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Hyster F187 (S40-70FT, S55FTS ) Service Manual – PDF DOWNLOAD


Hyster F187 (S40-70FT, S55FTS ) Service Manual – PDF DOWNLOAD

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Hyster F187 (S40-70FT, S55FTS ) Service Manual – PDF DOWNLOAD

DESCRIPTION:

Hyster F187 (S40-70FT, S55FTS ) Service Manual – PDF DOWNLOAD

SAFETY PRECAUTIONS MAINTENANCE AND REPAIR :

• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly
fastened, and that the load being lifted is balanced. Make sure the crane, cables, and
chains have the capacity to support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair
on electric lift trucks.
• Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT
THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance
section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts
must meet or exceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before
using force to remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit whenmaking repairs,
or if the unit needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel
are flammable. Be sure to follow the necessary safety precautions when handling these
fuels and when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks
away from the area. Make sure the area is well ventilated.

TABLE OF CONTENTS:

Hyster F187 (S40-70FT, S55FTS ) Service Manual – PDF DOWNLOAD

Alternator 2200SRM0002-(12-2004)-US-EN..............................................   1
	toc.............................................................................   1
		Alternator with Regulator...................................................   1
		Safety Precautions Maintenance and Repair...................................   2
		General.....................................................................   5
		Description.................................................................   5
		Alternator Repair...........................................................   7
			Alternator Type A.......................................................   7
				Remove and Disassemble..............................................   7
				Clean...............................................................   8
				Assemble............................................................   9
				Install.............................................................   9
			Alternator Type B.......................................................  12
				Remove and Disassemble..............................................  12
				Clean...............................................................  12
				Assemble............................................................  13
				Install.............................................................  14
		General Check and Adjustment................................................  15
		Low Output Check (Type A or Type B).........................................  15
		High Output Check (Type A or Type B)........................................  17
		Brushes Circuit Check.......................................................  18
			Delco Alternators.......................................................  18
			Motorola Alternators....................................................  19
		Diodes Check................................................................  20
		Diode Bridge Check..........................................................  20
			Delco and Leece-Neville Alternators.....................................  20
			Motorola Alternators....................................................  20
		Rotor Field Winding Check...................................................  21
		Stator Windings Check.......................................................  22
		Voltage Regulator Check.....................................................  22
		Troubleshooting.............................................................  22
Brakes (S Model)-1800SRM1135-(05-2005)-US-EN........................................  27
	toc.............................................................................  27
		Brake System................................................................  27
		Safety Precautions Maintenance and Repair...................................  28
		General.....................................................................  31
			Service Brakes..........................................................  31
			Master Cylinder.........................................................  31
			Brake Position Sensor...................................................  31
			Parking Brake...........................................................  32
		Service Brakes Repair.......................................................  32
			Remove and Disassemble..................................................  32
			Clean...................................................................  38
			Inspect.................................................................  39
			Assemble and Install....................................................  39
			Adjust..................................................................  44
		Parking Brake Repair........................................................  45
			Remove and Disassemble..................................................  45
			Assemble and Install....................................................  46
			Adjust..................................................................  47
		Master Cylinder Repair......................................................  47
			Remove..................................................................  47
			Disassemble.............................................................  47
			Clean and Inspect.......................................................  47
			Assemble................................................................  47
			Bench Bleed Master Cylinder.............................................  50
			Install and Adjust......................................................  50
		Service Brakes Adjustment...................................................  50
		Brake System Air Removal....................................................  51
			Using Pressure Bleed System.............................................  51
			Using Brake Pedal Pressure..............................................  51
		Brake Pedal Adjustment......................................................  52
		Free Pedal Adjustment.......................................................  53
		Torque Specifications.......................................................  54
Calibrations-8000SRM1134-(05-2005)-US-EN............................................  57
	toc.............................................................................  57
		Calibration Procedures......................................................  57
		Safety Precautions Maintenance and Repair...................................  58
		Description.................................................................  61
		Proc_Cal_001: Service Password Entry........................................  63
			When to Perform.........................................................  63
			Why Perform.............................................................  63
			How to Perform..........................................................  63
		Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed.............  64
			When to Perform.........................................................  64
			Calibration Order.......................................................  64
			Why Perform.............................................................  64
			How to Perform..........................................................  64
		Proc_Cal_003: Save and Exit.................................................  66
			When to Perform.........................................................  66
			Why Perform.............................................................  66
			How to Perform..........................................................  66
		Proc_Cal_004: Lift Valve Output Threshold...................................  68
			When to Perform.........................................................  68
			Calibration Order.......................................................  68
			Why Perform.............................................................  68
			How to Perform..........................................................  68
		Proc_Cal_005: Lower Valve Output Threshold..................................  71
			When to Perform.........................................................  71
			Calibration Order.......................................................  71
			Why Perform.............................................................  71
			How to Perform..........................................................  71
		Proc_Cal_006: Tilt Back Valve Output Threshold..............................  74
			When to Perform.........................................................  74
			Calibration Order.......................................................  74
			Why Perform.............................................................  74
			How to Perform..........................................................  74
		Proc_Cal_007: Tilt Forward Valve Output Threshold...........................  77
			When to Perform.........................................................  77
			Calibration Order.......................................................  77
			Why Perform.............................................................  77
			How to Perform..........................................................  77
		Proc_Cal_008: Aux 1 Dir A Valve Output Threshold............................  80
			When to Perform.........................................................  80
			Calibration Order.......................................................  80
			Why Perform.............................................................  80
			How to Perform..........................................................  80
		Proc_Cal_009: Aux 1 Dir B Valve Output Threshold............................  83
			When to Perform.........................................................  83
			Calibration Order.......................................................  83
			Why Perform.............................................................  83
			How to Perform..........................................................  83
		Proc_Cal_010: Aux 2 Dir A Valve Output Threshold............................  86
			When to Perform.........................................................  86
			Calibration Order.......................................................  86
			Why Perform.............................................................  86
			How to Perform..........................................................  86
		Proc_Cal_011: Aux 2 Dir B Valve Output Threshold............................  89
			When to Perform.........................................................  89
			Calibration Order.......................................................  89
			Why Perform.............................................................  89
			How to Perform..........................................................  89
		Proc_Cal_012: Aux 3 Dir A Valve Output Threshold............................  92
			When to Perform.........................................................  92
			Calibration Order.......................................................  92
			Why Perform.............................................................  92
			How to Perform..........................................................  92
		Proc_Cal_013: Aux 3 Dir B Valve Output Threshold............................  95
			When to Perform.........................................................  95
			Calibration Order.......................................................  95
			Why Perform.............................................................  95
			How to Perform..........................................................  95
		Proc_Cal_014: Load Weight Zero Point........................................  98
			When to Perform.........................................................  98
			Calibration Order.......................................................  98
			Why Perform.............................................................  98
			How to Perform..........................................................  98
		Proc_Cal_015: Loaded Weight Calibration..................................... 100
			When to Perform......................................................... 100
			Calibration Order....................................................... 100
			Why Perform............................................................. 100
			How to Perform.......................................................... 100
		Proc_Cal_016: Transmission Valve Calibration................................ 102
			Applicable System/Option................................................ 102
			When to Perform......................................................... 102
			Calibration Order....................................................... 102
			Why Perform............................................................. 102
			How to Perform.......................................................... 102
		Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment................. 104
			Required Tools.......................................................... 104
			When to Perform......................................................... 104
			Calibration Order....................................................... 104
			Why Perform............................................................. 104
			How to Perform.......................................................... 104
		Proc_Cal_025: Hydraulic Valve Pressure Gage Installation.................... 106
			When to Perform......................................................... 106
			Why Perform............................................................. 106
			How to Perform.......................................................... 106
	tables..........................................................................  57
		Table 1. Calibration Procedures.............................................  61
		Table 2. How to Read Calibration Procedure..................................  62
		Table 3. Proc_Cal_001: Service Password Entry...............................  63
		Table 4. Proc_Cal_002: Hydraulic Valve Calibration Warm Up and A............  64
		Table 5. Proc_Cal_003: Save and Exit........................................  67
		Table 6. Proc_Cal_004: Lift Valve Output Threshold..........................  68
		Table 7. Proc_Cal_005: Lower Valve Output Threshold.........................  71
		Table 8. Proc_Cal_006: Tilt Back Valve Output Threshold.....................  74
		Table 9. Proc_Cal_007: Tilt Forward Valve Output Threshold..................  77
		Table 10. Proc_Cal_008: Aux 1 Dir A Valve Output Threshold..................  80
		Table 11. Proc_Cal_009: Aux 1 Dir B Valve Output Threshold..................  83
		Table 12. Proc_Cal_010: Aux 2 Dir A Valve Output Threshold..................  86
		Table 13. Proc_Cal_011: Aux 2 Dir B Valve Output Threshold..................  89
		Table 14. Proc_Cal_012: Aux 3 Dir A Valve Output Threshold..................  92
		Table 15. Proc_Cal_013: Aux 3 Dir B Valve Output Threshold..................  95
		Table 16. Proc_Cal_014: Load Weight Zero Point..............................  98
		Table 17. Proc_Cal_015: Loaded Weight Calibration........................... 100
		Table 18. Proc_Cal_016: Transmission Valve Calibration...................... 102
		Table 19. Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjus............ 105
		Table 20. Proc_Cal_025: Hydraulic Valve Pressure Gage Installati............ 107
Capacity and Spec-8000SRM1151-(05-2005)-US-EN....................................... 111
	toc............................................................................. 111
		Capacities and Specifications............................................... 111
		Safety Precautions Maintenance and Repair................................... 112
		Lift Truck Lifting Capacity................................................. 115
		Counterweight Weights....................................................... 115
		Tire Sizes.................................................................. 115
		Capacities.................................................................. 116
		Electrical System........................................................... 119
		Transmission Oil Pressures.................................................. 120
		Hydraulic System Relief Pressures........................................... 122
		Steering System............................................................. 122
		Stall Speeds (in RPM ±100 rpm).............................................. 123
			Mazda 2.0L.............................................................. 123
			Mazda 2.2L.............................................................. 123
			GM 2.4L................................................................. 123
			Yanmar 2.6L............................................................. 123
			Yanmar 3.3L............................................................. 123
		Mast Speeds................................................................. 123
		Tilt Angles................................................................. 127
		Front End Equipment - Mast Creep............................................ 127
			Mast Creep.............................................................. 127
		Engine Specifications....................................................... 128
		Torque Specifications....................................................... 130
			Frame................................................................... 130
			Mast.................................................................... 130
			Steering System, Cushioned Tire Trucks.................................. 130
			Steering System, Pneumatic Tire Trucks.................................. 130
			Drive Axle.............................................................. 130
			Transmission............................................................ 131
			Engine - Mazda 2.0L and 2.2L............................................ 131
			Engine - GM 2.4L........................................................ 132
			Engine - Yanmar 2.6L and 3.3L Diesel.................................... 134
	tables.......................................................................... 111
		Table 1. Lift Truck Models S2.0-3.5FT (S40-70FT, S55FTS) (F187)............. 124
		Table 2. Lift Truck Models H2.0-3.5FT (H40-70FT) (L177)..................... 125
		Table 3. S2.0-3.5FT (S40-70FT, S55FTS) (F187) Lift Truck Models............. 127
		Table 4. H2.0-3.5FT (H40-70FT) (L177) Lift Truck Models..................... 127
		Table 5. S2.0-3.5FT (S40-70FT, S55FTS) (F187) Lift Truck Models............. 127
		Table 6. H2.0-3.5FT (H40-70FT) (L177) Lift Truck Models..................... 128
Cooling-0700SRM1123-(05-2005)-US-EN................................................. 137
	toc............................................................................. 137
		Cooling System.............................................................. 137
		Safety Precautions Maintenance and Repair................................... 138
		General..................................................................... 141
		Cooling System Checks....................................................... 141
			Exhaust Leaks Into Cooling System....................................... 141
			Water Flow Restrictions in Radiator..................................... 141
			Radiator Hoses.......................................................... 141
			Water Pump.............................................................. 141
		Radiator Replacement........................................................ 142
			Cooling System, Clean................................................... 142
			Radiator, Remove........................................................ 143
			Radiator, Install....................................................... 143
		Fan Assembly Replacement.................................................... 146
			Remove.................................................................. 146
			Inspect................................................................. 149
			Install................................................................. 149
Cylinder Repair-2100SRM1139-(05-2005)-US-EN......................................... 153
	toc............................................................................. 153
		Cylinder Repair............................................................. 153
		Safety Precautions Maintenance and Repair................................... 154
		General..................................................................... 157
		Description................................................................. 157
		Safety Procedures When Working Near Mast.................................... 157
		Tilt Cylinder Repair........................................................ 160
			Remove.................................................................. 160
			Disassemble............................................................. 161
			Inspect................................................................. 162
			Clean................................................................... 162
			Assemble................................................................ 162
			Install................................................................. 162
			Tilt Cylinders, Adjust.................................................. 163
			Tilt Cylinder Leak Check for Two-Stage LFL, Two-Stage FFL, and T........ 164
			Tilt Cylinder Leak Check for the Four-Stage Full Free-Lift.............. 164
			Torque Specifications................................................... 165
				Piston Rod.......................................................... 165
				Gland............................................................... 165
				Tilt Cylinder Mounting Capscrew..................................... 165
				Tilt Cylinder Rod End Capscrew...................................... 165
		Lift Cylinder Repair........................................................ 165
			Main Lift Cylinders, Remove............................................. 165
			Free-Lift Cylinder, Remove.............................................. 166
			Free-Lift and Main Lift Cylinders, Disassemble.......................... 171
			Two-Stage FFL Cylinder, Disassemble..................................... 172
			Inspect................................................................. 172
			Clean................................................................... 172
			Full Free-Lift and Main Lift Cylinders, Assemble........................ 174
			Two-Stage FFL and Main Lift Cylinders, Assemble......................... 174
			Main Lift Cylinders, Install............................................ 175
			Free-Lift Cylinder, Install............................................. 176
			Torque Specifications................................................... 177
			Lift Cylinders Leak Check............................................... 177
	tables.......................................................................... 153
		Table 1. Movement Rates (Maximum) for Tilt Cylinders........................ 164
Diagnostics 9000SRM1112-(12-2004)-US-EN............................................. 181
	toc............................................................................. 181
		Diagnostic Troubleshooting Manual........................................... 181
		Safety Precautions TROUBLESHOOTING PROCEDURES............................... 182
		How To Use This Troubleshooting Manual...................................... 184
			General Instructions and Safety Information............................. 184
			How to Use Diagnostic Troubleshooting Manual............................ 184
			General Instructions.................................................... 184
		Operational Diagnostic Procedures........................................... 187
			Operational Checkout Procedures......................................... 189
				DTC Check........................................................... 190
				Horn Circuit Check.................................................. 190
				Light Circuit Check................................................. 190
				Windshield Wiper/Washer Check (If equipped)......................... 190
				Indicator Light Power Check......................................... 191
				Seat Occupancy Check................................................ 192
				Engine Malfunction Indicator Check.................................. 192
				Brake Pedal Check................................................... 193
				Backup Alarm Check (If equipped).................................... 193
				Armrest Hydraulic Interlock Check (If equipped)..................... 193
				Engine Cover Latch Sensor Check (If equipped)....................... 194
				Brake and Inching Pedal Check....................................... 194
				Park Brake Sensor Check............................................. 194
				Park Brake Check.................................................... 195
				Transmission Anti-Rollback Check (Electronic Transmission Only)..... 195
				Engine Speed Check.................................................. 195
				Engine Power Check.................................................. 196
				Transmission Clutch Check........................................... 196
				Transmission Check.................................................. 197
				Transmission Speed Selection Check (If equipped).................... 197
				Brake and Axle Drag Check........................................... 197
				Hydraulic Pump Flow Check........................................... 198
				Priority Flow Divider Valve Check................................... 198
				Steering Relief Valve Low Pressure Check............................ 199
				Steering Relief Valve High Pressure Check........................... 199
				Control Valve Load Check Valve (Manual Valve)....................... 199
				Tilt Function Counterbalance Check.................................. 200
				Lift Drift Check.................................................... 200
				Tilt Function Drift Check........................................... 201
				Mast Cushion Check (All Except 2-Stage Mast)........................ 201
				Lift/Tilt Mast Adjustment Check..................................... 201
				Tilt Racking Check.................................................. 202
				Chain and Header Hose Adjustment Check.............................. 202
				Mast Mounting Check................................................. 202
				Mast Channel Check.................................................. 203
				Carriage Adjustment Check........................................... 203
				Chain Sheave Check.................................................. 203
				Carriage Stop Check................................................. 203
		Engine...................................................................... 205
			Engine Basics........................................................... 211
				General Terminology................................................. 211
				Combustion Theory................................................... 211
				Engine Components – Cylinder Block.................................. 212
				Camshaft and Timing Set............................................. 213
				Cylinder Head Assembly.............................................. 213
				Valve Train Assembly................................................ 213
				Manifolds........................................................... 213
				Air Cleaner/Filter.................................................. 214
