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Hyster D024 Service Manual – PDF DOWNLOAD
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Hyster D024 Service Manual – PDF DOWNLOAD
PART NO. 1579259
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Description
Hyster D024 Service Manual – PDF DOWNLOAD
DESCRIPTION:
Hyster D024 Service Manual – PDF DOWNLOAD
PART NO. 1579259
SAFETY PRECAUTIONS TROUBLESHOOTING PROCEDURES
• 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 HOW TO 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 D024 Service Manual – PDF DOWNLOAD
toc................................................................................... 1 Diagnostic Troubleshooting Manual................................................. 1 Safety Precautions TROUBLESHOOTING PROCEDURES..................................... 2 How To Use This Troubleshooting Manual............................................ 4 General Instructions and Safety Information................................... 4 How to Use Diagnostic Troubleshooting Manual.................................. 4 General Instructions.......................................................... 5 Operational Diagnostic Procedures................................................. 7 Operational Checkout Procedures............................................... 9 DTC Check................................................................. 10 Horn Circuit Check........................................................ 10 Light Circuit Check....................................................... 10 Windshield Washer Wiper Check (If equipped)............................... 10 Heater Check (If equipped)................................................ 11 Dome Light Check (If equipped)............................................ 11 Circulating (Accessory) Fan Check (If equipped)........................... 12 Indicator Light Power Check............................................... 13 Operator Presence System Check............................................ 14 Engine Malfunction Indicator Check........................................ 14 Cold Start Check (Cummins and Yanmar)..................................... 14 Brake Pedal Check......................................................... 15 Backup Alarm Check (If equipped).......................................... 15 Armrest Hydraulic Interlock Check (If equipped and with original.......... 15 Engine Cover Latch Sensor Check (If equipped)............................. 16 Brake and Inching Pedal Check............................................. 16 Park Brake Sensor Check................................................... 16 Park Brake Check.......................................................... 17 Engine Speed Check (All Cummins, Yanmar, and Mazda Engines Excep.......... 17 Engine Power Check........................................................ 18 Transmission Clutch Check................................................. 18 Transmission Check........................................................ 19 Transmission Speed Selection Check (If equipped).......................... 19 Brake and Axle Drag Check................................................. 19 Hydraulic Pump Flow Check................................................. 20 Priority Flow Divider Valve Check......................................... 21 Steering Relief Valve Low Pressure Check.................................. 21 Steering Relief Valve High Pressure Check................................. 22 Control Valve Load Check Valve (Manual Valve)............................. 22 Tilt Function Counterbalance Check........................................ 22 Lift Drift Check.......................................................... 23 Tilt Function Drift Check................................................. 23 Mast Cushion Check (All Except 2-Stage Mast).............................. 24 Lift/Tilt Mast Adjustment Check........................................... 24 Tilt Racking Check........................................................ 25 Chain and Header Hose Adjustment Check.................................... 25 Mast Mounting Check....................................................... 26 Mast Channel Check........................................................ 26 Carriage Adjustment Check................................................. 26 Chain Sheave Check........................................................ 27 Carriage Adjustment Check (Standard and Integral Side Shift).............. 27 Engine............................................................................ 29 Engine Basics................................................................. 35 General Terminology....................................................... 35 Combustion Theory......................................................... 35 Engine Components – Cylinder Block........................................ 36 Camshaft and Timing Set................................................... 37 Cylinder Head Assembly.................................................... 37 Valve Train Assembly...................................................... 37 Air Cleaner/Filter........................................................ 37 Carburetion............................................................... 37 Electronic Fuel Injection (EFI)........................................... 37 Positive Crankcase Ventilation (PCV)...................................... 38 Engine Electrical............................................................. 38 Introduction.............................................................. 38 Battery Construction...................................................... 38 Conventional Standard Battery............................................. 39 Maintenance-Free Battery.................................................. 39 Battery Charging.......................................................... 39 Battery Fast Charging..................................................... 40 Battery Slow Charging..................................................... 40 Starting System Principles of Operation................................... 40 Starting System Components - Ignition Switch.............................. 41 Starting System Components - Starter Solenoid............................. 41 Starting System Components - Flywheel and Ring Gear....................... 41 Starting System Components - Starter Motor and Drive...................... 41 Charging System - General................................................. 42 Charging System - Regulator............................................... 42 Charging System - Theory.................................................. 42 Engine Fuel System/Exhaust and Emissions...................................... 43 Introduction.............................................................. 43 Gasoline System Components - Fuel Tank.................................... 43 Electronic Fuel Injector (EFI) - General Description...................... 43 Port Fuel System Components - ECU......................................... 43 Port Fuel System Components - Fuel Pump/Filter............................ 43 Port Fuel System Components - Fuel Rail................................... 43 Port Fuel System Components - Pressure Regulator.......................... 44 Port Fuel System Components - Fuel Injectors.............................. 44 LPG Systems General Information........................................... 44 LPG Fuel Properties....................................................... 44 LPG Fuel Tank............................................................. 44 AISAN Closed-Loop System.................................................. 45 Filter/Lockoff and Regulator.......................................... 45 Carburetor............................................................ 45 Start Mode............................................................ 45 Idle Mode............................................................. 46 Run Mode.............................................................. 46 Main Fuel Lockoff Solenoid................................................ 46 Injector Fuel Lockoff Solenoid............................................ 46 Oxygen (O 2 ) Sensor.................................................. 46 Electronic Control Unit (ECU)............................................. 46 Catalytic Converter/Muffler............................................... 46 Engine Management............................................................. 47 Introduction.............................................................. 47 Ignition and Timing - Conventional Spark.................................. 47 Components - Ignition Coil................................................ 47 Components - Distributor.................................................. 47 Spark Timing.............................................................. 47 Components - Ignition Wires............................................... 47 Components - Spark Plugs.................................................. 48 Faulty or Fouled Spark Plugs.............................................. 48 Electric Controlled Governing System - Mazda LPG.......................... 48 Engine Identification......................................................... 48 Cummins (Diesel) Engine....................................................... 51 Description............................................................... 51 Diesel Fuel System........................................................ 52 Principle of Operation................................................ 52 Fuel Injection Pump and Governor.......................................... 53 Description........................................................... 53 Principles of Operation............................................... 54 Cummins Engine Control.................................................... 55 Engine Speed (RPM) Sensor............................................. 56 Throttle Position Sensor.............................................. 57 Electronic Throttle Actuator.......................................... 58 Engine Oil Pressure Sensor............................................ 58 Coolant Temperature Sensor............................................ 58 Air Restriction Switch................................................ 59 Fuel Filter/Water Separator........................................... 59 Fuel Level Sensor (In Tank)........................................... 59 Engine Electrical System.................................................. 60 Magnetic Valve (Engine Stop Solenoid)................................. 60 Alternator............................................................ 60 Grid Heater........................................................... 60 Cold Start Timing Advance (Fuel Injection Pump)....................... 60 Mazda Engine Overview......................................................... 61 Description............................................................... 61 Fuel System............................................................... 61 Engine Controls Unit (ECU) and Emissions.................................. 61 Cooling System............................................................ 61 Ignition System........................................................... 61 Mazda (LPG) Engine Controls................................................... 62 LPG System (Aisan/E-Controls-Mechanical).................................. 62 Description........................................................... 62 Principles of Operation............................................... 63 Control System........................................................ 66 Oxygen (O 2 ) Sensor.................................................. 67 Fuel Tank............................................................. 67 Regulator............................................................. 68 Start Mode........................................................ 68 Idle Mode......................................................... 68 Run Mode.......................................................... 69 Resonator............................................................. 70 Carburetor............................................................ 70 Start Mode........................................................ 70 Idle Mode......................................................... 71 Run Mode.......................................................... 71 Governor.............................................................. 71 LPG System (E-Controls)................................................... 72 Description........................................................... 