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Hyster F187 Service Manual – PDF DOWNLOAD
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Description
Hyster F187 Service Manual – PDF DOWNLOAD
DESCRIPTION:
Hyster F187 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 Service Manual – PDF DOWNLOAD
0100SRM1120............................................................................... 1 toc................................................................................... 1 Frame............................................................................. 1 Safety Precautions Maintenance and Repair......................................... 2 General........................................................................... 5 Description....................................................................... 5 Hood, Seat, and Side Covers Replacement........................................... 6 Remove........................................................................ 6 Install....................................................................... 12 LPG Tank and Bracket Replacement.................................................. 13 Remove........................................................................ 13 LPG Tank.................................................................. 13 LPG Bracket............................................................... 16 Install....................................................................... 16 LPG Bracket............................................................... 16 LPG Tank.................................................................. 17 Counterweight Replacement......................................................... 17 Remove........................................................................ 17 Install....................................................................... 19 Tow Pin, Remove and Install................................................... 19 Overhead Guard Replacement........................................................ 20 Remove and Install............................................................ 20 LED Tail, Backup, and Brake Lights, Replace................................... 21 Operator Restraint System Replacement............................................. 21 Engine Replacement................................................................ 22 Remove Engine Only............................................................ 22 Remove Engine and Transmission................................................ 24 Install Engine Only........................................................... 25 Install Engine and Transmission............................................... 26 Throttle Pedal and Cable Adjustment............................................... 26 Mazda Gas/LPG Engines......................................................... 26 Yanmar Diesel Engine With Basic Power Shift Transmission...................... 28 Yanmar Diesel Engine With Electronic Throttle................................. 29 Exhaust System Repair............................................................. 29 Lift Trucks With Counterweight Exhaust System................................. 29 Remove and Disassemble.................................................... 29 Inspect................................................................... 32 Assemble and Install...................................................... 32 Lift Trucks With Overhead Exhaust System...................................... 32 Yanmar Diesel Engine...................................................... 32 Remove and Disassemble................................................ 32 Inspect............................................................... 33 Assemble and Install.................................................. 33 Mazda Gas and LPG Engines................................................. 35 Remove and Disassemble................................................ 35 Inspect............................................................... 35 Assemble and Install.................................................. 35 Cooling System.................................................................... 37 Description................................................................... 37 Fuel and Hydraulic Tanks Repair................................................... 37 Inspect....................................................................... 37 Clean......................................................................... 38 Steam Method of Cleaning.................................................. 38 Chemical Solution Method of Cleaning...................................... 38 Additional Preparations for Repair............................................ 38 Small Leaks, Repair........................................................... 39 Large Leaks, Repair........................................................... 39 Preparations for Usage After Repair........................................... 39 Safety Labels..................................................................... 39 tables................................................................................ 1 Table 1. Weight of Counterweights, Lift Truck Models S2.0-3.5FT .................. 18 Table 2. Weight of Counterweights, Lift Truck Models S1.5FT, S1................... 19 Table 3. Weight of Counterweights, Lift Truck Models H1.6FT, H1................... 19 Table 4. Weight of Counterweights, Lift Truck Models H2.0-3.5FT .................. 19 0600SRM1122-(08-2005)-US-EN............................................................... 45 toc................................................................................... 45 Mazda Engine...................................................................... 45 Safety Precautions Maintenance and Repair......................................... 46 General........................................................................... 49 Serial Number................................................................. 49 Engine Removal and Installation................................................... 49 Cylinder Head, Camshaft, and Valve Mechanism Repair............................... 49 Remove........................................................................ 49 Clean......................................................................... 51 Inspect and Repair............................................................ 51 Cylinder Head............................................................. 51 Rocker Shaft Assembly..................................................... 52 Camshaft.................................................................. 52 Valve Guides.............................................................. 53 Valve Seats............................................................... 54 Valves.................................................................... 54 Valve Springs............................................................. 55 Install....................................................................... 55 Crankshaft and Main Bearings Repair............................................... 59 Remove........................................................................ 59 Inspect and Repair............................................................ 59 Crankshaft................................................................ 59 Main Bearings............................................................. 60 Install....................................................................... 60 Pistons and Connecting Rods Repair................................................ 61 Remove and Disassemble........................................................ 61 Clean......................................................................... 61 Inspect and Repair............................................................ 61 Pistons................................................................... 61 Piston Rings.............................................................. 