Versions Menu............................................5559 Table 7. View Engine Controller Versions Menu.......................................5560 Table 8. View Transmission Controller Versions Menu.................................5561 Table 9. View Truck Serial Number Menu..............................................5562 Table 10. View Truck Configuration Menu.............................................5563 Table 11. Clear Fault Log...........................................................5564 Table 12. View Fault Log............................................................5565 Table 13. No-Run Data Display.......................................................5566 Table 14. Engine Accelerator and Throttle Data Display..............................5567 Table 15. Engine Speeds and Governor Data Display...................................5568 Table 16. Engine Fuel and Emissions Data Display....................................5569 Table 17. Engine General Data Display...............................................5571 Table 18. XMSN Brake Data Display...................................................5572 Table 19. Hydraulic Data Display....................................................5574 Table 20. General Truck Data Display................................................5576 Table 21. Speed Limit Menu..........................................................5578 Table 22. Acceleration Rate Menu....................................................5579 Table 23. Auto-Decel Menu...........................................................5579 Table 24. Power Reversal Menu.......................................................5580 Table 25. Inch/Brake Overlap Menu...................................................5581 Table 26. Lift Speed Menu...........................................................5582 Table 27. Lower Speed Menu..........................................................5583 Table 28. Tilt Speed Menu...........................................................5583 Table 29. Auxiliary Function Speed Menu.............................................5585 Table 30. Auxiliary Function Speed Menu.............................................5585 Table 31. Auxiliary Function Speed Menu.............................................5586 Table 32. Auxiliary Function Speed Menu.............................................5586 Table 33. Auxiliary Function Speed Menu.............................................5587 Table 34. Auxiliary Function Speed Menu.............................................5587 Table 35. Lift/Lower Ramp Rate Menu.................................................5588 Table 36. Hydraulic Auxiliary Ramp Rate Menu........................................5589 Table 37. Tilt Delay Menu...........................................................5590 Table 38. Service Language Menu.....................................................5591 Table 39. Alarm Type Menu...........................................................5592 Table 40. Light Time-Out Menu.......................................................5593 Table 41. Restore Defaults Menu.....................................................5594 Table 42. Restore Settings Menu.....................................................5594 Table 43. Impact Sensor Enable/Disable..............................................5595 Table 44. Soft Impact Settings Menu.................................................5596 Table 45. Hard Impact Settings Menu.................................................5597 Table 46. Impact Sensor Default Settings............................................5598 Table 47. Recommended Starting Values for Impact Sensor Settings....................5598 Table 48. Shutdown Reset Menu.......................................................5600 Table 49. Alarm Duration Menu.......................................................5601 Table 50. View Event Log Menu.......................................................5602 Table 51. ECO-eLo Settings Menu.....................................................5603 Table 52. Calibrate Electro-Hydraulic Valve Menu....................................5605 Table 53. Calibrate Transmission Valve Menu.........................................5606 Table 54. Tilt Stop Point Menu......................................................5606 Table 55. Calibrate Loaded Weight...................................................5607 Table 56. Travel Speed Menu.........................................................5607 Table 57. Travel Speed Menu.........................................................5607 User Int. Tech..............................................................................5611 toc.....................................................................................5611 User Interface......................................................................5611 Safety Precautions Maintenance and Repair...........................................5612 General.............................................................................5615 Description.....................................................................5615 Dash Display Menu Access........................................................5615 Menu Navigation.....................................................................5616 Main Menu...........................................................................5617 Passwords...........................................................................5617 Adding Passwords................................................................5618 Hourmeters..........................................................................5619 View Versions.......................................................................5620 VSM Versions....................................................................5620 Dash Display Versions...........................................................5621 Engine Controller Version.......................................................5622 Transmission (Xmsn) Controller Version..........................................5623 Truck Serial Number.............................................................5624 Truck Configuration.............................................................5625 Diagnostics.........................................................................5626 Clear Fault Log.................................................................5626 View Fault Log..................................................................5627 No-Run Data Display.............................................................5628 Engine Accelerator and Throttle Data Display....................................5629 Engine Speeds and Governor Data Display.........................................5630 Engine Fuel and Emissions Data Display..........................................5631 Engine General Data Display.....................................................5633 XMSN/Brake Data Display.........................................................5634 Hydraulic Data Display..........................................................5636 General Truck Data Display......................................................5638 Set Travel and Braking..............................................................5640 Speed Limit.....................................................................5640 Acceleration Rate...............................................................5641 Auto-Deceleration Rate..........................................................5641 Set Power Reversal Rate.........................................................5642 Set Inching/Brake Overlap.......................................................5643 Setup Hydraulics....................................................................5644 Lift Maximum Speed..............................................................5644 Lower Maximum Speed.............................................................5645 Tilt Maximum