72 Principles of Operation............................................... 73 Manifold Absolute Pressure Sensor..................................... 73 Throttle Position Sensor.............................................. 73 Oxygen (O 2 ) Sensor.................................................. 74 Engine Coolant Temperature Sensor..................................... 74 Intake Air Temperature Sensor......................................... 74 Engine Control Unit................................................... 74 Accelerator Pedal Position Sensor..................................... 74 Three-Way Catalytic Converter......................................... 74 Camshaft Position Sensor.............................................. 74 Electric Controlled Governing System.................................. 76 Electronic Governor Sensor............................................ 76 Mazda (Gasoline) Engine Controls.............................................. 77 Gasoline System........................................................... 77 Description........................................................... 77 Principles of Operation............................................... 78 Control System............................................................ 80 Camshaft Position Sensor.............................................. 81 Intake Air Temperature Sensor......................................... 82 Mass Air Flow Sensor.................................................. 83 Throttle Position Sensor.............................................. 84 Electronic Governor Sensor............................................ 85 Electronic Governing System........................................... 86 Manifold Absolute Pressure Sensor/Boost Sensor........................ 86 Engine Coolant Temperature Sensor..................................... 87 Intake Air System......................................................... 88 Throttle Body......................................................... 88 Idle Air Control Valve................................................ 89 Fuel System............................................................... 90 Fuel Injector......................................................... 90 Pressure Regulator.................................................... 91 Exhaust System............................................................ 92 Heated Oxygen (O 2 ) Sensor........................................... 92 Three-Way Catalytic Converter......................................... 93 GM (LPG) Engine Controls...................................................... 94 Engine Control System .................................................... 94 Engine Control System Overview........................................ 95 Principles of Operation............................................... 95 Control System............................................................ 96 GM/TGFI 2.4L (Four Cylinder) Control System Component Location........ 96 GM/TGFI 4.3L (Six Cylinder) Control System Component Location......... 97 GM/TGFI 2.4L (Four-Cylinder) LPG System............................... 98 GM/TGFI 4.3L (Six-Cylinder) LPG System................................ 100 Fuel Tank............................................................. 102 Engine Control Unit................................................... 102 Electronic Throttle Body/Throttle Position Sensor..................... 103 Manifold Absolute Pressure/Manifold Air Temperature Sensor............ 103 Propane Injectors..................................................... 104 Engine Coolant Temperature Sensor..................................... 106 Oxygen (O 2 ) Sensor.................................................. 106 Crankshaft Position Sensor (Engine Speed Sensor)...................... 107 Oil Pressure Sensor................................................... 107 Power Latch Relay..................................................... 107 GM 2.4L Camshaft Position Sensor...................................... 107 GM 4.3L Camshaft Position Sensor...................................... 108 Injector Driver Module................................................ 109 Vaporizer/Regulator................................................... 109 Accelerator Pedal Position Sensor..................................... 112 Three-Way Catalytic Converter......................................... 112 Ignition System........................................................... 113 Ignition Coils........................................................ 113 Distributorless Ignition System Module................................ 113 Electronic Ignition Signals........................................... 114 Distributor Ignition (DI) System...................................... 115 Camshaft Position (CMP) Sensor........................................ 115 Ignition Coil and Ignition Control Module (ICM)....................... 115 Secondary Ignition Components......................................... 115 GM (Gasoline) Engine Controls................................................. 116 Engine Control System..................................................... 116 GM 2.4L (Four Cylinder) Engine Control System......................... 116 GM 4.3L (Six Cylinder) Engine Control System.......................... 117 Engine Control System Overview........................................ 118 Principles of Operation............................................... 118 Control System............................................................ 118 GM/TGFI 2.4L (Four Cylinder) Control System Component Location........ 118 GM/TGFI 4.3L (Six Cylinder) Control System Component Location......... 120 GM/TGFI 2.4L (Four-Cylinder) Gasoline System Components............... 121 GM/TGFI 4.3L (Six Cylinder) Gasoline System Components................ 123 Engine Control Unit................................................... 125 Electronic Throttle Body/Throttle Position Sensor..................... 125 Manifold Absolute Pressure/Manifold Air Temperature Sensor ........... 126 Fuel Injector......................................................... 127 Engine Coolant Temperature Sensor..................................... 128 Oxygen (O 2 ) Sensor.................................................. 129 Crankshaft Position Sensor (Engine Speed Sensor)...................... 129 Oil Pressure Sensor................................................... 129 Power Latch Relay..................................................... 129 Camshaft Position Sensor.............................................. 129 Accelerator Pedal Position Sensor..................................... 131 Three-Way Catalytic Converter......................................... 131 Ignition System........................................................... 131 Ignition Coils........................................................ 131 Distributorless Ignition System Module................................ 131 Electronic Ignition Signals........................................... 132 Yanmar (Diesel) Engine........................................................ 133 Description............................................................... 133 Diesel Fuel System........................................................ 134 Principles of Operation............................................... 134 Fuel Injection Pump and Governor.......................................... 135 Description........................................................... 135 Principles of Operation............................................... 137 Timer................................................................. 138 Feed Pump (Vane Type)................................................. 138 Regulating Valve...................................................... 139 Injection Pump Plunger................................................ 140 Suction Process................................................... 141 Injection Process................................................. 141 End of Injection.................................................. 142 Uniform Pressure Process.......................................... 142 Reverse Rotation Prevention Mechanism................................. 143 Fuel Injection Volume Adjustment Mechanism............................ 143 Delivery Valve Assembly............................................... 144 Delivery Valve Holder with Damping Valve.............................. 144 All - Speed Governor.................................................. 145 At Start of Engine.................................................... 147 During Idle........................................................... 148 At Full - Load Maximum Speed Control.................................. 149 At No-Load Maximum Speed Control...................................... 150 Full-Load Position Adjustment Mechanism............................... 151 Structure and Operation of Timer.......................................... 152 Standard Type Automatic Timer......................................... 152 Yanmar Engine Controls.................................................... 153 Engine Speed (RPM) Sensor............................................. 154 Throttle Position Sensor.............................................. 154 Electronic Throttle Actuator.......................................... 155 Engine Oil Pressure Sensor............................................ 155 Coolant Temperature Sensor............................................ 156 Air Filter Restriction Switch......................................... 157 Fuel Filter/Water Separator and Strainer.............................. 157 Fuel Level Sensor..................................................... 157 Engine Electrical System.................................................. 158 Magnetic Valve (Engine Stop Solenoid)................................. 158 Alternator............................................................ 158 Glow Plugs............................................................ 158 Cold Start Timing Advance (Fuel Injection Pump)....................... 158 Cooling System - All Engines.................................................. 159 Description............................................................... 159 Radiator.................................................................. 159 Combination Cooler/Standard Radiator.................................. 160 Radiator Cap.............................................................. 160 Thermostat................................................................ 160 Engine Coolant Pump....................................................... 161 Fan....................................................................... 161 GM Engine Coolant Flow Diagram............................................ 161 Yanmar Diesel Engine Coolant Flow Diagram................................. 162 Engine Does Not Crank......................................................... 163 Engine Does Not Start/Engine is Hard to Start................................. 166 Engine Idle Speed Incorrect................................................... 172 Engine Idle Speed is Unstable or Engine Stalls at Idle........................ 175 Engine Cuts Out, Misses, Hesitates, Sags, or Stumbles......................... 180 Engine Lack of Power.......................................................... 186 Engine Speed Surge Or Engine Speed Unstable................................... 193 Engine Backfires.............................................................. 197 Engine Is Knocking or Pinging................................................. 200 Excessive Engine Vibrations................................................... 204 Abnormal Engine and Exhaust Noises............................................ 208 Fan or Alternator Bearing Noise............................................... 212 Abnormal Engine and Exhaust Smells............................................ 214 High Engine Fuel Consumption.................................................. 216 Fuel Leaks.................................................................... 219 High Engine Oil Consumption................................................... 222 Engine Oil Leaks.............................................................. 224 Engine Oil is Discolored...................................................... 228 Engine Coolant Leaks.......................................................... 230 Engine Coolant is Discolored.................................................. 233 Engine Exhaust is Discolored.................................................. 234 Engine Fails Emission Compliance Check........................................ 238 Alternator Light is Illuminated............................................... 