				Carburetion......................................................... 214
				Electronic Fuel Injection (EFI)..................................... 214
				Positive Crankcase Ventilation (PCV)................................ 214
			Engine Electrical....................................................... 215
				Introduction........................................................ 215
				Battery Construction................................................ 215
				Conventional Standard Battery....................................... 215
				Maintenance-Free Battery............................................ 216
				Battery Charging.................................................... 216
				Battery Fast Charging............................................... 216
				Battery Slow Charging............................................... 217
				Starting System Principles of Operation............................. 217
				Starting System Components - Ignition Switch........................ 217
				Starting System Components - Starter Solenoid....................... 217
				Starting System Components - Flywheel and Ring Gear................. 217
				Starting System Components - Starter Motor and Drive................ 218
				Charging System - General........................................... 218
				Charging System - Regulator......................................... 218
				Charging System - Theory............................................ 218
			Engine Fuel System/Exhaust and Emissions................................ 219
				Introduction........................................................ 219
				Gasoline System Components - Fuel Tank.............................. 219
				Electronic Fuel Injector (EFI) - General Description................ 219
				Port Fuel System Components - ECU................................... 220
				Port Fuel System Components - Fuel Pump/Filter...................... 220
				Port Fuel System Components - Fuel Rail............................. 220
				Port Fuel System Components - Pressure Regulator.................... 220
				Port Fuel System Components - Fuel Injectors........................ 220
				LP Systems General Information...................................... 220
				LP Fuel Properties.................................................. 220
				LP Fuel Tank........................................................ 220
				AISAN Closed-Loop System............................................ 221
					Filter/Lockoff and Regulator.................................... 221
					Carburetor...................................................... 222
					Start Mode...................................................... 222
					Idle Mode....................................................... 222
					Run Mode........................................................ 222
				Main Fuel Lockoff Solenoid.......................................... 222
				Injector Fuel Lockoff Solenoid...................................... 222
					Oxygen Sensor................................................... 222
				Electronic Control Unit (ECU)....................................... 223
				Catalytic Converter/Muffler......................................... 223
			Engine Management....................................................... 223
				Introduction........................................................ 223
				Ignition and Timing - Conventional Spark............................ 223
				Components - Ignition Coil.......................................... 223
				Components - Distributor............................................ 223
				Spark Timing........................................................ 224
				Components - Ignition Wires......................................... 224
				Components - Spark Plugs............................................ 224
				Faulty or Fouled Spark Plugs........................................ 224
				Electric Controlled Governing System - Mazda LPG.................... 224
			Engine Identification................................................... 225
				GM and Mazda Engines................................................ 225
			Mazda Engine Overview................................................... 226
				Description......................................................... 226
				Fuel System......................................................... 226
				Engine Controls (ECU) and Emissions................................. 226
				Cooling System...................................................... 226
				Ignition System..................................................... 226
			Mazda (LPG) Engine Controls............................................. 227
				LPG System (Aisan/E-Controls-Mechanical)............................ 227
					Description..................................................... 227
					Principles of Operation......................................... 228
					Control System.................................................. 230
					Oxygen Sensor................................................... 231
					Fuel Tank....................................................... 231
					Regulator....................................................... 232
						Start Mode.................................................. 233
						Idle Mode................................................... 233
						Run Mode.................................................... 234
					Resonator....................................................... 234
					Carburetor...................................................... 234
						Start Mode.................................................. 234
						Idle Mode................................................... 235
						Run Mode.................................................... 235
					Governor........................................................ 235
				LPG System (E-Controls)............................................. 236
					Description..................................................... 236
					Principles of Operation......................................... 237
					Manifold Absolute Pressure Sensor............................... 237
					Throttle Position Sensor........................................ 238
					Oxygen Sensor................................................... 238
					Engine Coolant Temperature Sensor............................... 238
					Intake Air Temperature Sensor................................... 238
					Engine Control Unit............................................. 238
					Accelerator Pedal Position Sensor............................... 238
					Three-Way Catalytic Converter................................... 238
					Camshaft Position Sensor........................................ 239
					Electric Controlled Governing System............................ 240
					Electronic Governor Sensor...................................... 240
			Mazda (Gasoline) Engine Controls........................................ 241
				Gasoline System..................................................... 241
					Description..................................................... 241
					Principles of Operation......................................... 242
				Control System...................................................... 244
					Camshaft Position Sensor........................................ 245
					Intake Air Temperature Sensor................................... 246
					Mass Air Flow Sensor............................................ 247
					Throttle Position Sensor........................................ 248
					Electronic Governor Sensor...................................... 249
					Electronic Governing System..................................... 250
					Manifold Absolute Pressure Sensor/Boost Sensor.................. 250
					Engine Coolant Temperature Sensor............................... 251
				Intake Air System................................................... 252
					Throttle Body................................................... 252
					Idle Air Control Valve.......................................... 253
				Fuel System......................................................... 254
					Fuel Injector................................................... 254
					Pressure Regulator.............................................. 255
				Exhaust System...................................................... 256
					Heated Oxygen Sensor............................................ 256
					Three-Way Catalytic Converter................................... 257
			GM (LPG) Engine Controls................................................ 258
				Engine Control System .............................................. 258
					Engine Control System Overview.................................. 259
					Principles of Operation......................................... 259
				Control System...................................................... 260
					Control System Component Location............................... 260
					GM/TGFI Four-Cylinder LPG System................................ 261
					Fuel Tank....................................................... 263
					Engine Control Unit............................................. 263
					Electronic Throttle Body/Throttle Position Sensor............... 264
					Manifold Absolute Pressure/Manifold Air Temperature Sensor...... 264
					Propane Injectors............................................... 265
					Engine Coolant Temperature Sensor............................... 266
					Oxygen Sensor................................................... 267
					Crankshaft Position Sensor (Engine Speed Sensor)................ 268
					Oil Pressure Sensor............................................. 268
					Power Latch Relay............................................... 268
					Camshaft Position Sensor........................................ 269
					Injector Driver Module.......................................... 269
					Vaporizer/Regulator............................................. 270
					Accelerator Pedal Position Sensor............................... 273
					Three-Way Catalytic Converter................................... 273
				Ignition System..................................................... 274
					Ignition Coils.................................................. 274
					Distributorless Ignition System Module.......................... 274
					Electronic Ignition Signals..................................... 275
			GM (Gasoline) Engine Controls........................................... 276
				Engine Control System............................................... 276
					Engine Control System Overview.................................. 277
					Principles of Operation......................................... 277
				Control System...................................................... 278
					Control System Component Location............................... 278
					GM/TGFI Four Cylinder Gasoline System Components................ 279
					Engine Control Unit............................................. 281
					Electronic Throttle Body/Throttle Position Sensor............... 281
					Manifold Absolute Pressure/Manifold Air Temperature Sensor ..... 282
					Fuel Injector................................................... 283
					Engine Coolant Temperature Sensor............................... 284
					Oxygen Sensor................................................... 284
					Crankshaft Position Sensor (Engine Speed Sensor)................ 285
					Oil Pressure Sensor............................................. 285
					Power Latch Relay............................................... 285
					Camshaft Position Sensor........................................ 285
					Accelerator Pedal Position Sensor............................... 286
					Three-Way Catalytic Converter................................... 286
				Ignition System..................................................... 287
					Ignition Coils.................................................. 287
					Distributorless Ignition System Module.......................... 287
					Electronic Ignition Signals..................................... 288
			Cooling System.......................................................... 288
				Description......................................................... 288
				Radiator............................................................ 288
				Radiator Cap........................................................ 288
				Thermostat.......................................................... 289
				Water Pump.......................................................... 289
				Fan................................................................. 289
				GM Engine Coolant Flow Diagram...................................... 290
			Engine Does Not Crank................................................... 291
			Engine Does Not Start / Engine is Hard to Start......................... 294
			Engine Idle Speed Incorrect............................................. 298
			Engine Idle Speed is Unstable or Engine Stalls at Idle.................. 300
			Engine Cuts Out, Misses, Hesitates, Sags, or Stumbles................... 304
			Engine Lack of Power.................................................... 308
			Engine Surges and Chuggles.............................................. 312
			Engine Backfires........................................................ 316
			Engine Is Knocking or Pinging........................................... 319
			Excessive Engine Vibrations............................................. 323
			Abnormal Engine and Exhaust Noises...................................... 326
			Fan or Alternator Bearing Noise......................................... 329
			Abnormal Engine and Exhaust Smells...................................... 331
			High Engine Fuel Consumption............................................ 333
			Fuel Leaks.............................................................. 335
			High Engine Oil Consumption............................................. 337
			Engine Oil Leaks........................................................ 339
			Engine Oil is Discolored................................................ 343
			Engine Coolant Leaks.................................................... 344
			Engine Coolant is Discolored............................................ 347
			Engine Exhaust is Discolored............................................ 348
			Engine Fails Emission Compliance Check.................................. 350
			Alternator Light is Illuminated......................................... 354
			Engine is Overheating................................................... 355
			Radiator Bubble Test.................................................... 357
			Engine Compression Test................................................. 358
			Engine Oil Pressure Test................................................ 359
			Fuel System Pressure Test (Gas)......................................... 360
		Electrical System........................................................... 363
			Troubleshooting Guidelines and Procedures............................... 371
				Troubleshooting Guidelines.......................................... 371
				Troubleshooting Procedures.......................................... 374
					Troubleshooting Procedures, Identification...................... 374
					Troubleshooting Procedures, Location............................ 374
					Troubleshooting Procedures, Structure........................... 374
					Troubleshooting Procedures, Performance......................... 375
			Diagnostic Trouble Codes................................................ 376
				Diagnostic Trouble Codes............................................ 376
			Wiring Reference Data................................................... 381
				Harness Assembly Data............................................... 384
			Electrical System....................................................... 419
				General Description................................................. 419
				Description......................................................... 420
				Principles of Operation, Components................................. 424
				Principles Of Operation, System..................................... 430
			100-3................................................................... 439
			523859-3................................................................ 439
			524223-3................................................................ 439
			524224-3................................................................ 439
			524225-3................................................................ 439
			100-4................................................................... 445
			523859-4................................................................ 445
			524223-4................................................................ 445
			524224-4................................................................ 445
			524225-4................................................................ 445
			524223-0................................................................ 451
			524224-0................................................................ 451
			524225-0................................................................ 451
			524229-0................................................................ 451
			524270-0................................................................ 451
			524276-0................................................................ 451
			524223-1................................................................ 455
			524224-1................................................................ 455
			524225-1................................................................ 455
			524229-1................................................................ 455
			524270-1................................................................ 455
			524276-1................................................................ 455
			110-3................................................................... 459
			110-5................................................................... 459
			177-3................................................................... 459
			524235-3................................................................ 459
			110-4................................................................... 465
			177-4................................................................... 465
			524235-4................................................................ 465
			110-2................................................................... 470
			110-10.................................................................. 473
			522712-3................................................................ 477
			522713-3................................................................ 477
			522712-4................................................................ 482
			522713-4................................................................ 482
			51-2.................................................................... 487
			51-7.................................................................... 487
			91-2.................................................................... 491
			522710-3................................................................ 494
			522711-3................................................................ 494
			522714-3................................................................ 494
			522710-4................................................................ 500
			522711-4................................................................ 500
			522714-4................................................................ 500
			515-0................................................................... 506
			523780-3................................................................ 507
			523860-3................................................................ 507
			524245-3................................................................ 507
			524275-3................................................................ 507
			523780-4................................................................ 512
			523860-4................................................................ 512
			524245-4................................................................ 512
			524275-4................................................................ 512
			677-3................................................................... 517
			2350-3.................................................................. 517
			522754-3................................................................ 517
			522755-3................................................................ 517
			522764-3................................................................ 517
			522766-3................................................................ 517
			524230-3................................................................ 517
			SYMPTOMS WARNING........................................................ 517
			677-4................................................................... 523
			2350-4.................................................................. 523
			522754-4................................................................ 523
			522755-4................................................................ 523
			522764-4................................................................ 523
			522766-4................................................................ 523
			524230-4................................................................ 523
			676-3................................................................... 527
			524195-3................................................................ 527
			524269-3................................................................ 527
			676-4................................................................... 532
			524195-4................................................................ 532
			524269-4................................................................ 532
			524269-7................................................................ 536
			879-3................................................................... 538
			880-3................................................................... 538
			881-3................................................................... 538
			882-3................................................................... 538
			522772-3................................................................ 538
			879-4................................................................... 542
			880-4................................................................... 542
			881-4................................................................... 542
			882-4................................................................... 542
			522772-4................................................................ 542
			168-3................................................................... 545
			522760-3................................................................ 547
			522761-3................................................................ 547
			522762-3................................................................ 547
			524251-0................................................................ 554
			524260-0................................................................ 554
			524261-0................................................................ 554
			524261-3................................................................ 554
			168-4................................................................... 561
			522760-4................................................................ 563
			522761-4................................................................ 563
			522762-4................................................................ 563
			524251-1................................................................ 569
			524260-1................................................................ 569
			524261-1................................................................ 569
			524261-4................................................................ 569
			524260-2................................................................ 576
			524260-11............................................................... 576
			524261-2................................................................ 576
			524261-11............................................................... 576
			96-3.................................................................... 580
			96-4.................................................................... 580
			522810-4................................................................ 584
			524213-1................................................................ 588
			524213-3................................................................ 588
			524213-4................................................................ 588
			523920-3................................................................ 591
			523925-3................................................................ 591
			523930-3................................................................ 591
			523977-3................................................................ 591
			523978-3................................................................ 591
			523986-3................................................................ 591
			524284-3................................................................ 591
			524285-3................................................................ 591
			523978-4................................................................ 596
			523977-4................................................................ 596
			523986-4................................................................ 596
			524284-4................................................................ 596
			524285-4................................................................ 596
			523930-4................................................................ 596
			523920-4................................................................ 596
			523925-4................................................................ 596
			523920-6................................................................ 600
			523925-6................................................................ 600
			523930-6................................................................ 600
			523977-6................................................................ 600
			523978-6................................................................ 600
			523986-6................................................................ 600
			524284-6................................................................ 600
			524285-6................................................................ 600
			105-3................................................................... 604
			105-4................................................................... 608
			105-5................................................................... 611
			106-3................................................................... 613
			106-4................................................................... 617
			106-0................................................................... 621
			106-1................................................................... 621
			106-2................................................................... 621
			106-14.................................................................. 621
			522739-3................................................................ 624
			522739-5................................................................ 627
			522739-6................................................................ 630