62 Connecting Rods and Bearings.............................................. 62 Assemble and Install.......................................................... 63 Cylinder Block Repair............................................................. 64 Oil Pump Repair................................................................... 65 Remove........................................................................ 65 Disassemble................................................................... 66 Clean......................................................................... 66 Inspect....................................................................... 66 Assemble...................................................................... 66 Install....................................................................... 67 Cooling System Repair............................................................. 69 Thermostat.................................................................... 69 Replace................................................................... 69 Fan Assembly.................................................................. 69 Remove and Disassemble.................................................... 69 Assemble and Install...................................................... 69 Water Pump.................................................................... 70 Remove.................................................................... 70 Install................................................................... 71 Distributor Repair................................................................ 72 Remove........................................................................ 72 Install....................................................................... 72 Flywheel and Ring Gear Repair..................................................... 73 Remove........................................................................ 73 Install....................................................................... 73 Valve Adjustment.................................................................. 73 Compression Pressure Check........................................................ 74 Engine Timing Adjustment.......................................................... 75 Engine Specifications............................................................. 76 Engine Data................................................................... 76 Thermostat.................................................................... 76 Cylinder Head................................................................. 76 Valve Mechanism............................................................... 76 Camshaft...................................................................... 77 Crankshaft.................................................................... 77 Connecting Rods............................................................... 78 Cylinder Block................................................................ 78 Pistons....................................................................... 78 Oil Pump...................................................................... 79 Torque Specifications............................................................. 79 tables................................................................................ 45 Table 1. Pressure Specifications.................................................. 75 0700SRM1123-(10-2006)-US-EN............................................................... 83 toc................................................................................... 83 Cooling System.................................................................... 83 Safety Precautions Maintenance and Repair......................................... 84 General........................................................................... 87 Cooling System Checks............................................................. 87 Exhaust Leaks Into Cooling System............................................. 87 Water Flow Restrictions in Radiator........................................... 87 Radiator Hoses................................................................ 87 Water Pump.................................................................... 87 Radiator Replacement.............................................................. 88 Cooling System, Clean......................................................... 88 Radiator, Remove.............................................................. 89 Radiator, Install............................................................. 94 Fan Assembly Replacement.......................................................... 96 Remove........................................................................ 96 Inspect....................................................................... 99 Install....................................................................... 99 0700SRM1123............................................................................... 105 toc................................................................................... 105 Cooling System.................................................................... 105 Safety Precautions Maintenance and Repair......................................... 106 General........................................................................... 109 Description....................................................................... 109 Radiator...................................................................... 111 Radiator Cap.................................................................. 111 Thermostat.................................................................... 111 Water Pump.................................................................... 112 Fan........................................................................... 112 Cooling System Checks............................................................. 112 Exhaust Leaks Into Cooling System............................................. 112 Water Flow Restrictions in Radiator........................................... 112 Radiator Hoses................................................................ 113 Water Pump.................................................................... 113 Radiator Replacement.............................................................. 113 Cooling System, Clean......................................................... 113 Radiator, Remove.............................................................. 114 Radiator, Install............................................................. 114 Water Pump Repair................................................................. 116 Mazda 2.0L and 2.2L Engine.................................................... 116 Remove.................................................................... 116 Inspect................................................................... 117 Install................................................................... 117 GM 2.4L Engine................................................................ 118 Remove.................................................................... 118 Inspect................................................................... 121 Install................................................................... 121 Yanmar 2.6L and 3.3L Engines.................................................. 122 Thermostat Replacement............................................................ 123 Mazda 2.0L and 2.2L Engine.................................................... 123 Remove.................................................................... 123 Check..................................................................... 123 Install................................................................... 124 GM 2.4L Engine................................................................ 124 Remove.................................................................... 