242 Engine is Overheating......................................................... 243 Engine Coolant Temperature is Low............................................. 246 Engine Oil Pressure is Low.................................................... 247 Radiator Bubble Test.......................................................... 249 Engine Compression Test (GM and Mazda)........................................ 250 Engine Compression Test (Yanmar Diesel)....................................... 251 Engine Oil Pressure Test...................................................... 252 Fuel System Pressure Test (Gasoline Engines Only)............................. 254 Fuel Injection Nozzle Test (Yanmar Diesel).................................... 256 Vacuum Leak................................................................... 257 Vacuum Leak Detection..................................................... 257 Vacuum Leak Repairs....................................................... 257 Coolant System Test........................................................... 258 Electrical System................................................................. 259 Troubleshooting Guidelines and Procedures..................................... 273 Troubleshooting Guidelines................................................ 273 Troubleshooting Procedures................................................ 276 Troubleshooting Procedures, Identification............................ 276 Troubleshooting Procedures, Location.................................. 276 Troubleshooting Procedures, Structure................................. 277 Troubleshooting Procedures, Performance............................... 278 Diagnostic Trouble Codes...................................................... 278 Diagnostic Trouble Codes.................................................. 278 Wiring Reference Data......................................................... 288 Harness Assembly Data......................................................... 291 Electrical System............................................................. 337 General Description....................................................... 337 Description............................................................... 338 Principles of Operation, Components....................................... 342 Principles Of Operation, System........................................... 350 100-2......................................................................... 357 100-3......................................................................... 357 523859-3...................................................................... 357 524223-3...................................................................... 357 524224-3...................................................................... 357 524225-3...................................................................... 357 524282-3...................................................................... 357 523958-3...................................................................... 357 523959-3...................................................................... 357 100-4......................................................................... 365 523859-4...................................................................... 365 523958-4...................................................................... 365 523959-4...................................................................... 365 524223-4...................................................................... 365 524224-4...................................................................... 365 524225-4...................................................................... 365 524282-4...................................................................... 365 524223-0...................................................................... 373 524224-0...................................................................... 373 524225-0...................................................................... 373 524229-0...................................................................... 373 524270-0...................................................................... 373 524276-0...................................................................... 373 524223-1...................................................................... 377 524224-1...................................................................... 377 524225-1...................................................................... 377 524229-1...................................................................... 377 524270-1...................................................................... 377 524276-1...................................................................... 377 110-3......................................................................... 381 110-5......................................................................... 381 177-3......................................................................... 381 522231-3...................................................................... 381 522555-3...................................................................... 381 522603-3...................................................................... 381 524235-3...................................................................... 381 110-4......................................................................... 389 177-4......................................................................... 389 522231-4...................................................................... 389 522555-4...................................................................... 389 522603-4...................................................................... 389 524235-4...................................................................... 389 110-2......................................................................... 397 110-10........................................................................ 400 522712-3...................................................................... 404 522713-3...................................................................... 404 522712-4...................................................................... 411 522713-4...................................................................... 411 51-2.......................................................................... 418 51-7.......................................................................... 418 91-2.......................................................................... 425 522708-3...................................................................... 430 522710-3...................................................................... 430 522711-3...................................................................... 430 522714-3...................................................................... 430 522708-4...................................................................... 437 522710-4...................................................................... 437 522711-4...................................................................... 437 522714-4...................................................................... 437 515-0......................................................................... 443 523780-3...................................................................... 445 523860-3...................................................................... 445 524245-3...................................................................... 445 524275-3...................................................................... 445 523780-4...................................................................... 451 523860-4...................................................................... 451 524245-4...................................................................... 451 524275-4...................................................................... 451 677-3......................................................................... 456 2350-3........................................................................ 456 522754-3...................................................................... 456 522755-3...................................................................... 456 522764-3...................................................................... 456 522766-3...................................................................... 456 524230-3...................................................................... 456 SYMPTOMS WARNING.............................................................. 456 677-4......................................................................... 462 2350-4........................................................................ 462 522754-4...................................................................... 462 522755-4...................................................................... 462 522764-4...................................................................... 462 522766-4...................................................................... 462 524230-4...................................................................... 462 676-3......................................................................... 466 524195-3...................................................................... 466 524269-3...................................................................... 466 676-4......................................................................... 472 524195-4...................................................................... 472 524269-4...................................................................... 472 524269-7...................................................................... 478 524215-3...................................................................... 480 524215-6...................................................................... 480 524237-3...................................................................... 484 524238-3...................................................................... 484 524240-3...................................................................... 484 524237-4...................................................................... 489 524238-4...................................................................... 489 524240-4...................................................................... 489 879-3......................................................................... 494 880-3......................................................................... 494 881-3......................................................................... 494 882-3......................................................................... 494 522772-3...................................................................... 494 879-4......................................................................... 498 880-4......................................................................... 498 881-4......................................................................... 498 882-4......................................................................... 498 522772-4...................................................................... 498 168-0......................................................................... 502 168-3......................................................................... 502 521982-3...................................................................... 505 522760-3...................................................................... 505 522761-3...................................................................... 505 522762-3...................................................................... 505 522128-3...................................................................... 514 524251-0...................................................................... 514 524260-0...................................................................... 514 524260-3...................................................................... 514 524261-0...................................................................... 514 524261-3...................................................................... 514 168-1......................................................................... 523 168-4......................................................................... 523 521982-4...................................................................... 526 522760-4...................................................................... 526 522761-4...................................................................... 526 522761-6...................................................................... 