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Hyster F001 (H1.6-1.8FT, H2.0FTS Europe) Service Manual – PDF DOWNLOAD
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Description
Hyster F001 (H1.6-1.8FT, H2.0FTS Europe) Service Manual – PDF DOWNLOAD
FILE DETAILS:
Hyster F001 (H1.6-1.8FT, H2.0FTS Europe) Service Manual – PDF DOWNLOAD
Language : English
Pages : 2689
Downloadable : Yes
File Type : PDF
Size: 97.9 MB
TABLE OF CONTENTS:
Hyster F001 (H1.6-1.8FT, H2.0FTS Europe) Service Manual – PDF DOWNLOAD
9000SRM1112_DTC 110-6 chg DTC 110-16...................................................... 1 9000SRM1112_Operational Checkout.......................................................... 2 toc................................................................................... 2 Operational Diagnostic Procedures................................................. 2 Operational Checkout Procedures............................................... 2 DTC Check................................................................. 3 Horn Circuit Check........................................................ 3 Light Circuit Check....................................................... 3 Windshield Washer Wiper Check (If equipped)............................... 3 Heater Check (If equipped)................................................ 4 Dome Light Check (If equipped)............................................ 4 Circulating (Accessory) Fan Check (If equipped)........................... 5 Indicator Light Power Check............................................... 6 Engine Malfunction Indicator Check........................................ 7 Cold Start Check (Cummins and Yanmar)..................................... 7 Brake Pedal Check......................................................... 7 Backup Alarm Check (If equipped).......................................... 8 Operator Presence System Check............................................ 8 Hydraulic Interlock Check................................................. 8 Armrest Hydraulic Interlock Check (If equipped and with original.......... 8 Engine Cover Latch Sensor Check (If equipped)............................. 9 Brake and Inching Pedal Check............................................. 9 Park Brake Sensor Check................................................... 9 Park Brake Check.......................................................... 10 Engine Speed Check (All Cummins, Yanmar, and Mazda Engines Excep.......... 10 Engine Power Check........................................................ 11 Transmission Clutch Check................................................. 11 Transmission Check........................................................ 12 Transmission Speed Selection Check (If equipped).......................... 12 Brake and Axle Drag Check................................................. 12 Hydraulic Pump Flow Check................................................. 13 Priority Flow Divider Valve Check......................................... 14 Steering Relief Valve Low Pressure Check.................................. 14 Steering Relief Valve High Pressure Check................................. 15 Control Valve Load Check Valve (Manual Valve)............................. 15 Lift E-Valve Check............................................................ 15 Lift Check (E-Valve)...................................................... 15 Tilt Function Counterbalance Check........................................ 16 Lift Drift Check.......................................................... 16 Tilt Function Drift Check................................................. 17 Mast Cushion Check (All Except 2-Stage Mast).............................. 17 Lift/Tilt Mast Adjustment Check........................................... 17 Tilt Racking Check........................................................ 18 Chain and Header Hose Adjustment Check.................................... 18 Mast Mounting Check....................................................... 19 Mast Channel Check........................................................ 19 Carriage Adjustment Check................................................. 20 Chain Sheave Check........................................................ 20 Carriage Adjustment Check (Standard and Integral Side Shift).............. 20 9000SRM1112_Speed Sensor Direction or Direction Check Logical Failure..................... 21 toc................................................................................... 21 522155-2.......................................................................... 21 522157-2.......................................................................... 21 9000SRM1112_TOSS_TISS Sensor 1 & 2 No Output.............................................. 28 9000SRM1112_TSP MLM Data Error.pdf........................................................ 29 toc................................................................................... 29 Electrical System................................................................. 29 2802-12....................................................................... 29 628-12........................................................................ 29 523261-3...................................................................... 29 523261-4...................................................................... 29 523257-3...................................................................... 29 523257-4...................................................................... 29 523253-3...................................................................... 29 523253-4...................................................................... 29 523249-3...................................................................... 29 523249-4...................................................................... 29 630-12........................................................................ 29 9000SRM1112_UPDATE CUMMINS QSB 3.3L FAULT CODES DTC 627-12............................... 31 910442-8000SRM0231-(12-2004)-UK-EN........................................................ 32 toc................................................................................... 32 Metric and Inch (SAE) Fasteners................................................... 32 Safety Precautions Maintenance and Repair......................................... 33 General........................................................................... 36 Threaded Fasteners............................................................ 36 Nomenclature, Threads......................................................... 36 Strength Identification....................................................... 37 Cotter (Split) Pins........................................................... 37 Fastener Torque Tables........................................................ 42 Conversion Table.............................................................. 44 tables................................................................................ 32 Table 1. Bolts and Screws......................................................... 38 Table 2. Studs and Nuts........................................................... 39 Table 3. Torque Nuts.............................................................. 40 Table 4. Torque Nuts With Nylon Insert............................................ 41 Table 5. Torque Values for Metric Fasteners*...................................... 42 Table 6. Torque Values for Inch Fasteners*........................................ 43 Table 7. Conversion Table for Metric and English Units............................ 44 Table 8. Cotter Pin Dimensional Data.............................................. 45 Table 9. Cotter Pin Dimensional Data.............................................. 46 Table 10. Cotter Pin Dimensional Data............................................. 47 Table 11. Cotter Pin Dimensional Data............................................. 49 1579259-9000SRM1112-(07-2008)-UK-EN....................................................... 54 toc................................................................................... 54 Diagnostic Troubleshooting Manual................................................. 54 Safety Precautions TROUBLESHOOTING PROCEDURES..................................... 55 How To Use This Troubleshooting Manual............................................ 57 General Instructions and Safety Information................................... 57 How to Use Diagnostic Troubleshooting Manual.................................. 57 General Instructions.......................................................... 58 Operational Diagnostic Procedures................................................. 60 Operational Checkout Procedures............................................... 62 DTC Check................................................................. 63 Horn Circuit Check........................................................ 63 Light Circuit Check....................................................... 63 Windshield Washer Wiper Check (If equipped)............................... 63 Heater Check (If equipped)................................................ 64 Dome Light Check (If equipped)............................................ 64 Circulating (Accessory) Fan Check (If equipped)........................... 65 Indicator Light Power Check............................................... 66 Operator Presence System Check............................................ 67 Engine Malfunction Indicator Check........................................ 67 Cold Start Check (Cummins and Yanmar)..................................... 67 Brake Pedal Check......................................................... 68 Backup Alarm Check (If equipped).......................................... 68 Armrest Hydraulic Interlock Check (If equipped and with original.......... 68 Engine Cover Latch Sensor Check (If equipped)............................. 69 Brake and Inching Pedal Check............................................. 69 Park Brake Sensor Check................................................... 69 Park Brake Check.......................................................... 70 Engine Speed Check (All Cummins, Yanmar, and Mazda Engines Excep.......... 70 Engine Power Check........................................................ 71 Transmission Clutch Check................................................. 71 Transmission Check........................................................ 72 Transmission Speed Selection Check (If equipped).......................... 72 Brake and Axle Drag Check................................................. 72 Hydraulic Pump Flow Check................................................. 73 Priority Flow Divider Valve Check......................................... 74 Steering Relief Valve Low Pressure Check.................................. 74 Steering Relief Valve High Pressure Check................................. 75 Control Valve Load Check Valve (Manual Valve)............................. 75 Lift E-Valve Check............................................................ 75 Lift Check (E-Valve)...................................................... 75 Tilt Function Counterbalance Check........................................ 76 Lift Drift Check.......................................................... 76 Tilt Function Drift Check................................................. 77 Mast Cushion Check (All Except 2-Stage Mast).............................. 77 Lift/Tilt Mast Adjustment Check........................................... 77 Tilt Racking Check........................................................ 78 Chain and Header Hose Adjustment Check.................................... 78 Mast Mounting Check....................................................... 79 Mast Channel Check........................................................ 79 Carriage Adjustment Check................................................. 80 Chain Sheave Check........................................................ 80 Carriage Adjustment Check (Standard and Integral Side Shift).............. 80 Engine............................................................................ 82 Engine Basics................................................................. 88 General Terminology....................................................... 88 Combustion Theory......................................................... 88 Engine Components – Cylinder Block........................................ 89 Camshaft and Timing Set................................................... 90 Cylinder Head Assembly.................................................... 90 Valve Train Assembly...................................................... 90 Air Cleaner/Filter........................................................ 90 Carburetion............................................................... 90 Electronic Fuel Injection (EFI)........................................... 90 Positive Crankcase Ventilation (PCV)...................................... 91 Engine Electrical............................................................. 91 Introduction.............................................................. 91 Battery Construction...................................................... 91 Conventional Standard Battery............................................. 92 Maintenance-Free Battery.................................................. 92 Battery Charging.......................................................... 92 Battery Fast Charging..................................................... 93 Battery Slow Charging..................................................... 93 Starting System Principles of Operation................................... 93 Starting System Components - Ignition Switch.............................. 94 Starting System Components - Starter Solenoid............................. 94 Starting System Components - Flywheel and Ring Gear....................... 94 Starting System Components - Starter Motor and Drive...................... 94 Charging System - General................................................. 95 Charging System - Regulator............................................... 95 Charging System - Theory.................................................. 95 Engine Fuel System/Exhaust and Emissions...................................... 96 Introduction.............................................................. 96 Gasoline System Components - Fuel Tank.................................... 96 Electronic Fuel Injector (EFI) - General Description...................... 96 Port Fuel System Components - ECU......................................... 96 Port Fuel System Components - Fuel Pump/Filter............................ 96 Port Fuel System Components - Fuel Rail................................... 96 Port Fuel System Components - Pressure Regulator.......................... 96 Port Fuel System Components - Fuel Injectors.............................. 97 LPG Systems General Information........................................... 97 LPG Fuel Properties....................................................... 97 LPG Fuel Tank............................................................. 97 AISAN Closed-Loop System.................................................. 98 Filter/Lockoff and Regulator.......................................... 98 Carburetor............................................................ 98 Start Mode............................................................ 98 Idle Mode............................................................. 99 Run Mode.............................................................. 99 Main Fuel Lockoff Solenoid................................................ 99 Injector Fuel Lockoff Solenoid............................................ 99 Oxygen (O 2 ) Sensor.................................................. 99 Electronic Control Unit (ECU)............................................. 99 Catalytic Converter/Muffler............................................... 99 Engine Management............................................................. 99 Introduction.............................................................. 99 Ignition and Timing - Conventional Spark.................................. 99 Components - Ignition Coil................................................ 100 Components - Distributor.................................................. 100 Spark Timing.............................................................. 100 Components - Ignition Wires............................................... 100 Components - Spark Plugs.................................................. 100 Faulty or Fouled Spark Plugs.............................................. 101 Electric Controlled Governing System - Mazda LPG.......................... 101 Engine Identification......................................................... 102 Cummins (Diesel) Engine....................................................... 104 Description............................................................... 104 Diesel Fuel System........................................................ 105 Principle of Operation................................................ 105 Fuel Injection Pump and Governor.......................................... 106 Description........................................................... 106 Principles of Operation............................................... 107 Cummins Engine Control.................................................... 108 Engine Speed (RPM) Sensor............................................. 109 Throttle Position Sensor.............................................. 110 Electronic Throttle Actuator.......................................... 111 Engine Oil Pressure Sensor............................................ 111 Coolant Temperature Sensor............................................ 111 Air Restriction Switch................................................ 112 Fuel Filter/Water Separator........................................... 112 Fuel Level Sensor (In Tank)........................................... 112 Engine Electrical System.................................................. 113 Magnetic Valve (Engine Stop Solenoid)................................. 113 Alternator............................................................ 113 Grid Heater........................................................... 113 Cold Start Timing Advance (Fuel Injection Pump)....................... 113 Cummins QSB 3.3L (Diesel) Engine.............................................. 114 Description............................................................... 114 Diesel Fuel System........................................................ 115 Electronics System........................................................ 118 Engine Protection..................................................... 119 Diagnostics........................................................... 119 Grid Heater........................................................... 119 Turbocharger and Charge Air Cooler........................................ 119 Cooling System............................................................ 121 Crankcase Oil Separator................................................... 122 Lubrication System........................................................ 123 Mazda Engine Overview......................................................... 124 Description............................................................... 124 Fuel System............................................................... 124 Engine Controls Unit (ECU) and Emissions.................................. 124 Cooling System............................................................ 124 Ignition System........................................................... 124 Mazda (LPG) Engine Controls................................................... 125 LPG System (Aisan/E-Controls-Mechanical).................................. 125 Description........................................................... 125 Principles of Operation............................................... 126 Control System........................................................ 129 Oxygen (O 2 ) Sensor.................................................. 130 Fuel Tank............................................................. 130 Regulator............................................................. 131 Start Mode........................................................ 132 Idle Mode......................................................... 132 Run Mode.......................................................... 133 Resonator............................................................. 133 Carburetor............................................................ 133 Start Mode........................................................ 133 Idle Mode......................................................... 134 Run Mode.......................................................... 134 Governor.............................................................. 135 LPG System (E-Controls)................................................... 135 Description........................................................... 135 Principles of Operation............................................... 136 Manifold Absolute Pressure Sensor..................................... 136 Throttle Position Sensor.............................................. 136 Oxygen (O 2 ) Sensor.................................................. 137 Engine Coolant Temperature Sensor..................................... 137 Intake Air Temperature Sensor......................................... 137 Engine Control Unit................................................... 137 Accelerator Pedal Position Sensor..................................... 137 Three-Way Catalytic Converter......................................... 137 Camshaft Position Sensor.............................................. 137 Electric Controlled Governing System.................................. 138 Electronic Governor Sensor............................................ 139 Mazda (Gasoline) Engine Controls.............................................. 140 Gasoline System........................................................... 140 Description........................................................... 140 Principles of Operation............................................... 141 Control System............................................................ 143 Camshaft Position Sensor.............................................. 144 Intake Air Temperature Sensor......................................... 145 Mass Air Flow Sensor.................................................. 146 Throttle Position Sensor.............................................. 147 Electronic Governor Sensor............................................ 148 Electronic Governing System........................................... 149 Manifold Absolute Pressure Sensor/Boost Sensor........................ 149 Engine Coolant Temperature Sensor..................................... 150 Intake Air System......................................................... 151 Throttle Body......................................................... 151 Idle Air Control Valve................................................ 152 Fuel System............................................................... 153 Fuel Injector......................................................... 153 Pressure Regulator.................................................... 154 Exhaust System............................................................ 155 Heated Oxygen (O 2 ) Sensor........................................... 155 Three-Way Catalytic Converter......................................... 156 GM (LPG) Engine Controls...................................................... 157 Engine Control System .................................................... 157 Engine Control System Overview........................................ 158 Principles of Operation............................................... 158 Control System............................................................ 159 GM/TGFI 2.4L (Four Cylinder) Control System Component Location........ 159 GM/TGFI 4.3L (Six Cylinder) Control System Component Location......... 160 GM/TGFI 2.4L (Four-Cylinder) LPG System............................... 161 GM/TGFI 4.3L (Six-Cylinder) LPG System................................ 163 Fuel Tank............................................................. 165 Engine Control Unit................................................... 165 Electronic Throttle Body/Throttle Position Sensor..................... 166 Manifold Absolute Pressure/Manifold Air Temperature Sensor............ 166 Propane Injectors..................................................... 167 Engine Coolant Temperature Sensor..................................... 169 Oxygen (O 2 ) Sensor.................................................. 169 Crankshaft Position Sensor (Engine Speed Sensor)...................... 170 Oil Pressure Sensor................................................... 170 Power Latch Relay..................................................... 170 GM 2.4L Camshaft Position Sensor...................................... 170 GM 4.3L Camshaft Position Sensor...................................... 171 Injector Driver Module................................................ 172 Vaporizer/Regulator................................................... 172 Accelerator Pedal Position Sensor..................................... 175 Three-Way Catalytic Converter......................................... 175 Ignition System........................................................... 176 Ignition Coils........................................................ 176 Distributorless Ignition System Module................................ 176 Electronic Ignition Signals........................................... 177 Distributor Ignition (DI) System...................................... 177 Camshaft Position (CMP) Sensor........................................ 178 Ignition Coil and Ignition Control Module (ICM)....................... 178 Secondary Ignition Components......................................... 178 GM (Gasoline) Engine Controls................................................. 179 Engine Control System..................................................... 179 GM 2.4L (Four Cylinder) Engine Control System......................... 179 GM 4.3L (Six Cylinder) Engine Control System.......................... 180 Engine Control System Overview........................................ 181 Principles of Operation............................................... 181 Control System............................................................ 181 GM/TGFI 2.4L (Four Cylinder) Control System Component Location........ 181 GM/TGFI 4.3L (Six Cylinder) Control System Component Location......... 183 GM/TGFI 2.4L (Four-Cylinder) Gasoline System Components............... 184 GM/TGFI 4.3L (Six Cylinder) Gasoline System Components................ 186 Engine Control Unit................................................... 188 Electronic Throttle Body/Throttle Position Sensor..................... 188 Manifold Absolute Pressure/Manifold Air Temperature Sensor ........... 189 Fuel Injector......................................................... 190 Engine Coolant Temperature Sensor..................................... 191 Oxygen (O 2 ) Sensor.................................................. 192 Crankshaft Position Sensor (Engine Speed Sensor)...................... 192 Oil Pressure Sensor................................................... 192 Power Latch Relay..................................................... 192 Camshaft Position Sensor.............................................. 193 Accelerator Pedal Position Sensor..................................... 194 Three-Way Catalytic Converter......................................... 195 Ignition System........................................................... 195 Ignition Coils........................................................ 195 Distributorless Ignition System Module................................ 195 Electronic Ignition Signals........................................... 196 Yanmar (Diesel) Engine........................................................ 197 Description............................................................... 197 Diesel Fuel System........................................................ 198 Principles of Operation............................................... 198 Fuel Injection Pump and Governor.......................................... 199 Description........................................................... 199 Principles of Operation............................................... 201 Timer................................................................. 202 Feed Pump (Vane Type)................................................. 202 Regulating Valve...................................................... 203 Injection Pump Plunger................................................ 204 Suction Process................................................... 205 Injection Process................................................. 205 End of Injection.................................................. 206 Uniform Pressure Process.......................................... 206 Reverse Rotation Prevention Mechanism................................. 207 Fuel Injection Volume Adjustment Mechanism............................ 207 Delivery Valve Assembly............................................... 207 Delivery Valve Holder with Damping Valve.............................. 208 All - Speed Governor.................................................. 209 At Start of Engine.................................................... 211 During Idle........................................................... 212 At Full - Load Maximum Speed Control.................................. 213 At No-Load Maximum Speed Control...................................... 214 Full-Load Position Adjustment Mechanism............................... 215 Structure and Operation of Timer.......................................... 216 Standard Type Automatic Timer......................................... 216 Yanmar Engine Controls.................................................... 217 Engine Speed (RPM) Sensor............................................. 218 Throttle Position Sensor.............................................. 218 Electronic Throttle Actuator.......................................... 219 Engine Oil Pressure Sensor............................................ 219 Coolant Temperature Sensor............................................ 220 Air Filter Restriction Switch......................................... 220 Fuel Filter/Water Separator and Strainer.............................. 221 Fuel Level Sensor..................................................... 221 Engine Electrical System.................................................. 221 Magnetic Valve (Engine Stop Solenoid)................................. 221 Alternator............................................................ 222 Glow Plugs............................................................ 222 Cold Start Timing Advance (Fuel Injection Pump)....................... 222 Cooling System - All Engines.................................................. 223 Description............................................................... 223 Radiator.................................................................. 223 Combination Cooler/Standard Radiator.................................. 224 Radiator Cap.............................................................. 224 Thermostat................................................................ 224 Engine Coolant Pump....................................................... 225 Fan....................................................................... 225 GM Engine Coolant Flow Diagram............................................ 225 Yanmar Diesel Engine Coolant Flow Diagram................................. 226 Engine Does Not Crank......................................................... 228 Engine Does Not Start/Engine is Hard to Start................................. 231 Engine Idle Speed Incorrect................................................... 237 Engine Idle Speed is Unstable or Engine Stalls at Idle........................ 240 Engine Cuts Out, Misses, Hesitates, Sags, or Stumbles......................... 245 Engine Lack of Power.......................................................... 251 Engine Speed Surge Or Engine Speed Unstable................................... 258 Engine Backfires.............................................................. 262 Engine Is Knocking or Pinging................................................. 265 Excessive Engine Vibrations................................................... 269 Abnormal Engine and Exhaust Noises............................................ 274 Fan or Alternator Bearing Noise............................................... 278 Abnormal Engine and Exhaust Smells............................................ 280 High Engine Fuel Consumption.................................................. 282 Fuel Leaks.................................................................... 285 High Engine Oil Consumption................................................... 288 Engine Oil Leaks.............................................................. 290 Engine Oil is Discolored...................................................... 295 Engine Coolant Leaks.......................................................... 297 Engine Coolant is Discolored.................................................. 300 Engine Exhaust is Discolored.................................................. 301 Engine Fails Emission Compliance Check........................................ 305 Alternator Light is Illuminated............................................... 309 Engine is Overheating......................................................... 