Speed..............................................................5645 Auxiliary Function One, Direction A, Maximum Speed..............................5647 Auxiliary Function One, Direction B, Maximum Speed..............................5647 Auxiliary Function Two, Direction A, Maximum Speed..............................5648 Auxiliary Function Two, Direction B, Maximum Speed..............................5648 Auxiliary Function Three, Direction A, Maximum Speed............................5649 Auxiliary Function Three, Direction B, Maximum Speed............................5649 Lift/Lower Ramp Rate............................................................5650 Hydraulic Auxiliary Ramp Rate...................................................5651 Return to Set Tilt Delay/On/Off.................................................5652 Setup Display.......................................................................5653 Set Service Language............................................................5653 Setup General Items.................................................................5654 Motion Alarm Activation Type....................................................5654 Light Shutdown Time-Out.........................................................5655 Restore Default Settings........................................................5656 Restore Engine Controller Default Calibration...................................5656 Impact Sensor - Enable/Disable..................................................5657 Impact Sensor - Soft Impact Settings............................................5658 Impact Sensor - Hard Impact Settings............................................5659 Adjust Impact Sensor Settings...................................................5660 Initial Adjustment of Soft and Hard Impact Settings.........................5662 Readjustment of Soft and Hard Impact Settings...............................5662 Impact Sensor - Impact Alarm/Shutdown Reset.....................................5662 Impact Sensor - Alarm Time Duration and Deactivation............................5663 Impact Sensor - View Impact Event Log...........................................5664 Economy Mode Indicator (ECO-eLo)................................................5665 Calibrations........................................................................5666 Calibrate Transmission Valve....................................................5668 Set Tilt Stop Point.............................................................5668 Calibrate Loaded Weight.........................................................5668 Calibrate Travel Speed Sensor...................................................5669 Calibrate Mazda LP and Gas Accelerator Pedal....................................5669 tables..................................................................................5611 Table 1. Password Screen............................................................5615 Table 2. Exit Menu..................................................................5616 Table 3. Add Password Menu..........................................................5618 Table 4. Hourmeters Menu............................................................5619 Table 5. View VSM Versions Menu.....................................................5620 Table 6. View Dash Display Versions Menu............................................5621 Table 7. View Engine Controller Versions Menu.......................................5622 Table 8. View Transmission Controller Versions Menu.................................5623 Table 9. View Truck Serial Number Menu..............................................5624 Table 10. View Truck Configuration Menu.............................................5625 Table 11. Clear Fault Log...........................................................5626 Table 12. View Fault Log............................................................5627 Table 13. No-Run Data Display.......................................................5628 Table 14. Engine Accelerator and Throttle Data Display..............................5629 Table 15. Engine Speeds and Governor Data Display...................................5630 Table 16. Engine Fuel and Emissions Data Display....................................5631 Table 17. Engine General Data Display...............................................5633 Table 18. XMSN Brake Data Display...................................................5634 Table 19. Hydraulic Data Display....................................................5636 Table 20. General Truck Data Display................................................5638 Table 21. Speed Limit Menu..........................................................5640 Table 22. Acceleration Rate Menu....................................................5641 Table 23. Auto-Decel Menu...........................................................5641 Table 24. Power Reversal Menu.......................................................5642 Table 25. Inch/Brake Overlap Menu...................................................5643 Table 26. Lift Speed Menu...........................................................5644 Table 27. Lower Speed Menu..........................................................5645 Table 28. Tilt Speed Menu...........................................................5645 Table 29. Auxiliary Function Speed Menu.............................................5647 Table 30. Auxiliary Function Speed Menu.............................................5647 Table 31. Auxiliary Function Speed Menu.............................................5648 Table 32. Auxiliary Function Speed Menu.............................................5648 Table 33. Auxiliary Function Speed Menu.............................................5649 Table 34. Auxiliary Function Speed Menu.............................................5649 Table 35. Lift/Lower Ramp Rate Menu.................................................5650 Table 36. Hydraulic Auxiliary Ramp Rate Menu........................................5651 Table 37. Tilt Delay Menu...........................................................5652 Table 38. Service Language Menu.....................................................5653 Table 39. Alarm Type Menu...........................................................5654 Table 40. Light Time-Out Menu.......................................................5655 Table 41. Restore Defaults Menu.....................................................5656 Table 42. Restore Settings Menu.....................................................5656 Table 43. Impact Sensor Enable/Disable..............................................5657 Table 44. Soft Impact Settings Menu.................................................5658 Table 45. Hard Impact Settings Menu.................................................5659 Table 46. Impact Sensor Default Settings............................................5660 Table 47. Recommended Starting Values for Impact Sensor Settings....................5660 Table 48. Shutdown Reset Menu.......................................................5662 Table 49. Alarm Duration Menu.......................................................5663 Table 50. View Event Log Menu.......................................................5664 Table 51. ECO-eLo Settings Menu.....................................................5665 Table 52. Calibrate Electro-Hydraulic Valve Menu....................................5667 Table 53. Calibrate Transmission Valve Menu.........................................5668 Table 54. Tilt Stop Point Menu......................................................5668 Table 55. Calibrate Loaded Weight...................................................5669 Table 56. Travel Speed Menu.........................................................5669 Table 57. Travel Speed Menu.........................................................5669
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