124 Check..................................................................... 125 Install................................................................... 125 Yanmar 2.6L and 3.3L Engines.................................................. 126 Fan Assembly Replacement.......................................................... 126 Remove........................................................................ 126 Inspect....................................................................... 128 Install....................................................................... 129 Fan Belt Replacement.............................................................. 129 Mazda 2.0L and 2.2L Engine.................................................... 129 Remove.................................................................... 129 Inspect................................................................... 130 Install................................................................... 130 GM 2.4L Engine................................................................ 130 Remove.................................................................... 130 Inspect................................................................... 131 Install................................................................... 131 Yanmar 2.6L and 3.3L Engines.................................................. 131 0900SRM1125-(05-2005)-US-EN............................................................... 135 toc................................................................................... 135 LPG Fuel System................................................................... 135 Safety Precautions Maintenance and Repair......................................... 136 General........................................................................... 139 Hoses Replacement................................................................. 139 LPG Tank Replacement.............................................................. 139 Remove........................................................................ 139 Install....................................................................... 139 Fuel Filter....................................................................... 141 Remove........................................................................ 141 Clean and Inspect............................................................. 142 Install....................................................................... 143 Relief Valve Replacement.......................................................... 144 Remove and Install............................................................ 144 Carburetor Repair................................................................. 144 Remove........................................................................ 144 Disassemble................................................................... 144 Clean......................................................................... 146 Assemble...................................................................... 146 Install....................................................................... 146 Fuel Injector Repair.............................................................. 147 Remove........................................................................ 147 Clean and Inspect............................................................. 147 Install....................................................................... 147 Governor Repair................................................................... 147 Remove........................................................................ 147 Install....................................................................... 147 Regulator Repair.................................................................. 148 Remove........................................................................ 148 Install....................................................................... 149 Control System.................................................................... 149 Engine Control Unit (ECU)..................................................... 149 Remove.................................................................... 149 Install................................................................... 149 Engine Coolant Temperature (ECT) Sensor....................................... 150 Remove.................................................................... 150 Install................................................................... 150 Camshaft Position (CMP) Sensor................................................ 150 Voltage Check............................................................. 150 Intake Air Temperature (IAT) Sensor........................................... 151 Remove.................................................................... 151 Install................................................................... 151 Manifold Absolute Pressure (MAP) Sensor....................................... 152 Remove.................................................................... 152 Install................................................................... 152 Oxygen Sensor................................................................. 152 Remove.................................................................... 152 Install................................................................... 152 Throttle Position (TP) Sensor................................................. 153 Remove.................................................................... 153 Install................................................................... 153 0900SRM1127-(05-2005)-US-EN............................................................... 157 toc................................................................................... 157 Gasoline Fuel System.............................................................. 157 Safety Precautions Maintenance and Repair......................................... 158 General........................................................................... 161 Abbreviations..................................................................... 161 Engine Tune-up.................................................................... 161 Engine Tune-Up Preparation.................................................... 161 Idle Speed Adjustment......................................................... 161 Idle-Up Speed Check........................................................... 161 Intake-Air System................................................................. 163 Intake-Air System Manifold Vacuum Check....................................... 163 Throttle Body................................................................. 164 Remove.................................................................... 164 Install................................................................... 164 Electronic Governor........................................................... 164 Remove.................................................................... 164 Install................................................................... 164 Intake-Air Control (IAC) Valve................................................ 164 Remove.................................................................... 164 Install................................................................... 166 Intake Manifold............................................................... 166 Remove.................................................................... 166 Install................................................................... 166 Fuel System....................................................................... 167 Before Repair Procedure....................................................... 167 Fuel Line Safety Procedure................................................ 167 After Repair Procedure........................................................ 