310 Air Intake Manifold Temperature too High (Cummins QSB 3.3L Only).............. 313 Air Intake Manifold Pressure (Boost) is Below Normal (Cummins QS.............. 314 Engine Coolant Temperature is Low............................................. 315 Engine Oil Pressure is Low.................................................... 316 Radiator Bubble Test.......................................................... 318 Engine Compression Test (GM and Mazda)........................................ 319 Engine Compression Test (Yanmar Diesel)....................................... 320 Engine Oil Pressure Test...................................................... 321 Fuel System Pressure Test (Gasoline Engines Only)............................. 323 Fuel Injection Nozzle Test (Yanmar Diesel).................................... 325 Vacuum Leak................................................................... 326 Vacuum Leak Detection..................................................... 326 Vacuum Leak Repairs....................................................... 326 Coolant System Test........................................................... 327 Electrical System................................................................. 328 Troubleshooting Guidelines and Procedures..................................... 342 Troubleshooting Guidelines................................................ 342 Troubleshooting Procedures................................................ 345 Troubleshooting Procedures, Identification............................ 345 Troubleshooting Procedures, Location.................................. 345 Troubleshooting Procedures, Structure................................. 345 Troubleshooting Procedures, Performance............................... 346 Diagnostic Trouble Codes...................................................... 347 Diagnostic Trouble Codes.................................................. 347 Wiring Reference Data......................................................... 361 Post 2007 Engine Connections.................................................. 365 Cummins 4.5L.............................................................. 365 GM 2.4L (GAS/LPG)......................................................... 366 GM 4.3L (GAS/LPG)......................................................... 367 Mazda 2.0/2.2L (GAS/LPG).................................................. 368 Yanmar 2.6/3.3L........................................................... 369 Harness Assembly Data......................................................... 370 Electrical System............................................................. 416 General Description....................................................... 416 Description............................................................... 417 Principles of Operation, Components....................................... 421 Principles Of Operation, System........................................... 429 100-2......................................................................... 436 100-2......................................................................... 436 100-3......................................................................... 436 523859-3...................................................................... 436 524223-3...................................................................... 436 524224-3...................................................................... 436 524225-3...................................................................... 436 524282-3...................................................................... 436 523958-3...................................................................... 436 523959-3...................................................................... 436 100-4......................................................................... 444 523859-4...................................................................... 444 523958-4...................................................................... 444 523959-4...................................................................... 444 524223-4...................................................................... 444 524224-4...................................................................... 444 524225-4...................................................................... 444 524282-4...................................................................... 444 524223-0...................................................................... 452 524224-0...................................................................... 452 524225-0...................................................................... 452 524229-0...................................................................... 452 524270-0...................................................................... 452 524276-0...................................................................... 452 524223-1...................................................................... 456 524224-1...................................................................... 456 524225-1...................................................................... 456 524229-1...................................................................... 456 524270-1...................................................................... 456 524276-1...................................................................... 456 110-3......................................................................... 460 110-3......................................................................... 460 110-5......................................................................... 460 177-3......................................................................... 460 522231-3...................................................................... 460 522555-3...................................................................... 460 522603-3...................................................................... 460 524235-3...................................................................... 460 110-4......................................................................... 468 110-4......................................................................... 468 177-4......................................................................... 468 522231-4...................................................................... 468 522555-4...................................................................... 468 522603-4...................................................................... 468 524235-4...................................................................... 468 110-2......................................................................... 476 110-2......................................................................... 476 110-10........................................................................ 479 522712-3...................................................................... 484 522713-3...................................................................... 484 522712-4...................................................................... 491 522713-4...................................................................... 491 51-2.......................................................................... 498 51-7.......................................................................... 498 91-2.......................................................................... 506 91-2.......................................................................... 506 522708-3...................................................................... 510 522710-3...................................................................... 510 522711-3...................................................................... 510 522714-3...................................................................... 510 522708-4...................................................................... 517 522710-4...................................................................... 517 522711-4...................................................................... 517 522714-4...................................................................... 517 515-0......................................................................... 524 523780-3...................................................................... 526 523860-3...................................................................... 526 524245-3...................................................................... 526 524275-3...................................................................... 526 523780-4...................................................................... 532 523860-4...................................................................... 532 524245-4...................................................................... 532 524275-4...................................................................... 532 677-3......................................................................... 537 2350-3........................................................................ 537 522754-3...................................................................... 537 522755-3...................................................................... 537 522764-3...................................................................... 537 522766-3...................................................................... 537 524230-3...................................................................... 537 SYMPTOMS WARNING.............................................................. 537 677-4......................................................................... 543 2350-4........................................................................ 543 522754-4...................................................................... 543 522755-4...................................................................... 543 522764-4...................................................................... 543 522766-4...................................................................... 543 524230-4...................................................................... 543 676-3......................................................................... 547 524195-3...................................................................... 547 524269-3...................................................................... 547 676-4......................................................................... 553 524195-4...................................................................... 553 524269-4...................................................................... 553 524269-7...................................................................... 559 524215-3...................................................................... 561 524215-6...................................................................... 561 524237-3...................................................................... 565 524238-3...................................................................... 565 524240-3...................................................................... 565 524237-4...................................................................... 570 524238-4...................................................................... 570 524240-4...................................................................... 570 879-3......................................................................... 575 880-3......................................................................... 575 881-3......................................................................... 575 882-3......................................................................... 575 522772-3...................................................................... 575 879-4......................................................................... 579 880-4......................................................................... 579 881-4......................................................................... 579 882-4......................................................................... 579 522772-4...................................................................... 579 168-0......................................................................... 583 168-3......................................................................... 583 521982-3...................................................................... 586 522760-3...................................................................... 586 522761-3...................................................................... 586 522762-3...................................................................... 586 522128-3...................................................................... 595 524251-0...................................................................... 595 524260-0...................................................................... 595 524260-3...................................................................... 595 524261-0...................................................................... 595 524261-3...................................................................... 595 168-1......................................................................... 604 168-4......................................................................... 604 521982-4...................................................................... 607 522760-4...................................................................... 607 522761-4...................................................................... 607 522761-6...................................................................... 607 522762-4...................................................................... 607 522128-4...................................................................... 614 524251-1...................................................................... 614 524260-1...................................................................... 614 524260-4...................................................................... 614 524261-1...................................................................... 614 524261-4...................................................................... 614 524260-2...................................................................... 624 524260-11..................................................................... 624 524261-2...................................................................... 624 524261-11..................................................................... 624 96-3.......................................................................... 628 96-4.......................................................................... 628 522810-4...................................................................... 632 524213-1...................................................................... 636 524213-3...................................................................... 636 524213-4...................................................................... 636 523920-3...................................................................... 639 523925-3...................................................................... 639 523930-3...................................................................... 639 523977-3...................................................................... 639 523978-3...................................................................... 639 523986-3...................................................................... 639 524284-3...................................................................... 639 524285-3...................................................................... 639 523920-4...................................................................... 645 523925-4...................................................................... 645 523930-4...................................................................... 645 523977-4...................................................................... 645 523978-4...................................................................... 645 523986-4...................................................................... 645 524284-4...................................................................... 645 524285-4...................................................................... 645 523920-6...................................................................... 650 523925-6...................................................................... 650 523930-6...................................................................... 650 523977-6...................................................................... 650 523978-6...................................................................... 650 523986-6...................................................................... 650 524284-6...................................................................... 650 524285-6...................................................................... 650 105-3......................................................................... 654 105-3......................................................................... 654 522570-3...................................................................... 654 105-4......................................................................... 659 105-4......................................................................... 659 522570-4...................................................................... 659 105-5......................................................................... 663 106-3......................................................................... 666 106-4......................................................................... 670 106-0......................................................................... 674 106-1......................................................................... 674 106-2......................................................................... 674 106-14........................................................................ 674 522739-3...................................................................... 677 522740-3...................................................................... 677 522739-5...................................................................... 682 522740-5...................................................................... 682 522739-6...................................................................... 686 522740-6...................................................................... 686 522735-2...................................................................... 690 522735-4...................................................................... 693 522735-5...................................................................... 696 522735-6...................................................................... 699 522630-2...................................................................... 703 522631-2...................................................................... 703 522632-2...................................................................... 703 522633-2...................................................................... 703 522635-3...................................................................... 703 522636-4...................................................................... 703 522637-3...................................................................... 703 522638-4...................................................................... 703 522606-10..................................................................... 707 522737-10..................................................................... 707 651-3......................................................................... 710 652-3......................................................................... 710 653-3......................................................................... 710 654-3......................................................................... 710 655-3......................................................................... 710 656-3......................................................................... 710 522599-3...................................................................... 710 522600-3...................................................................... 710 522601-3...................................................................... 710 522602-3...................................................................... 710 522721-3...................................................................... 710 522722-3...................................................................... 710 522723-3...................................................................... 710 522724-3...................................................................... 710 522725-3...................................................................... 710 522726-3...................................................................... 710 522599-3...................................................................... 710 522600-3...................................................................... 710 522601-3...................................................................... 710 522602-3...................................................................... 710 651-5......................................................................... 718 651-5......................................................................... 718 652-5......................................................................... 718 652-5......................................................................... 718 653-5......................................................................... 718 653-5......................................................................... 718 654-5......................................................................... 718 654-5......................................................................... 718 655-5......................................................................... 718 656-5......................................................................... 718 522721-5...................................................................... 718 522722-5...................................................................... 718 522723-5...................................................................... 718 522724-5...................................................................... 718 522725-5...................................................................... 718 522726-5...................................................................... 718 651-6......................................................................... 723 652-6......................................................................... 723 653-6......................................................................... 723 654-6......................................................................... 723 655-6......................................................................... 723 656-6......................................................................... 723 522599-4...................................................................... 723 522600-4...................................................................... 723 522601-4...................................................................... 723 522602-4...................................................................... 723 522721-6...................................................................... 723 522722-6...................................................................... 723 522723-6...................................................................... 723 522724-6...................................................................... 723 522725-6...................................................................... 723 522726-6...................................................................... 723 2000-9........................................................................ 731 2000-12....................................................................... 731 2000-12....................................................................... 731 2000-12....................................................................... 731 2000-12....................................................................... 731 2000-14....................................................................... 731 2003-12....................................................................... 731 2023-12....................................................................... 731 2039-2........................................................................ 731 2039-12....................................................................... 731 2235-12....................................................................... 731 2236-12....................................................................... 731 2238-12....................................................................... 731 521670-12..................................................................... 731 524258-2...................................................................... 731 522215-12..................................................................... 739 522215-14..................................................................... 739 524236-14..................................................................... 739 524262-12..................................................................... 739 524262-14..................................................................... 739 524263-1...................................................................... 739 524268-12..................................................................... 739 628-12........................................................................ 741 630-12........................................................................ 741 522690-2...................................................................... 741 522690-12..................................................................... 741 522691-2...................................................................... 741 522691-12..................................................................... 741 522692-2...................................................................... 741 522693-12..................................................................... 741 522694-12..................................................................... 741 522695-2...................................................................... 741 522696-2...................................................................... 741 522697-12..................................................................... 741 522698-2...................................................................... 741 522699-2...................................................................... 741 522700-2...................................................................... 741 190-2......................................................................... 743 190-2......................................................................... 743 190-7......................................................................... 743 522120-1...................................................................... 743 522585-2...................................................................... 743 522752-9...................................................................... 749 524249-2...................................................................... 753 524250-2...................................................................... 753 524264-2...................................................................... 753 524264-14..................................................................... 753 524265-2...................................................................... 753 524271-2...................................................................... 753 524225-14..................................................................... 753 628-12........................................................................ 758 630-12........................................................................ 758 2660-3........................................................................ 758 2660-4........................................................................ 758 2661-3........................................................................ 758 2661-4........................................................................ 758 2802-12....................................................................... 758 523510-12..................................................................... 758 523511-12..................................................................... 758 523515-3...................................................................... 758 523515-4...................................................................... 758 523519-3...................................................................... 758 523519-4...................................................................... 758 2802-12....................................................................... 760 628-12........................................................................ 760 630-12........................................................................ 760 523261-3...................................................................... 760 523261-4...................................................................... 760 523257-3...................................................................... 760 523257-4...................................................................... 760 523253-3...................................................................... 760 523253-4...................................................................... 760 523249-3...................................................................... 760 523249-4...................................................................... 760 522780-3...................................................................... 762 522781-3...................................................................... 762 522780-4...................................................................... 766 522781-4...................................................................... 766 522780-2...................................................................... 769 522781-2...................................................................... 769 111-1......................................................................... 772 524252-2...................................................................... 776 524253-14..................................................................... 778 524255-2...................................................................... 779 108-0......................................................................... 780 108-1......................................................................... 780 522655-0...................................................................... 783 522655-1...................................................................... 783 522660-0...................................................................... 783 522660-1...................................................................... 783 524212-2...................................................................... 787 524211-2...................................................................... 787 524210-2...................................................................... 787 524209-2...................................................................... 787 524208-2...................................................................... 787 524207-2...................................................................... 787 524206-2...................................................................... 787 524205-2...................................................................... 787 524204-2...................................................................... 787 524203-2...................................................................... 787 524202-2...................................................................... 787 524201-2...................................................................... 787 524200-2...................................................................... 787 524199-2...................................................................... 787 524198-2...................................................................... 787 524197-2...................................................................... 787 522800-13..................................................................... 789 522801-13..................................................................... 791 522130-0...................................................................... 792 522131-0...................................................................... 792 522132-0...................................................................... 792 522133-0...................................................................... 792 522134-0...................................................................... 792 522130-1...................................................................... 796 522131-1...................................................................... 796 522132-1...................................................................... 796 522133-1...................................................................... 796 522134-1...................................................................... 796 522130-3...................................................................... 801 522131-3...................................................................... 801 522132-3...................................................................... 801 522133-3...................................................................... 801 522134-3...................................................................... 