			522735-2................................................................ 632
			522735-4................................................................ 634
			522735-5................................................................ 636
			522735-6................................................................ 638
			522630-2................................................................ 640
			522631-2................................................................ 640
			522635-3................................................................ 640
			522635-4................................................................ 640
			522737-10............................................................... 643
			651-3................................................................... 645
			652-3................................................................... 645
			653-3................................................................... 645
			654-3................................................................... 645
			522721-3................................................................ 645
			522722-3................................................................ 645
			522723-3................................................................ 645
			522724-3................................................................ 645
			651-5................................................................... 649
			652-5................................................................... 649
			653-5................................................................... 649
			654-5................................................................... 649
			651-6................................................................... 652
			652-6................................................................... 652
			653-6................................................................... 652
			654-6................................................................... 652
			522721-6................................................................ 652
			522722-6................................................................ 652
			522723-6................................................................ 652
			522724-6................................................................ 652
			2000-9.................................................................. 656
			2000-12................................................................. 656
			2000-12................................................................. 656
			2003-12................................................................. 656
			2023-12................................................................. 656
			2039-12................................................................. 656
			2235-12................................................................. 656
			2236-12................................................................. 656
			524258-2................................................................ 656
			524236-14............................................................... 663
			524262-12............................................................... 663
			524263-1................................................................ 663
			524268-12............................................................... 663
			522690-2................................................................ 665
			522690-12............................................................... 665
			522691-2................................................................ 665
			522691-12............................................................... 665
			522692-2................................................................ 665
			522694-12............................................................... 665
			522695-2................................................................ 665
			522696-2................................................................ 665
			522698-2................................................................ 665
			522699-2................................................................ 665
			522700-2................................................................ 665
			628-12.................................................................. 665
			630-12.................................................................. 665
			522697-12............................................................... 665
			190-2................................................................... 667
			190-7................................................................... 667
			522752-9................................................................ 671
			524264-2................................................................ 674
			524264-14............................................................... 674
			524265-2................................................................ 674
			524271-2................................................................ 674
			628-12.................................................................. 679
			630-12.................................................................. 679
			2660-3.................................................................. 679
			2660-4.................................................................. 679
			2661-3.................................................................. 679
			2661-4.................................................................. 679
			2802-12................................................................. 679
			523515-3................................................................ 679
			523515-4................................................................ 679
			523519-3................................................................ 679
			523519-4................................................................ 679
			2802-12................................................................. 681
			628-12.................................................................. 681
			630-12.................................................................. 681
			523261-3................................................................ 681
			523261-4................................................................ 681
			523257-3................................................................ 681
			523257-4................................................................ 681
			523253-3................................................................ 681
			523253-4................................................................ 681
			523249-3................................................................ 681
			523249-4................................................................ 681
			522780-3................................................................ 683
			522781-3................................................................ 683
			522780-4................................................................ 686
			522781-4................................................................ 686
			522780-2................................................................ 688
			111-1................................................................... 690
			524252-2................................................................ 694
			524253-14............................................................... 695
			524255-2................................................................ 696
			108-0................................................................... 697
			108-1................................................................... 697
			522655-0................................................................ 699
			522655-1................................................................ 699
			522660-0................................................................ 699
			522660-1................................................................ 699
			Engine Continues to Run When Engine Cover is Raised..................... 703
			Engine Stops or Fails to Start.......................................... 705
			Electrical Functions Do Not Operate..................................... 707
			Electrical Function Does Not Turn Off................................... 712
			Electro-Hydraulics Do Not Function With Armrest Down ................... 717
			Electro-Hydraulics Can Still Function With Armrest Raised............... 720
			Vehicle Does Not Power On............................................... 723
		Drive Train................................................................. 729
			Transmission............................................................ 731
				Description......................................................... 731
			Single-Speed Transmission............................................... 731
				Description......................................................... 731
			Two-Speed Transmission.................................................. 734
				Description......................................................... 734
			Mechanical Overview..................................................... 735
			Engine.................................................................. 735
				Description......................................................... 735
			Torque Converter........................................................ 735
				Description......................................................... 735
				Principles of Operation............................................. 736
					Stator.......................................................... 736
					Turbine......................................................... 736
			Chain Drive............................................................. 738
				Description......................................................... 738
			Clutch Assemblies....................................................... 739
				Description......................................................... 739
				Single-Speed Power Flow............................................. 740
				Two-Speed Power Flow................................................ 741
			Driveshaft, Differential, and Drive Axle................................ 743
				Driveshaft.......................................................... 743
				Differential and Drive Axle......................................... 743
				Brake System........................................................ 745
					Description..................................................... 745
					Service Brakes.................................................. 745
					Master Cylinder................................................. 745
					Brake Position Sensor........................................... 745
					Parking Brake - Dry Brake....................................... 745
			Transmission Hydraulic System........................................... 746
				Principles of Operation............................................. 746
			Transmission Control System Overview.................................... 750
				Transmission Control System......................................... 750
			Transmission Control Hardware........................................... 752
				Control Valve and Sensors........................................... 752
					Description..................................................... 752
					Principles of Operation......................................... 754
				MONOTROL® Pedal..................................................... 754
					Description..................................................... 754
					Principles of Operation......................................... 754
				Directional Control Lever........................................... 755
					Principles of Operation......................................... 755
			Transmission Control Software........................................... 755
				Transmission Control Modes.......................................... 755
					Neutral Mode ( Basic Powershift, and Duramatch™ )............... 755
					Gear Engagement Mode............................................ 756
						Basic Powershift Gear Engagement Mode....................... 756
						Duramatch™ Gear Engagement Mode............................. 756
					Controlled Creep Mode ( Basic Powershift Transmission Only)..... 756
					Normal Mode (Forward or Reverse)................................ 756
					Inching Mode.................................................... 756
						Basic Powershift Inching Mode............................... 756
						Duramatch™ Inching Mode..................................... 756
					Controlled Creep Mode - Duramatch™ Transmission................. 757
					Roll Back Mode - Duramatch™ Transmission........................ 757
					Auto Decel Mode - Duramatch™ Transmission....................... 757
					Auto-Shift Mode (Multispeed Only)............................... 757
					1st Gear Lock Mode (Multispeed Only)............................ 757
					Extended Drawbar Pull (2-Speed Only)............................ 757
			Transmission Proportional Valve......................................... 758
				Description......................................................... 758
				Principles of Operation............................................. 758
				Neutral............................................................. 758
				Proportional Control................................................ 758
				Forward............................................................. 759
				Forward-Inching..................................................... 759
			Overheating Brakes...................................................... 761
			Poor Brake Performance.................................................. 763
			Brakes Make Too Much Noise.............................................. 765
			Brakes Pull To One Side................................................. 766
			Parking Brake Will Not Release.......................................... 768
			Parking Brake Will Not Hold Lift Truck.................................. 769
			Abnormal Drive Axle Noise............................................... 770
			Discolored Drive Axle Oil............................................... 772
			Lift Truck Does Not Move (Drive Axle)................................... 773
			Abnormal Transmission Noise............................................. 774
			Bubbles or Foaming In Transmission Dipstick Tube........................ 776
			Inching Operation Is Not Smooth or Chatters............................. 778
			Lift Truck Does Not Move In One or Both Directions...................... 780
			Loss of Power/Drivetrain Performance.................................... 783
			Transmission Is Too Hot................................................. 785
			Transmission Will Not Shift To Forward High Range....................... 787
			Transmission Warm-Up Procedure.......................................... 789
			Transmission Pressure Test.............................................. 789
				Transmission Charge Pump Pressure Test.............................. 790
				Clutch Pack Pressure Test (Proportional Solenoid Valves)............ 790
				Torque Converter Pressure Test...................................... 791
				Lubrication Pressure Test........................................... 791
			Transmission Clutch Drag Test........................................... 791
			Torque Converter Stall Test............................................. 792
		Hydraulic Systems........................................................... 795
			Main Hydraulic System................................................... 799
				Description......................................................... 799
				Principles of Operation............................................. 799
				Hydraulic Schematics................................................ 801
					Manual Control Valve Schematic.................................. 801
					Electro-Hydraulic Control Valve Schematic....................... 803
			Manual Hydraulic Control Valve.......................................... 805
				Description......................................................... 805
				Principles of Operation............................................. 806
					Lift Section.................................................... 806
						Lift Operation.............................................. 806
						Lower Operation............................................. 806
					Tilt Section.................................................... 806
						Tilt Backward............................................... 806
						Tilt Forward................................................ 806
					Auxiliary Section............................................... 808
					Anti-stall Feature.............................................. 809
					Relief Valves................................................... 809
						Main Relief Valve........................................... 809
						Secondary Relief Valve...................................... 810
			Electro-Hydraulic Control Valve......................................... 810
				Description......................................................... 810
				Principles of Operation............................................. 810
					Inlet Pressure Compensator/Unloader............................. 810
					Lift/Lower EHPVs................................................ 813
						EHPV Operation.............................................. 814
					Tilt and Auxiliary Spool Functions.............................. 816
					Tilt Forward Function........................................... 818
					Main Relief Valve .............................................. 819
					Secondary Relief Valve.......................................... 819
					Secondary Function Anti-stall Valve............................. 819
					Manual Lowering Valve........................................... 821
			Steering System......................................................... 821
				Component Locations................................................. 821
					Description..................................................... 821
					Steering Axle Assembly.......................................... 821
					Steering Control Unit........................................... 821
				Steering Schematic.................................................. 823
					Principles of Operation......................................... 824
					Steering Control Unit........................................... 824
			Actuation Functions With Armrest Up (E-Valve)........................... 825
			Cycle Times Too Fast - Fast Actuation (E-Valve)......................... 826
			Jump/Delay In Lift or Lower Activation After Moving Joystick or ........ 828
			Jump/Delay In Secondary Function Actuation After Moving Joystick........ 830
			Jump/Delay In Tilt Forward Actuation (E-Valve).......................... 832
			Forks Drop Slightly Before Lifting (E-Valve)............................ 834
			Forks Lower Without Command (E-Valve)................................... 835
			Forks Raise or Actuate Without Command (E-Valve)........................ 837
			Forks Tilt Forward Without Command (E-Valve)............................ 839
			Intermittent Activation (E-Valve) While Commanding Function............. 841
			Lift/Lower Function Maximum Speed Too Slow (E-Valve).................... 843
			Lift Function Will Not Move With Joystick or MLM Movement (E-Val........ 846
			Lift/Lower Continues To Move For Awhile After Joystick or MLM Is........ 849
			Lift/Lower/Secondary Function Suddenly Jumps In Middle Of Stroke........ 850
			Lower Function Will Not Move With Joystick or MLM Movement (E-Va........ 851
			Poor Metering On Lift or Lower Functions (E-Valve)...................... 852
			Secondary Function Continues To Move For Awhile After Joystick O........ 855
			Secondary Function Exhibits Slight Movement In Opposite Directio........ 856
			Secondary Function Maximum Speed Too Slow (E-Valve)..................... 857
			Secondary Function or Tilt Back Moves Without Command (E-Valve)......... 860
			Secondary Function and Tilt Back Will Not Move With Joystick or ........ 861
			Tilt Forward Function Continues To Move For Awhile When Joystick........ 864
			Tilt Forward Will Not Move Upon Joystick or MLM Movement (E-Valv........ 865
			Too Much Joystick Or MLM Movement (Deadband) To Start Function M........ 867
			Wrong Actuation Operates or Actuation is Backward (E-Valve)............. 868
			Actuation Exhibits Slight Movement in Opposite Direction Before ........ 869
			Auxiliary Function is Slow or Does Not Function (Manual Valve).......... 870
			Cycle Times Too Fast - Fast Actuation (Manual Valve).................... 872
			Function Continues to Activate After Returning to Neutral............... 873
			Lift Function Is Slow Or Does Not Function (Manual Valve)............... 874
			Tilt Back Function Will Not Operate (Manual Valve)...................... 876
			Tilt Forward Functions When Spool is Activated Forward With Engi........ 877
			Tilt Forward Will Not Function When Activated (Manual Valve)............ 878
			Abnormal Steer Axle Noise............................................... 879
			Abnormal Steering Wheel Vibration....................................... 881
			Back Lash/Kick Back in Steering Wheel................................... 882
			No Steering (All Other Hydraulic Functions OK).......................... 884
			Steering Is Slow or Difficult........................................... 886
			Steering Operation Is Not Smooth........................................ 888
			Steering Wheel End Lock Position Cannot Be Felt By Operator............. 890
			Steering Wheel Turns By Itself or Does Not Return To Neutral............ 891
			Steering Wheel Turns the Tires in the Wrong Direction................... 892
			Abnormal Hydraulic Noise and/or Vibration............................... 893
			Abnormal Smell/Discoloration/Foaming of Oil............................. 896
			Actuations Do Not Act Simultaneously.................................... 897
			Oil Leaking/Component Life Too Short.................................... 898
			Hydraulic Warm-up Procedure............................................. 901
			Main Relief Valve Test and Adjustment................................... 902
			Secondary Relief Valve Test and Adjustment.............................. 904
			Hydraulic Pump Flow Test................................................ 906
			Main Control Valve LS Leakage Test (E-Valve)............................ 907
			Main Control Valve Unloader Margin Test................................. 908
			Electro-Hydraulic Poppet Valve (EHPV) Leakage Test...................... 909
			PPRV Pilot Pressure Test................................................ 912
			Steering Relief Pressure Test and Adjustment............................ 913
			Steering Control Unit LS Pressure Test.................................. 914
			Lift Cylinder Leakage Test.............................................. 915
			Tilt Cylinder Leakage Test.............................................. 917
			Steering Cylinder Leakage Test.......................................... 918
		Operators Station........................................................... 921
			Operators Station General Description and Principles of Operatio........ 923
				General Description and Location.................................... 923
			Display Switch Cluster (DSC)............................................ 925
				Detailed Description................................................ 925
				Control Inputs, Right Side.......................................... 927
				Right Indicator and Warning Group................................... 928
				LCD Display......................................................... 928
				Left Indicator and Warning Group.................................... 930
			Transmission Control and Braking........................................ 931
				Description......................................................... 931
					Vehicle System Manager (VSM).................................... 932
					Display Switch Cluster.......................................... 932
						Interlock and Switching Features............................ 932
					MONOTROL® Directional Control................................... 932
					Inch Brake/Service Brake Pedal.................................. 932
					Parking Brake................................................... 933
			Programming - Menus..................................................... 933
				Menus............................................................... 933
					Main Menu....................................................... 936
					Save and Exit or Exit Without Saving............................ 936
					Back One Level.................................................. 936
					Hourmeters...................................................... 936
					View Versions................................................... 936
					Passwords....................................................... 936
					Diagnostics..................................................... 936
					Setup Travel and Braking........................................ 936
					Setup Hydraulics................................................ 936
					Setup Display................................................... 937
					Setup General Items............................................. 937
					Calibrations.................................................... 937
			Manual Hydraulic Control Levers......................................... 937
				General Description................................................. 937
				System Components................................................... 937
					Lift/Lower...................................................... 938
					Tilt............................................................ 938
					Auxiliary 1..................................................... 938
					Auxiliary 2..................................................... 938
			E-Hydraulic System Interface............................................ 938
				General Description................................................. 938
				System Components................................................... 938
				E-Hydraulic Control Input Device.................................... 938
					Joystick........................................................ 938
						Lift/Lower.................................................. 938
						Tilt........................................................ 938
						Auxiliary 1................................................. 939
						Auxiliary 2................................................. 939
						Push Button................................................. 939
					Mini Lever Module (MLM)......................................... 939
						Lever 1..................................................... 939
						Lever 2..................................................... 939
						Lever 3..................................................... 941
						Lever 4..................................................... 941
				System Modes........................................................ 941
					Hydraulic Interlock Mode........................................ 941
					Fault Mode...................................................... 941
					Engine Off Mode................................................. 941
				Normal Operation.................................................... 941
					Normal Operation Mode........................................... 941
					Lifting Control................................................. 941
					Lowering Control................................................ 941
					Tilt Control (Forward and Backward)............................. 941
					Auxiliary Control............................................... 941
			Lighting Control........................................................ 942
				Description......................................................... 942