526 522762-4...................................................................... 526 522128-4...................................................................... 533 524251-1...................................................................... 533 524260-1...................................................................... 533 524260-4...................................................................... 533 524261-1...................................................................... 533 524261-4...................................................................... 533 524260-2...................................................................... 543 524260-11..................................................................... 543 524261-2...................................................................... 543 524261-11..................................................................... 543 96-3.......................................................................... 547 96-4.......................................................................... 547 522810-4...................................................................... 551 524213-1...................................................................... 555 524213-3...................................................................... 555 524213-4...................................................................... 555 523920-3...................................................................... 558 523925-3...................................................................... 558 523930-3...................................................................... 558 523977-3...................................................................... 558 523978-3...................................................................... 558 523986-3...................................................................... 558 524284-3...................................................................... 558 524285-3...................................................................... 558 523920-4...................................................................... 564 523925-4...................................................................... 564 523930-4...................................................................... 564 523977-4...................................................................... 564 523978-4...................................................................... 564 523986-4...................................................................... 564 524284-4...................................................................... 564 524285-4...................................................................... 564 523920-6...................................................................... 569 523925-6...................................................................... 569 523930-6...................................................................... 569 523977-6...................................................................... 569 523978-6...................................................................... 569 523986-6...................................................................... 569 524284-6...................................................................... 569 524285-6...................................................................... 569 105-3......................................................................... 573 522570-3...................................................................... 573 105-4......................................................................... 578 522570-4...................................................................... 578 105-5......................................................................... 582 106-3......................................................................... 585 106-4......................................................................... 589 106-0......................................................................... 593 106-1......................................................................... 593 106-2......................................................................... 593 106-14........................................................................ 593 522739-3...................................................................... 596 522739-5...................................................................... 600 522739-6...................................................................... 604 522735-2...................................................................... 608 522735-4...................................................................... 611 522735-5...................................................................... 614 522735-6...................................................................... 617 522630-2...................................................................... 621 522631-2...................................................................... 621 522632-2...................................................................... 621 522633-2...................................................................... 621 522635-3...................................................................... 621 522636-4...................................................................... 621 522637-3...................................................................... 621 522638-4...................................................................... 621 522606-10..................................................................... 625 522737-10..................................................................... 625 651-3......................................................................... 628 652-3......................................................................... 628 653-3......................................................................... 628 654-3......................................................................... 628 655-3......................................................................... 628 656-3......................................................................... 628 522599-3...................................................................... 628 522600-3...................................................................... 628 522601-3...................................................................... 628 522602-3...................................................................... 628 522721-3...................................................................... 628 522722-3...................................................................... 628 522723-3...................................................................... 628 522724-3...................................................................... 628 522725-3...................................................................... 628 522726-3...................................................................... 628 522599-3...................................................................... 628 522600-3...................................................................... 628 522601-3...................................................................... 628 522602-3...................................................................... 628 651-5......................................................................... 635 652-5......................................................................... 635 653-5......................................................................... 635 654-5......................................................................... 635 655-5......................................................................... 635 656-5......................................................................... 635 522721-5...................................................................... 635 522722-5...................................................................... 635 522723-5...................................................................... 635 522724-5...................................................................... 635 522725-5...................................................................... 635 522726-5...................................................................... 635 651-6......................................................................... 640 652-6......................................................................... 640 653-6......................................................................... 640 654-6......................................................................... 640 655-6......................................................................... 640 656-6......................................................................... 640 522599-4...................................................................... 640 522600-4...................................................................... 640 522601-4...................................................................... 640 522602-4...................................................................... 640 522721-6...................................................................... 640 522722-6...................................................................... 640 522723-6...................................................................... 640 522724-6...................................................................... 640 522725-6...................................................................... 640 522726-6...................................................................... 640 2000-9........................................................................ 648 2000-12....................................................................... 648 2000-12....................................................................... 648 2000-12....................................................................... 648 2000-12....................................................................... 648 2000-14....................................................................... 648 2003-12....................................................................... 648 2023-12....................................................................... 648 2039-2........................................................................ 648 2039-12....................................................................... 648 2235-12....................................................................... 648 2236-12....................................................................... 648 2238-12....................................................................... 648 521670-12..................................................................... 648 524258-2...................................................................... 648 522215-12..................................................................... 656 522215-14..................................................................... 656 524236-14..................................................................... 656 524262-12..................................................................... 656 524262-14..................................................................... 656 524263-1...................................................................... 656 524268-12..................................................................... 656 628-12........................................................................ 658 630-12........................................................................ 658 522690-2...................................................................... 658 522690-12..................................................................... 658 522691-2...................................................................... 658 522691-12..................................................................... 658 522692-2...................................................................... 658 522693-12..................................................................... 658 522694-12..................................................................... 658 522695-2...................................................................... 658 522696-2...................................................................... 658 522697-12..................................................................... 658 522698-2...................................................................... 658 522699-2...................................................................... 658 522700-2...................................................................... 