801 522130-4...................................................................... 806 522131-4...................................................................... 806 522132-4...................................................................... 806 522133-4...................................................................... 806 522134-4...................................................................... 806 522135-0...................................................................... 810 522137-0...................................................................... 810 522138-0...................................................................... 810 522135-1...................................................................... 814 522137-1...................................................................... 814 522138-1...................................................................... 814 522135-3...................................................................... 818 522137-3...................................................................... 818 522138-3...................................................................... 818 522135-4...................................................................... 822 522137-4...................................................................... 822 522138-4...................................................................... 822 522155-2...................................................................... 826 522157-2...................................................................... 826 522122-0...................................................................... 833 522124-0...................................................................... 833 522125-0...................................................................... 833 522126-0...................................................................... 833 522127-0...................................................................... 833 522122-1...................................................................... 837 522124-1...................................................................... 837 522125-1...................................................................... 837 522126-1...................................................................... 837 522127-1...................................................................... 837 522122-6...................................................................... 841 522124-6...................................................................... 841 522125-6...................................................................... 841 522126-6...................................................................... 841 522127-6...................................................................... 841 522122-8...................................................................... 846 522124-8...................................................................... 846 522125-8...................................................................... 846 522126-8...................................................................... 846 522127-8...................................................................... 846 522129-3...................................................................... 850 522129-4...................................................................... 850 522197-0...................................................................... 852 522198-0...................................................................... 852 522199-0...................................................................... 852 522200-0...................................................................... 852 522201-0...................................................................... 852 522197-1...................................................................... 855 522198-1...................................................................... 855 522199-1...................................................................... 855 522200-1...................................................................... 855 522201-1...................................................................... 855 522197-6...................................................................... 856 522198-6...................................................................... 856 522199-6...................................................................... 856 522200-6...................................................................... 856 522201-6...................................................................... 856 522197-7...................................................................... 857 522198-7...................................................................... 857 522199-7...................................................................... 857 522200-7...................................................................... 857 522201-7...................................................................... 857 522197-8...................................................................... 858 522198-8...................................................................... 858 522199-8...................................................................... 858 522200-8...................................................................... 858 522201-8...................................................................... 858 522197-14..................................................................... 860 522198-14..................................................................... 860 522199-14..................................................................... 860 522200-14..................................................................... 860 522201-14..................................................................... 860 522197-27..................................................................... 861 522198-27..................................................................... 861 522199-27..................................................................... 861 522200-27..................................................................... 861 522201-27..................................................................... 861 2039-2........................................................................ 864 522540-3...................................................................... 867 522540-4...................................................................... 871 522604-3...................................................................... 876 522604-4...................................................................... 880 522604-5...................................................................... 884 522697-12..................................................................... 889 190-2......................................................................... 890 190-4......................................................................... 890 190-8......................................................................... 890 522752-2...................................................................... 890 522752-4...................................................................... 890 522752-5...................................................................... 896 522598-3...................................................................... 899 522598-4...................................................................... 903 522592-0...................................................................... 907 522592-1...................................................................... 909 522593-12..................................................................... 911 522594-12..................................................................... 915 522595-12..................................................................... 915 522596-12..................................................................... 915 522597-12..................................................................... 915 522614-7...................................................................... 918 522616-8...................................................................... 918 522617-5...................................................................... 918 524226-3...................................................................... 919 524226-4...................................................................... 921 524239........................................................................ 923 524241........................................................................ 923 524246........................................................................ 923 524267........................................................................ 923 524248........................................................................ 923 524746-2...................................................................... 926 Engine Continues to Run When Engine Cover is Raised........................... 928 Engine Stops or Fails to Start................................................ 930 Electrical Functions Do Not Operate........................................... 932 Electrical Function Does Not Turn Off......................................... 937 Electro-Hydraulics Do Not Function With Armrest Down ......................... 943 Electro-Hydraulics Can Still Function With Armrest Raised..................... 946 Vehicle Does Not Power On..................................................... 949 Heater Fan Does Not Operate Properly.......................................... 954 Heater Airflow Does Not Reach Desired Temperature............................. 957 Heater Output Has Insufficient Airflow........................................ 958 Circulating (Accessory) Fan Inoperative....................................... 959 Dome Light Inoperative........................................................ 962 Horn Failure.................................................................. 965 Drive Train....................................................................... 968 Mechanical Overview........................................................... 972 Engine........................................................................ 972 Description............................................................... 972 Torque Converter.............................................................. 972 Description............................................................... 972 Stator................................................................ 973 Turbine............................................................... 973 Pump PTO...................................................................... 974 Chain Drive PTO........................................................... 974 Spur Gear PTO............................................................. 975 Transmission.................................................................. 976 Description............................................................... 976 1.0-5.5 Ton Lift Truck Transmissions...................................... 979 Description........................................................... 979 Single-Speed...................................................... 979 Two-Speed......................................................... 980 Clutch Pack........................................................... 981 Power Flow............................................................ 983 Single-Speed...................................................... 983 Two-Speed......................................................... 984 Transmission Hydraulic Schematic...................................... 986 Transmission Oil Flow................................................. 987 Control Valve Oil Flow................................................ 987 6.0-7.0 Ton Lift Truck Transmissions...................................... 989 Description........................................................... 989 Two-Speed......................................................... 989 Three-Speed....................................................... 989 Clutch Pack........................................................... 991 Input Shaft and Range Clutches.................................... 991 Directional Clutches.............................................. 991 Output Section.................................................... 992 Power Flow............................................................ 993 Two-Speed and Three-Speed......................................... 993 Transmission Hydraulic Schematic...................................... 997 Two-Speed......................................................... 997 Three-Speed....................................................... 998 Transmission Control System Overview..........................................1000 Transmission Control System...............................................1000 Transmission Control Software.................................................1003 Transmission Control Modes................................................1003 Neutral...............................................................1003 Gear Engagement Control...............................................1003 Basic Powershift Gear Engagement Mode.............................1003 DuraMatch™ and Electronic Extended Features Gear Engagement Mo....1003 Normal Forward or Reverse.............................................1003 Basic Powershift..................................................1003 DuraMatch™ and Electronic Extended Features Transmission..........1003 Auto-Shift............................................................1003 1st Gear Lock.........................................................1004 Inching...............................................................1004 Basic Powershift Inching Mode.....................................1004 DuraMatch™ Inching Mode...........................................1004 Electronic Extended Features Inching Mode.........................1004 Inch/Brake Overlap Adjustment.........................................1004 Brake Wear Compensation...............................................1004 Auto Decel............................................................1005 Controlled Power Reversal.............................................1005 Basic Multi-Speed.................................................1005 Electronic Extended Features......................................1005 Controlled Creep......................................................1005 Basic Powershift..................................................1005 DuraMatch™ and Electronic Extended Features.......................1006 Controlled Roll Back..................................................1006 DuraMatch™ .......................................................1006 Electronic Extended Features......................................1006 Travel Speed Limit (Optional).........................................1006 Extended Drawbar Pull ( Electronic Extended Features Multi-Speed......1006 Auto-Speed Hydraulics ( Electronic Extended Features Transmissio......1006 Throttle Response Management ( Electronic Extended Features Tran......1007 Steady Travel Speed...............................................1007 Transmission Control Hardware.................................................1007 Control Valve and Sensors.................................................1007 Description...........................................................1007 Principles of Operation...............................................1009 Transmission Proportional Valve...........................................1010 Description...........................................................1010 Neutral...............................................................1010 Proportional Control..................................................1010 MONOTROL® Pedal...........................................................1011 Description...........................................................1011 Principles of Operation...............................................1011 Directional Control Lever.................................................1011 Principles of Operation...............................................1011 Driveshaft, Differential, Drive Axle, and Brakes (Dry Brake Only..............1012 Driveshaft................................................................1012 Differential and Drive Axle...............................................1012 Brake System..............................................................1014 Description...........................................................1014 Service Brakes........................................................1014 Master Cylinder.......................................................1014 Brake Position Sensor.................................................1015 Parking Brake.........................................................1015 Driveshaft, Differential, Drive Axle, and Brakes (Wet Brake Only..............1015 Driveshaft................................................................1015 Differential..............................................................1016 Brake System..............................................................1018 Description...........................................................1018 Service Brakes, 2.0-3.5 Ton Only......................................1018 Service Brakes, 4.0-7.0 Ton...........................................1020 Brake Adjustment and Service..........................................1020 Parking Brake.........................................................1020 Overheating Brakes (Dry Brake Axle Only)......................................1024 Overheating Brakes (Wet Brake Axle Only)......................................1026 Poor Brake Performance (Dry Brake Axle Only)..................................1029 Poor Brake Performance (Wet Brake Axle Only)..................................1032 Brakes Make Too Much Noise (Dry Brake Axle Only)..............................1034 Brakes Pull To One Side (Dry Brake Axle Only).................................1035 Parking Brake Will Not Release................................................1038 Parking Brake Will Not Hold Lift Truck (Dry Brake Axle Only)..................1039 Parking Brake Will Not Hold Lift Truck (Wet Brake Axle Only)..................1040 Abnormal Drive Axle Noise.....................................................1041 Discolored Drive Axle Oil.....................................................1044 Lift Truck Does Not Move (Drive Axle).........................................1046 Abnormal Transmission Noise...................................................1049 Bubbles or Foaming In Transmission Dipstick Tube..............................1051 Inching Operation Is Not Smooth or Chatters...................................1053 Lift Truck Does Not Move In One or Both Directions (Transmission..............1055 Loss of Power/Drivetrain Performance..........................................1058 Transmission Is Too Hot.......................................................1061 Transmission Will Not Shift To Forward High Range.............................1064 Transmission Warmup Procedure.................................................1066 Transmission Pressure Test....................................................1066 Transmission Charge Pump Pressure Test....................................1068 Clutch Pack Pressure Test (Proportional Solenoid Valves)..................1068 Torque Converter Pressure Test............................................1069 Lubrication Pressure Test.................................................1069 Transmission Clutch Drag Test (1.0-5.5 Ton Trucks Only).......................1070 Torque Converter Stall Test...................................................1070 Hydraulic Systems.................................................................1074 Main Hydraulic System.........................................................1078 Description...............................................................1078 Principles of Operation...................................................1081 Hydraulic Schematics......................................................1082 Manual Control Valve Schematics.......................................1082 Electro-Hydraulic Control Valve Schematics............................1087 Manual Hydraulic Control Valve................................................1091 Description...............................................................1091 Principles of Operation...................................................1093 Lift Section..........................................................1093 Lift Operation....................................................1093 Lower Operation...................................................1093 Tilt Section..........................................................1094 Tilt Backward.....................................................1094 Tilt Forward......................................................1094 Auxiliary Section.....................................................1096 Anti-stall Feature....................................................1097 Relief Valves.........................................................1097 Main Relief Valve.................................................1097 Secondary Relief Valve............................................1097 Electro-Hydraulic Control Valve...............................................1098 Description...............................................................1098 Principles of Operation...................................................1099 Inlet Pressure Compensator/Unloader...................................1099 Lift/Lower EHPVs......................................................1101 EHPV Operation....................................................1102 Tilt and Auxiliary Spool Functions....................................1103 Tilt Forward Function.................................................1105 Main Relief Valve ....................................................1106 Secondary Relief Valve................................................1106 Secondary Function Anti-stall Valve...................................1107 Emergency Lowering Valve..............................................1108 Steering System...............................................................1108 Component Locations.......................................................1108 Description...........................................................1108 Steering Axle Assembly................................................1108 Steering Control Unit.................................................1108 Steering Schematic........................................................1110 Principles of Operation...............................................1111 Steering Control Unit.................................................1111 Actuation Functions With Armrest Up (E-Valve).................................1112 Cycle Times Too Fast - Fast Actuation (E-Valve)...............................1113 Jump/Delay In Lift or Lower Activation After Moving Joystick or ..............1115 Jump/Delay In Secondary Function Actuation After Moving Joystick..............1118 Jump/Delay In Tilt Forward Actuation (E-Valve)................................1120 Forks Drop Slightly Before Lifting (E-Valve)..................................1122 Forks Lower Without Command (E-Valve).........................................1123 Forks Raise or Actuate Without Command (E-Valve)..............................1125 Forks Tilt Forward Without Command (E-Valve)..................................1127 Intermittent Activation (E-Valve) While Commanding Function...................1129 Lift/Lower Function Maximum Speed Too Slow (E-Valve)..........................1131 Lift Function Will Not Move With Joystick or MLM Movement (E-Val..............1134 Lift/Lower Continues To Move For Awhile After Joystick or MLM Is..............1138 Lift/Lower/Secondary Function Suddenly Jumps In Middle of Stroke..............1139 Lower Function Will Not Move With Joystick or MLM Movement (E-Va..............1140 Poor Metering on Lift or Lower Functions (E-Valve)............................1142 Secondary Function Continues to Move for Awhile After Joystick o..............1145 Secondary Function Exhibits Slight Movement in Opposite Directio..............1146 Secondary Function Maximum Speed Too Slow (E-Valve)...........................1147 Secondary Function or Tilt Back Moves Without Command (E-Valve)...............1150 Secondary Function and Tilt Back Will Not Move With Joystick or ..............1152 Tilt Forward Function Continues to Move for Awhile When Joystick..............1156 Tilt Forward Will Not Move Upon Joystick or MLM Movement (E-Valv..............1157 Too Much Joystick or MLM Movement (Deadband) to Start Function M..............1159 Wrong Actuation Operates or Actuation is Backward (E-Valve)...................1160 Actuation Exhibits Slight Movement in Opposite Direction Before ..............1161 Auxiliary Function is Slow or Does Not Function (Manual Valve)................1162 Cycle Times Too Fast - Fast Actuation (Manual Valve)..........................1164 Function Continues to Activate After Returning to Neutral.....................1165 Lift Function Is Slow or Does Not Function (Manual Valve).....................1166 Tilt Back Function Will Not Operate (Manual Valve)............................1168 Tilt Forward Functions When Spool is Activated Forward With Engi..............1169 Tilt Forward Will Not Function When Activated (Manual Valve)..................1170 Abnormal Steer Axle Noise.....................................................1171 Abnormal Steering Wheel Vibration.............................................1173 Back Lash/Kick Back in Steering Wheel.........................................1174 No Steering (All Other Hydraulic Functions OK)................................1176 Steering Is Slow or Difficult.................................................1178 Steering Operation Is Not Smooth..............................................1180 Steering Wheel End Lock Position Cannot Be Felt by Operator...................1182 Steering Wheel Turns By Itself or Does Not Return To Neutral..................1183 Steering Wheel Turns the Tires in the Wrong Direction.........................1184 Abnormal Hydraulic Noise and/or Vibration.....................................1185 Abnormal Smell/Discoloration/Foaming of Oil...................................1188 Actuations Do Not Act Simultaneously..........................................1189 Oil Leaking/Component Life Too Short..........................................1190 Hydraulic Warmup Procedure....................................................1194 Main Relief Valve Test and Adjustment.........................................1195 Secondary Relief Valve Test and Adjustment....................................1197 Hydraulic Pump Flow Test......................................................1199 Main Control Valve LS Leakage Test (E-Valve)..................................1201 Main Control Valve Unloader Margin Test.......................................1202 Electro-Hydraulic Poppet Valve (EHPV) Leakage Test............................1203 PPRV Pilot Pressure Test......................................................1206 Steering Relief Pressure Test and Adjustment..................................1207 Steering Control Unit LS Pressure Test........................................1208 Lift Cylinder Leakage Test....................................................1210 Tilt Cylinder Leakage Test....................................................1211 Steering Cylinder Leakage Test................................................1212 Operators Station.................................................................1214 Operator Station General Description and Principles of Operation..............1216 General Description and Location..........................................1216 Display Switch Cluster (DSC)..................................................1218 Detailed Description......................................................1218 Control Inputs, Right Side................................................1219 Right Indicator and Warning Group.........................................1221 LCD Display...............................................................1222 Left Indicator and Warning Group..........................................1223 Control Inputs, Left Side (Cab Option Only)...............................1224 Transmission Control and Braking..............................................1225 Description...............................................................1225 Vehicle System Manager (VSM)..........................................1226 Display Switch Cluster................................................1226 Interlock and Switching Features..................................1226 MONOTROL® Directional Control.........................................1226 Inch Brake/Service Brake Pedal........................................1226 Parking Brake.........................................................1227 Programming - Menus...........................................................1227 Menus.....................................................................1227 Main Menu.............................................................1230 Save and Exit or Exit Without Saving..................................1230 Back One Level........................................................1230 Hourmeters............................................................1230 View Versions.........................................................1231 Passwords.............................................................1231 Diagnostics...........................................................1231 Setup Travel and Braking..............................................1231 Setup Hydraulics......................................................1231 Setup Display.........................................................1231 Setup General Items...................................................1231 Calibrations..........................................................1231 Manual Hydraulic Control Levers...............................................1232 General Description.......................................................1232 System Components.........................................................1232 Lift/Lower............................................................1232 Tilt..................................................................1232 Auxiliary 1...........................................................1232 Auxiliary 2...........................................................1232 E-Hydraulic System Interface..................................................1233 General Description.......................................................1233 System Components.........................................................1233 E-Hydraulic Control Input Device..........................................1233 Joystick..............................................................1233 Lift/Lower........................................................1234 Tilt..............................................................1234 Auxiliary 1.......................................................1234 Auxiliary 2.......................................................1234 Push Button.......................................................1234 Mini Lever Module (MLM)...............................................1235 Lever 1...........................................................1235 Lever 2...........................................................1235 Lever 3...........................................................1236 Lever 4...........................................................1236 System Modes..............................................................1236 Hydraulic Interlock Mode..............................................1236 Fault Mode............................................................1236 Engine Off Mode.......................................................1236 Normal Operation..........................................................1236 Normal Operation Mode.................................................1236 Lifting Control.......................................................1236 Lowering Control......................................................1237 Tilt Control (Forward and Backward)...................................1237 Auxiliary Control.....................................................1237 Lighting Control..............................................................1237 Description...............................................................1237 Front Work Lights.....................................................1240 Front Marker Lights (if equipped).....................................1240 Front/Rear Turn Signal Lights.........................................1240 Rear Tail/Marker Lights...............................................1240 Rear Work Light.......................................................1240 Rear Backup Lights....................................................1240 Rear Stop Lights......................................................1240 Strobe Light(s).......................................................1240 Spot Light (if equipped)..............................................1240 Cab...........................................................................1240 Description...............................................................1240 Component Descriptions....................................................1242 Cab Heating System....................................................1242 Lighting Control System...............................................1242 Wiper/Washer System...................................................1242 Cab Systems Operation.....................................................1243 Front End (Mast) and Chassis......................................................1246 Front