					Front Work Lights............................................... 943
					Front Marker Lights (if equipped)............................... 943
					Front/Rear Turn Signal Lights................................... 943
					Rear Tail/Marker Lights......................................... 943
					Rear Work Light................................................. 943
					Rear Backup Lights.............................................. 944
					Rear Stop Lights................................................ 944
					Strobe Light(s)................................................. 944
					Cab Light (if equipped)......................................... 944
					Spot Light (if equipped)........................................ 944
		Front End (Mast) and Chassis................................................ 945
			Front End, Mast......................................................... 947
				Description......................................................... 947
			Carriages............................................................... 947
				Description......................................................... 947
				Principles of Operation............................................. 947
					Integral Sideshift Carriage..................................... 947
			Mast Mounts............................................................. 949
				Description......................................................... 949
				Principles of Operation............................................. 949
			Two-Stage Limited Free-Lift (LFL) Mast.................................. 949
				Description......................................................... 949
				Principles of Operation............................................. 950
			Two-Stage Full Free-Lift (FFL) Mast..................................... 951
				Description......................................................... 951
				Principles of Operation............................................. 952
			Three-Stage Full Free-Lift (FFL) Mast................................... 953
				Description......................................................... 953
				Principles of Operation............................................. 954
			Four-Stage Full Free-Lift (FFL) Mast.................................... 956
				Description......................................................... 956
				Principles of Operation............................................. 957
			Cylinder Cushion During Lifting Sequence................................ 959
				Description......................................................... 959
				Principles of Operation............................................. 959
			Cylinder Cushion During Lowering Sequence............................... 960
				Description......................................................... 960
				Principles of Operation............................................. 960
			Tilt and Sideshift Cylinders............................................ 960
				Description......................................................... 960
					Tilt Cylinder................................................... 960
					Sideshift Cylinder.............................................. 960
			Lowering Control Valves................................................. 961
				Description......................................................... 961
				Principles of Operation............................................. 961
			Chassis................................................................. 963
				Description......................................................... 963
			Abnormal Channel Wear................................................... 965
			Abnormal Hose Wear...................................................... 967
			Abnormal Mast Noise..................................................... 968
			Body Panels Making Noise................................................ 971
			External Leakage From Free-Lift or Main Lift Cylinders.................. 972
			FFL Mast Banging During Phasing......................................... 973
			High Tire Wear - Drive Axle............................................. 974
			High Tire Wear - Steer Axle............................................. 975
			Hoses Not Tracking Correctly............................................ 976
			Integral Sideshift Moving Too Fast...................................... 977
			Integral Sideshift Not Moving or Slow................................... 978
			LP Tank Bracket Disengages.............................................. 981
			LP Tank Rattles and Does Not Stay Latched............................... 982
			Mast is Loose........................................................... 983
			Mast Lift Chains Are Loose.............................................. 984
			Mast or Carriage Binding................................................ 985
			Mast/Carriage Bounces or is Spongy...................................... 987
			Misphasing of Full Free-Lift Mast....................................... 988
			Overhead Guard Loose or Damaged......................................... 990
			Racking During Lift..................................................... 991
			Racking During Tilt..................................................... 992
			Truck Feels Unstable.................................................... 993
			Truck Wanders, Does Not Track Straight or Steer Well.................... 995
			Wheels Appear Tipped or Misaligned...................................... 997
			Wheels Spinning On Uneven Floors........................................ 998
			Wheel Studs Breaking.................................................... 999
		Supplementary Data..........................................................1001
			Abbreviations and Acronyms..............................................1003
			Special Tools List......................................................1011
			Fault Mode Indicator (FMI) Reference List...............................1013
			TSP Reference Tables....................................................1015
	tables.......................................................................... 181
		Table 9020-40-1. Test Specifications........................................ 357
		Table 9020-40-2. Test Specifications........................................ 358
		Table 9020-40-3. Service Tools.............................................. 358
		Table 9020-40-4. Test Specifications........................................ 359
		Table 9020-40-5. Service Tools.............................................. 359
		Table 9020-40-6. Test Specifications - Mazda................................ 360
		Table 9020-40-7. Test Specifications - GM................................... 360
		Table 9020-40-8. Service Tools.............................................. 360
		Table 9030-03-1. Circuit Group Identification............................... 382
		Table 9030-03-2. NMHG Wiring Color Codes.................................... 383
		Table 9040-10-1. Transmission Control Mode.................................. 751
		Table 9040-40-1. Test Specifications........................................ 789
		Table 9040-40-2. Service Tools.............................................. 789
		Table 9040-40-3. Service Tools.............................................. 789
		Table 9040-40-4. Test Specifications........................................ 790
		Table 9040-40-5. Test Specifications........................................ 790
		Table 9040-40-6. Test Specifications........................................ 791
		Table 9040-40-7. Test Specifications........................................ 791
		Table 9040-40-8. Test Specifications........................................ 791
		Table 9040-40-9. Service Tools.............................................. 791
		Table 9040-40-10. Stall Speeds.............................................. 792
		Table 9050-40-1. Test Specifications........................................ 901
		Table 9050-40-2. Service Tools.............................................. 901
		Table 9050-40-3. Test Specifications........................................ 902
		Table 9050-40-4. Service Tools.............................................. 902
		Table 9050-40-5. Test Specifications........................................ 904
		Table 9050-40-6. Service Tools.............................................. 904
		Table 9050-40-7. Test Specifications........................................ 906
		Table 9050-40-8. Service Tools.............................................. 906
		Table 9050-40-9. Test Specifications........................................ 907
		Table 9050-40-10. Test Specifications....................................... 908
		Table 9050-40-11. Service Tools............................................. 908
		Table 9050-40-12. Test Specifications....................................... 909
		Table 9050-40-13. Service Tools............................................. 909
		Table 9050-40-14. Test Specifications....................................... 912
		Table 9050-40-15. Service Tools............................................. 912
		Table 9050-40-16. Test Specifications....................................... 913
		Table 9050-40-17. Service Tools............................................. 913
		Table 9050-40-18. Test Specifications....................................... 914
		Table 9050-40-19. Service Tools............................................. 914
		Table 9050-40-20. Test Specifications....................................... 915
		Table 9050-40-21. Service Tools............................................. 915
		Table 9050-40-22. Test Specifications....................................... 917
		Table 9050-40-23. Service Tools............................................. 917
		Table 9050-40-24. Test Specifications....................................... 918
		Table 9050-40-25. Service Tools............................................. 918
		Table 9080-50-1. Abbreviations and Acronyms.................................1003
		Table 9080-60-1. Special Tools..............................................1011
		Table 9080-70-1. FMI........................................................1013
		Table 9080-80-1. Resistor-Temperature Characteristics ......................1015
Diagrams-8000SRM1152-(05-2005)-US-EN................................................1019
	toc.............................................................................1019
		Diagrams and Schematics.....................................................1019
		Safety Precautions Maintenance and Repair...................................1020
Drive Axle Differential1-1400SRM1132-(05-2005)-US-EN................................1057
	toc.............................................................................1057
		Drive Axle and Differential Assembly Repair.................................1057
		Safety Precautions Maintenance and Repair...................................1058
		General.....................................................................1061
		Drive Axle Repair...........................................................1061
			Remove and Disassemble..................................................1061
			Clean and Inspect.......................................................1061
			Assemble and Install....................................................1063
		Differential Repair.........................................................1065
			Remove..................................................................1065
				Differential Assembly From Center Section...........................1065
				Drive Pinion, Pinion Gear, and Bearings From Center Section.........1068
			Disassemble.............................................................1072
				Differential Assembly...............................................1072
				Drop Box Housing....................................................1075
				Center Section......................................................1076
			Clean and Inspect.......................................................1078
			Assemble................................................................1078
				Center Section......................................................1078
				Drop Box Housing....................................................1081
				Differential Assembly...............................................1082
			Install.................................................................1085
				Pinion Inner Shim Set, Adjust Thickness (Depth of Pinion)...........1085
				Drive Pinion, Pinion Gear, and Bearings Into Center Section.........1088
				Differential Assembly Into Center Section...........................1091
				Ring Gear Backlash, Adjust..........................................1095
				Ring Gear, Runout Check.............................................1096
				Gear Set, Tooth Contact Pattern Check...............................1096
		Torque Specifications.......................................................1099
	tables..........................................................................1057
		Table 1. Pinion Variation Numbers Examples..................................1087
		Table 2. Ring and Pinion Tooth Contact Adjustment...........................1097
		Table 3. Correct Tooth Contact..............................................1097
		Table 4. Incorrect Tooth Contact............................................1098
Drive Axle Dry Brakes-1400SRM1214-(05-2005)-US-EN...................................1103
	toc.............................................................................1103
		Drive Axle and Differential Assembly Repair.................................1103
		Safety Precautions Maintenance and Repair...................................1104
		General.....................................................................1107
		Drive Axle Repair...........................................................1107
			Remove and Disassemble..................................................1107
			Clean and Inspect.......................................................1109
			Assemble and Install....................................................1109
		Differential Repair.........................................................1111
			Remove..................................................................1111
				Differential Assembly From Center Section...........................1111
				Drive Pinion, Pinion Gear, and Bearings From Center Section.........1114
			Disassemble.............................................................1120
				Differential Assembly...............................................1120
				Drop Box Housing....................................................1123
				Center Section......................................................1124
			Clean and Inspect.......................................................1126
			Assemble................................................................1127
				Center Section......................................................1127
				Drop Box Housing....................................................1130
				Differential Assembly...............................................1131
			Install.................................................................1134
				Pinion Inner Shim Set, Adjust Thickness (Depth of Pinion)...........1134
				Drive Pinion, Pinion Gear, and Bearings Into Center Section.........1136
				Differential Assembly Into Center Section...........................1141
				Ring Gear Backlash, Adjust..........................................1146
				Ring Gear, Runout Check.............................................1147
				Gear Set, Tooth Contact Pattern Check...............................1147
		Torque Specifications.......................................................1150
	tables..........................................................................1103
		Table 1. Pinion Variation Numbers Examples..................................1136
		Table 2. Ring and Pinion Tooth Contact Adjustment...........................1147
		Table 3. Correct Tooth Contact..............................................1148
		Table 4. Incorrect Tooth Contact............................................1149
Electrical System Mazda1-2200SRM1143-(05-2005)-US-EN................................1153
	toc.............................................................................1153
		Electrical System...........................................................1153
		Safety Precautions Maintenance and Repair...................................1154
		Ignition System.............................................................1157
			General.................................................................1157
			Ignition Timing Adjustment, Gasoline and LPG............................1157
			Spark Plugs Check.......................................................1157
			Spark Plug Wires Check..................................................1157
		Distributor Repair..........................................................1160
			Remove..................................................................1160
			Disassemble.............................................................1161
			Inspect.................................................................1161
			Assemble................................................................1162
			Install.................................................................1162
			Igniter.................................................................1163
				Remove..............................................................1163
				Test................................................................1163
				Install.............................................................1163
			Camshaft Position (CMP) Sensor..........................................1164
				Voltage Check.......................................................1164
		Ignition Coil Check.........................................................1165
			Primary Coil Winding....................................................1165
			Secondary Coil Winding..................................................1165
		Starter Repair..............................................................1166
			General.................................................................1166
			Remove..................................................................1166
			No-Load Test............................................................1167
			Magnetic Switch Test....................................................1167
				Pull-Out Test.......................................................1167
				Holding Coil Test...................................................1168
				Return Test.........................................................1168
				Pinion Movement Inspection..........................................1168
			Install.................................................................1168
		Alternator Repair...........................................................1169
			General.................................................................1169
			Charging System Inspection..............................................1169
			Output Current Check....................................................1170
			No-Load Adjusted Voltage Check..........................................1170
			Remove..................................................................1171
			Inspect.................................................................1171
				Rectifier Check.....................................................1171
			Install.................................................................1172
	tables..........................................................................1153
		Table 1. Spark Plug Wire....................................................1157
		Table 2. Starter Specifications.............................................1166
		Table 3. Problem Diagnosis Chart............................................1167
		Table 4. Specifications.....................................................1170
		Table 5. Rectifier Check Table..............................................1171
Electrical Systems-2200SRM1142-(05-2005)-US-EN......................................1175
	toc.............................................................................1175
		Electrical System...........................................................1175
		Safety Precautions Maintenance and Repair...................................1176
		General.....................................................................1183
		Display Switch Cluster......................................................1184
			Remove..................................................................1184
			Replace.................................................................1184
			Direction Control and Turn Signal Levers................................1185
				Remove..............................................................1185
				Replace.............................................................1185
			Key Switch..............................................................1186
				Remove..............................................................1186
				Replace.............................................................1187
			Display Switch Cluster Panel Bezel and Overlay..........................1187
				Remove..............................................................1187
				Replace.............................................................1187
		Steering Column Repair......................................................1188
			Remove..................................................................1188
			Disassemble.............................................................1188
			Assemble................................................................1188
			Install.................................................................1190
		Sensors and Switches........................................................1190
			General.................................................................1190
			Accelerator Pedal Position Sensor.......................................1190
				Remove..............................................................1190
				Replace.............................................................1192
			Brake Fluid Level Switch................................................1194
				Remove..............................................................1194
				Replace.............................................................1194
			Service Brake Pedal Position Sensor.....................................1194
				Remove..............................................................1194
				Replace.............................................................1194
			Parking Brake Sensor....................................................1195
				Remove..............................................................1195
				Replace.............................................................1195
			Service Brake Pressure Sensor...........................................1195
				Remove..............................................................1195
				Replace.............................................................1195
			MONOTROL® Sensor Microswitch............................................1196
				Remove..............................................................1196
				Replace.............................................................1197
			Low Coolant Level Sensor................................................1198
				Remove..............................................................1198
				Replace.............................................................1198
			Fuel Level Sensor, Gas and Diesel Engines Only..........................1198
				Remove..............................................................1198
				Replace.............................................................1198
			Armrest Switch..........................................................1199
				Remove..............................................................1199
				Replace.............................................................1199
			Seat Sensor.............................................................1201
				Non-Suspension and Semi-Suspension Seats............................1201
					Remove..........................................................1201
					Replace.........................................................1201
				Full Suspension Seats...............................................1202
					Remove..........................................................1202
					Replace.........................................................1202
			Hood Switch.............................................................1202
				Remove..............................................................1202
				Replace.............................................................1202
			Hydraulic Filter Pressure Switch........................................1204
				Remove..............................................................1204
				Replace.............................................................1204
			Transmission Speed Sensor...............................................1204
				Remove..............................................................1204
				Replace.............................................................1205
			Transmission Pressure Sensors...........................................1205
				Remove..............................................................1205
				Replace.............................................................1205
			Transmission Temperature Sensor.........................................1205
				Remove..............................................................1205
				Replace.............................................................1205
			Return to Set Tilt (Tilt Angle) Sensor..................................1206
				Remove..............................................................1206
				Replace.............................................................1206
			Rear Horn Button Switch.................................................1206
				Remove..............................................................1206
				Replace.............................................................1206
			Engine and Fuel Sensors - Mazda 2.0L and 2.2L Gas and LPG Engine........1207
				Oxygen Sensor.......................................................1207
					Remove..........................................................1207
					Replace.........................................................1207
				Intake Air Temperature (IAT) Sensor.................................1207
					Remove..........................................................1207
					Replace.........................................................1207
				Manifold Absolute Pressure (MAP)/Boost Sensor.......................1208
					Remove..........................................................1208
					Replace.........................................................1208
				Throttle Position (TPS) Sensor......................................1208
					Remove..........................................................1208
					Replace.........................................................1208
			Engine and Fuel Sensors and Switches - Mazda 2.0L and 2.2L LPG E........1209
				Oil Pressure Sensor.................................................1209
					Remove..........................................................1209
					Replace.........................................................1209
				Low LPG Pressure Switch.............................................1210
					Remove..........................................................1210
					Replace.........................................................1210
				Air Filter Restriction Switch.......................................1210
					Remove..........................................................1210
					Replace.........................................................1210