658 190-2......................................................................... 660 190-7......................................................................... 660 522120-1...................................................................... 660 522585-2...................................................................... 660 522752-9...................................................................... 666 524249-2...................................................................... 669 524250-2...................................................................... 669 524264-2...................................................................... 669 524264-14..................................................................... 669 524265-2...................................................................... 669 524271-2...................................................................... 669 524225-14..................................................................... 669 628-12........................................................................ 674 630-12........................................................................ 674 2660-3........................................................................ 674 2660-4........................................................................ 674 2661-3........................................................................ 674 2661-4........................................................................ 674 2802-12....................................................................... 674 523510-12..................................................................... 674 523511-12..................................................................... 674 523515-3...................................................................... 674 523515-4...................................................................... 674 523519-3...................................................................... 674 523519-4...................................................................... 674 2802-12....................................................................... 676 628-12........................................................................ 676 630-12........................................................................ 676 523261-3...................................................................... 676 523261-4...................................................................... 676 523257-3...................................................................... 676 523257-4...................................................................... 676 523253-3...................................................................... 676 523253-4...................................................................... 676 523249-3...................................................................... 676 523249-4...................................................................... 676 522780-3...................................................................... 678 522781-3...................................................................... 678 522780-4...................................................................... 682 522781-4...................................................................... 682 522780-2...................................................................... 685 522781-2...................................................................... 685 111-1......................................................................... 688 524252-2...................................................................... 692 524253-14..................................................................... 694 524255-2...................................................................... 695 108-0......................................................................... 696 108-1......................................................................... 696 522655-0...................................................................... 699 522655-1...................................................................... 699 522660-0...................................................................... 699 522660-1...................................................................... 699 524212-2...................................................................... 703 524211-2...................................................................... 703 524210-2...................................................................... 703 524209-2...................................................................... 703 524208-2...................................................................... 703 524207-2...................................................................... 703 524206-2...................................................................... 703 524205-2...................................................................... 703 524204-2...................................................................... 703 524203-2...................................................................... 703 524202-2...................................................................... 703 524201-2...................................................................... 703 524200-2...................................................................... 703 524199-2...................................................................... 703 524198-2...................................................................... 703 524197-2...................................................................... 703 522800-13..................................................................... 705 522801-13..................................................................... 707 522130-0...................................................................... 708 522131-0...................................................................... 708 522132-0...................................................................... 708 522133-0...................................................................... 708 522134-0...................................................................... 708 522130-1...................................................................... 712 522131-1...................................................................... 712 522132-1...................................................................... 712 522133-1...................................................................... 712 522134-1...................................................................... 712 522130-3...................................................................... 717 522131-3...................................................................... 717 522132-3...................................................................... 717 522133-3...................................................................... 717 522134-3...................................................................... 717 522130-4...................................................................... 722 522131-4...................................................................... 722 522132-4...................................................................... 722 522133-4...................................................................... 722 522134-4...................................................................... 722 522135-0...................................................................... 726 522137-0...................................................................... 726 522138-0...................................................................... 726 522135-1...................................................................... 730 522137-1...................................................................... 730 522138-1...................................................................... 730 522135-3...................................................................... 734 522137-3...................................................................... 734 522138-3...................................................................... 734 522135-4...................................................................... 738 522137-4...................................................................... 738 522138-4...................................................................... 738 522135-2...................................................................... 742 522137-2...................................................................... 742 522122-0...................................................................... 749 522124-0...................................................................... 749 522125-0...................................................................... 749 522126-0...................................................................... 749 522127-0...................................................................... 749 522122-1...................................................................... 753 522124-1...................................................................... 753 522125-1...................................................................... 753 522126-1...................................................................... 753 522127-1...................................................................... 753 522122-6...................................................................... 757 522124-6...................................................................... 757 522125-6...................................................................... 757 522126-6...................................................................... 757 522127-6...................................................................... 757 522122-8...................................................................... 762 522124-8...................................................................... 762 522125-8...................................................................... 762 522126-8...................................................................... 762 522127-8...................................................................... 762 522129-3...................................................................... 766 522129-4...................................................................... 766 522197-0...................................................................... 768 522198-0...................................................................... 768 522199-0...................................................................... 768 522200-0...................................................................... 768 522201-0...................................................................... 768 522197-1...................................................................... 771 522198-1...................................................................... 771 522199-1...................................................................... 771 522200-1...................................................................... 771 522201-1...................................................................... 771 522197-6...................................................................... 772 522198-6...................................................................... 772 522199-6...................................................................... 772 522200-6...................................................................... 772 522201-6...................................................................... 772 522197-7...................................................................... 773 522198-7...................................................................... 773 522199-7...................................................................... 773 522200-7...................................................................... 773 522201-7...................................................................... 773 522197-8...................................................................... 774 522198-8...................................................................... 774 522199-8...................................................................... 774 522200-8...................................................................... 774 522201-8...................................................................... 774 522197-14..................................................................... 776 522198-14..................................................................... 776 522199-14..................................................................... 776 522200-14..................................................................... 