End, Mast...............................................................1248 Description...............................................................1248 Carriages.....................................................................1248 Description...............................................................1248 Principles of Operation...................................................1249 Integral Sideshift Carriage...........................................1249 Mast Mounts...................................................................1251 Description...............................................................1251 Principles of Operation...................................................1251 Two-Stage Limited Free-Lift (LFL) Mast........................................1253 Description...............................................................1253 Principles of Operation...................................................1254 Two-Stage Full Free-Lift (FFL) Mast...........................................1255 Description...............................................................1255 Principles of Operation...................................................1256 Three-Stage Full Free-Lift (FFL) Mast.........................................1257 Description...............................................................1257 Principles of Operation...................................................1257 Four-Stage Full Free-Lift (FFL) Mast..........................................1259 Description...............................................................1259 Principles of Operation...................................................1260 Cylinder Cushion During Lifting Sequence......................................1262 Description...............................................................1262 Principles of Operation...................................................1262 Cylinder Cushion During Lowering Sequence.....................................1263 Description...............................................................1263 Principles of Operation...................................................1263 Tilt and Sideshift Cylinders..................................................1263 Description...............................................................1263 Tilt Cylinder.........................................................1263 Sideshift Cylinder....................................................1263 Lowering Control Valves.......................................................1264 Description...............................................................1264 Principles of Operation...................................................1264 Chassis.......................................................................1266 Description...............................................................1266 Abnormal Channel Wear.........................................................1268 Abnormal Hose Wear............................................................1270 Abnormal Mast Noise...........................................................1272 Body Panels Making Noise......................................................1276 External Leakage From Free-Lift or Main Lift Cylinders........................1277 FFL Mast Banging During Phasing...............................................1278 High Tire Wear - Drive Axle...................................................1280 High Tire Wear - Steer Axle...................................................1282 Hoses Not Tracking Correctly..................................................1284 Integral Sideshift Moving Too Fast............................................1285 Integral Sideshift Not Moving or Slow.........................................1286 LP Tank Bracket Disengages....................................................1289 LP Tank Rattles and Does Not Stay Latched.....................................1290 Mast is Loose.................................................................1291 Mast Lift Chains Are Loose....................................................1293 Mast or Carriage Binding......................................................1294 Mast/Carriage Bounces or is Spongy............................................1296 Misphasing of Full Free-Lift Mast.............................................1297 Overhead Guard Loose or Damaged...............................................1299 Racking During Lift...........................................................1300 Racking During Tilt...........................................................1302 Truck Feels Unstable..........................................................1303 Truck Wanders, Does Not Track Straight or Steer Well..........................1305 Wheels Appear Tipped or Misaligned............................................1307 Wheels Spinning On Uneven Floors..............................................1309 Wheel Studs Breaking..........................................................1310 Supplementary Data................................................................1312 Abbreviations and Acronyms....................................................1314 Special Tools List............................................................1322 Fault Mode Indicator (FMI) Reference List.....................................1328 TSP Reference Tables..........................................................1330 tables................................................................................ 54 Table 9020-10-1. IAT Ambient Temperature.......................................... 145 Table 9020-40-1. Test Specifications.............................................. 318 Table 9020-40-2. Test Specifications.............................................. 319 Table 9020-40-3. Service Tools.................................................... 319 Table 9020-40-4. Test Specifications.............................................. 320 Table 9020-40-5. Service Tools.................................................... 320 Table 9020-40-6. Test Specifications.............................................. 321 Table 9020-40-7. Service Tools.................................................... 322 Table 9020-40-8. Test Specifications - Mazda...................................... 323 Table 9020-40-9. Test Specifications - GM......................................... 323 Table 9020-40-10. Service Tools................................................... 323 Table 9020-40-11. Test Specifications............................................. 325 Table 9020-40-12. Service Tools................................................... 325 Table 9020-40-13. Test Specifications............................................. 327 Table 9020-40-14. Service Tools................................................... 327 Table 9030-03-1. Cummins QSB 3.3L Fault Codes..................................... 358 Table 9030-03-2. Circuit Group Identification..................................... 361 Table 9030-03-3. Hyster Wiring Color Codes........................................ 362 Table 9040-10-1. Two-Speed Transmission Clutch Pack Solenoid Val.................. 998 Table 9040-10-2. Three-Speed Transmission Electronic Proportiona.................. 999 Table 9040-10-3. Transmission Control Mode........................................1001 Table 9040-40-1. Test Specifications..............................................1066 Table 9040-40-2. Service Tools....................................................1066 Table 9040-40-3. Service Tools....................................................1066 Table 9040-40-4. Test Specifications..............................................1068 Table 9040-40-5. Test Specifications..............................................1068 Table 9040-40-6. Test Specifications..............................................1069 Table 9040-40-7. Test Specifications..............................................1069 Table 9040-40-8. Test Specifications..............................................1070 Table 9040-40-9. Service Tools....................................................1070 Table 9040-40-10. Stall Speeds....................................................1071 Table 9050-10-1. Standby Pressure Table...........................................1100 Table 9050-40-1. Test Specifications..............................................1194 Table 9050-40-2. Service Tools....................................................1194 Table 9050-40-3. Test Specifications..............................................1195 Table 9050-40-4. Service Tools....................................................1195 Table 9050-40-5. Test Specifications..............................................1197 Table 9050-40-6. Service Tools....................................................1197 Table 9050-40-7. Test Specifications..............................................1199 Table 9050-40-8. Service Tools....................................................1200 Table 9050-40-9. Test Specifications..............................................1201 Table 9050-40-10. Test Specifications.............................................1202 Table 9050-40-11. Service Tools...................................................1202 Table 9050-40-12. Test Specifications.............................................1203 Table 9050-40-13. Service Tools...................................................1203 Table 9050-40-14. Test Specifications.............................................1206 Table 9050-40-15. Service Tools...................................................1206 Table 9050-40-16. Test Specifications.............................................1207 Table 9050-40-17. Service Tools...................................................1207 Table 9050-40-18. Test Specifications.............................................1208 Table 9050-40-19. Service Tools...................................................1209 Table 9050-40-20. Test Specifications.............................................1210 Table 9050-40-21. Service Tools...................................................1210 Table 9050-40-22. Test Specifications.............................................1211 Table 9050-40-23. Service Tools...................................................1211 Table 9050-40-24. Test Specifications.............................................1212 Table 9050-40-25. Service Tools...................................................1212 Table 9080-50-1. Abbreviations and Acronyms.......................................1314 Table 9080-60-1. Special Tools....................................................1322 Table 9080-70-1. FMI..............................................................1328 Table 9080-80-1. Resistor-Temperature Characteristics ............................1330 1580502-0100SRM1120-(01-2007)-UK-EN.......................................................1334 toc...................................................................................1334 Frame.............................................................................1334 Safety Precautions Maintenance and Repair.........................................1335 General...........................................................................1338 Description.......................................................................1339 Hood, Seat, and Side Covers Replacement...........................................1339 Remove........................................................................1339 Install.......................................................................1344 LPG Tank and Bracket Replacement..................................................1346 Remove........................................................................1346 LPG Tank..................................................................1346 LPG Bracket...............................................................1349 Install.......................................................................1349 LPG Bracket...............................................................1349 LPG Tank..................................................................1350 Counterweight Replacement.........................................................1351 Remove........................................................................1351 Install.......................................................................1352 Tow Pin, Remove and Install...................................................1353 Overhead Guard Replacement........................................................1353 Remove and Install............................................................1353 LED Tail, Backup, and Brake Lights, Replace...................................1354 Operator Restraint System Replacement.............................................1355 Description...................................................................1355 Automatic Locking Retractor (ALR).........................................1355 Emergency Locking Retractor (ELR).........................................1355 Engine Replacement................................................................1356 Remove Engine Only............................................................1356 Remove Engine and Transmission................................................1360 Install Engine Only...........................................................1360 Install Engine and Transmission...............................................1361 Throttle Pedal and Cable Adjustment...............................................1362 Mazda Gas/LPG Engines With Basic Power Shift Transmission and Ma..............1362 Mazda Gasoline Engine With Electronic Transmission............................1365 Throttle Pedal Stop Adjustment, Mazda 2007 Emission Compliant En..............1366 Yanmar Diesel Engine With Basic Power Shift Transmission......................1366 Yanmar Diesel Engine With Electronic Throttle.................................1366 Exhaust System Repair.............................................................1368 Lift Trucks With Counterweight Exhaust System.................................1368 Mazda and GM Gas and LPG Engines..........................................1368 Remove and Disassemble................................................1368 Inspect...............................................................1368 Assemble and Install..................................................1370 Yanmar Diesel Engine......................................................1372 Remove and Disassemble................................................1372 Inspect...............................................................1372 Assemble and Install..................................................1372 Lift Trucks With Overhead Exhaust System......................................1374 Yanmar Diesel Engine......................................................1374 Remove and Disassemble................................................1374 Inspect...............................................................1374 Assemble and Install..................................................1375 Mazda Gas and LPG Engines.................................................1377 Remove and Disassemble................................................1377 Inspect...............................................................1377 Assemble and Install..................................................1377 Cooling System....................................................................1381 Description...................................................................1381 Fuel and Hydraulic Tanks Repair...................................................1381 Inspect.......................................................................1381 Clean.........................................................................1381 Steam Method of Cleaning..................................................1381 Chemical Solution Method of Cleaning......................................1382 Additional Preparations for Repair............................................1382 Small Leaks, Repair...........................................................1383 Large Leaks, Repair...........................................................1383 Preparations for Use After Repair.............................................1383 Safety Labels.....................................................................1383 tables................................................................................1334 Table 1. Weight of Counterweights, Lift Truck Models S2.0-3.5FT ..................1352 Table 2. Weight of Counterweights, Lift Truck Models S30FT, S35F..................1352 Table 3. Weight of Counterweights, Lift Truck Models H1.6FT, H1...................1352 Table 4. Weight of Counterweights, Lift Truck Models H2.0-3.5FT ..................1352 1580504-0600SRM1122-(12-2006)-UK-EN.......................................................1388 toc...................................................................................1388 Mazda Engine......................................................................1388 Safety Precautions Maintenance and Repair.........................................1389 General...........................................................................1392 Serial Number.................................................................1392 Engine Removal and Installation...................................................1392 Cylinder Head, Camshaft, and Valve Mechanism Repair...............................1393 Remove........................................................................1393 Clean.........................................................................1395 Inspect and Repair............................................................1395 Cylinder Head.............................................................1395 Rocker Shaft Assembly.....................................................1395 Camshaft..................................................................1395 Valve Guides..............................................................1397 Valve Seats...............................................................1397 Valves....................................................................1397 Valve Springs.............................................................1398 Install.......................................................................1398 Crankshaft and Main Bearings Repair...............................................1402 Remove........................................................................1402 Inspect and Repair............................................................1403 Crankshaft................................................................1403 Main Bearings.............................................................1403 Install.......................................................................1404 Pistons and Connecting Rods Repair................................................1405 Remove and Disassemble........................................................1405 Clean.........................................................................1405 Inspect and Repair............................................................1405 Pistons...................................................................1405 Piston Rings..............................................................1405 Connecting Rods and Bearings..............................................1406 Assemble and Install..........................................................1406 Cylinder Block Repair.............................................................1408 Oil Pump Repair...................................................................1408 Remove........................................................................1408 Disassemble...................................................................1410 Clean.........................................................................1410 Inspect.......................................................................1410 Assemble......................................................................1411 Install.......................................................................1411 Cooling System Repair.............................................................1413 Thermostat....................................................................1413 Replace...................................................................1413 Fan Assembly..................................................................1413 Remove and Disassemble....................................................1413 Assemble and Install......................................................1413 Water Pump....................................................................1414 Remove....................................................................1414 Install...................................................................1415 Flywheel and Ring Gear Repair.....................................................1415 Remove........................................................................1415 Install.......................................................................1415 Valve Adjustment..................................................................1416 Compression Pressure Check........................................................1417 Engine Timing Adjustment..........................................................1418 Engine Specifications.............................................................1418 Engine Data...................................................................1418 Engine Speeds.................................................................1418 2007 Emission Compliant Engines...........................................1418 All Engines Except 2007 Emission Compliant Engines........................1419 Thermostat....................................................................1419 Cylinder Head.................................................................1419 Valve Mechanism...............................................................1419 Camshaft......................................................................1420 Crankshaft....................................................................1420 Connecting Rods...............................................................1421 Cylinder Block................................................................1421 Pistons.......................................................................1421 Oil Pump......................................................................1422 Torque Specifications.............................................................1422 tables................................................................................1388 Table 1. Pressure Specifications..................................................1417 1580505-0700SRM1123-(04-2008)-UK-EN.......................................................1426 toc...................................................................................1426 Cooling System....................................................................1426 Safety Precautions Maintenance and Repair.........................................1427 General...........................................................................1430 Cooling System Checks.............................................................1430 Exhaust Leaks Into Cooling System.............................................1430 Water Flow Restrictions in Radiator...........................................1430 Radiator Hoses................................................................1430 Water Pump....................................................................1430 Flushing the Cooling System.......................................................1431 Cooling System, Clean.........................................................1431 Radiator Replacement..............................................................1432 Radiator, Remove for Lift Trucks Models S30FT, S35FT, S40FTS (E0..............1432 Radiator, Remove for Lift Truck Models S6.0FT, S7.0FT (S135FT, S..............1440 Radiator, Remove for Lift Truck Models H6.0FT, H7.0FT (H135FT, H..............1441 Radiator, Install for Lift Truck Models S30FT, S35FT, S40FTS (E0..............1443 Radiator, Install for Lift Truck Models S6.0FT, S7.0FT (S135FT, ..............1445 Radiator, Install for Lift Truck Models H6.0FT, H7.0FT (H135FT, ..............1447 Fan Assembly Replacement..........................................................1451 Fan Removal...................................................................1451 Inspect.......................................................................1455 Fan Installation..............................................................1457 1580507-0900SRM1125-(05-2005)-UK-EN.......................................................1462 toc...................................................................................1462 LPG Fuel System...................................................................1462 Safety Precautions Maintenance and Repair.........................................1463 General...........................................................................1466 Hoses Replacement.................................................................1466 LPG Tank Replacement..............................................................1466 Remove........................................................................1466 Install.......................................................................1466 Fuel Filter.......................................................................1468 Remove........................................................................1468 Clean and Inspect.............................................................1469 Install.......................................................................1470 Relief Valve Replacement..........................................................1471 Remove and Install............................................................1471 Carburetor Repair.................................................................1471 Remove........................................................................1471 Disassemble...................................................................1471 Clean.........................................................................1473 Assemble......................................................................1473 Install.......................................................................1473 Fuel Injector Repair..............................................................1474 Remove........................................................................1474 Clean and Inspect.............................................................1474 Install.......................................................................1474 Governor Repair...................................................................1474 Remove........................................................................1474 Install.......................................................................1474 Regulator Repair..................................................................1475 Remove........................................................................1475 Install.......................................................................1476 Control System....................................................................1476 Engine Control Unit (ECU).....................................................1476 Remove....................................................................1476 Install...................................................................1476 Engine Coolant Temperature (ECT) Sensor.......................................1477 Remove....................................................................1477 Install...................................................................1477 Camshaft Position (CMP) Sensor................................................1477 Voltage Check.............................................................1477 Intake Air Temperature (IAT) Sensor...........................................1478 Remove....................................................................1478 Install...................................................................1478 Manifold Absolute Pressure (MAP) Sensor.......................................1479 Remove....................................................................1479 Install...................................................................1479 Oxygen Sensor.................................................................1479 Remove....................................................................1479 Install...................................................................1479 Throttle Position (TP) Sensor.................................................1480 Remove....................................................................1480 Install...................................................................1480 1580510-1300SRM1129-(07-2008)-UK-EN.......................................................1484 toc...................................................................................1484 Powershift Transmission...........................................................1484 Safety Precautions Maintenance and Repair.........................................1485 General...........................................................................1488 Serial Number.................................................................1488 Charge Pump Repair................................................................1489 Remove........................................................................1489 Inspect.......................................................................1489 Install.......................................................................1489 Torque Converter Replace..........................................................1490 Remove........................................................................1490 Install.......................................................................1494 Front Cover Housing and Chain Drive Repair........................................1500 Remove........................................................................1500 Clean.........................................................................1507 Inspect.......................................................................1507 Install.......................................................................1507 Clutch Packs Repair...............................................................1513 Remove and Disassemble........................................................1513 Transmission, Remove and Disassemble......................................1513 Clutch Assemblies, Remove and Disassemble.................................1524 Clean.........................................................................1530 Inspect.......................................................................1530 Assemble and Install..........................................................1531 Clutch Assemblies, Assemble and Install...................................1531 Transmission, Assemble and Install........................................1539 Control Valve Repair..............................................................1544 Remove and Disassemble........................................................1544 Clean.........................................................................1545 Inspect.......................................................................1545 Assemble and Install..........................................................1547 MONOTROL® Pedal Repair............................................................1548 Remove and Disassemble........................................................1548 Assemble and Install..........................................................1551 Direction Control Lever...........................................................1552 Remove........................................................................1552 Install.......................................................................1552 1580512-1600SRM1133-(07-2008)-UK-EN.......................................................1556 toc...................................................................................1556 Steering Axle.....................................................................1556 Safety Precautions Maintenance and Repair.........................................1557 General...........................................................................1560 Steering Axle Assembly Repair.....................................................1561 Remove........................................................................1561 Disassemble...................................................................1562 Clean.........................................................................1562 Inspect.......................................................................1562 Assemble......................................................................1569 Install.......................................................................1574 Spindles, Bearings, and Tie Rods Repair...........................................1575 Spindles and Bearings.........................................................1575 S2.0-3.5FT (S40-70FT, S55FTS) (F187), S4.0, 4.5, 5.5FT, S5.5FTS,..........1575 Remove................................................................1575 Disassemble...........................................................1576 Clean.................................................................1577 Inspect...............................................................1577 Assemble..............................................................1577 Install...............................................................1578 Spindles and Bearings.........................................................1581 S30FT, S35FT, S40FTS (E010), H1.6FT, H1.8FT, H2.0FTS (H30FT, H35..........1581 Remove and Disassemble................................................1581 Assemble