				Engine Coolant Temperature (ECT) Sensor.............................1210
					Remove..........................................................1210
					Replace.........................................................1210
			Engine and Fuel Sensors and Switches- Mazda 2.0L and 2.2L Gas En........1211
				Oil Pressure Sensor.................................................1211
					Remove..........................................................1211
					Replace.........................................................1211
				Mass Air Flow (MAF) Sensor..........................................1211
					Remove..........................................................1211
					Replace.........................................................1211
				Air Filter Restriction Switch.......................................1212
					Remove..........................................................1212
					Replace.........................................................1212
				Engine Coolant Temperature (ECT) Sensor.............................1212
					Remove..........................................................1212
					Replace.........................................................1212
			Engine and Fuel Sensors and Switches, GM 2.4L Gas and LPG Trucks........1213
				Crankshaft Sensor...................................................1213
					Remove..........................................................1213
					Replace.........................................................1213
				Camshaft Position (CMP) Sensor......................................1213
					Remove..........................................................1213
					Replace.........................................................1214
				Camshaft Position (CMP) Sensor Assembly.............................1214
					Remove..........................................................1214
					Install.........................................................1214
				Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) ....1214
					Remove..........................................................1214
					Replace.........................................................1214
				Engine Coolant Temperature (ECT) Sensor.............................1215
					Remove..........................................................1215
					Replace.........................................................1215
				Air Flow Restriction Switch.........................................1215
					Remove..........................................................1215
					Replace.........................................................1215
				Oil Pressure Sensor.................................................1216
					Remove..........................................................1216
					Replace.........................................................1216
				Oxygen Sensor.......................................................1216
					Remove..........................................................1216
					Replace.........................................................1217
			Engine and Fuel Switches, GM 2.4L LPG Trucks Only.......................1218
				Low LPG Pressure Switch.............................................1218
					Remove..........................................................1218
					Replace.........................................................1218
			Engine and Fuel Sensors and Switches, Yanmar Diesel Trucks..............1218
				Air Filter Restriction Switch.......................................1218
					Remove..........................................................1218
					Replace.........................................................1218
				Oil Pressure Sensor.................................................1218
					Remove..........................................................1218
					Replace.........................................................1218
				Engine Speed Sensor.................................................1218
					Remove..........................................................1218
					Replace.........................................................1218
				Engine Coolant Temperature (ECT) Sensor.............................1220
					Remove..........................................................1220
					Replace.........................................................1220
				Throttle Position Sensor (TPS)......................................1220
					Remove..........................................................1220
					Replace.........................................................1221
		Vehicle System Manager (VSM)................................................1221
			General.................................................................1221
			VSM Replacement.........................................................1221
				Remove..............................................................1221
				Replace.............................................................1221
			Programming a New VSM and/or Display Switch Cluster.....................1222
				General.............................................................1222
				PC Service Tool Software............................................1223
				Data Transferring...................................................1223
					New or Used VSM.................................................1223
					New (Blank) Display Switch Cluster..............................1223
					Used (Non-Blank) Display Switch Cluster.........................1224
		Power Distribution Module (PDM) And Component Parts.........................1225
			Remove..................................................................1225
				PDM as a Unit.......................................................1225
			Replace.................................................................1225
				PDM as a Unit.......................................................1225
			Remove and Replace......................................................1227
				PDM Component Parts.................................................1227
		Battery.....................................................................1228
			Remove..................................................................1228
			Replace.................................................................1228
		Lights......................................................................1228
			Work Lights (Front and Rear)............................................1228
				Remove..............................................................1228
				Replace.............................................................1228
			Strobe Light............................................................1228
				Remove..............................................................1228
				Replace.............................................................1229
			LED Tail, Backup, and Brake Lights......................................1229
				Remove..............................................................1229
				Replace.............................................................1229
		Electronic-Hydraulic Controls...............................................1230
			General.................................................................1230
			Mini-Levers.............................................................1230
				Remove..............................................................1230
				Replace.............................................................1231
			Joystick................................................................1231
				Remove and Disassemble..............................................1231
				Inspect.............................................................1231
				Assemble and Replace................................................1231
	tables..........................................................................1175
		Table 1. VSM and Display Switch Cluster Replacement.........................1225
Frame-0100SRM1120-(05-2005)-US-EN...................................................1235
	toc.............................................................................1235
		Frame.......................................................................1235
		Safety Precautions Maintenance and Repair...................................1236
		General.....................................................................1239
		Description.................................................................1240
		Hood, Seat, and Side Covers Replacement.....................................1240
			Remove..................................................................1240
			Install.................................................................1245
		LPG Tank and Bracket Replacement............................................1247
			Remove..................................................................1247
				LPG Tank............................................................1247
				LPG Bracket.........................................................1247
			Install.................................................................1250
				LPG Bracket.........................................................1250
				LPG Tank............................................................1250
		Counterweight Replacement...................................................1251
			Remove..................................................................1251
			Install.................................................................1252
			Tow Pin, Remove and Install.............................................1253
		Overhead Guard Replacement..................................................1253
			Remove and Install......................................................1253
			LED Tail, Backup, and Brake Lights, Replace.............................1254
		Operator Restraint System Replacement.......................................1255
		Engine Replacement..........................................................1256
			Remove Engine Only......................................................1256
			Remove Engine and Transmission..........................................1258
			Install Engine Only.....................................................1258
			Install Engine and Transmission.........................................1259
		Throttle Pedal and Cable Adjustment.........................................1259
			Mazda Gas/LPG Engines...................................................1259
			Yanmar Diesel Engine With Basic Power Shift Transmission................1261
			Yanmar Diesel Engine With Electronic Throttle...........................1261
		Exhaust System Repair.......................................................1262
			Lift Trucks With Counterweight Exhaust System...........................1262
				Mazda and GM Gas and LPG Engines....................................1262
					Remove and Disassemble..........................................1262
					Inspect.........................................................1264
					Assemble and Install............................................1264
				Yanmar Diesel Engine................................................1264
					Remove and Disassemble..........................................1264
					Inspect.........................................................1266
					Assemble and Install............................................1266
			Lift Trucks With Overhead Exhaust System................................1266
				Yanmar Diesel Engine................................................1267
					Remove and Disassemble..........................................1267
					Inspect.........................................................1267
					Assemble and Install............................................1267
				Mazda Gas and LPG Engines...........................................1269
					Remove and Disassemble..........................................1269
					Inspect.........................................................1269
					Assemble and Install............................................1269
		Cooling System..............................................................1271
			Description.............................................................1271
		Fuel and Hydraulic Tanks Repair.............................................1271
			Inspect.................................................................1271
			Clean...................................................................1272
				Steam Method of Cleaning............................................1272
				Chemical Solution Method of Cleaning................................1272
			Additional Preparations for Repair......................................1273
			Small Leaks, Repair.....................................................1273
			Large Leaks, Repair.....................................................1273
			Preparations for Usage After Repair.....................................1273
		Safety Labels...............................................................1273
	tables..........................................................................1235
		Table 1. Weight of Counterweights, Lift Truck Models S2.0-3.5FT ............1252
		Table 2. Weight of Counterweights, Lift Truck Models S30FT, S35F............1252
		Table 3. Weight of Counterweights, Lift Truck Models H1.6FT, H1.............1252
		Table 4. Weight of Counterweights, Lift Truck Models H2.0-3.5FT ............1252
Gasoline Fuel System GM-0900SRM1126-(05-2005)-US-EN.................................1279
	toc.............................................................................1279
		Gasoline Fuel System........................................................1279
		Safety Precautions Maintenance and Repair...................................1280
		General.....................................................................1283
		Electronic Throttle Body Repair.............................................1283
			Electronic Throttle Body................................................1283
				Remove..............................................................1283
				Install.............................................................1283
		Fuel System Repair..........................................................1284
			Before Repair Procedure.................................................1284
			After Repair Procedure..................................................1284
				Fuel Leakage Check..................................................1284
			Fuel Line Pressure Check................................................1285
			Fuel Injectors..........................................................1286
				Remove..............................................................1286
				Install.............................................................1287
			Pressure Regulator......................................................1287
				Remove..............................................................1287
				Install.............................................................1288
		Control System..............................................................1288
			Electronic Control Unit (ECU)...........................................1288
				Remove..............................................................1288
				Install.............................................................1289
			Power Latch Relay.......................................................1289
				Remove..............................................................1289
				Install.............................................................1290
			Camshaft Position (CMP) Sensor..........................................1290
				Remove..............................................................1290
				Install.............................................................1290
			Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) ........1291
				Remove..............................................................1291
				Install.............................................................1291
			Engine Coolant Temperature (ECT) Sensor.................................1291
				Remove..............................................................1291
				Install.............................................................1292
			Oxygen Sensor...........................................................1292
				Remove..............................................................1292
				Install.............................................................1293
Gasoline Fuel System Mazda-0900SRM1127-(05-2005)-US-EN..............................1297
	toc.............................................................................1297
		Gasoline Fuel System........................................................1297
		Safety Precautions Maintenance and Repair...................................1298
		General.....................................................................1301
		Abbreviations...............................................................1301
		Engine Tune-up..............................................................1301
			Engine Tune-Up Preparation..............................................1301
			Idle Speed Adjustment...................................................1301
			Idle-Up Speed Check.....................................................1301
		Intake-Air System...........................................................1303
			Intake-Air System Manifold Vacuum Check.................................1303
			Throttle Body...........................................................1304
				Remove..............................................................1304
				Install.............................................................1304
			Electronic Governor.....................................................1304
				Remove..............................................................1304
				Install.............................................................1304
			Intake-Air Control (IAC) Valve..........................................1304
				Remove..............................................................1304
				Install.............................................................1306
			Intake Manifold.........................................................1306
				Remove..............................................................1306
				Install.............................................................1306
		Fuel System.................................................................1307
			Before Repair Procedure.................................................1307
				Fuel Line Safety Procedure..........................................1307
			After Repair Procedure..................................................1307
				Fuel Hose, Install..................................................1307
				Fuel Leakage Check..................................................1308
			Fuel Line Pressure Check................................................1308
			Fuel Injector...........................................................1309
				Remove..............................................................1309
				Install.............................................................1309
			Pressure Regulator......................................................1310
				Remove..............................................................1310
				Install.............................................................1311
		Exhaust System..............................................................1312
			Exhaust System, Inspect.................................................1312
			Three-Way Catalytic (TWC) Converter.....................................1312
				Remove and Install..................................................1312
			Exhaust Manifold........................................................1312
				Remove..............................................................1312
				Install.............................................................1312
			Positive Crankcase Ventilation (PCV) Valve..............................1314
				Remove..............................................................1314
				Inspect.............................................................1314
				Install.............................................................1314
		Control System..............................................................1314
			Engine Control Unit (ECU)...............................................1314
				Remove..............................................................1314
				Install.............................................................1316
			Intake Air Temperature (IAT) Sensor.....................................1317
				Remove..............................................................1317
				Install.............................................................1317
			Mass Air Flow (MAF) Sensor..............................................1317
				Remove..............................................................1317
				Install.............................................................1317
			Throttle Position (TP) Sensor...........................................1318
				TP Sensor, Adjust...................................................1318
				Remove..............................................................1319
				Install.............................................................1319
			Engine Coolant Temperature (ECT) Sensor.................................1319
				Remove..............................................................1319
				Install.............................................................1320
			Camshaft Position (CMP) Sensor..........................................1320
				Voltage Check.......................................................1320
			Oxygen Sensor...........................................................1320
				Remove..............................................................1320
				Install.............................................................1320
			Manifold Absolute Pressure (MAP)/Boost Sensor...........................1321
				Remove..............................................................1321
				Install.............................................................1321
		Technical Data..............................................................1322
	tables..........................................................................1297
		Table 1. PCV Valve Specifications...........................................1314
		Table 2. Closed Throttle Position Specifications............................1319
		Table 3. Gasoline Fuel Systems Technical Data...............................1322
GM Engine Repair-0600SRM1121-(05-2005)-US-EN........................................1325
	toc.............................................................................1325
		GM Engine Repair............................................................1325
		Safety Precautions Maintenance and Repair...................................1326
		General.....................................................................1331
		Engine Serial Number........................................................1331
		Engine Removal and Installation.............................................1332
		Intake Manifold.............................................................1332
			Remove..................................................................1332
			Clean and Inspect.......................................................1333
			Install.................................................................1333
		Exhaust Manifold............................................................1334
			Remove..................................................................1334
			Clean and Inspect.......................................................1335
			Install.................................................................1335
		Camshaft and Cylinder Head Repair...........................................1335
			Rocker Arm Cover........................................................1335
				Remove..............................................................1335
				Install.............................................................1336
			Camshaft Timing Pulley and/or Front Seal................................1336
				Remove..............................................................1336
				Install.............................................................1336
			Camshaft Position (CMP) Sensor Assembly.................................1337
				Remove..............................................................1337
				Install.............................................................1337
			Camshaft Carrier and Cylinder Head......................................1337
				Remove..............................................................1337
				Disassemble.........................................................1339
					Camshaft Carrier................................................1339
					Cylinder Head...................................................1340
				Clean and Inspect...................................................1341
					Camshaft Carrier................................................1341
					Cylinder Head...................................................1342
				Valve and Valve Seat................................................1344
				Assemble............................................................1344
					Cylinder Head...................................................1344
					Camshaft Carrier................................................1344
				Install.............................................................1345
		Timing Belt.................................................................1346
			Timing Belt Front Cover.................................................1346
				Remove..............................................................1346
				Install.............................................................1347
			Timing Belt and Timing Belt Tensioner...................................1347
				Remove..............................................................1347
				Install.............................................................1349
			Timing Belt Rear Cover..................................................1349
				Remove..............................................................1349
				Install.............................................................1349
		Lubrication System Repair...................................................1350
			Oil Pan.................................................................1350
				Remove..............................................................1350
				Install.............................................................1350
			Oil Pump................................................................1352
				Remove..............................................................1352
				Clean and Inspect...................................................1353
				Install.............................................................1354
		Piston and Piston Rod Assemblies Repair.....................................1355
			Piston Rod Bearings, Replace............................................1355
			Piston and Piston Rod Assemblies........................................1357
				Remove..............................................................1357
				Disassemble.........................................................1358
				Pistons, Clean and Inspect..........................................1358
				Cylinder Bores, Inspect and Repair..................................1359
				Piston Rings, Inspect...............................................1360
				Assemble............................................................1361
				Install.............................................................1361
		Crankshaft and Main Bearings................................................1362
			Crankshaft Timing Pulley and/or Front Seal..............................1362
				Remove..............................................................1362