776 522201-14..................................................................... 776 522197-27..................................................................... 777 522198-27..................................................................... 777 522199-27..................................................................... 777 522200-27..................................................................... 777 522201-27..................................................................... 777 2039-2........................................................................ 780 522540-3...................................................................... 783 522540-4...................................................................... 786 522604-3...................................................................... 790 522604-4...................................................................... 794 522604-5...................................................................... 798 522697-12..................................................................... 803 190-2......................................................................... 804 190-4......................................................................... 804 190-8......................................................................... 804 522752-2...................................................................... 804 522752-4...................................................................... 804 522752-5...................................................................... 810 522598-3...................................................................... 813 522598-4...................................................................... 816 522592-0...................................................................... 820 522592-1...................................................................... 822 522593-12..................................................................... 824 522594-12..................................................................... 828 522595-12..................................................................... 828 522596-12..................................................................... 828 522597-12..................................................................... 828 Engine Continues to Run When Engine Cover is Raised........................... 831 Engine Stops or Fails to Start................................................ 833 Electrical Functions Do Not Operate........................................... 835 Electrical Function Does Not Turn Off......................................... 840 Electro-Hydraulics Do Not Function With Armrest Down ......................... 846 Electro-Hydraulics Can Still Function With Armrest Raised..................... 849 Vehicle Does Not Power On..................................................... 852 Heater Fan Does Not Operate Properly.......................................... 858 Heater Airflow Does Not Reach Desired Temperature............................. 861 Heater Output Has Insufficient Airflow........................................ 862 Circulating (Accessory) Fan Inoperative....................................... 863 Dome Light Inoperative........................................................ 866 Horn Failure.................................................................. 869 Drive Train....................................................................... 873 Mechanical Overview........................................................... 877 Engine........................................................................ 877 Description............................................................... 877 Torque Converter.............................................................. 877 Description............................................................... 877 Stator................................................................ 878 Turbine............................................................... 878 Pump PTO...................................................................... 879 Chain Drive PTO........................................................... 879 Spur Gear PTO............................................................. 880 Transmission.................................................................. 881 Description............................................................... 881 1.0-5.5 Ton Lift Truck Transmissions...................................... 884 Description........................................................... 884 Single-Speed...................................................... 884 Two-Speed......................................................... 885 Clutch Pack........................................................... 886 Power Flow............................................................ 888 Single-Speed...................................................... 888 Two-Speed......................................................... 889 Transmission Hydraulic Schematic...................................... 891 Transmission Oil Flow................................................. 892 Control Valve Oil Flow................................................ 892 6.0-7.0 Ton Lift Truck Transmissions...................................... 893 Description........................................................... 893 Two-Speed......................................................... 893 Three-Speed....................................................... 893 Clutch Pack........................................................... 895 Input Shaft and Range Clutches.................................... 895 Directional Clutches.............................................. 895 Output Section.................................................... 896 Power Flow............................................................ 896 Two-Speed and Three-Speed......................................... 896 Transmission Hydraulic Schematic...................................... 900 Two-Speed......................................................... 900 Three-Speed....................................................... 902 Transmission Control System Overview.......................................... 904 Transmission Control System............................................... 904 Transmission Control Software................................................. 906 Transmission Control Modes................................................ 906 Neutral............................................................... 906 Gear Engagement Control............................................... 907 Basic Powershift Gear Engagement Mode............................. 907 DuraMatch™ and Electronic Extended Features Gear Engagement Mo.... 907 Normal Forward or Reverse............................................. 907 Basic Powershift.................................................. 907 DuraMatch™ and Electronic Extended Features Transmission.......... 907 Auto-Shift............................................................ 907 1st Gear Lock......................................................... 907 Inching............................................................... 907 Basic Powershift Inching Mode..................................... 907 DuraMatch™ Inching Mode........................................... 907 Electronic Extended Features Inching Mode......................... 908 Inch/Brake Overlap Adjustment......................................... 908 Brake Wear Compensation............................................... 908 Auto Decel............................................................ 908 Controlled Power Reversal............................................. 909 Basic Multi-Speed................................................. 909 Electronic Extended Features...................................... 909 Controlled Creep...................................................... 909 Basic Powershift.................................................. 909 DuraMatch™ and Electronic Extended Features....................... 909 Controlled Roll Back.................................................. 910 DuraMatch™ ....................................................... 910 Electronic Extended Features...................................... 910 Travel Speed Limit (Optional)......................................... 910 Extended Drawbar Pull ( Electronic Extended Features Multi-Speed...... 910 Auto-Speed Hydraulics ( Electronic Extended Features Transmissio...... 910 Throttle Response Management ( Electronic Extended Features Tran...... 910 Steady Travel Speed............................................... 910 Transmission Control Hardware................................................. 911 Control Valve and Sensors................................................. 911 Description........................................................... 911 Principles of Operation............................................... 913 Transmission Proportional Valve........................................... 914 Description........................................................... 914 Neutral............................................................... 914 Proportional Control.................................................. 914 MONOTROL® Pedal........................................................... 915 Description........................................................... 915 Principles of Operation............................................... 915 Directional Control Lever................................................. 915 Principles of Operation............................................... 915 Driveshaft, Differential, Drive Axle, and Brakes (Dry Brake Only.............. 916 Driveshaft................................................................ 916 Differential and Drive Axle............................................... 916 Brake System.............................................................. 918 Description........................................................... 918 Service Brakes........................................................ 918 Master Cylinder....................................................... 918 Brake Position Sensor................................................. 918 Parking Brake......................................................... 918 Driveshaft, Differential, Drive Axle, and Brakes (Wet Brake Only.............. 919 Driveshaft................................................................ 919 Differential.............................................................. 920 Brake System.............................................................. 922 Description........................................................... 922 Service Brakes, 2.0-3.5 Ton Only...................................... 922 Service Brakes, 4.0-7.0 Ton........................................... 924 Brake Adjustment and Service.......................................... 924 Parking Brake......................................................... 924 Overheating Brakes (Dry Brake Axle Only)...................................... 927 Overheating Brakes (Wet Brake Axle Only)...................................... 929 Poor Brake Performance (Dry Brake Axle Only).................................. 932 Poor Brake Performance (Wet Brake Axle Only).................................. 935 Brakes Make Too Much Noise (Dry Brake Axle Only).............................. 937 Brakes Pull To One Side (Dry Brake Axle Only)................................. 938 Parking Brake Will Not Release................................................ 941 Parking Brake Will Not Hold Lift Truck (Dry Brake Axle Only).................. 942 Parking Brake Will Not Hold Lift Truck (Wet Brake Axle Only).................. 943 Abnormal Drive Axle Noise..................................................... 944 Discolored Drive Axle Oil..................................................... 947 Lift Truck Does Not Move (Drive Axle)......................................... 949 Abnormal Transmission Noise................................................... 951 Bubbles or Foaming In Transmission Dipstick Tube.............................. 953 Inching Operation Is Not Smooth or Chatters................................... 955 Lift Truck Does Not Move In One or Both Directions (Transmission.............. 957 Loss of Power/Drivetrain Performance.......................................... 960 Transmission Is Too Hot....................................................... 963 Transmission Will Not Shift To Forward High Range............................. 966 Transmission Warmup Procedure................................................. 