and Install..................................................1581 Tie Rods......................................................................1582 S2.0-3.5FT (S40-70FT, S55FTS) (F187), and S4.0, 4.5, 5.5FT, S5.5..........1582 Remove................................................................1582 Install...............................................................1583 Tie Rods......................................................................1584 S30FT, S35FT, S40FTS (E010), H1.6FT, H1.8FT, H2.0FTS (H30FT, H35..........1584 Remove................................................................1584 Install...............................................................1584 Steering Cylinder Repair..........................................................1587 Remove and Disassemble........................................................1587 Clean and Inspect.............................................................1588 Assemble and Install..........................................................1588 Torque Specifications.............................................................1589 1580513-1800SRM1135-(10-2006)-UK-EN.......................................................1594 toc...................................................................................1594 Brake System......................................................................1594 Safety Precautions Maintenance and Repair.........................................1595 General...........................................................................1598 Dry Brake System..............................................................1598 Wet Brake System..............................................................1598 Service Brakes Repair (Dry Brake).................................................1599 Remove and Disassemble........................................................1599 Clean.........................................................................1604 Inspect.......................................................................1605 Assemble and Install..........................................................1605 Adjust........................................................................1612 Parking Brake Repair..............................................................1613 Remove and Disassemble........................................................1613 Assemble and Install..........................................................1613 Adjust........................................................................1616 Master Cylinder Repair............................................................1616 Remove (Dry Brake)............................................................1616 Disassemble (Dry Brake).......................................................1617 Clean and Inspect (Dry Brake).................................................1619 Assemble (Dry Brake)..........................................................1619 Bench Bleed Master Cylinder (Dry Brake).......................................1619 Install and Adjust (Dry Brake)................................................1619 Remove (Wet Brake)............................................................1620 Disassemble (Wet Brake).......................................................1621 Clean and Inspect (Wet Brake).................................................1622 Assemble (Wet Brake)..........................................................1622 Install and Adjust (Wet Brake)................................................1622 Service Brakes Adjustment (Dry Brake).............................................1623 Brake System Air Removal..........................................................1624 Using Pressure Bleed System...................................................1624 Using Brake Pedal Pressure....................................................1624 Brake Pedal Adjustment............................................................1625 Free Pedal Adjustment.............................................................1626 Torque Specifications.............................................................1627 1580514-1900SRM1136-(07-2008)-UK-EN.......................................................1630 toc...................................................................................1630 Hydraulic Gear Pump...............................................................1630 Safety Precautions Maintenance and Repair.........................................1631 General...........................................................................1634 Single Gear Pump Assembly Repair..................................................1634 Remove........................................................................1634 Disassemble...................................................................1635 Clean.........................................................................1635 Inspect.......................................................................1635 Assemble......................................................................1635 Install.......................................................................1639 Tandem Gear Pump Assembly.........................................................1640 Remove........................................................................1640 Disassemble...................................................................1642 Clean.........................................................................1644 Inspect.......................................................................1644 Assemble......................................................................1644 Install.......................................................................1645 Gear Pump Specifications..........................................................1645 Torque Specifications.............................................................1649 tables................................................................................1630 Table 1. Standard Gear Pump for Lift Truck Models S30FT, S35FT, ..................1645 Table 2. High Pressure Gear Pump for Lift Truck Models S30FT, S3..................1646 Table 3. Standard Gear Pump for Lift Truck Models S4.0, 4.5, 5.5..................1647 Table 4. High Pressure Gear Pump for Lift Truck Models S4.0, 4.5..................1647 Table 5. Standard Gear Pump for Lift Truck Models S6.0FT, S7.0FT..................1648 Table 6. High Pressure Gear Pump for Lift Truck Models S6.0FT, S..................1648 1580515-2000SRM1137-(07-2008)-UK-EN.......................................................1652 toc...................................................................................1652 Main Control Valve................................................................1652 Safety Precautions Maintenance and Repair.........................................1653 General...........................................................................1658 Electro-Hydraulic Main Control Valve..............................................1659 Description...................................................................1659 Remove........................................................................1662 Electro-Hydraulic Control Valve Sections......................................1666 General...................................................................1666 Outlet Control Valve Section..............................................1666 Remove................................................................1666 Disassemble...........................................................1666 Clean.................................................................1666 Inspect...............................................................1666 Assemble..............................................................1668 Install...............................................................1668 Auxiliary Control Valve Sections..........................................1668 Remove................................................................1668 Disassemble...........................................................1670 Clean.................................................................1671 Inspect...............................................................1671 Assemble..............................................................1671 Install...............................................................1671 Tilt Control Valve Section................................................1672 Remove................................................................1672 Disassemble...........................................................1672 Clean.................................................................1672 Inspect...............................................................1675 Assemble..............................................................1675 Install...............................................................1675 Lift/Lower Control Valve Section..........................................1675 Remove................................................................1675 Disassemble...........................................................1675 Clean.................................................................1678 Inspect...............................................................1678 Assemble..............................................................1678 Install...............................................................1679 Mid-Inlet Section.........................................................1679 Remove................................................................1679 Clean.................................................................1680 Inspect...............................................................1680 Install...............................................................1680 Install.......................................................................1680 Electro Hydraulic Poppet Valve (EHPV) Pilot Pin Adjustment....................1684 Lift Pilot Pin............................................................1684 Lower Pilot Pin...........................................................1686 Abnormal/Erroneous EHPV Adjustment........................................1688 Manual Main Control Valve.........................................................1688 Description...................................................................1688 Remove........................................................................1689 Manual Control Valve Sections.................................................1694 General...................................................................1694 Outlet Control Valve Section..............................................1694 Remove................................................................1694 Disassemble...........................................................1694 Clean.................................................................1696 Inspect...............................................................1696 Assemble..............................................................1696 Install...............................................................1696 Auxiliary Control Valve Sections..........................................1696 Remove................................................................1696 Disassemble...........................................................1697 Clean.................................................................1697 Inspect...............................................................1697 Assemble..............................................................1697 Install...............................................................1699 Lift/Tilt Control Valve Section...........................................1699 Remove................................................................1699 Disassemble...........................................................1699 Clean.................................................................1702 Inspect...............................................................1702 Assemble..............................................................1702 Install...............................................................1703 Mid-Inlet Section.........................................................1703 Remove................................................................1703 Clean.................................................................1704 Inspect...............................................................1704 Install...............................................................1704 Install.......................................................................1704 Pressure Relief Valve Check and Adjustment........................................1708 Primary Relief Valve..........................................................1708 Secondary Relief Valve........................................................1709 Steering Control Unit Repair......................................................1712 Steering Control Unit, Remove.................................................1712 Steering Control Unit, Disassemble............................................1715 Steering Control Unit, Clean..................................................1715 Steering Control Unit, Inspect................................................1715 Steering Control Unit, Assemble...............................................1717 Relief Valve, Disassemble.....................................................1717 Relief Valve, Clean...........................................................1718 Relief Valve, Inspect.........................................................1718 Relief Valve, Assemble........................................................1718 Steering Control Unit, Install................................................1718 tables................................................................................1652 Table 1. Relief Valve Settings....................................................1709 Table 2. Steering Relief Pressures................................................1719 1580516-2100SRM1139-(07-2008)-UK-EN.......................................................1722 toc...................................................................................1722 Cylinder Repair...................................................................1722 Safety Precautions Maintenance and Repair.........................................1723 General...........................................................................1726 Description.......................................................................1726 Safety Procedures When Working Near Mast..........................................1727 Tilt Cylinder Repair..............................................................1729 Remove........................................................................1729 Disassemble...................................................................1729 Inspect.......................................................................1730 Clean.........................................................................1730 Assemble......................................................................1730 Install.......................................................................1733 Tilt Cylinders, Adjust........................................................1733 Tilt Cylinder Leak Check......................................................1735 Torque Specifications.........................................................1736 Piston Rod Nut............................................................1736 Gland.....................................................................1736 Tilt Cylinder Mounting Capscrew...........................................1737 Tilt Cylinder Rod End Capscrew............................................1737 Lift Cylinder Repair..............................................................1737 Main Lift Cylinders...........................................................1737 Remove....................................................................1737 Disassemble...............................................................1738 Clean.....................................................................1739 Inspect...................................................................1739 Assemble..................................................................1739 Install...................................................................1740 Two-Stage FFL Left Side Main Lift Cylinder....................................1741 Disassemble...............................................................1741 Clean.....................................................................1743 Inspect...................................................................1743 Assemble..................................................................1743 Install...................................................................1743 Free-Lift Cylinder............................................................1743 Remove....................................................................1743 Disassemble...............................................................1746 Clean.....................................................................1747 Inspect...................................................................1747 Assemble..................................................................1747 Install...................................................................1748 Torque Specifications.........................................................1748 Lift Cylinders Leak Check.....................................................1749 tables................................................................................1722 Table 1. Movement Rates (Maximum) for Tilt Cylinders..............................1736 1580517-2200SRM1128-(08-2008)-UK-EN.......................................................1752 toc...................................................................................1752 Wire Harness Repair...............................................................1752 Safety Precautions Maintenance and Repair.........................................1753 General...........................................................................1758 Deutsch Crimping Tool.............................................................1758 How to Strip a Wire for Use With Deutsch Crimping Tool........................1758 How to Crimp With the Deutsch Crimping Tool...................................1759 Calibration Test for the Deutsch Crimping Tool................................1760 Deutsch Connectors................................................................1762 DT, DTM, and DTP Series Connectors............................................1762 Connector Receptacle Replacement..........................................1770 Connector Plug Replacement................................................1775 Connector Receptacle Pin Replacement......................................1781 Connector Plug Socket Replacement.........................................1787 HD Series Connectors..........................................................1795 Connector Receptacle Replacement..........................................1797 Connector Plug Replacement................................................1800 Connector Receptacle Pin Replacement......................................1803 Connector Plug Socket Replacement.........................................1808 Sealing Plugs.................................................................1812 Metri-Pack Connectors.............................................................1814 Remove and Install............................................................1814 Micro-Pack Connectors.............................................................1816 Weather-Pack Connectors...........................................................1817 Weather-Pack Terminal Repair..................................................1817 AMPSEAL Crimping Tools............................................................1818 AMP Hand Crimping Tool With Certi-Crimp.......................................1818 Description...............................................................1818 Stripping Wire for Use With AMP Hand Crimping Tool........................1819 Insulation Crimp Adjustment...............................................1819 Maintenance and Inspection for AMP Hand Crimping Tool.....................1820 AMP Hand Crimping Tool................................................1820 Crimp Height Inspection...............................................1820 How to Use AMP Hand Crimping Tool.............................................1821 AMP Pro-Crimper II Tool.......................................................1821 Description...............................................................1821 Remove and Install Die Set and Locator Assembly.......................1822 Stripping Wire for Use With AMP PRO-CRIMPER II Tool.......................1823 Contact Support Adjustment................................................1823 Crimp Height Adjustment...................................................1824 Maintenance and Inspection Procedures.....................................1824 PRO-CRIMPER II Tool...................................................1824 Crimp Height Inspection...............................................1824 How to Use AMP PRO-CRIMPER II Tool............................................1825 AMPSEAL Connector Assemblies......................................................1826 Description for Plug Connector Assembly.......................................1826 Seal Plug.................................................................1826 Contact Crimping..........................................................1827 Contact Removal...........................................................1827 Contact Insertion.........................................................1829 Description for Plug Connector and Header Assembly............................1831 Voltage Reading...........................................................1832 Seal Plug.................................................................1832 Contact Crimping..........................................................1833 Contact Removal...........................................................1835 Contact Insertion.........................................................1837 AMP Superseal 1.5 Crimping Tools..................................................1839 Mini Mic Receptacle and Tab Contacts..........................................1839 Description...............................................................1839 Crimping Conditions and Measurements......................................1839 Insertion of Rubber Seal on Cable.........................................1841 Correction or Replacement of Parts........................................1842 AMP Hand Application Tool.....................................................1846 Description...............................................................1846 Maintenance and Inspection................................................1846 Crimp Height Inspection...............................................1846 Crimp Height Adjustment...................................................1847 How to Use AMP Hand Application Tool..........................................1847 AMP Pro-Crimper II Tool.......................................................1848 Description...............................................................1848 Remove and Install Die Set and Locator Assembly.......................1848 Adjustments...............................................................1849 Contact Support.......................................................1849 Crimp Height..........................................................1849 Inspections and Maintenance...............................................1851 Crimp Height Inspection...............................................1851 Visual Inspection.....................................................1851 Maintenance...........................................................1851 How to Use Pro-Crimper II Tool................................................1851 AMP Superseal 1.5 Connector Assemblies............................................1852 Description...................................................................1852 Harness Assembly..........................................................1852 Positioning of anti-backout device....................................1853 Removal of Contacts...................................................1855 Repair and Maintenance........................................................1859 Panel Mount Option............................................................1859 AMP Fastin-Faston Hand Tools......................................................1859 Description - AMP Double Action Hand Tool.....................................1859 Maintenance and Inspection Procedures.........................................1861 Daily Maintenance.........................................................1861 Periodic Tool Inspection..................................................1861 Lubrication...........................................................1861 Visual Inspection.....................................................1861 Crimp Height Inspection...................................................1862 Certi-Crimp Ratchet Inspection............................................1862 How to Use AMP Double Action Hand Tool........................................1863 Description - AMP Extraction Tool.............................................1864 Maintenance and Inspection....................................................1864 How to Use AMP Extraction Tool................................................1865 AMP Fastin-Faston Receptacles and Housings........................................1866 Description...................................................................1866 Wire Repair.......................................................................1872 Wire Splicing Requirements....................................................1872 Deutsch Jiffy Splice..........................................................1873 Assemble..................................................................1873 Disassemble...............................................................1875 Del-City Crimp-Solder-Shrink Splice...........................................1877 Twisted/Shielded Cable and Leads Repair...........................................1878 Twisted/Shielded Cable Repair.................................................1878 Twisted Leads Repair..........................................................1880 Special Tools.....................................................................1881 tables................................................................................1752 Table 1. Wire Strip Length Specifications.........................................1759 Table 2. Wire Size (AWG)..........................................................1820 Table 3. Crimp Height.............................................................1821 Table 4. Strip Length for PRO-CRIMPER II Tool.....................................1823 Table 5. Crimp Measurement........................................................1824 Table 6. Current Rating...........................................................1826 Table 7. Crimp Conditions.........................................................1834 Table 8. Wire Strip Lengths.......................................................1846 Table 9. Wire Strip Lengths.......................................................1847 Table 10. Crimp Height - Dimension ...............................................1851 Table 11. Wire Size and Crimp Height..............................................1862 Table 12. Wire Strip Length.......................................................1863 Table 13. Wire Strip Length and Crimp Measurements................................1868 Table 14. Crimp Pull-Out Test.....................................................1871 Table 15. Wire Strip Length Specifications........................................1872 Table 16. Wire Splice Size........................................................1877 1580518-2200SRM1130-(08-2008)-UK-EN.......................................................1890 toc...................................................................................1890 User Interface....................................................................1890 Safety Precautions Maintenance and Repair.........................................1891 General...........................................................................1894 Description...................................................................1894 Dash Display Menu Access......................................................1894 Menu Navigation...................................................................1895 Standard Display..............................................................1895 Main Menu.........................................................................1895 Passwords Menu....................................................................1896 Password Administration...........................................................1896 Add Password..................................................................1896 Delete Password...............................................................1897 Edit Password.................................................................1897 Other Password Functions..........................................................1898 Operator Passwords - Enable/Disable...........................................1898 Password Time-Out Delay.......................................................1899 Passwords - Number Wrong to Disable...........................................1899 Lockout Reset Password........................................................1900 View Password Log.............................................................1900 View Versions.....................................................................1901 VSM Versions..................................................................1901 Dash Display Versions.........................................................1902 Engine Controller Version.....................................................1903 Transmission (Xmsn) Controller Version........................................1904 Truck Serial Number...........................................................1905 Diagnostics.......................................................................1906 View Fault Log................................................................1906 Set Travel and Braking............................................................1907 Speed Limit...................................................................1907 Acceleration Rate.............................................................1908 Auto-Deceleration Rate........................................................1908 Set Power Reversal Rate.......................................................1909 Set Inching/Brake Overlap.....................................................1910 Setup Display Menu................................................................1911 Set Operator Language.........................................................1911 Set Units.....................................................................1912 Set Time Format (12/24 Hour)..................................................1912 Set Daylight Saving Time......................................................1913 Set Time......................................................................1915 Set Date Format...............................................................1915 Set Date......................................................................1915 Setup Hydraulics..................................................................1916 Return to Set Tilt Delay/On/Off...............................................1916 Setup General Items...............................................................1917 Light Shutdown Time-Out.......................................................1917 Impact Sensor - Enable/Disable................................................1918 Impact Sensor - Soft Impact Settings..........................................1919 Impact Sensor - Hard Impact Settings..........................................1919 Adjust Impact Sensor Settings.................................................1920 Initial Adjustment of Soft and Hard Impact Settings.......................1922 Readjustment of Soft and Hard Impact Settings.............................1923 Impact Sensor - Impact Alarm/Shutdown Reset...................................1923 Impact Sensor - Alarm Time Duration and Deactivation..........................1924 Impact Sensor - View Impact Event Log.........................................1925 Operator Checklist................................................................1926 Operator Checklist Off-On Mode................................................1926 Edit Operator Checklist.......................................................1926 Set Operator Checklist Expiration.............................................1927 View Checklist Log............................................................1927 Clear Operator Checklist Log..................................................1928 Clear Operator Checklist Fault................................................1928 Calibrations......................................................................1929 Set Tilt Stop Point...........................................................1929 Calibrate Loaded Weight.......................................................1929 tables................................................................................1890 Table 1. Password Screen..........................................................1894 Table 2. Exit Options Menu........................................................1895 Table 3. Add Password Menu........................................................1896 