				Install.............................................................1363
			Crankshaft Rear Main Oil Seal...........................................1364
				Remove..............................................................1364
				Install.............................................................1364
			Crankshaft/RPM Sensor...................................................1365
				Remove..............................................................1365
				Install.............................................................1365
			Crankshaft Reluctor Wheel...............................................1365
				Remove and Install..................................................1365
			Crankshaft and Main Bearings............................................1366
				Remove..............................................................1366
				Inspect and Repair..................................................1366
				Bearing Selection...................................................1367
				Main Bearings and Journal Clearance, Check..........................1368
				Install.............................................................1369
		Flywheel and Flywheel Housing...............................................1371
			Remove..................................................................1371
			Install.................................................................1371
		Cooling System Repair.......................................................1372
			Serpentine Belt.........................................................1372
				Remove..............................................................1372
				Inspect.............................................................1372
				Install.............................................................1372
			Water Pump..............................................................1373
				Remove..............................................................1373
				Inspect.............................................................1375
				Install.............................................................1375
			Thermostat..............................................................1376
				Remove..............................................................1376
				Check...............................................................1377
				Install.............................................................1377
			Thermostat Housing......................................................1378
				Remove..............................................................1378
				Clean and Inspect...................................................1378
				Install.............................................................1379
		Ignition System.............................................................1380
			Spark Plug Wire Inspection..............................................1380
			Spark Plug Wire Replacement.............................................1380
				Remove..............................................................1380
				Install.............................................................1381
			Spark Plug Replacement..................................................1381
				Remove..............................................................1381
				Install.............................................................1381
			Spark Plug Inspection...................................................1382
				Usage...............................................................1382
				Inspect.............................................................1382
				Visual Inspection...................................................1383
			Coil Pack...............................................................1384
				Remove..............................................................1384
				Install.............................................................1384
		Alternator Repair...........................................................1384
			Alternator..............................................................1384
				Remove..............................................................1384
				Install.............................................................1384
			Alternator Fuse, Replace................................................1385
		Starter Repair..............................................................1385
			Remove..................................................................1385
			Install.................................................................1385
		Engine Specifications.......................................................1386
			Engine Data.............................................................1386
			Cylinder Bore...........................................................1386
			Piston..................................................................1386
			Piston Rings............................................................1386
			Wrist Pin...............................................................1387
			Crankshaft..............................................................1387
			Piston Rod..............................................................1388
			Camshaft and Camshaft Carrier...........................................1388
			Valve System............................................................1388
			Cylinder Head Warpage...................................................1389
			Lubrication System......................................................1389
			Cooling System..........................................................1389
		Torque Specifications.......................................................1390
		Special Tools...............................................................1391
Hydraulic Gear Pump-1900SRM1136-(05-2005)-US-EN.....................................1397
	toc.............................................................................1397
		Hydraulic Gear Pump.........................................................1397
		Safety Precautions Maintenance and Repair...................................1398
		General.....................................................................1401
		Gear Pump Assembly Repair...................................................1401
			Remove..................................................................1401
			Disassemble.............................................................1401
			Inspect.................................................................1404
			Clean...................................................................1404
			Assemble................................................................1404
			Install.................................................................1404
		Gear Pump Specifications....................................................1405
		Torque Specifications.......................................................1406
	tables..........................................................................1397
		Table 1. Standard Gear Pump.................................................1405
		Table 2. High Pressure Gear Pump............................................1405
LP Fuel System Mazda-0900SRM1125-(05-2005)-US-EN....................................1409
	toc.............................................................................1409
		LPG Fuel System.............................................................1409
		Safety Precautions Maintenance and Repair...................................1410
		General.....................................................................1413
		Hoses Replacement...........................................................1413
		LPG Tank Replacement........................................................1413
			Remove..................................................................1413
			Install.................................................................1413
		Fuel Filter.................................................................1415
			Remove..................................................................1415
			Clean and Inspect.......................................................1416
			Install.................................................................1417
		Relief Valve Replacement....................................................1418
			Remove and Install......................................................1418
		Carburetor Repair...........................................................1418
			Remove..................................................................1418
			Disassemble.............................................................1418
			Clean...................................................................1420
			Assemble................................................................1420
			Install.................................................................1420
		Fuel Injector Repair........................................................1421
			Remove..................................................................1421
			Clean and Inspect.......................................................1421
			Install.................................................................1421
		Governor Repair.............................................................1421
			Remove..................................................................1421
			Install.................................................................1421
		Regulator Repair............................................................1422
			Remove..................................................................1422
			Install.................................................................1423
		Control System..............................................................1423
			Engine Control Unit (ECU)...............................................1423
				Remove..............................................................1423
				Install.............................................................1423
			Engine Coolant Temperature (ECT) Sensor.................................1424
				Remove..............................................................1424
				Install.............................................................1424
			Camshaft Position (CMP) Sensor..........................................1424
				Voltage Check.......................................................1424
			Intake Air Temperature (IAT) Sensor.....................................1425
				Remove..............................................................1425
				Install.............................................................1425
			Manifold Absolute Pressure (MAP) Sensor.................................1426
				Remove..............................................................1426
				Install.............................................................1426
			Oxygen Sensor...........................................................1426
				Remove..............................................................1426
				Install.............................................................1426
			Throttle Position (TP) Sensor...........................................1427
				Remove..............................................................1427
				Install.............................................................1427
LP Fuel Systems GM-0900SRM1124-(05-2005)-US-EN......................................1431
	toc.............................................................................1431
		LPG Fuel System.............................................................1431
		Safety Precautions Maintenance and Repair...................................1432
		General.....................................................................1435
		Hoses Replacement...........................................................1435
		LPG Tank Replacement........................................................1435
			Remove..................................................................1435
			Install.................................................................1435
		Fuel Filter Unit Repair.....................................................1437
			Fuel Filter Element.....................................................1437
				Remove..............................................................1437
				Install.............................................................1438
			Fuel Filter Housing.....................................................1438
				Remove..............................................................1438
				Disassemble.........................................................1439
				Assemble............................................................1439
				Install.............................................................1439
		Electronic Throttle Body Repair.............................................1440
			Electronic Throttle Body................................................1440
				Remove..............................................................1440
				Install.............................................................1440
			Electronic Throttle Body Adapter Plate..................................1441
				Remove..............................................................1441
				Install.............................................................1441
		Fuel Injector Repair........................................................1441
			Fuel Rail...............................................................1441
				Remove..............................................................1441
				Install.............................................................1442
			Fuel Injector...........................................................1443
				Remove..............................................................1443
				Clean...............................................................1443
				Install.............................................................1443
			Fuel Injector Adapters..................................................1444
				Remove..............................................................1444
				Install.............................................................1445
		Vaporizer Repair............................................................1445
			Vaporizer...............................................................1445
				Remove..............................................................1445
				Install.............................................................1446
			Vaporizer Fuel Filter...................................................1447
				Remove..............................................................1447
				Install.............................................................1447
			Lock-Off Solenoid and Cartridge.........................................1448
				Remove..............................................................1448
				Install.............................................................1448
		Control System..............................................................1448
			Electronic Control Unit (ECU)...........................................1448
				Remove..............................................................1448
				Install.............................................................1450
			Power Latch Relay.......................................................1450
				Remove..............................................................1450
				Install.............................................................1450
			Injector Driver Module..................................................1451
				Remove..............................................................1451
				Install.............................................................1451
			Camshaft Position (CMP) Sensor..........................................1452
				Remove..............................................................1452
				Install.............................................................1452
			Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) ........1452
				Remove..............................................................1452
				Install.............................................................1453
			Engine Coolant Temperature (ECT) Sensor.................................1453
				Remove..............................................................1453
				Install.............................................................1453
			Oxygen Sensor...........................................................1453
				Remove..............................................................1453
				Install.............................................................1454
Main Control Valve-2000SRM1137-(05-2005)-US-EN......................................1457
	toc.............................................................................1457
		Main Control Valve..........................................................1457
		Safety Precautions Maintenance and Repair...................................1458
		General.....................................................................1461
		Electro-Hydraulic Main Control Valve........................................1461
			Description.............................................................1461
			Remove..................................................................1462
			Electro-Hydraulic Control Valve Sections................................1465
				General.............................................................1465
				Outlet Control Valve Section........................................1465
					Remove..........................................................1465
					Disassemble.....................................................1465
					Clean...........................................................1466
					Inspect.........................................................1467
					Assemble........................................................1467
					Install.........................................................1467
				Auxiliary Control Valve Section.....................................1467
					Remove..........................................................1467
					Disassemble.....................................................1469
					Clean...........................................................1469
					Inspect.........................................................1470
					Assemble........................................................1470
					Install.........................................................1470
				Tilt Control Valve Section..........................................1470
					Remove..........................................................1470
					Disassemble.....................................................1471
					Clean...........................................................1472
					Inspect.........................................................1472
					Assemble........................................................1472
					Install.........................................................1472
				Lift/Lower Control Valve Section....................................1472
					Remove..........................................................1472
					Disassemble.....................................................1472
					Clean...........................................................1474
					Inspect.........................................................1474
					Assemble........................................................1475
					Install.........................................................1475
			Install.................................................................1475
		Manual Main Control Valve...................................................1478
			Description.............................................................1478
			Remove..................................................................1479
			Manual Control Valve Sections...........................................1482
				General.............................................................1482
				Outlet Control Valve Section........................................1482
					Remove..........................................................1482
					Disassemble.....................................................1482
					Clean...........................................................1484
					Inspect.........................................................1484
					Assemble........................................................1484
					Install.........................................................1484
				Auxiliary Control Valve Section.....................................1484
					Remove..........................................................1484
					Disassemble.....................................................1485
					Clean...........................................................1486
					Inspect.........................................................1486
					Assemble........................................................1486
					Install.........................................................1486
				Lift/Tilt Control Valve Section.....................................1486
					Remove..........................................................1486
					Disassemble.....................................................1487
					Clean...........................................................1487
					Inspect.........................................................1487
					Assemble........................................................1489
					Install.........................................................1489
			Install.................................................................1489
		Steering Control Unit Repair................................................1492
			Steering Control Unit, Remove...........................................1492
			Steering Control Unit, Disassemble......................................1494
			Steering Control Unit, Clean............................................1494
			Steering Control Unit, Inspect..........................................1494
			Steering Control Unit, Assemble.........................................1496
			Relief Valve, Disassemble...............................................1496
			Relief Valve, Clean.....................................................1497
			Relief Valve, Inspect...................................................1497
			Relief Valve, Assemble..................................................1497
			Steering Control Unit, Install..........................................1497
Mast Repair 2 3 4 Stage-4000SRM1148-(05-2005)-US-EN.................................1501
	toc.............................................................................1501
		Mast Repairs................................................................1501
		Safety Precautions Maintenance and Repair...................................1502
		General.....................................................................1505
		Safety Procedures When Working Near Mast....................................1505
		Forks Repair................................................................1507
			Remove..................................................................1507
			Install.................................................................1507
			Checks..................................................................1508
		Carriages Repair............................................................1509
			Standard Carriage.......................................................1509
				Remove..............................................................1509
				Repair..............................................................1510
				Install.............................................................1510
			Integral Sideshift Carriage.............................................1511
				Remove..............................................................1511
				Clean and Inspect...................................................1513
				Repair..............................................................1514
				Install.............................................................1515
		Mast Repair.................................................................1515
			Mast, Remove............................................................1515
			Two-Stage LFL and Two-Stage FFL Masts, Disassemble......................1518
			Clean and Inspect.......................................................1524
			Three-Stage FFL Mast....................................................1525
				Disassemble.........................................................1525
				Clean and Inspect...................................................1526
			Two-Stage LFL and Two-Stage FFL Mast, Assemble..........................1530
			Three-Stage FFL Mast, Assemble..........................................1531
			Four-Stage FFL, Disassemble.............................................1532
			Clean and Inspect.......................................................1536
			Four-Stage FFL, Assemble................................................1538
			Mast, Install...........................................................1541
		Header Hose Arrangement.....................................................1542
			Two-Stage LFL...........................................................1542
			Two-Stage FFL...........................................................1548
			Three-Stage FFL.........................................................1560
			Four-Stage FFL..........................................................1575
			Adjustment..............................................................1581
		Lift Chains Adjustment......................................................1583
		Carriage Adjustments........................................................1584
		Tilt Cylinders Adjustment...................................................1584
		Mast Adjustments............................................................1586
	tables..........................................................................1501
		Table 1. Fork Tip Alignment.................................................1508
		Table 2. Pneumatic Tire Trucks..............................................1545
		Table 3. Cushion Tire Trucks................................................1545
		Table 4. Standard Two-Stage Hose Dimensions.................................1548
		Table 5. Pneumatic Tire Trucks..............................................1551
		Table 6. Cushion Tire Trucks................................................1551
		Table 7. Pneumatic Tire Trucks..............................................1569
		Table 8. Cushion Tire Trucks................................................1569
		Table 9. Standard Three-Stage Hose Dimensions...............................1571
		Table 10. Standard Four-Stage Hose Dimensions...............................1576
Mazda Engine-0600SRM1122-(05-2005)-US-EN............................................1591
	toc.............................................................................1591
		Mazda Engine................................................................1591
		Safety Precautions Maintenance and Repair...................................1592
		General.....................................................................1595
		Engine Removal and Installation.............................................1595
		Cylinder Head, Camshaft, and Valve Mechanism Repair.........................1595
			Remove..................................................................1595
			Clean...................................................................1597
			Inspect and Repair......................................................1597
				Cylinder Head.......................................................1597
				Rocker Shaft Assembly...............................................1598
				Camshaft............................................................1598
				Valve Guides........................................................1599
				Valve Seats.........................................................1599