167 Fuel Hose, Install........................................................ 167 Fuel Leakage Check........................................................ 168 Fuel Line Pressure Check...................................................... 168 Fuel Injector................................................................. 169 Remove.................................................................... 169 Install................................................................... 169 Pressure Regulator............................................................ 170 Remove.................................................................... 170 Install................................................................... 171 Exhaust System.................................................................... 172 Exhaust System, Inspect....................................................... 172 Three-Way Catalytic (TWC) Converter........................................... 172 Remove and Install........................................................ 172 Exhaust Manifold.............................................................. 172 Remove.................................................................... 172 Install................................................................... 172 Positive Crankcase Ventilation (PCV) Valve.................................... 174 Remove.................................................................... 174 Inspect................................................................... 174 Install................................................................... 174 Control System.................................................................... 174 Engine Control Unit (ECU)..................................................... 174 Remove.................................................................... 174 Install................................................................... 176 Intake Air Temperature (IAT) Sensor........................................... 177 Remove.................................................................... 177 Install................................................................... 177 Mass Air Flow (MAF) Sensor.................................................... 177 Remove.................................................................... 177 Install................................................................... 177 Throttle Position (TP) Sensor................................................. 178 TP Sensor, Adjust......................................................... 178 Remove.................................................................... 179 Install................................................................... 179 Engine Coolant Temperature (ECT) Sensor....................................... 179 Remove.................................................................... 179 Install................................................................... 180 Camshaft Position (CMP) Sensor................................................ 180 Voltage Check............................................................. 180 Oxygen Sensor................................................................. 180 Remove.................................................................... 180 Install................................................................... 180 Manifold Absolute Pressure (MAP)/Boost Sensor................................. 181 Remove.................................................................... 181 Install................................................................... 181 Technical Data.................................................................... 182 tables................................................................................ 157 Table 1. PCV Valve Specifications................................................. 174 Table 2. Closed Throttle Position Specifications.................................. 179 Table 3. Gasoline Fuel Systems Technical Data..................................... 182 1300SRM1129............................................................................... 185 toc................................................................................... 185 Powershift Transmission........................................................... 185 Safety Precautions Maintenance and Repair......................................... 186 General........................................................................... 189 Charge Pump Repair................................................................ 189 Remove........................................................................ 189 Inspect....................................................................... 189 Install....................................................................... 189 Torque Converter Repair........................................................... 190 Remove........................................................................ 190 Install....................................................................... 195 Front Cover Housing and Chain Drive Repair........................................ 200 Remove........................................................................ 200 Clean......................................................................... 206 Inspect....................................................................... 206 Install....................................................................... 206 Clutch Packs Repair............................................................... 211 Remove and Disassemble........................................................ 211 Transmission, Remove and Disassemble...................................... 211 Clutch Assemblies, Remove and Disassemble................................. 220 Clean......................................................................... 225 Inspect....................................................................... 225 Assemble and Install.......................................................... 226 Clutch Assemblies, Assemble and Install................................... 226 Transmission, Assemble and Install........................................ 231 Control Valve Repair.............................................................. 235 Remove and Disassemble........................................................ 235 Clean......................................................................... 238 Inspect....................................................................... 238 Assemble and Install.......................................................... 238 MONOTROL® Pedal Repair............................................................ 239 Remove and Disassemble........................................................ 239 Assemble and Install.......................................................... 242 Direction Control Lever........................................................... 244 Remove........................................................................ 244 Install....................................................................... 244 1400SRM1206............................................................................... 249 toc................................................................................... 249 Drive Axle and Differential Assembly Repair....................................... 249 Safety Precautions Maintenance and Repair......................................... 250 General........................................................................... 253 Drive Axle Repair................................................................. 253 Remove and Disassemble........................................................ 253 Clean and Inspect............................................................. 255 Assemble and Install.......................................................... 255 Differential Repair............................................................... 