Table 4. Delete Password Menu.....................................................1897 Table 5. Edit Password Menu.......................................................1898 Table 6. Operator Passwords Menu..................................................1898 Table 7. Password Time-Out Delay Menu.............................................1899 Table 8. Passwords - Number Wrong to Disable Menu.................................1899 Table 9. View Password Log Menu...................................................1900 Table 10. View VSM Versions Menu..................................................1901 Table 11. View Dash Display Versions Menu.........................................1902 Table 12. View Engine Controller Versions Menu....................................1903 Table 13. View Transmission Controller Versions Menu..............................1904 Table 14. View Truck Serial Number Menu...........................................1905 Table 15. View Fault Log..........................................................1906 Table 16. Speed Limit Menu........................................................1907 Table 17. Acceleration Rate Menu..................................................1908 Table 18. Auto-Decel Menu.........................................................1908 Table 19. Power Reversal Menu.....................................................1909 Table 20. Inch/Brake Overlap Menu.................................................1910 Table 21. Set Language Menu.......................................................1911 Table 22. Set Units Menu..........................................................1912 Table 23. Set Time Format Menu....................................................1912 Table 24. Set Daylight Saving Time Menu...........................................1913 Table 25. Set Time Menu...........................................................1915 Table 26. Set Date Format Menu....................................................1915 Table 27. Set Date Menu...........................................................1915 Table 28. Tilt Delay Menu.........................................................1916 Table 29. Light Time-Out Menu.....................................................1917 Table 30. Impact Sensor Enable/Disable............................................1918 Table 31. Soft Impact Settings Menu...............................................1919 Table 32. Hard Impact Settings Menu...............................................1920 Table 33. Impact Sensor Default Settings..........................................1920 Table 34. Recommended Starting Values for Impact Sensor Settings..................1922 Table 35. Shutdown Reset Menu.....................................................1923 Table 36. Alarm Duration Menu.....................................................1924 Table 37. View Event Log Menu.....................................................1925 Table 38. Checklist Off-On Mode Menu..............................................1926 Table 39. Edit Checklist Menu.....................................................1926 Table 40. Checklist Expiration Menu...............................................1927 Table 41. View Checklist Log Menu.................................................1927 Table 42. Clear Checklist Log Menu................................................1928 Table 43. Clear Checklist Fault Menu..............................................1928 Table 44. Tilt Stop Point Menu....................................................1929 Table 45. Calibrate Loaded Weight.................................................1929 1580519-2200SRM1131-(08-2008)-UK-EN.......................................................1932 toc...................................................................................1932 User Interface....................................................................1932 Safety Precautions Maintenance and Repair.........................................1933 General...........................................................................1936 Description...................................................................1936 Dash Display Menu Access......................................................1936 Menu Navigation...................................................................1937 Main Menu.........................................................................1938 Passwords.........................................................................1938 Adding Passwords..............................................................1939 Hourmeters........................................................................1940 View Versions.....................................................................1941 VSM Versions..................................................................1941 Dash Display Versions.........................................................1942 Engine Controller Version.....................................................1943 Transmission (Xmsn) Controller Version........................................1944 Truck Serial Number...........................................................1945 Truck Configuration...........................................................1946 Diagnostics.......................................................................1947 Clear Fault Log...............................................................1947 View Fault Log................................................................1948 No-Run Data Display...........................................................1949 Engine Accelerator and Throttle Data Display..................................1950 Engine Speeds and Governor Data Display.......................................1951 Engine Fuel and Emissions Data Display........................................1953 Engine General Data Display...................................................1956 XMSN/Brake Data Display.......................................................1957 Hydraulic Data Display........................................................1959 General Truck Data Display....................................................1961 Set Travel and Braking............................................................1963 Speed Limit...................................................................1963 Acceleration Rate.............................................................1964 Auto-Deceleration Rate........................................................1964 Set Power Reversal Rate.......................................................1965 Set Inching/Brake Overlap.....................................................1966 Setup Hydraulics..................................................................1967 Lift Maximum Speed............................................................1967 Lower Maximum Speed...........................................................1968 Tilt Maximum Speed............................................................1968 Auxiliary Function One, Direction A, Maximum Speed............................1970 Auxiliary Function One, Direction B, Maximum Speed............................1970 Auxiliary Function Two, Direction A, Maximum Speed............................1971 Auxiliary Function Two, Direction B, Maximum Speed............................1971 Auxiliary Function Three, Direction A, Maximum Speed..........................1972 Auxiliary Function Three, Direction B, Maximum Speed..........................1972 Lift/Lower Ramp Rate..........................................................1973 Hydraulic Auxiliary Ramp Rate.................................................1974 Return to Set Tilt Delay/On/Off...............................................1975 Setup Display.....................................................................1976 Set Service Language..........................................................1976 Setup General Items...............................................................1977 Motion Alarm Activation Type..................................................1977 Light Shutdown Time-Out.......................................................1978 Restore Default Settings......................................................1979 Restore Engine Controller Default Calibration.................................1979 Impact Sensor - Enable/Disable................................................1980 Impact Sensor - Soft Impact Settings..........................................1981 Impact Sensor - Hard Impact Settings..........................................1981 Adjust Impact Sensor Settings.................................................1982 Initial Adjustment of Soft and Hard Impact Settings.......................1984 Readjustment of Soft and Hard Impact Settings.............................1985 Impact Sensor - Impact Alarm/Shutdown Reset...................................1985 Impact Sensor - Alarm Time Duration and Deactivation..........................1986 Impact Sensor - View Impact Event Log.........................................1987 Calibrations......................................................................1988 Calibrate Transmission Valve..................................................1990 Set Tilt Stop Point...........................................................1990 Calibrate Loaded Weight.......................................................1991 Calibrate Travel Speed Sensor.................................................1991 Calibrate Mazda LP and Gas Accelerator Pedal..................................1992 tables................................................................................1932 Table 1. Password Screen..........................................................1936 Table 2. Exit Menu................................................................1937 Table 3. Add Password Menu........................................................1939 Table 4. Hourmeters Menu..........................................................1940 Table 5. View VSM Versions Menu...................................................1941 Table 6. View Dash Display Versions Menu..........................................1942 Table 7. View Engine Controller Versions Menu.....................................1943 Table 8. View Transmission Controller Versions Menu...............................1944 Table 9. View Truck Serial Number Menu............................................1945 Table 10. View Truck Configuration Menu...........................................1946 Table 11. Clear Fault Log.........................................................1947 Table 12. View Fault Log..........................................................1948 Table 13. No-Run Data Display.....................................................1949 Table 14. Engine Accelerator and Throttle Data Display............................1950 Table 15. Engine Speeds and Governor Data Display.................................1952 Table 16. Engine Fuel and Emissions Data Display..................................1954 Table 17. Engine General Data Display.............................................1956 Table 18. XMSN Brake Data Display.................................................1957 Table 19. Hydraulic Data Display..................................................1959 Table 20. General Truck Data Display..............................................1961 Table 21. Speed Limit Menu........................................................1963 Table 22. Acceleration Rate Menu..................................................1964 Table 23. Auto-Decel Menu.........................................................1964 Table 24. Power Reversal Menu.....................................................1965 Table 25. Inch/Brake Overlap Menu.................................................1966 Table 26. Lift Speed Menu.........................................................1967 Table 27. Lower Speed Menu........................................................1968 Table 28. Tilt Speed Menu.........................................................1968 Table 29. Auxiliary Function Speed Menu...........................................1970 Table 30. Auxiliary Function Speed Menu...........................................1970 Table 31. Auxiliary Function Speed Menu...........................................1971 Table 32. Auxiliary Function Speed Menu...........................................1971 Table 33. Auxiliary Function Speed Menu...........................................1972 Table 34. Auxiliary Function Speed Menu...........................................1972 Table 35. Lift/Lower Ramp Rate Menu...............................................1973 Table 36. Hydraulic Auxiliary Ramp Rate Menu......................................1974 Table 37. Tilt Delay Menu.........................................................1975 Table 38. Service Language Menu...................................................1976 Table 39. Alarm Type Menu.........................................................1977 Table 40. Light Time-Out Menu.....................................................1978 Table 41. Restore Defaults Menu...................................................1979 Table 42. Restore Settings Menu...................................................1979 Table 43. Impact Sensor Enable/Disable............................................1980 Table 44. Soft Impact Settings Menu...............................................1981 Table 45. Hard Impact Settings Menu...............................................1982 Table 46. Impact Sensor Default Settings..........................................1982 Table 47. Recommended Starting Values for Impact Sensor Settings..................1984 Table 48. Shutdown Reset Menu.....................................................1985 Table 49. Alarm Duration Menu.....................................................1986 Table 50. View Event Log Menu.....................................................1987 Table 51. Calibrate Electro-Hydraulic Valve Menu..................................1989 Table 52. Calibrate Transmission Valve Menu.......................................1990 Table 53. Tilt Stop Point Menu....................................................1990 Table 54. Calibrate Loaded Weight.................................................1991 Table 55. Travel Speed Menu.......................................................1991 Table 56. Travel Speed Menu.......................................................1992 1580520-2200SRM1142-(09-2008)-UK-EN.......................................................1996 toc...................................................................................1996 Electrical System.................................................................1996 Safety Precautions Maintenance and Repair.........................................1997 General...........................................................................2006 Display Switch Cluster............................................................2007 Remove........................................................................2007 Install.......................................................................2009 Direction Control and Turn Signal Levers......................................2009 Remove....................................................................2009 Install...................................................................2009 Key Switch....................................................................2011 Remove....................................................................2011 Install...................................................................2011 Display Switch Cluster Panel Bezel and Overlay................................2012 Remove....................................................................2012 Install...................................................................2012 Steering Column Repair............................................................2012 Remove........................................................................2012 Disassemble...................................................................2012 Assemble......................................................................2012 Install.......................................................................2013 Sensors and Switches..............................................................2015 General.......................................................................2015 Dash and Kick Panel, Remove and Install...................................2015 Remove................................................................2015 Install...............................................................2015 Accelerator Pedal Position Sensor.............................................2017 Remove....................................................................2017 Install...................................................................2017 Brake Fluid Level Switch......................................................2020 Remove....................................................................2020 Install...................................................................2020 Service Brake Pedal Position Sensor...........................................2021 Remove....................................................................2021 Install...................................................................2021 Parking Brake Sensor..........................................................2022 Remove....................................................................2022 Install...................................................................2022 Service Brake Pressure Sensor.................................................2023 Remove....................................................................2023 Install...................................................................2023 MONOTROL® Sensor Microswitch..................................................2023 Remove....................................................................2023 Install...................................................................2025 Low Coolant Level Sensor......................................................2025 Remove....................................................................2027 Install...................................................................2027 Fuel Level Sensor, Gas and Diesel Engines Only................................2027 Remove....................................................................2027 Install...................................................................2027 Armrest Switch................................................................2028 Remove....................................................................2028 Install...................................................................2028 Seat Sensor (Operator Presence System)........................................2030 Non-Suspension and Semi-Suspension Seats; All Lift truck Models ..........2030 Remove................................................................2030 Install...............................................................2030 Non-Suspension Seats; Lift Truck Models H6.0FT, H7.0FT (H135FT, ..........2031 Remove................................................................2031 Install...............................................................2031 Full Suspension Seats; All Lift Truck Models..............................2032 Remove................................................................2032 Install...............................................................2032 Hood Shut Off Switch..........................................................2032 Remove....................................................................2032 Install...................................................................2032 Hydraulic Filter Pressure Switch..............................................2036 Remove....................................................................2036 Install...................................................................2036 Transmission Speed Sensor.....................................................2036 Remove....................................................................2036 Install...................................................................2037 Transmission Pressure Sensors.................................................2037 Remove....................................................................2037 Install...................................................................2037 Transmission Temperature Sensor...............................................2037 Remove....................................................................2037 Install...................................................................2038 Engine Speed Sensor...........................................................2039 Remove....................................................................2039 Install...................................................................2039 Intermediate Speed Sensor.....................................................2039 Remove....................................................................2039 Install...................................................................2039 Return to Set Tilt (Tilt Angle) Sensor........................................2039 Lift Truck Models S30FT, S35FT, S40FTS (E010); H1.6FT, H1.8FT, H..........2039 Remove................................................................2039 Install...............................................................2040 Lift Truck Models S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024); ..........2040 Remove................................................................2040 Install...............................................................2041 Rear Horn Button Switch.......................................................2041 Remove....................................................................2041 Install...................................................................2041 Impact Sensor.................................................................2042 All Lift Truck Models Except H6.0FT, H7.0FT (H135FT, H155FT) (H0..........2042 Remove................................................................2042 Install...............................................................2042 Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006)............2044 Remove................................................................2044 Install...............................................................2045 Load Weight Sensor............................................................2045 Remove....................................................................2045 Install...................................................................2046 Engine and Fuel Sensors - Mazda 2.0L and 2.2L Gas and LPG Engine..............2046 Oxygen Sensor.............................................................2046 Remove................................................................2046 Install...............................................................2046 Intake Air Temperature (IAT) Sensor.......................................2047 Remove................................................................2047 Install...............................................................2047 Manifold Absolute Pressure (MAP)/Boost Sensor.............................2047 Remove................................................................2047 Install...............................................................2047 Throttle Position (TPS) Sensor............................................2048 Remove................................................................2048 Install...............................................................2048 Engine and Fuel Sensors and Switches - Mazda 2.0L and 2.2L LPG E..............2048 Oil Pressure Sensor.......................................................2048 Remove................................................................2048 Install...............................................................2048 Low LPG Pressure Switch...................................................2049 Remove................................................................2049 Install...............................................................2049 Air Filter Restriction Switch.............................................2049 Remove................................................................2049 Install...............................................................2050 Engine Coolant Temperature (ECT) Sensor...................................2050 Remove................................................................2050 Install...............................................................2050 Engine and Fuel Sensors and Switches- Mazda 2.0L and 2.2L Gas En..............2050 Oil Pressure Sensor.......................................................2050 Remove................................................................2050 Install...............................................................2050 Mass Air Flow (MAF) Sensor................................................2051 Remove................................................................2051 Install...............................................................2051 Air Filter Restriction Switch.............................................2051 Remove................................................................2051 Install...............................................................2051 Engine Coolant Temperature (ECT) Sensor...................................2052 Remove................................................................2052 Install...............................................................2052 Engine and Fuel Sensors and Switches - Mazda 2.0L and 2.2L Gas a..............2052 Oil Pressure Sensor.......................................................2052 Remove................................................................2052 Install...............................................................2052 Air Filter Restriction Switch.............................................2053 Remove................................................................2053 Install...............................................................2053 CAM Angle Sensor..........................................................2054 Voltage Check.........................................................2054 Oxygen Sensor.............................................................2055 Remove................................................................2055 Install...............................................................2055 Engine and Fuel Sensors and Switches - Mazda 2.0L and 2.2L LPG E..............2055 Engine Coolant Temperature (ECT) Sensor...................................2055 Remove................................................................2055 Install...............................................................2056 Manifold Absolute Pressure (MAP) Sensor...................................2057 Remove................................................................2057 Install...............................................................2057 Intake Air Temperature (IAT) Sensor.......................................2057 Remove................................................................2057 Install...............................................................2057 Fuel Temperature Sensor...................................................2058 Remove................................................................2058 Install...............................................................2058 Low LPG Pressure Switch...................................................2059 Remove................................................................2059 Install...............................................................2059 Engine and Fuel Sensors and Switches- Mazda 2.0L and 2.2L Gas En..............2060 Intake Air Temperature (IAT) Sensor.......................................2060 Remove................................................................2060 Install...............................................................2060 Engine Coolant Temperature (ECT) Sensor...................................2061 Remove................................................................2061 Install...............................................................2061 Manifold Absolute Pressure (MAP) Sensor...................................2062 Remove................................................................2062 Install...............................................................2062 Engine and Fuel Sensors and Switches, GM 2.4L and 4.3L Gas and L..............2063 Crankshaft Sensor.........................................................2063 Remove................................................................2063 Install...............................................................2063 Camshaft Position (CMP) Sensor............................................2064 Remove................................................................2064 Install...............................................................2064 Camshaft Position (CMP) Sensor Assembly...................................2065 Remove................................................................2065 Install...............................................................2065 Oil Pressure Sensor.......................................................2065 Remove................................................................2065 Install...............................................................2065 Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) ..........2066 Remove................................................................2066 Install...............................................................2066 Engine Coolant Temperature (ECT) Sensor...................................2067 Remove................................................................2067 Install...............................................................2067 Air Flow Restriction Switch...............................................2067 Remove................................................................2067 Install...............................................................2068 Oxygen Sensor.............................................................2068 Remove................................................................2068 Install...............................................................2071 Engine and Fuel Switches, GM 2.4L and GM 4.3L LPG Trucks Only.................2072 Low LPG Pressure Switch...................................................2072 Remove................................................................2072 Install...............................................................2072 LPG Pressure Sensor, GM 4.3L Engine Only..................................2073 Remove................................................................2073 Install...............................................................2073 Engine and Fuel Sensors and Switches, Yanmar Diesel Trucks....................2073 Air Filter Restriction Switch.............................................2073 Remove................................................................2073 Install...............................................................2073 Oil Pressure Sensor.......................................................2073 Remove................................................................2073 Install...............................................................2073 Engine Speed Sensor.......................................................2073 Remove................................................................2073 Install...............................................................2073 Engine Coolant Temperature (ECT) Sensor...................................2075 Remove................................................................2075 Install...............................................................2075 Throttle Position Sensor (TPS)............................................2075 Remove................................................................2075 Install...............................................................2075 Fuel/Water Separator Sensor...............................................2076 Remove................................................................2076 Install...............................................................2076 Glow Plug Relay...........................................................2077 Remove................................................................2077 Install...............................................................2079 Engine and Fuel Sensors and Switches, Cummins Diesel Engines..................2079 Air Filter Restriction Switch.............................................2079 Remove................................................................2079 Install...............................................................2079 Oil Pressure Sensor.......................................................2081 Remove................................................................2081 Install...............................................................2081 Engine Speed Sensor (Cummins 4.5L Only)...................................2081 Remove................................................................2081 Install...............................................................2081 Engine Coolant Temperature (ECT) Sensor...................................2082 Remove................................................................2082 Install...............................................................2082 Throttle Position Sensor (TPS) (Cummins 4.5L Only)........................2082 Remove................................................................2082 Install...............................................................2083 Fuel/Water Separator Sensor...............................................2083 Remove................................................................2083 