				Valves..............................................................1600
				Valve Springs.......................................................1600
			Install.................................................................1601
		Crankshaft and Main Bearings Repair.........................................1605
			Remove..................................................................1605
			Inspect and Repair......................................................1605
				Crankshaft..........................................................1605
				Main Bearings.......................................................1606
			Install.................................................................1606
		Pistons and Connecting Rods Repair..........................................1607
			Remove and Disassemble..................................................1607
			Clean...................................................................1607
			Inspect and Repair......................................................1607
				Pistons.............................................................1607
				Piston Rings........................................................1608
				Connecting Rods and Bearings........................................1608
			Assemble and Install....................................................1609
		Cylinder Block Repair.......................................................1610
		Oil Pump Repair.............................................................1611
			Remove..................................................................1611
			Disassemble.............................................................1612
			Clean...................................................................1612
			Inspect.................................................................1612
			Assemble................................................................1612
			Install.................................................................1613
		Cooling System Repair.......................................................1615
			Thermostat..............................................................1615
				Replace.............................................................1615
			Fan Assembly............................................................1615
				Remove and Disassemble..............................................1615
				Assemble and Install................................................1615
			Water Pump..............................................................1616
				Remove..............................................................1616
				Install.............................................................1617
		Distributor Repair..........................................................1618
			Remove..................................................................1618
			Install.................................................................1618
		Flywheel and Ring Gear Repair...............................................1619
			Remove..................................................................1619
			Install.................................................................1619
		Valve Adjustment............................................................1619
		Compression Pressure Check..................................................1620
		Engine Timing Adjustment....................................................1621
		Engine Specifications.......................................................1622
			Engine Data.............................................................1622
			Thermostat..............................................................1622
			Cylinder Head...........................................................1622
			Valve Mechanism.........................................................1622
			Camshaft................................................................1623
			Crankshaft..............................................................1623
			Connecting Rods.........................................................1624
			Cylinder Block..........................................................1624
			Pistons.................................................................1624
			Oil Pump................................................................1625
		Torque Specifications.......................................................1625
	tables..........................................................................1591
		Table 1. Pressure Specifications............................................1621
Periodic Maintenance-8000SRM1150-(05-2005)-US-EN....................................1629
	toc.............................................................................1629
		Periodic Maintenance........................................................1629
		Safety Precautions Maintenance and Repair...................................1630
		General.....................................................................1635
			Serial Number Data......................................................1635
			How to Move Disabled Lift Truck.........................................1635
				How to Tow Lift Truck...............................................1635
			How to Put Lift Truck on Blocks.........................................1636
				How to Raise Drive Tires............................................1636
				How to Raise Steering Tires.........................................1636
		Maintenance Schedule........................................................1638
		Maintenance Procedures Every 8 Hours or Daily...............................1650
			How To Make Checks With Engine Stopped..................................1650
				Tires and Wheels....................................................1650
				Safety Labels.......................................................1651
				Mast, Carriage, Lift Chains, Attachment.............................1651
				Seat Belt, Hip Restraints, and Seat Rails...........................1652
				Hood and Seat Latches...............................................1652
				Engine Compartment..................................................1652
				Fuel, Oil, and Coolant Leaks, Check.................................1654
				Hydraulic Hoses.....................................................1654
				Coolant Hoses.......................................................1654
				Steering Column Gas Cylinder........................................1654
				Transmission........................................................1654
				Hydraulic System Oil................................................1654
				Engine Oil..........................................................1655
				Forks...............................................................1659
					Remove..........................................................1659
					Inspect.........................................................1659
					Install.........................................................1660
					Adjust..........................................................1660
			How To Make Checks With Engine Running..................................1660
				Indicator Lights, Horn, Fuses, and Relays...........................1661
				Service Brakes......................................................1661
					Brake Fluid Level...............................................1661
					Operation, Check................................................1662
				Parking Brake.......................................................1662
				Engine Oil Pressure.................................................1662
				Cooling System......................................................1663
				Steering System.....................................................1663
				Control Levers and Pedals...........................................1664
				Lift System, Operate................................................1664
		First Service After First 100 Hours of Operation............................1664
			Mazda and GM Engine Oil and Filter......................................1664
			Yanmar Engine Oil and Filter............................................1664
			Hydraulic System........................................................1666
				Hydraulic Filter, Replace...........................................1666
			Transmission............................................................1667
				Transmission Oil Filter, Replace....................................1667
		Maintenance Procedures Every 250 Hours or 6 Weeks...........................1668
			Hydraulic System Oil....................................................1668
			Hydraulic Tank Breather.................................................1668
			Battery.................................................................1669
			Mazda and GM Engine Oil and Filter......................................1669
			Air Filter..............................................................1670
			Drive Belt..............................................................1670
				Mazda 2.0L and 2.2L Engines.........................................1670
					Fan and Alternator Drive Belt...................................1670
				GM 2.4L Engine......................................................1671
					Fan and Alternator Drive Belt...................................1671
			Drain Tar From LPG Regulator............................................1671
			Cooling System..........................................................1672
				Clean Debris From Radiator Core.....................................1672
			Check Transmission Oil Level............................................1672
			Forks...................................................................1673
			Brake Fluid.............................................................1673
			Differential and Drive Axle Oil.........................................1673
		Maintenance Procedures Every 500 Hours or 3 Months..........................1674
			Yanmar Engine Oil and Filter............................................1674
			Drive Belt..............................................................1674
				Yanmar Diesel Engine................................................1674
					Fan and Alternator Drive Belt...................................1674
			PCV Valve...............................................................1674
			Mast Lubrication........................................................1675
			Lift Chain Lubrication..................................................1677
			Tilt Cylinder Lubrication...............................................1677
			Master Brake Cylinder Rod End Pin Lubrication...........................1678
			Manual Hydraulic Levers Lubrication.....................................1678
			Tie Rod Lubrication (H40-70FT)..........................................1678
		Maintenance Procedures Every 1000 Hours or 6 Months.........................1679
			Valve Clearance, Check and Adjust.......................................1679
			Ignition System.........................................................1679
				GM 2.4L Engine......................................................1679
				Mazda 2.0L and 2.2L Engines.........................................1679
			LPG Fuel Filter Element Replace, GM 2.4L Engine.........................1679
				Remove..............................................................1679
				Install.............................................................1679
			LPG Vapor Fuel Filter Replace, Mazda Engines............................1680
			Fuel Filter Replacement, Yanmar Engine..................................1681
			Fuel Tank In-Line Fuel Filter Replacement...............................1682
				Removal.............................................................1682
				Installation........................................................1682
			Priming the Fuel System.................................................1682
			Lift Chains Wear Check..................................................1683
			Lift Chain Lubrication..................................................1683
			Integral Sideshift Carriage, Check Bearings.............................1683
			Steering Axle...........................................................1684
			Control Levers and Pedals...............................................1684
		Maintenance Procedures Every 2000 Hours or Annually.........................1685
			Hydraulic System........................................................1685
				Hydraulic Filter, Replace...........................................1685
				Hydraulic Tank Breather, Replace....................................1686
			Air Filter Element......................................................1686
			PCV Valve...............................................................1687
			Oxygen Sensor...........................................................1687
			LPG Regulator Fuel Filter, Mazda Engines................................1688
				Remove and Replace..................................................1688
			LPG Regulator Fuel Filter, GM Engine....................................1688
				Remove..............................................................1688
				Install.............................................................1688
			Gasoline Fuel Filter....................................................1689
				Remove and Replace..................................................1689
			Timing Belt.............................................................1689
				Mazda Engines.......................................................1689
				GM 2.4L Engine......................................................1689
			LPG Fuel Injector, Mazda Engines........................................1689
			Gasoline Fuel Injector, Mazda Engines...................................1689
			LPG Fuel Injector, GM Engines...........................................1689
			Gasoline Fuel Injector, GM Engines......................................1690
			Fuel Injector, Yanmar Engines...........................................1690
			Transmission............................................................1690
				Transmission Oil and Filter, Replace................................1690
			Forks...................................................................1691
			Integral Sideshift Carriage.............................................1691
				Bearings, Replace...................................................1691
			Brake Fluid Change......................................................1691
			Brake Fluid, Remove.....................................................1691
			Wheel Bearings..........................................................1691
				Steer and Drive Wheel Bearings, Lubricate...........................1691
			Service Brakes..........................................................1691
			Differential............................................................1693
		Maintenance Procedures Every 4000 Hours or 2 Years..........................1694
			Hydraulic Oil, Replace..................................................1694
			Cooling System..........................................................1694
		Safety Procedures When Working Near Mast....................................1696
		Hood Latch Check............................................................1698
		Lift Chain Adjustments......................................................1699
		Jump-Starting the Lift Truck................................................1700
			Jump-Starting Using a Battery Charger...................................1700
			Jump-Starting a Lift Truck Using Another Lift Truck.....................1700
		Welding Repairs.............................................................1700
		Overhead Guard Changes......................................................1701
		Wheel and Tire Replacement..................................................1701
			General.................................................................1701
			Solid Rubber Tire, Change...............................................1701
				Remove and Install Tire on Wheel....................................1701
			Pneumatic Tire, Repair .................................................1702
				Remove Wheels From Lift Truck.......................................1702
				Remove Wheel From Tire..............................................1703
					Remove Tire From Two-Piece Wheel................................1703
					Remove Tire From Three- and Four-Piece Wheels...................1704
				Install Wheel on Tire...............................................1705
					Install Tire on Three- or Four-Piece Wheels.....................1705
					Install Three-Piece or Four-Piece Wheel in Tire.................1706
					Install Tire on Two-Piece Wheel.................................1707
					Install Two-Piece Wheel in Tire.................................1707
			Add Air to Pneumatic Tires..............................................1708
				Wheels, Install.....................................................1708
				Dual Drive Wheels, Install..........................................1708
			Solid Rubber Tire, Change...............................................1709
				Remove Wheel From Tire..............................................1709
				Install Wheel in Tire...............................................1711
		Adhesives and Sealants......................................................1713
	tables..........................................................................1629
		Table 1. Maintenance Schedule...............................................1643
		Table 2. V-Belt Deflection Table............................................1674
		Table 3. Carriage Chain Adjustment, Forks Not Installed.....................1700
Powershift Transmission Repair-1300SRM1129-(05-2005)-US-EN..........................1717
	toc.............................................................................1717
		Powershift Transmission.....................................................1717
		Safety Precautions Maintenance and Repair...................................1718
		General.....................................................................1721
		Charge Pump Repair..........................................................1721
			Remove..................................................................1721
			Inspect.................................................................1721
			Install.................................................................1721
		Torque Converter Replace....................................................1721
			Remove..................................................................1721
			Install.................................................................1726
		Front Cover Housing and Chain Drive Repair..................................1730
			Remove..................................................................1730
			Clean...................................................................1734
			Inspect.................................................................1734
			Install.................................................................1735
		Clutch Packs Repair.........................................................1740
			Remove and Disassemble..................................................1740
				Transmission, Remove and Disassemble................................1740
				Clutch Assemblies, Remove and Disassemble...........................1748
			Clean...................................................................1754
			Inspect.................................................................1754
			Assemble and Install....................................................1755
				Clutch Assemblies, Assemble and Install.............................1755
				Transmission, Assemble and Install..................................1763
		Control Valve Repair........................................................1766
			Remove and Disassemble..................................................1766
			Clean...................................................................1769
			Inspect.................................................................1769
			Assemble and Install....................................................1769
		MONOTROL® Pedal Repair......................................................1770
			Remove and Disassemble..................................................1770
			Assemble and Install....................................................1771
		Direction Control Lever.....................................................1775
			Remove..................................................................1775
			Install.................................................................1775
Starter 2200SRM0106-(12-2004)-US-EN.................................................1779
	toc.............................................................................1779
		Starter.....................................................................1779
		Safety Precautions Maintenance and Repair...................................1780
		General.....................................................................1783
		Description and Operation...................................................1783
		Starter Repair..............................................................1785
			Remove..................................................................1785
			Disassemble.............................................................1785
			Clean...................................................................1786
			Assemble................................................................1786
			Install.................................................................1787
		General Checks and Adjustments..............................................1787
		Troubleshooting.............................................................1790
Steer Axle-1600SRM1133-(05-2005)-US-EN..............................................1795
	toc.............................................................................1795
		Steering Axle...............................................................1795
		Safety Precautions Maintenance and Repair...................................1796
		General.....................................................................1799
		Steering Axle Assembly Repair...............................................1800
			Remove..................................................................1800
			Disassemble.............................................................1800
			Clean...................................................................1802
			Inspect.................................................................1803
			Assemble................................................................1804
			Install.................................................................1805
		Spindles, Bearings, and Tie Rods Repair.....................................1806
			Spindles and Bearings...................................................1806
				S2.0-3.5FT (S40-70FT, S55FTS) [F187]................................1806
					Remove and Disassemble..........................................1806
					Assemble and Install............................................1807
				S30FT, S35FT, S40FTS (E010), H1.6FT, H1.8FT, H2.0FTS (H30FT, H35....1808
					Remove and Disassemble..........................................1808
					Assemble and Install............................................1808
			Tie Rods................................................................1809
				S2.0-3.5FT (S40-70FT, S55FTS) [F187]................................1809
					Remove..........................................................1809
					Install.........................................................1810
				S30FT, S35FT, S40FTS (E010), H1.6FT, H1.8FT, H2.0FTS (H30FT, H35....1811
					Remove..........................................................1811
					Install.........................................................1811
		Steering Cylinder Repair....................................................1813
			Remove and Disassemble..................................................1813
			Clean and Inspect.......................................................1813
			Assemble and Install....................................................1813
		Torque Specifications.......................................................1814
User Interface Service-2200SRM1131-(05-2005)-US-EN..................................1817
	toc.............................................................................1817
		User Interface..............................................................1817
		Safety Precautions Maintenance and Repair...................................1818
		General.....................................................................1821
			Description.............................................................1821
			Dash Display Menu Access................................................1821
		Menu Navigation.............................................................1822
		Main Menu...................................................................1822
		Passwords...................................................................1823
			Adding Passwords........................................................1823
		Hourmeters..................................................................1824
		View Versions...............................................................1825
			VSM Versions............................................................1825
			Dash Display Versions...................................................1826
			Engine Controller Version...............................................1827
			Transmission Controller Version.........................................1828
			Truck Serial Number.....................................................1828
			Truck Configuration.....................................................1829
		Diagnostics.................................................................1830
			Clear Fault Log.........................................................1830
			View Fault Log..........................................................1831
			No-Run Data Display.....................................................1832
			Engine Accelerator and Throttle Data Display............................1833
			Engine Speeds and Governor Data Display.................................1834
			Engine Fuel and Emissions Data Display..................................1835
			Engine General Data Display.............................................1837
			XMSN/Brake Data Display.................................................1838
			Hydraulic Data Display..................................................1840
			General Truck Data Display..............................................1842
		Set Travel and Braking......................................................1844
			Speed Limit.............................................................1844
			Acceleration Rate.......................................................1845
			Auto-Deceleration Rate..................................................1845
			Set Power Reversal Rate.................................................1846
			Set Inching/Brake Overlap...............................................1847
		Setup Hydraulics............................................................1848
			Lift Maximum Speed......................................................1848
			Lower Maximum Speed.....................................................1848
			Tilt Maximum Speed......................................................1849
			Auxiliary Function One, Direction A, Maximum Speed......................1850
			Auxiliary Function One, Direction B, Maximum Speed......................1850
			Auxiliary Function Two, Direction A, Maximum Speed......................1851
			Auxiliary Function Two, Direction B, Maximum Speed......................1851
			Auxiliary Function Three, Direction A, Maximum Speed....................1852