967 Transmission Pressure Test.................................................... 967 Transmission Charge Pump Pressure Test.................................... 969 Clutch Pack Pressure Test (Proportional Solenoid Valves).................. 969 Torque Converter Pressure Test............................................ 970 Lubrication Pressure Test................................................. 970 Transmission Clutch Drag Test (1.0-5.5 Ton Trucks Only)....................... 971 Torque Converter Stall Test................................................... 971 Hydraulic Systems................................................................. 975 Main Hydraulic System......................................................... 979 Description............................................................... 979 Principles of Operation................................................... 982 Hydraulic Schematics...................................................... 983 Manual Control Valve Schematics....................................... 983 Electro-Hydraulic Control Valve Schematics............................ 988 Manual Hydraulic Control Valve................................................ 992 Description............................................................... 992 Principles of Operation................................................... 994 Lift Section.......................................................... 994 Lift Operation.................................................... 994 Lower Operation................................................... 994 Tilt Section.......................................................... 996 Tilt Backward..................................................... 996 Tilt Forward...................................................... 996 Auxiliary Section..................................................... 998 Anti-stall Feature.................................................... 999 Relief Valves......................................................... 999 Main Relief Valve................................................. 999 Secondary Relief Valve............................................ 999 Electro-Hydraulic Control Valve...............................................1000 Description...............................................................1000 Principles of Operation...................................................1002 Inlet Pressure Compensator/Unloader...................................1002 Lift/Lower EHPVs......................................................1003 EHPV Operation....................................................1004 Tilt and Auxiliary Spool Functions....................................1006 Tilt Forward Function.................................................1008 Main Relief Valve ....................................................1009 Secondary Relief Valve................................................1009 Secondary Function Anti-stall Valve...................................1010 Emergency Lowering Valve..............................................1011 Steering System...............................................................1011 Component Locations.......................................................1011 Description...........................................................1011 Steering Axle Assembly................................................1011 Steering Control Unit.................................................1011 Steering Schematic........................................................1013 Principles of Operation...............................................1014 Steering Control Unit.................................................1014 Actuation Functions With Armrest Up (E-Valve).................................1015 Cycle Times Too Fast - Fast Actuation (E-Valve)...............................1016 Jump/Delay In Lift or Lower Activation After Moving Joystick or ..............1018 Jump/Delay In Secondary Function Actuation After Moving Joystick..............1020 Jump/Delay In Tilt Forward Actuation (E-Valve)................................1022 Forks Drop Slightly Before Lifting (E-Valve)..................................1024 Forks Lower Without Command (E-Valve).........................................1025 Forks Raise or Actuate Without Command (E-Valve)..............................1027 Forks Tilt Forward Without Command (E-Valve)..................................1029 Intermittent Activation (E-Valve) While Commanding Function...................1031 Lift/Lower Function Maximum Speed Too Slow (E-Valve)..........................1033 Lift Function Will Not Move With Joystick or MLM Movement (E-Val..............1036 Lift/Lower Continues To Move For Awhile After Joystick or MLM Is..............1039 Lift/Lower/Secondary Function Suddenly Jumps In Middle of Stroke..............1040 Lower Function Will Not Move With Joystick or MLM Movement (E-Va..............1041 Poor Metering on Lift or Lower Functions (E-Valve)............................1043 Secondary Function Continues to Move for Awhile After Joystick o..............1046 Secondary Function Exhibits Slight Movement in Opposite Directio..............1047 Secondary Function Maximum Speed Too Slow (E-Valve)...........................1048 Secondary Function or Tilt Back Moves Without Command (E-Valve)...............1051 Secondary Function and Tilt Back Will Not Move With Joystick or ..............1052 Tilt Forward Function Continues to Move for Awhile When Joystick..............1055 Tilt Forward Will Not Move Upon Joystick or MLM Movement (E-Valv..............1056 Too Much Joystick or MLM Movement (Deadband) to Start Function M..............1058 Wrong Actuation Operates or Actuation is Backward (E-Valve)...................1059 Actuation Exhibits Slight Movement in Opposite Direction Before ..............1060 Auxiliary Function is Slow or Does Not Function (Manual Valve)................1061 Cycle Times Too Fast - Fast Actuation (Manual Valve)..........................1063 Function Continues to Activate After Returning to Neutral.....................1064 Lift Function Is Slow or Does Not Function (Manual Valve).....................1065 Tilt Back Function Will Not Operate (Manual Valve)............................1067 Tilt Forward Functions When Spool is Activated Forward With Engi..............1068 Tilt Forward Will Not Function When Activated (Manual Valve)..................1069 Abnormal Steer Axle Noise.....................................................1070 Abnormal Steering Wheel Vibration.............................................1072 Back Lash/Kick Back in Steering Wheel.........................................1073 No Steering (All Other Hydraulic Functions OK)................................1075 Steering Is Slow or Difficult.................................................1077 Steering Operation Is Not Smooth..............................................1079 Steering Wheel End Lock Position Cannot Be Felt by Operator...................1081 Steering Wheel Turns By Itself or Does Not Return To Neutral..................1082 Steering Wheel Turns the Tires in the Wrong Direction.........................1083 Abnormal Hydraulic Noise and/or Vibration.....................................1084 Abnormal Smell/Discoloration/Foaming of Oil...................................1087 Actuations Do Not Act Simultaneously..........................................1088 Oil Leaking/Component Life Too Short..........................................1089 Hydraulic Warmup Procedure....................................................1093 Main Relief Valve Test and Adjustment.........................................1093 Secondary Relief Valve Test and Adjustment....................................1095 Hydraulic Pump Flow Test......................................................1097 Main Control Valve LS Leakage Test (E-Valve)..................................1100 Main Control Valve Unloader Margin Test.......................................1100 Electro-Hydraulic Poppet Valve (EHPV) Leakage Test............................1102 PPRV Pilot Pressure Test......................................................1105 Steering Relief Pressure Test and Adjustment..................................1107 Steering Control Unit LS Pressure Test........................................1108 Lift Cylinder Leakage Test....................................................1110 Tilt Cylinder Leakage Test....................................................1111 Steering Cylinder Leakage Test................................................1112 Operators Station.................................................................1115 Operator Station General Description and Principles of Operation..............1117 General Description and Location..........................................1117 Display Switch Cluster (DSC)..................................................1120 Detailed Description......................................................1120 Control Inputs, Right Side................................................1121 Right Indicator and Warning Group.........................................1122 LCD Display...............................................................1122 Left Indicator and Warning Group..........................................1124 Control Inputs, Left Side (Cab Option Only)...............................1125 Transmission Control and Braking..............................................1126 Description...............................................................1126 Vehicle System Manager (VSM)..........................................1126 Display Switch Cluster................................................1127 Interlock and Switching Features..................................1127 MONOTROL® Directional Control.........................................1127 Inch Brake/Service Brake Pedal........................................1127 Parking Brake.........................................................1127 Programming - Menus...........................................................1128 Menus.....................................................................1128 Main Menu.............................................................1131 Save and Exit or Exit Without Saving..................................1131 Back One Level........................................................1131 Hourmeters............................................................1131 View Versions.........................................................1132 Passwords.............................................................1132 Diagnostics...........................................................1132 Setup Travel and Braking..............................................1132 Setup Hydraulics......................................................1132 Setup Display.........................................................1132 Setup General Items...................................................1132 Calibrations..........................................................1132 Manual Hydraulic Control Levers...............................................1133 General Description.......................................................1133 System Components.........................................................1133 Lift/Lower............................................................1133 Tilt..................................................................1133 Auxiliary 1...........................................................1133 Auxiliary 2...........................................................1133 E-Hydraulic System Interface..................................................1134 General Description.......................................................1134 System Components.........................................................1134 E-Hydraulic Control Input Device..........................................1134 Joystick..............................................................1134 Lift/Lower........................................................1135 Tilt..............................................................1135 Auxiliary 1.......................................................1135 Auxiliary 2.......................................................1135 Push Button.......................................................1135 Mini Lever Module (MLM)...............................................1136 Lever 1...........................................................1136 Lever 2...........................................................1136 Lever 3...........................................................1137 Lever 4...........................................................1137 System Modes..............................................................1137 Hydraulic Interlock Mode..............................................1137 Fault Mode............................................................1137 