Install...............................................................2083 Vehicle System Manager (VSM)......................................................2084 General.......................................................................2084 VSM Replacement...............................................................2084 Remove....................................................................2084 Install...................................................................2085 Programming a New VSM and/or Display Switch Cluster...........................2086 General...................................................................2086 PC Service Tool Software..................................................2086 Data Transferring.........................................................2087 New or Used VSM.......................................................2087 New (Blank) Display Switch Cluster....................................2087 Used (Non-Blank) Display Switch Cluster...............................2087 Power Distribution Module (PDM) and Component Parts...............................2088 Remove........................................................................2088 PDM as a Unit.............................................................2088 Install.......................................................................2091 PDM as a Unit.............................................................2091 Remove and Install............................................................2091 PDM Component Parts.......................................................2091 Transmission Control Unit.........................................................2092 Remove S6.0FT, S7.0FT, (S135FT,S155FT) (D024, E024) and H6.0FT, ..............2092 Install S6.0FT, S7.0FT, (S135FT,S155FT) (D024, E024) and H6.0FT,..............2093 Battery...........................................................................2093 Remove........................................................................2093 Install.......................................................................2093 Lights............................................................................2093 Work Lights (Front and Rear)..................................................2093 Remove....................................................................2093 Install...................................................................2093 Strobe Light..................................................................2094 Remove....................................................................2094 Install...................................................................2095 LED Tail, Backup, and Brake Lights............................................2095 Remove....................................................................2095 Install...................................................................2095 Electronic-Hydraulic Controls.....................................................2097 General.......................................................................2097 Mini-Lever Replacement........................................................2097 Remove....................................................................2097 Clean and Inspect.........................................................2098 Install...................................................................2098 Push Button Switch Replacement................................................2099 Remove....................................................................2099 Install...................................................................2100 Test..........................................................................2101 Mini-Levers...............................................................2101 Full Stroke Test..........................................................2101 Function Returns to Neutral Test..........................................2101 Push Button Switch........................................................2101 Mini-Lever Module (MLM).......................................................2102 Remove....................................................................2102 Install...................................................................2102 tables................................................................................1996 Table 1. VSM and Display Switch Cluster Replacement...............................2088 1580521-2200SRM1143-(05-2005)-UK-EN.......................................................2106 toc...................................................................................2106 Electrical System.................................................................2106 Safety Precautions Maintenance and Repair.........................................2107 Ignition System...................................................................2110 General.......................................................................2110 Ignition Timing Adjustment, Gasoline and LPG..................................2110 Spark Plugs Check.............................................................2110 Spark Plug Wires Check........................................................2110 Distributor Repair................................................................2113 Remove........................................................................2113 Disassemble...................................................................2114 Inspect.......................................................................2114 Assemble......................................................................2115 Install.......................................................................2115 Igniter.......................................................................2116 Remove....................................................................2116 Test......................................................................2116 Install...................................................................2116 Camshaft Position (CMP) Sensor................................................2117 Voltage Check.............................................................2117 Ignition Coil Check...............................................................2118 Primary Coil Winding..........................................................2118 Secondary Coil Winding........................................................2118 Starter Repair....................................................................2119 General.......................................................................2119 Remove........................................................................2119 No-Load Test..................................................................2120 Magnetic Switch Test..........................................................2120 Pull-Out Test.............................................................2120 Holding Coil Test.........................................................2121 Return Test...............................................................2121 Pinion Movement Inspection................................................2121 Install.......................................................................2121 Alternator Repair.................................................................2122 General.......................................................................2122 Charging System Inspection....................................................2122 Output Current Check..........................................................2123 No-Load Adjusted Voltage Check................................................2123 Remove........................................................................2124 Inspect.......................................................................2124 Rectifier Check...........................................................2124 Install.......................................................................2125 tables................................................................................2106 Table 1. Spark Plug Wire..........................................................2110 Table 2. Starter Specifications...................................................2119 Table 3. Problem Diagnosis Chart..................................................2120 Table 4. Specifications...........................................................2123 Table 5. Rectifier Check Table....................................................2124 1580524-4000SRM1148-(11-2008)-UK-EN.......................................................2128 toc...................................................................................2128 Mast Repairs......................................................................2128 Safety Precautions Maintenance and Repair.........................................2129 General...........................................................................2132 Safety Procedures When Working Near Mast..........................................2132 Fork Repair.......................................................................2134 Remove........................................................................2134 Install.......................................................................2134 Checks........................................................................2135 Carriages Repair..................................................................2136 Standard Carriage.............................................................2136 Remove....................................................................2136 Repair....................................................................2137 Install...................................................................2137 Integral Sideshift Carriage...................................................2137 Remove....................................................................2137 Clean and Inspect.........................................................2140 Repair....................................................................2141 Install...................................................................2142 Mast Repair.......................................................................2142 Mast, Remove..................................................................2142 Two-Stage LFL and Two-Stage FFL Masts, Disassemble............................2146 Clean and Inspect.............................................................2152 Three-Stage FFL Mast..........................................................2153 Disassemble...............................................................2153 Clean and Inspect.........................................................2157 Two-Stage LFL and Two-Stage FFL Mast, Assemble................................2158 Three-Stage FFL Mast, Assemble................................................2159 Four-Stage FFL, Disassemble...................................................2161 Clean and Inspect.............................................................2165 Four-Stage FFL, Assemble......................................................2167 Mast, Install.................................................................2169 Header Hose Arrangement...........................................................2172 Two-Stage LFL.................................................................2172 Two-Stage FFL.................................................................2179 Three-Stage FFL...............................................................2191 Four-Stage FFL................................................................2206 Adjustment....................................................................2214 Lift Chains Adjustment............................................................2215 Carriage Adjustments..............................................................2217 Tilt Cylinders Adjustment.........................................................2217 Mast Adjustments..................................................................2221 Load Roller Adjustment........................................................2221 Mast Side Kicking Adjustment..................................................2223 tables................................................................................2128 Table 1. Fork Tip Alignment.......................................................2135 Table 2. Pneumatic Tire Trucks....................................................2175 Table 3. Cushion Tire Trucks......................................................2175 Table 4. Standard Two-Stage Hose Dimensions.......................................2178 Table 5. Pneumatic Tire Trucks....................................................2182 Table 6. Cushion Tire Trucks......................................................2182 Table 7. Pneumatic Tire Trucks....................................................2200 Table 8. Cushion Tire Trucks......................................................2200 Table 9. Standard Three-Stage Hose Dimensions.....................................2202 Table 10. Standard Four-Stage Hose Dimensions.....................................2207 Table 11. Hook-Type Carriage Chain Adjustment.....................................2215 Table 12. Pin-Type Carriage Chain Adjustment......................................2216 1580528-8000SRM1134-(07-2008)-UK-EN.......................................................2226 toc...................................................................................2226 Calibration Procedures............................................................2226 Safety Precautions Maintenance and Repair.........................................2227 Description.......................................................................2232 Proc_Cal_001: Service Password Entry..............................................2235 When to Perform...............................................................2235 Why Perform...................................................................2235 How to Perform................................................................2235 Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed...................2237 When to Perform...............................................................2237 Calibration Order.............................................................2237 Why Perform...................................................................2237 How to Perform................................................................2237 Proc_Cal_003: Save and Exit.......................................................2239 When to Perform...............................................................2239 Why Perform...................................................................2239 How to Perform................................................................2239 Proc_Cal_004: Lift Valve Output Threshold.........................................2241 When to Perform...............................................................2241 Calibration Order.............................................................2241 Why Perform...................................................................2241 How to Perform................................................................2241 Proc_Cal_005: Lower Valve Output Threshold........................................2243 When to Perform...............................................................2243 Calibration Order.............................................................2243 Why Perform...................................................................2243 How to Perform................................................................2243 Proc_Cal_006: Tilt Back Valve Output Threshold....................................2247 When to Perform...............................................................2247 Calibration Order.............................................................2247 Why Perform...................................................................2247 How to Perform................................................................2247 Proc_Cal_007: Tilt Forward Valve Output Threshold.................................2249 When to Perform...............................................................2249 Calibration Order.............................................................2249 Why Perform...................................................................2249 How to Perform................................................................2250 Proc_Cal_008: Aux 1 Dir A Valve Output Threshold..................................2253 When to Perform...............................................................2253 Calibration Order.............................................................2253 Why Perform...................................................................2253 How to Perform................................................................2253 Proc_Cal_009: Aux 1 Dir B Valve Output Threshold..................................2255 When to Perform...............................................................2255 Calibration Order.............................................................2255 Why Perform...................................................................2255 How to Perform................................................................2255 Proc_Cal_010: Aux 2 Dir A Valve Output Threshold..................................2259 When to Perform...............................................................2259 Calibration Order.............................................................2259 Why Perform...................................................................2259 How to Perform................................................................2259 Proc_Cal_011: Aux 2 Dir B Valve Output Threshold..................................2261 When to Perform...............................................................2261 Calibration Order.............................................................2261 Why Perform...................................................................2261 How to Perform................................................................2262 Proc_Cal_012: Aux 3 Dir A Valve Output Threshold..................................2265 When to Perform...............................................................2265 Calibration Order.............................................................2265 Why Perform...................................................................2265 How to Perform................................................................2265 Proc_Cal_013: Aux 3 Dir B Valve Output Threshold..................................2267 When to Perform...............................................................2267 Calibration Order.............................................................2267 Why Perform...................................................................2267 How to Perform................................................................2268 Proc_Cal_014: Load Weight Zero Point..............................................2271 When to Perform...............................................................2271 Calibration Order.............................................................2271 Why Perform...................................................................2271 How to Perform................................................................2271 Proc_Cal_015: Loaded Weight Calibration...........................................2273 When to Perform...............................................................2273 Calibration Order.............................................................2273 Why Perform...................................................................2273 How to Perform................................................................2273 Proc_Cal_016: Transmission Valve Calibration......................................2275 Applicable System/Option......................................................2275 When to Perform...............................................................2275 Calibration Order.............................................................2275 Why Perform...................................................................2276 How to Perform................................................................2276 Applicable System/Option......................................................2277 When to Perform...............................................................2277 Calibration Order.............................................................2277 Why Perform...................................................................2277 How to Perform................................................................2277 Proc_Cal_016A: Transmission Valve Calibration-Electronic Extende..................2279 Applicable System/Option......................................................2279 When to Perform...............................................................2279 Calibration Order.............................................................2279 Why Perform...................................................................2279 How to Perform................................................................2279 Proc_Cal_016B: Trans. Valve Calibration-Electronic and Electroni..................2281 Applicable System/Option......................................................2281 When to Perform...............................................................2281 Calibration Order.............................................................2281 Why Perform...................................................................2281 How to Perform................................................................2281 Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment.......................2283 Required Tools................................................................2283 When to Perform...............................................................2283 Calibration Order.............................................................2283 Why Perform...................................................................2283 How to Perform................................................................2283 Proc_Cal_025: Hydraulic Valve Pressure Gage Installation..........................2285 When to Perform...............................................................2285 Why Perform...................................................................2285 How to Perform................................................................2285 Proc_Cal_026: Travel Speed Calibration............................................2287 When to Perform...............................................................2287 Calibration Order.............................................................2287 Why Perform...................................................................2287 How to Perform................................................................2287 tables................................................................................2226 Table 1. Calibration Procedures...................................................2232 Table 2. How to Read Calibration Procedure........................................2233 Table 3. Proc_Cal_001: Service Password Entry.....................................2236 Table 4. Proc_Cal_002: Hydraulic Valve Calibration Warm Up and A..................2237 Table 5. Proc_Cal_003: Save and Exit..............................................2240 Table 6. Proc_Cal_004: Lift Valve Output Threshold................................2241 Table 7. Proc_Cal_005: Lower Valve Output Threshold...............................2244 Table 8. Proc_Cal_006: Tilt Back Valve Output Threshold...........................2247 Table 9. Proc_Cal_007: Tilt Forward Valve Output Threshold........................2250 Table 10. Proc_Cal_008: Aux 1 Dir A Valve Output Threshold........................2253 Table 11. Proc_Cal_009: Aux 1 Dir B Valve Output Threshold........................2256 Table 12. Proc_Cal_010: Aux 2 Dir A Valve Output Threshold........................2259 Table 13. Proc_Cal_011: Aux 2 Dir B Valve Output Threshold........................2262 Table 14. Proc_Cal_012: Aux 3 Dir A Valve Output Threshold........................2265 Table 15. Proc_Cal_013: Aux 3 Dir B Valve Output Threshold........................2268 Table 16. Proc_Cal_014: Load Weight Zero Point....................................2271 Table 17. Proc_Cal_015: Loaded Weight Calibration.................................2273 Table 18. Proc_Cal_016: Transmission Valve Calibration............................2276 Table 19. Proc_Cal_016: Transmission Valve Calibration ( S6.0FT,..................2278 Table 20. Proc_Cal_016A: Transmission Valve Calibration...........................2280 Table 21. Proc_Cal_016B: Transmission Valve Calibration...........................2282 Table 22. Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjus..................2284 Table 23. Proc_Cal_025: Hydraulic Valve Pressure Gage Installati..................2286 Table 24. Proc_Cal_026: Travel Speed Calibration..................................2287 1598588-0600SRM1205-(03-2007)-UK-EN.......................................................2292 toc...................................................................................2292 Yanmar Diesel Engines.............................................................2292 Safety Precautions Maintenance and Repair.........................................2293 General...........................................................................2298 Engine Identification.........................................................2298 Major Engine Component Identification.....................................2298 Location of Labels........................................................2298 Engine Removal and Installation...................................................2299 Cylinder Head Assembly Repair.....................................................2299 Glow Plugs....................................................................2301 Remove....................................................................2301 Install...................................................................2301 Valve Cover...................................................................2301 Remove....................................................................2301 Clean and Inspect.........................................................2301 Install...................................................................2302 Rocker Arm Assembly...........................................................2302 Remove....................................................................2302 Disassemble...............................................................2303 Clean and Inspect.........................................................2303 Push Rods.............................................................2303 Rocker Arm Assembly...................................................2303 Assemble..................................................................2304 Install...................................................................2304 Valve Clearance Adjustments...................................................2304 Cylinder Head Assembly........................................................2306 Remove....................................................................2306 Disassemble...............................................................2309 Valves and Valve Springs, Remove......................................2309 Valve Guides, Remove..................................................2310 Clean and Inspect.........................................................2310 Cylinder Head.........................................................2311 Valve Guides..........................................................2311 Valves................................................................2311 Valve Sink............................................................2311 Valve Seat............................................................2312 Valve Springs.........................................................2312 Assemble..................................................................2313 Valve Guides, Install.................................................2313 Valves and Valve Springs, Install.....................................2313 Install...................................................................2314 Timing Gear Case and Timing Gears Repair..........................................2315 Timing Gear Case Cover........................................................2315 Remove....................................................................2315 Clean and Inspect.........................................................2316 Install...................................................................2316 Timing Gears..................................................................2317 Crankshaft Gear...........................................................2317 Remove................................................................2317 Install...............................................................2317 Idler Gear................................................................2317 Remove................................................................2317 Inspect...............................................................2318 Install...............................................................2318 Camshaft Gear.............................................................2318 Remove................................................................2318 Install...............................................................2319 Timing Gear Case..............................................................2319 Remove....................................................................2319 Clean and Inspect.........................................................2319 Install...................................................................2319 Drive Train, Camshaft, and Cylinder Block Repair..................................2320 Remove........................................................................2320 Disassemble...................................................................2320 Pistons and Connecting Rods...............................................2320 Crankshaft................................................................2321 Camshaft..................................................................2323 Clean and Inspect.............................................................2324 Cylinder Block............................................................2324 Honing and Boring.....................................................2327 Pistons...................................................................2328 Piston Pin................................................................2328 Connecting Rod............................................................2329 Tappets...................................................................2329 Crankshaft................................................................2329 Camshaft..................................................................2331 Camshaft Bushing..........................................................2331 Assemble......................................................................2331 Camshaft..................................................................2331 Crankshaft................................................................2332 Pistons and Connecting Rods...............................................2332 Install.......................................................................2333 Lubrication System Repair.........................................................2334 Engine Oil and Oil Filter Change..............................................2334 Oil Pan.......................................................................2334 Remove....................................................................2334 Install...................................................................2335 Oil Suction Tube..............................................................2335 Remove....................................................................2335 Clean.....................................................................2335 Install...................................................................2336 Oil Pump......................................................................2336 Remove....................................................................2336 Clean and Inspect.........................................................2336 Outer Rotor Outside Clearance.........................................2337 Outer Rotor to Inner Rotor Tip Clearance..............................2337 Outer Rotor Side Clearance............................................2337 Rotor Shaft Clearance.................................................2337 Install...................................................................2338 Fuel System Repair................................................................2338 Fuel Injectors................................................................2338 Remove....................................................................2338 Inspect...................................................................2339 Clean.....................................................................2339 Test......................................................................2340 Install...................................................................2342 Electronic Throttle System....................................................2342 Remove....................................................................2342 Install...................................................................2345 Inspect...................................................................2346 Adjust....................................................................2346 Fuel Injection Pump...........................................................2346 Remove....................................................................2346 Clean and