			Auxiliary Function Three, Direction B, Maximum Speed....................1852
			Lift/Lower Ramp Rate....................................................1853
			Hydraulic Auxiliary Ramp Rate...........................................1853
			Return to Set Tilt Delay/On/Off.........................................1854
		Setup Display...............................................................1855
			Set Service Language....................................................1855
		Setup General Items.........................................................1856
			Motion Alarm Activation Type............................................1856
			Light Shutdown Time-Out.................................................1857
			Restore Default Settings................................................1858
			Restore Engine Controller Default Calibration...........................1858
		Calibrations................................................................1859
			Calibrate Transmission Valve............................................1860
			Set Tilt Stop Point.....................................................1861
			Calibrate Travel Speed Sensor...........................................1862
	tables..........................................................................1817
		Table 1. Password Screen....................................................1821
		Table 2. Exit Menu..........................................................1822
		Table 3. Add Password Menu..................................................1823
		Table 4. Hourmeters Menu....................................................1824
		Table 5. View VSM Versions Menu.............................................1825
		Table 6. View Dash Display Versions Menu....................................1826
		Table 7. View Engine Controller Versions Menu...............................1827
		Table 8. View Transmission Controller Versions Menu.........................1828
		Table 9. View Truck Serial Number Menu......................................1829
		Table 10. View Truck Configuration Menu.....................................1829
		Table 11. Clear Fault Log...................................................1830
		Table 12. View Fault Log....................................................1831
		Table 13. No-Run Data Display...............................................1832
		Table 14. Engine Accelerator and Throttle Data Display......................1833
		Table 15. Engine Speeds and Governor Data Display...........................1834
		Table 16. Engine Fuel and Emissions Data Display............................1835
		Table 17. Engine General Data Display.......................................1837
		Table 18. XMSN Brake Data Display...........................................1838
		Table 19. Hydraulic Data Display............................................1840
		Table 20. General Truck Data Display........................................1842
		Table 21. Speed Limit Menu..................................................1844
		Table 22. Acceleration Rate Menu............................................1845
		Table 23. Auto-Decel Menu...................................................1845
		Table 24. Power Reversal Menu...............................................1846
		Table 25. Inch/Brake Overlap Menu...........................................1847
		Table 26. Lift Speed Menu...................................................1848
		Table 27. Lower Speed Menu..................................................1849
		Table 28. Tilt Speed Menu...................................................1849
		Table 29. Auxiliary Function Speed Menu.....................................1850
		Table 30. Auxiliary Function Speed Menu.....................................1850
		Table 31. Auxiliary Function Speed Menu.....................................1851
		Table 32. Auxiliary Function Speed Menu.....................................1851
		Table 33. Auxiliary Function Speed Menu.....................................1852
		Table 34. Auxiliary Function Speed Menu.....................................1852
		Table 35. Lift/Lower Ramp Rate Menu.........................................1853
		Table 36. Hydraulic Auxiliary Ramp Rate Menu................................1853
		Table 37. Tilt Delay Menu...................................................1854
		Table 38. Service Language Menu.............................................1855
		Table 39. Alarm Type Menu...................................................1856
		Table 40. Light Time-Out Menu...............................................1857
		Table 41. Restore Defaults Menu.............................................1858
		Table 42. Restore Settings Menu.............................................1858
		Table 43. Calibrate Electro-Hydraulic Valve Menu............................1859
		Table 44. Calibrate Transmission Valve Menu.................................1861
		Table 45. Tilt Stop Point Menu..............................................1861
		Table 46. Travel Speed Menu.................................................1862
User Interface Supervisor-2200SRM1130-(05-2005)-US-EN...............................1865
	toc.............................................................................1865
		User Interface..............................................................1865
		Safety Precautions Maintenance and Repair...................................1866
		General.....................................................................1869
			Description.............................................................1869
			Dash Display Menu Access................................................1869
		Menu Navigation.............................................................1870
			Standard Display........................................................1870
		Main Menu...................................................................1870
		Password s Menu.............................................................1870
		Password Administration.....................................................1871
			Add Password............................................................1871
			Delete Password.........................................................1871
			Edit Password...........................................................1872
		Other Password Functions....................................................1873
			Operator Passwords - Enable/Disable.....................................1873
			Password Time-Out Delay.................................................1873
			Passwords - Number Wrong to Disable.....................................1874
			Lockout Reset Password..................................................1874
			View Password Log.......................................................1875
		Setup Display Menu..........................................................1876
			Set Operator Language...................................................1876
			Set Units...............................................................1877
			Set Time Format (12/24 Hour)............................................1877
			Set Daylight Saving Time................................................1878
			Set Time................................................................1880
			Set Date Format.........................................................1880
			Set Date................................................................1881
		Operator Checklist..........................................................1881
			Operator Checklist Off-On Mode..........................................1881
			Edit Operator Checklist.................................................1882
			Set Operator Checklist Expiration.......................................1882
			View Checklist Log......................................................1883
			Clear Operator Checklist Log............................................1883
			Clear Operator Checklist Fault..........................................1884
	tables..........................................................................1865
		Table 1. Password Screen....................................................1869
		Table 2. Exit Options Menu..................................................1870
		Table 3. Add Password Menu..................................................1871
		Table 4. Delete Password Menu...............................................1871
		Table 5. Edit Password Menu.................................................1872
		Table 6. Operator Passwords Menu............................................1873
		Table 7. Password Time-Out Delay Menu.......................................1873
		Table 8. Passwords - Number Wrong to Disable Menu...........................1874
		Table 9. View Password Log Menu.............................................1875
		Table 10. Set Language Menu.................................................1876
		Table 11. Set Units Menu....................................................1877
		Table 12. Set Time Format Menu..............................................1877
		Table 13. Set Daylight Saving Time Menu.....................................1878
		Table 14. Set Time Menu.....................................................1880
		Table 15. Set Date Format Menu..............................................1880
		Table 16. Set Date Menu.....................................................1881
		Table 17. Checklist Off-On Mode Menu........................................1881
		Table 18. Edit Checklist Menu...............................................1882
		Table 19. Checklist Expiration Menu.........................................1882
		Table 20. View Checklist Log Menu...........................................1883
		Table 21. Clear Checklist Log Menu..........................................1883
		Table 22. Clear Checklist Fault Menu........................................1884
Wire Harness Repair-2200SRM1128-(05-2005)-US-EN.....................................1887
	toc.............................................................................1887
		Wire Harness Repair.........................................................1887
		Safety Precautions Maintenance and Repair...................................1888
		General.....................................................................1891
		Deutsch Crimping Tool.......................................................1891
			How to Strip a Wire for Use With Deutsch Crimping Tool..................1891
			How to Crimp With the Deutsch Crimping Tool.............................1892
			Calibration Test for the Deutsch Crimping Tool..........................1893
		Deutsch Connectors..........................................................1895
			DT, DTM, and DTP Series Connectors......................................1895
				Connector Receptacle Replacement....................................1902
				Connector Plug Replacement..........................................1908
				Connector Receptacle Pin Replacement................................1913
				Connector Plug Socket Replacement...................................1920
			HD Series Connectors....................................................1927
				Connector Receptacle Replacement....................................1929
				Connector Plug Replacement..........................................1933
				Connector Receptacle Pin Replacement................................1936
				Connector Plug Socket Replacement...................................1941
			Sealing Plugs...........................................................1945
		Metri-Pack Connectors.......................................................1947
			Remove and Install......................................................1947
		Micro-Pack Connectors.......................................................1949
		Weather-Pack Connectors.....................................................1949
			Weather-Pack Terminal Repair............................................1950
		Wire Repair.................................................................1951
			Wire Splicing Requirements..............................................1951
			Deutsch Jiffy Splice....................................................1951
				Assemble............................................................1951
				Disassemble.........................................................1953
			Del-City Crimp-Solder-Shrink Splice.....................................1955
		Twisted/Shielded Cable and Leads Repair.....................................1956
			Twisted/Shielded Cable Repair...........................................1956
			Twisted Leads Repair....................................................1957
		Special Tools...............................................................1958
	tables..........................................................................1887
		Table 1. Wire Strip Length Specifications...................................1892
		Table 2. Wire Splice Size...................................................1955
Yanmar -0600SRM1205-(05-2005)-US-EN.................................................1963
	toc.............................................................................1963
		Yanmar Diesel Engines.......................................................1963
		Safety Precautions Maintenance and Repair...................................1964
		General.....................................................................1969
			Engine Identification...................................................1969
				Major Engine Component Identification...............................1969
				Location of Labels..................................................1969
		Engine Removal and Installation.............................................1970
		Cylinder Head Assembly Repair...............................................1970
			Glow Plugs..............................................................1970
				Remove..............................................................1970
				Install.............................................................1970
			Valve Cover.............................................................1972
				Remove..............................................................1972
				Clean and Inspect...................................................1972
				Install.............................................................1973
			Rocker Arm Assembly.....................................................1973
				Remove..............................................................1973
				Disassemble.........................................................1973
				Clean and Inspect...................................................1973
					Push Rods.......................................................1974
					Rocker Arm Assembly.............................................1974
				Assemble............................................................1975
				Install.............................................................1975
			Valve Clearance Adjustments.............................................1976
			Cylinder Head Assembly..................................................1977
				Remove..............................................................1977
				Disassemble.........................................................1980
					Valves and Valve Springs, Remove................................1980
					Valve Guides, Remove............................................1981
				Clean and Inspect...................................................1981
					Cylinder Head...................................................1981
					Valve Guides....................................................1982
					Valves..........................................................1982
					Valve Sink......................................................1982
					Valve Seat......................................................1983
					Valve Springs...................................................1983
				Assemble............................................................1984
					Valve Guides, Install...........................................1984
					Valves and Valve Springs, Install...............................1984
				Install.............................................................1985
		Timing Gear Case and Timing Gears Repair....................................1986
			Timing Gear Case Cover..................................................1986
				Remove..............................................................1986
				Clean and Inspect...................................................1986
				Install.............................................................1987
			Timing Gears............................................................1987
				Crankshaft Gear.....................................................1988
					Remove..........................................................1988
					Install.........................................................1988
				Idler Gear..........................................................1988
					Remove..........................................................1988
					Inspect.........................................................1988
					Install.........................................................1988
				Camshaft Gear.......................................................1989
					Remove..........................................................1989
					Install.........................................................1989
			Timing Gear Case........................................................1990
				Remove..............................................................1990
				Clean and Inspect...................................................1990
				Install.............................................................1990
		Drive Train, Camshaft, and Cylinder Block Repair............................1991
			Remove..................................................................1991
			Disassemble.............................................................1991
				Pistons and Connecting Rods.........................................1991
				Crankshaft..........................................................1993
				Camshaft............................................................1994
			Clean and Inspect.......................................................1994
				Cylinder Block......................................................1994
					Honing and Boring...............................................1997
				Pistons.............................................................1998
				Piston Pin..........................................................1999
				Connecting Rod......................................................1999
				Tappets.............................................................1999
				Crankshaft..........................................................2000
				Camshaft............................................................2001
				Camshaft Bushing....................................................2001
			Assemble................................................................2001
				Camshaft............................................................2001
				Crankshaft..........................................................2002
				Pistons and Connecting Rods.........................................2002
			Install.................................................................2003
		Lubrication System Repair...................................................2004
			Engine Oil and Oil Filter Change........................................2004
			Oil Pan.................................................................2004
				Remove..............................................................2004
				Install.............................................................2005
			Oil Suction Tube........................................................2005
				Remove..............................................................2005
				Clean...............................................................2005
				Install.............................................................2005
			Oil Pump................................................................2006
				Remove..............................................................2006
				Clean and Inspect...................................................2006
					Outer Rotor Outside Clearance...................................2006
					Outer Rotor to Inner Rotor Tip Clearance........................2006
					Outer Rotor Side Clearance......................................2007
					Rotor Shaft Clearance...........................................2007
				Install.............................................................2007
		Fuel System Repair..........................................................2008
			Fuel Injectors..........................................................2008
				Remove..............................................................2008
				Inspect.............................................................2009
				Clean...............................................................2009
				Test................................................................2009
				Install.............................................................2010
			Electronic Throttle System..............................................2012
				Remove..............................................................2012
				Install.............................................................2014
				Inspect.............................................................2015
				Adjust..............................................................2015
			Fuel Injection Pump.....................................................2015
				Remove..............................................................2015
				Clean and Inspect...................................................2018
				Install.............................................................2018
				Check/Adjust Fuel Injection Timing..................................2019
		Cooling System Repair.......................................................2021
			V-Belt..................................................................2021
				Remove..............................................................2021
				Inspect.............................................................2021
				Install.............................................................2021
				Adjust..............................................................2021
			Water Pump..............................................................2022
				4TNE92-NMHA Engines.................................................2022
					Remove..........................................................2022
					Install.........................................................2023
				4TNE92-NMH and 4TNE98-NMH Engines...................................2024
					Remove..........................................................2024
					Install.........................................................2025
			Thermostat..............................................................2026
				Remove..............................................................2026
				Inspect.............................................................2027
				Install.............................................................2027
		Electrical Equipment Repair.................................................2028
			Alternator..............................................................2028
				Remove..............................................................2028
				Bench Test..........................................................2029
				Regulate Voltage Check..............................................2030
				No Load Test........................................................2030
				Output Test.........................................................2030
				Install.............................................................2030
			Starter.................................................................2032
				Remove..............................................................2033
				No Load Test........................................................2034
				Install.............................................................2034
		Engine Specifications.......................................................2035
			Engine Data.............................................................2035
			Engine Tuning...........................................................2038
			Cylinder Head...........................................................2038
			Intake/Exhaust Valve and Guide..........................................2039
			Valve Spring............................................................2039
			Rocker Arm and Shaft....................................................2039
			Push Rod................................................................2039
			Gear Train and Camshaft.................................................2040
				Camshaft............................................................2040
				Idle Gear Shaft and Bushing.........................................2040
				Backlash of Each Gear...............................................2041
			Cylinder Block..........................................................2041
			Crankshaft..............................................................2041
			Thrust Bearing..........................................................2042
			Piston..................................................................2042
			Piston Ring.............................................................2042
			Connecting Rod..........................................................2043
				Rod Small End.......................................................2043
				Tappet..............................................................2043
			Oil Pump................................................................2043
				Engine Oil Pressure.................................................2043
				Outer Rotor Outside Clearance.......................................2044
				Outer Rotor Side Clearance..........................................2044
				Outer Rotor to Inner Rotor Tip Clearance............................2044
				Rotor Shaft Clearance...............................................2044
		Standard Torque Specifications..............................................2044
			Standard Torque Chart...................................................2044
		Special Torque Specifications...............................................2045
		Special Tools...............................................................2046
	tables..........................................................................1963
		Table 1. Cylinder Measurement Worksheet.....................................1996
		Table 2. Fuel Injector Spray Patterns.......................................2011
		Table 3. V-Belt Deflection Table............................................2021
		Table 4. Alternator Specifications..........................................2028
		Table 5. Starter Specifications.............................................2032
		Table 6. No Load Test Specifications........................................2034
		Table 7. 4TNE92-NMH Engine..................................................2035
		Table 8. 4TNE92-NMHA Engine.................................................2036
		Table 9. 4TNE98-NMH Engine..................................................2037

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PLEASE NOTE:

  • This is the SAME MANUAL used by the dealerships to diagnose your vehicle
  • No waiting for couriers / posts as this is a PDF manual and you can download it within 2 minutes time once you make the payment.
  • Your payment is all safe and the delivery of the manual is INSTANT – You will be taken to the DOWNLOAD PAGE.
  • So have no hesitations whatsoever and write to us about any queries you may have : heydownloadss @gmail.com

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