Engine Off Mode.......................................................1137 Normal Operation..........................................................1137 Normal Operation Mode.................................................1137 Lifting Control.......................................................1137 Lowering Control......................................................1138 Tilt Control (Forward and Backward)...................................1138 Auxiliary Control.....................................................1138 Lighting Control..............................................................1138 Description...............................................................1138 Front Work Lights.....................................................1141 Front Marker Lights (if equipped).....................................1141 Front/Rear Turn Signal Lights.........................................1141 Rear Tail/Marker Lights...............................................1141 Rear Work Light.......................................................1141 Rear Backup Lights....................................................1141 Rear Stop Lights......................................................1141 Strobe Light(s).......................................................1141 Spot Light (if equipped)..............................................1141 Cab...........................................................................1141 Description...............................................................1141 Component Descriptions....................................................1143 Cab Heating System....................................................1143 Lighting Control System...............................................1143 Wiper/Washer System...................................................1143 Cab Systems Operation.....................................................1144 Front End (Mast) and Chassis......................................................1147 Front End, Mast...............................................................1149 Description...............................................................1149 Carriages.....................................................................1149 Description...............................................................1149 Principles of Operation...................................................1150 Integral Sideshift Carriage...........................................1150 Mast Mounts...................................................................1151 Description...............................................................1151 Principles of Operation...................................................1152 Two-Stage Limited Free-Lift (LFL) Mast........................................1152 Description...............................................................1152 Principles of Operation...................................................1153 Two-Stage Full Free-Lift (FFL) Mast...........................................1154 Description...............................................................1154 Principles of Operation...................................................1155 Three-Stage Full Free-Lift (FFL) Mast.........................................1156 Description...............................................................1156 Principles of Operation...................................................1157 Four-Stage Full Free-Lift (FFL) Mast..........................................1158 Description...............................................................1158 Principles of Operation...................................................1160 Cylinder Cushion During Lifting Sequence......................................1162 Description...............................................................1162 Principles of Operation...................................................1162 Cylinder Cushion During Lowering Sequence.....................................1162 Description...............................................................1162 Principles of Operation...................................................1162 Tilt and Sideshift Cylinders..................................................1163 Description...............................................................1163 Tilt Cylinder.........................................................1163 Sideshift Cylinder....................................................1163 Lowering Control Valves.......................................................1164 Description...............................................................1164 Principles of Operation...................................................1164 Chassis.......................................................................1166 Description...............................................................1166 Abnormal Channel Wear.........................................................1167 Abnormal Hose Wear............................................................1169 Abnormal Mast Noise...........................................................1171 Body Panels Making Noise......................................................1175 External Leakage From Free-Lift or Main Lift Cylinders........................1176 FFL Mast Banging During Phasing...............................................1177 High Tire Wear - Drive Axle...................................................1179 High Tire Wear - Steer Axle...................................................1181 Hoses Not Tracking Correctly..................................................1183 Integral Sideshift Moving Too Fast............................................1184 Integral Sideshift Not Moving or Slow.........................................1185 LP Tank Bracket Disengages....................................................1188 LP Tank Rattles and Does Not Stay Latched.....................................1189 Mast is Loose.................................................................1190 Mast Lift Chains Are Loose....................................................1192 Mast or Carriage Binding......................................................1193 Mast/Carriage Bounces or is Spongy............................................1195 Misphasing of Full Free-Lift Mast.............................................1196 Overhead Guard Loose or Damaged...............................................1198 Racking During Lift...........................................................1199 Racking During Tilt...........................................................1201 Truck Feels Unstable..........................................................1202 Truck Wanders, Does Not Track Straight or Steer Well..........................1204 Wheels Appear Tipped or Misaligned............................................1206 Wheels Spinning On Uneven Floors..............................................1208 Wheel Studs Breaking..........................................................1209 Supplementary Data................................................................1211 Abbreviations and Acronyms....................................................1213 Special Tools List............................................................1221 Fault Mode Indicator (FMI) Reference List.....................................1227 TSP Reference Tables..........................................................1229 tables................................................................................ 1 Table 9020-10-1. IAT Ambient Temperature.......................................... 82 Table 9020-40-1. Test Specifications.............................................. 249 Table 9020-40-2. Test Specifications.............................................. 250 Table 9020-40-3. Service Tools.................................................... 250 Table 9020-40-4. Test Specifications.............................................. 251 Table 9020-40-5. Service Tools.................................................... 251 Table 9020-40-6. Test Specifications.............................................. 252 Table 9020-40-7. Service Tools.................................................... 253 Table 9020-40-8. Test Specifications - Mazda...................................... 254 Table 9020-40-9. Test Specifications - GM......................................... 254 Table 9020-40-10. Service Tools................................................... 254 Table 9020-40-11. Test Specifications............................................. 256 Table 9020-40-12. Service Tools................................................... 256 Table 9020-40-13. Test Specifications............................................. 258 Table 9020-40-14. Service Tools................................................... 258 Table 9030-03-1. Circuit Group Identification..................................... 288 Table 9030-03-2. Hyster Wiring Color Codes........................................ 289 Table 9040-10-1. Two-Speed Transmission Clutch Pack Solenoid Val.................. 901 Table 9040-10-2. Three-Speed Transmission Electronic Proportiona.................. 903 Table 9040-10-3. Transmission Control Mode........................................ 905 Table 9040-40-1. Test Specifications.............................................. 967 Table 9040-40-2. Service Tools.................................................... 967 Table 9040-40-3. Service Tools.................................................... 967 Table 9040-40-4. Test Specifications.............................................. 969 Table 9040-40-5. Test Specifications.............................................. 969 Table 9040-40-6. Test Specifications.............................................. 970 Table 9040-40-7. Test Specifications.............................................. 970 Table 9040-40-8. Test Specifications.............................................. 971 Table 9040-40-9. Service Tools.................................................... 971 Table 9040-40-10. Stall Speeds.................................................... 972 Table 9050-10-1. Standby Pressure Table...........................................1002 Table 9050-40-1. Test Specifications..............................................1093 Table 9050-40-2. Service Tools....................................................1093 Table 9050-40-3. Test Specifications..............................................1093 Table 9050-40-4. Service Tools....................................................1094 Table 9050-40-5. Test Specifications..............................................1095 Table 9050-40-6. Service Tools....................................................1096 Table 9050-40-7. Test Specifications..............................................1097 Table 9050-40-8. Service Tools....................................................1098 Table 9050-40-9. Test Specifications..............................................1100 Table 9050-40-10. Test Specifications.............................................1100 Table 9050-40-11. Service Tools...................................................1100 Table 9050-40-12. Test Specifications.............................................1102 Table 9050-40-13. Service Tools...................................................1102 Table 9050-40-14. Test Specifications.............................................1105 Table 9050-40-15. Service Tools...................................................1105 Table 9050-40-16. Test Specifications.............................................1107 Table 9050-40-17. Service Tools...................................................1107 Table 9050-40-18. Test Specifications.............................................1108 Table 9050-40-19. Service Tools...................................................1108 Table 9050-40-20. Test Specifications.............................................1110 Table 9050-40-21. Service Tools...................................................1110 Table 9050-40-22. Test Specifications.............................................1111 Table 9050-40-23. Service Tools...................................................1111 Table 9050-40-24. Test Specifications.............................................1112 Table 9050-40-25. Service Tools...................................................1112 Table 9080-50-1. Abbreviations and Acronyms.......................................1213 Table 9080-60-1. Special Tools....................................................1221 Table 9080-70-1. FMI..............................................................1227 Table 9080-80-1. Resistor-Temperature Characteristics ............................1229
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