Inspect.........................................................2349 Install...................................................................2349 Check/Adjust Fuel Injection Timing........................................2350 Cooling System Repair.............................................................2352 V-Belt........................................................................2352 Remove....................................................................2352 Inspect...................................................................2352 Install...................................................................2352 Adjust....................................................................2352 Water Pump....................................................................2353 4TNE92-NMHA Engines.......................................................2353 Remove................................................................2353 Install...............................................................2354 4TNE92-NMH and 4TNE98-NMH Engines.........................................2355 Remove................................................................2355 Install...............................................................2356 Thermostat....................................................................2357 Remove....................................................................2357 Inspect...................................................................2357 Install...................................................................2358 Flywheel and Flywheel Housing.....................................................2359 Flywheel......................................................................2359 Remove....................................................................2359 Install...................................................................2359 Flywheel Housing..............................................................2360 Remove....................................................................2360 Install...................................................................2360 Electrical Equipment Repair.......................................................2361 Alternator....................................................................2361 Remove....................................................................2361 Bench Test................................................................2363 Regulate Voltage Check....................................................2363 No Load Test..............................................................2365 Output Test...............................................................2365 Install...................................................................2365 Starter.......................................................................2365 Remove....................................................................2367 No Load Test..............................................................2367 Install...................................................................2367 Engine Specifications.............................................................2368 Engine Data...................................................................2368 Engine Tuning.................................................................2371 Cylinder Head.................................................................2372 Intake/Exhaust Valve and Guide................................................2372 Valve Spring..................................................................2373 Rocker Arm and Shaft..........................................................2373 Push Rod......................................................................2373 Gear Train and Camshaft.......................................................2373 Camshaft..................................................................2373 Idle Gear Shaft and Bushing...............................................2374 Backlash of Each Gear.....................................................2374 Cylinder Block................................................................2375 Crankshaft....................................................................2375 Thrust Bearing................................................................2375 Piston........................................................................2375 Piston Ring...................................................................2376 Connecting Rod................................................................2376 Rod Small End.............................................................2377 Tappet....................................................................2377 Oil Pump......................................................................2377 Engine Oil Pressure.......................................................2377 Outer Rotor Outside Clearance.............................................2377 Outer Rotor Side Clearance................................................2377 Outer Rotor to Inner Rotor Tip Clearance..................................2377 Rotor Shaft Clearance.....................................................2378 Standard Torque Specifications....................................................2378 Standard Torque Chart.........................................................2378 Special Torque Specifications.....................................................2379 Special Tools.....................................................................2380 tables................................................................................2292 Table 1. Cylinder Measurement Worksheet...........................................2326 Table 2. Fuel Injector Spray Patterns.............................................2341 Table 3. V-Belt Deflection Table..................................................2352 Table 4. Alternator Specifications................................................2361 Table 5. Starter Specifications...................................................2366 Table 6. No Load Test Specifications..............................................2367 Table 7. 4TNE92-NMH Engine........................................................2368 Table 8. 4TNE92-NMHA Engine.......................................................2369 Table 9. 4TNE98-NMH Engine........................................................2370 1598589-1400SRM1206-(11-2008)-UK-EN.......................................................2388 toc...................................................................................2388 Drive Axle and Differential Assembly Repair.......................................2388 Safety Precautions Maintenance and Repair.........................................2389 General...........................................................................2392 Drive Axle Repair.................................................................2392 Remove and Disassemble........................................................2392 Clean and Inspect.............................................................2394 Assemble and Install..........................................................2394 Differential Repair...............................................................2397 Remove........................................................................2397 Differential Assembly From Center Section Assembly........................2397 Drive Pinion, Pinion Gear, and Bearings From Center Section...............2401 Disassemble...................................................................2406 Differential Assembly.....................................................2406 Drop Box Housing..........................................................2410 Center Section............................................................2411 Clean and Inspect.............................................................2413 Assemble......................................................................2413 Center Section............................................................2413 Drop Box Housing..........................................................2416 Differential Assembly.....................................................2417 Install.......................................................................2421 Pinion Inner Shim Set, Adjust Thickness (Depth of Pinion).................2421 Drive Pinion, Pinion Gear, and Bearings Into Center Section...............2423 Differential Assembly Into Center Section.................................2426 Ring Gear Backlash, Adjust................................................2431 Ring Gear, Runout Check...................................................2433 Gear Set, Tooth Contact Pattern Check.....................................2433 Torque Specifications.............................................................2436 tables................................................................................2388 Table 1. Pinion Variation Numbers Examples........................................2422 Table 2. Ring and Pinion Tooth Contact Adjustment.................................2433 Table 3. Correct Tooth Contact....................................................2434 Table 4. Incorrect Tooth Contact..................................................2435 1598591-8000SRM1208-(06-2007)-UK-EN.......................................................2440 toc...................................................................................2440 Capacities and Specifications.....................................................2440 Safety Precautions Maintenance and Repair.........................................2441 Lift Truck Lifting Capacity.......................................................2444 Counterweight Weights.............................................................2444 Tire Sizes........................................................................2444 Capacities........................................................................2444 Electrical System.................................................................2447 Transmission Oil Pressures........................................................2448 Hydraulic System Relief Pressures.................................................2449 Steering System...................................................................2449 Stall Speeds (in RPM ±100 rpm)....................................................2450 Mazda (Except 2007 Emission Compliant Engines)................................2450 Mazda (2007 Emission Compliant Engines Only)..................................2450 Yanmar 2.6L...................................................................2450 Mast Speeds ......................................................................2450 Tilt Angles.......................................................................2451 Front End Equipment - Mast Creep..................................................2452 Mast Creep....................................................................2452 Engine Specifications.............................................................2452 Torque Specifications.............................................................2454 Frame.........................................................................2454 Mast..........................................................................2454 Steering System, Cushion Tire Trucks..........................................2454 Steering System, Pneumatic Tire Trucks........................................2454 Drive Axle....................................................................2454 Transmission..................................................................2455 Engine - Mazda 2.0L...........................................................2455 Engine - Yanmar 2.6L Diesel...................................................2456 tables................................................................................2440 Table 1. Lift Truck Models S30FT, S35FT, S40FTS (E010) With Mazd..................2450 Table 2. Lift Truck Models H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT..................2451 Table 3. Lift Truck Models H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT..................2451 Table 4. S30FT, S35FT, S40FTS (E010) Lift Truck Models............................2451 Table 5. H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) (F001) L..................2451 Table 6. S30FT, S35FT, S40FTS (E010) Lift Truck Models............................2452 Table 7. H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) (F001) L..................2452 1602994-8000SRM1207-(07-2008)-UK-EN.......................................................2460 toc...................................................................................2460 Periodic Maintenance..............................................................2460 Safety Precautions Maintenance and Repair.........................................2461 General...........................................................................2466 Serial Number Data............................................................2466 How to Move Disabled Lift Truck...............................................2466 How to Tow Lift Truck.....................................................2466 How to Put Lift Truck on Blocks...............................................2467 How to Raise Drive Tires..................................................2467 How to Raise Steering Tires...............................................2468 Maintenance Schedule..............................................................2468 Maintenance Procedures Every 8 Hours or Daily.....................................2476 How to Make Checks With Engine Stopped........................................2476 Tires and Wheels..........................................................2476 Safety Labels.............................................................2476 Mast, Carriage, Lift Chains, Header Hoses, Attachment.....................2477 Operator Restraint System.................................................2477 Emergency Locking Retractor (ELR).....................................2477 Hood and Seat Latches.....................................................2478 Engine Compartment........................................................2478 Fuel, Oil, and Coolant Leaks, Check.......................................2479 Hydraulic Hoses...........................................................2479 Coolant Hoses.............................................................2479 Steering Column Gas Cylinder..............................................2479 Transmission..............................................................2479 Hydraulic System Oil......................................................2479 Engine Oil................................................................2480 Air Filter................................................................2481 Forks.....................................................................2481 Remove................................................................2481 Inspect...............................................................2481 Install...............................................................2482 Adjust................................................................2482 How to Make Checks With Engine Running........................................2483 Indicator Lights, Horn, Fuses, and Relays.................................2483 Service Brakes............................................................2485 Brake Fluid Level.....................................................2485 Operation, Check......................................................2486 Parking Brake.............................................................2486 Engine Oil Pressure.......................................................2486 Cooling System............................................................2487 Steering System...........................................................2487 Control Levers and Pedals.................................................2487 Lift System, Operate......................................................2488 First Service After First 100 Hours of Operation..................................2488 Mazda Engine Oil Filter.......................................................2488 Yanmar Engine Oil Filter......................................................2489 Hydraulic System..............................................................2489 Hydraulic Filter, Replace.................................................2489 Transmission Oil Filter, Replace..............................................2490 Maintenance Procedures Every 500 Hours or 6 Months................................2491 Hydraulic System Oil..........................................................2491 Hydraulic Tank Breather.......................................................2491 Inspect...................................................................2491 Battery.......................................................................2492 Engine Oil and Filter, Mazda and Yanmar Engines...............................2492 Drive Belt....................................................................2493 Mazda 2.0L Engines........................................................2493 Fan and Alternator Drive Belt.........................................2493 Yanmar Diesel Engine......................................................2494 Fan and Alternator Drive Belt.........................................2494 PCV Valve.....................................................................2494 Clean Debris From Radiator Core...............................................2495 Transmission Oil Level........................................................2495 Forks.........................................................................2495 Mast Lubrication..............................................................2496 Header Hose Checks............................................................2498 Lift Chain Lubrication........................................................2499 Tilt Cylinder Lubrication.....................................................2499 Master Brake Cylinder Rod End Pin Lubrication.................................2500 Manual Hydraulic Levers Lubrication...........................................2500 Brake Fluid...................................................................2501 Drain Tar From LPG Regulator..................................................2501 Tie Rod Lubrication ..........................................................2501 Differential and Drive Axle Oil (Dry Brake)...................................2502 Maintenance Procedures Every 1000 Hours or 6 Months...............................2503 Valve Clearance, Check and Adjust.............................................2503 Ignition System...............................................................2503 Mazda 2.0L Engines........................................................2503 LPG Vapor Fuel Filter Replace, Mazda Engines .................................2503 Fuel Filter Replacement, Yanmar Engine........................................2503 Priming the Fuel System (Yanmar)..............................................2505 Lift Chains Wear Check........................................................2506 Lift Chain Lubrication........................................................2506 Integral Sideshift Carriage, Check Bearings...................................2506 Steering Axle.................................................................2507 Control Levers and Pedals.....................................................2507 Maintenance Procedures Every 2000 Hours or Annually...............................2507 Hydraulic System..............................................................2507 Hydraulic Filter, Replace.................................................2507 Hydraulic Tank Breather, Replace..........................................2509 Air Filter....................................................................2509 PCV Valve.....................................................................2510 Oxygen Sensor.................................................................2511 LPG Regulator Fuel Filter, Mazda Engines (Except 2007 Mazda Emis..............2511 Remove and Replace........................................................2511 Timing Belt...................................................................2511 Mazda Engines.............................................................2511 LPG Fuel Injector, Mazda Engines (Except 2007 Mazda Emission Com..............2511 Fuel Injector, Yanmar Engines.................................................2511 Forks.........................................................................2512 Integral Sideshift Carriage...................................................2512 Bearings, Replace.........................................................2512 Transmission Oil and Filter (Dry Brake), Replace..............................2512 Brake Fluid (Master Cylinder), Change.........................................2513 Brake Fluid (Dry Brake), Remove...............................................2514 Service Brakes (Dry Brake)....................................................2514 Differential (Dry Brake)......................................................2514 Valve Clearance, Check and Adjust for Cummins QSB 3.3L Diesel En..............2515 Maintenance Procedures Every 4000 Hours or 2 Years................................2516 Hydraulic Oil, Replace........................................................2516 Cooling System................................................................2517 Safety Procedures When Working Near Mast..........................................2518 Hood Latch Check..................................................................2521 Lift Chain Adjustments............................................................2522 Jump-Starting the Lift Truck......................................................2523 Jump-Starting Using a Battery Charger.........................................2523 Jump-Starting a Lift Truck Using Another Lift Truck...........................2523 Welding Repairs...................................................................2524 Overhead Guard Changes............................................................2524 Wheel Repair......................................................................2525 General.......................................................................2525 Pneumatic Tire With Tube, Repair..............................................2525 Remove Wheels From Lift Truck.............................................2525 Remove Tire From Wheel....................................................2525 Remove Tire From Two-Piece Wheel......................................2526 Remove Tire From Three- and Four-Piece Wheels.........................2527 Install Wheel in Tire.....................................................2528 Install Two-Piece Wheel in Tire.......................................2529 Install Three- or Four-Piece Wheel in Tire............................2530 Add Air to Pneumatic Tires With Tube......................................2531 Wheels, Install...........................................................2531 Pneumatic Tubeless Tire, Repair...............................................2531 Remove Wheels From Lift Truck.............................................2531 Remove Tire From Wheel....................................................2532 Install Tire on Wheel.....................................................2534 Add Air to Pneumatic Tubeless Tire........................................2536 Wheels, Install...........................................................2537 Solid Rubber Tires on Pneumatic Wheels, Change................................2537 Remove Tire From Wheel....................................................2537 Install Tire on Wheel.....................................................2539 Snap-On-Tire, Change..........................................................2541 Remove Snap-On-Tire, Solid Tire From Wheel................................2541 Install Snap-On-Tire, Solid Tire on Wheel.................................2542 Adhesives and Sealants............................................................2543 tables................................................................................2460 Table 1. Maintenance Schedule.....................................................2471 Table 2. V-Belt Deflection Table..................................................2494 Table 3. Carriage Chain Adjustment, Forks Not Installed...........................2523 1673866-0100SRM1290-(07-2008)-UK-EN.......................................................2546 toc...................................................................................2546 Operator's Cab....................................................................2546 Safety Precautions Maintenance and Repair.........................................2547 General...........................................................................2552 Cab Replacement...................................................................2553 Remove, for Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F001); H2...............2553 Install, for Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F001); H2..............2564 Remove, for Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (H..............2565 Install, for Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (..............2569 Door Assemblies...................................................................2570 Right Side Door Assembly, Lift Truck Models H1.6FT, H1.8FT, 2.0F..............2570 Remove....................................................................2570 Disassemble...............................................................2575 Door Cover............................................................2575 Heater Assembly.......................................................2577 Door Lock Assembly....................................................2578 Windows...............................................................2579 Clean.....................................................................2579 Inspect...................................................................2579 Assemble..................................................................2579 Windows...............................................................2579 Door Lock Assembly....................................................2579 Heater Assembly.......................................................2580 Door Cover............................................................2580 Install...................................................................2580 Left Side Door Assembly, Lift Truck Models H1.6FT, H1.8FT, 2.0FT..............2580 Remove....................................................................2580 Disassemble...............................................................2580 Door Cover............................................................2580 Door Lock Assembly....................................................2582 Windows...............................................................2582 Clean.....................................................................2582 Inspect...................................................................2582 Assemble..................................................................2582 Windows...............................................................2582 Door Lock Assembly....................................................2582 Door Cover............................................................2582 Install...................................................................2582 Right and Left Side Door Assemblies, Lift Truck Models H6.0FT, H..............2583 Remove....................................................................2583 Disassemble...............................................................2583 Door Cover............................................................2583 Door Lock Assembly....................................................2585 Windows...............................................................2585 Clean.....................................................................2585 Inspect...................................................................2585 Assemble..................................................................2586 Windows...............................................................2586 Door Lock Assembly....................................................2586 Door Cover............................................................2586 Install...................................................................2587 Window Wipers Replacement.........................................................2587 General.......................................................................2587 Front Wiper Assembly and Motor................................................2587 Remove, Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F001) and H2.0..........2587 Install, Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F001) and H2...........2587 Remove, Lift Truck Models H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-5..........2589 Install, Lift Truck Models H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-..........2589 Rear Wiper Assembly and Motor.................................................2591 Remove, Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F001)...................2591 Install, Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F001)..................2591 Remove, Lift Truck Models H2.0-3.5FT (H40-70FT) (L177)....................2593 Install, Lift Truck Models H2.0-3.5FT (H40-70FT) (L177)...................2593 Remove, Lift Truck Models H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-5..........2596 Install, Lift Truck Models H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-..........2596 Remove, Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (H006,..........2598 Install, Lift Truck Models H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-..........2598 Window Replacement................................................................2600 General.......................................................................2600 Remove Door Window, Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F0..............2600 Install Door Windows, Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (..............2601 Remove Door Window, Lift Truck Models H6.0FT, H7.0FT (H135FT, H1..............2602 Install Door Window, Lift Truck Models H6.0FT, H7.0FT (H135FT, H..............2603 Heater Replacement................................................................2603 Remove, for Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (H..............2603 Install, for Lift truck Models H6.0FT, H7.0FT (H135FT, H155FT) (..............2606 Light Replacement.................................................................2607 Work Lights (Front and Rear)..................................................2607 Remove....................................................................2607 Install...................................................................2607 Strobe Light..................................................................2609 Remove....................................................................2609 Install...................................................................2609 Turn, Stop, Tail, and Backup Light............................................2610 Remove....................................................................2610 Install...................................................................2610 Front Marker/Turn Signal Lights...............................................2610 Remove....................................................................2610 Install...................................................................2610 Display Switches..................................................................2611 Electrical Schematics.............................................................2615 Optional Equipment................................................................2618 Heavy Duty Pre-Cleaner........................................................2618 Remove....................................................................2618 Clean.....................................................................2619 Inspect...................................................................2619 Install...................................................................2619 Fan...........................................................................2619 Remove....................................................................2619 Install...................................................................2619 Mirror........................................................................2619 Remove....................................................................2619 Install...................................................................2619 Label Replacement.................................................................2619 1698613-8000SRM1387-(07-2008)-UK-EN.......................................................2624 toc...................................................................................2624 Diagrams and Schematics...........................................................2624 Safety Precautions Maintenance and Repair.........................................2625 General Information About Diagrams and Schematics.................................2628 Symbol Definitions............................................................2628 tables................................................................................2624 Table 1. Wire Colors..............................................................2628 Table 2. Symbol Definitions.......................................................2628
HYSTER F001 (H1.6-1.8FT, H2.0FTS EUROPE) SERVICE MANUAL – PDF DOWNLOAD:
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