257 Remove........................................................................ 257 Differential Assembly From Center Section Assembly........................ 257 Drive Pinion, Pinion Gear, and Bearings From Center Section............... 260 Disassemble................................................................... 264 Differential Assembly..................................................... 265 Drop Box Housing.......................................................... 269 Center Section............................................................ 269 Clean and Inspect............................................................. 271 Assemble...................................................................... 272 Center Section............................................................ 272 Drop Box Housing.......................................................... 274 Differential Assembly..................................................... 275 Install....................................................................... 278 Pinion Inner Shim Set, Adjust Thickness (Depth of Pinion)................. 278 Drive Pinion, Pinion Gear, and Bearings Into Center Section............... 280 Differential Assembly Into Center Section................................. 284 Ring Gear Backlash, Adjust................................................ 287 Ring Gear, Runout Check................................................... 289 Gear Set, Tooth Contact Pattern Check..................................... 289 Torque Specifications............................................................. 291 tables................................................................................ 249 Table 1. Pinion Variation Numbers Examples........................................ 280 Table 2. Ring and Pinion Tooth Contact Adjustment................................. 289 Table 3. Correct Tooth Contact.................................................... 290 Table 4. Incorrect Tooth Contact.................................................. 291 1400SRM1214............................................................................... 295 toc................................................................................... 295 Drive Axle and Differential Assembly Repair....................................... 295 Safety Precautions Maintenance and Repair......................................... 296 General........................................................................... 299 Drive Axle Repair................................................................. 299 Remove and Disassemble........................................................ 299 Clean and Inspect............................................................. 301 Assemble and Install.......................................................... 301 Differential Repair............................................................... 303 Remove........................................................................ 303 Differential Assembly From Center Section................................. 303 Drive Pinion, Pinion Gear, and Bearings From Center Section............... 306 Disassemble................................................................... 312 Differential Assembly..................................................... 312 Drop Box Housing.......................................................... 315 Center Section............................................................ 315 Clean and Inspect............................................................. 318 Assemble...................................................................... 319 Center Section............................................................ 319 Drop Box Housing.......................................................... 322 Differential Assembly..................................................... 323 Install....................................................................... 326 Pinion Inner Shim Set, Adjust Thickness (Depth of Pinion)................. 326 Drive Pinion, Pinion Gear, and Bearings Into Center Section............... 328 Differential Assembly Into Center Section................................. 333 Ring Gear Backlash, Adjust................................................ 337 Ring Gear, Runout Check................................................... 339 Gear Set, Tooth Contact Pattern Check..................................... 339 Torque Specifications............................................................. 341 tables................................................................................ 295 Table 1. Pinion Variation Numbers Examples........................................ 327 Table 2. Ring and Pinion Tooth Contact Adjustment................................. 339 Table 3. Correct Tooth Contact.................................................... 340 Table 4. Incorrect Tooth Contact.................................................. 341 2200SRM1130............................................................................... 345 toc................................................................................... 345 User Interface.................................................................... 345 Safety Precautions Maintenance and Repair......................................... 346 General........................................................................... 349 Description................................................................... 349 Dash Display Menu Access...................................................... 349 Menu Navigation................................................................... 350 Standard Display.............................................................. 350 Main Menu......................................................................... 350 Password s Menu................................................................... 350 Password Administration........................................................... 350 Add Password.................................................................. 350 Delete Password............................................................... 351 Edit Password................................................................. 351 Other Password Functions.......................................................... 352 Operator Passwords - Enable/Disable........................................... 352 Password Time-Out Delay....................................................... 353 Passwords - Number Wrong to Disable........................................... 353 Lockout Reset Password........................................................ 354 View Password Log............................................................. 354 Setup Display Menu................................................................ 354 Set Operator Language......................................................... 354 Set Units..................................................................... 355 Set Time Format (12/24 Hour).................................................. 356 Set Daylight Saving Time...................................................... 356 Set Time...................................................................... 358 Set Date Format............................................................... 358 Set Date...................................................................... 359 Operator Checklist................................................................ 359 Operator Checklist Off-On Mode................................................ 359 Edit Operator Checklist....................................................... 360 Set Operator Checklist Expiration............................................. 360 View Checklist Log............................................................ 361 Clear Operator Checklist Log.................................................. 361 Clear Operator Checklist Fault................................................ 361 Setup General Items............................................................... 362 Impact Sensor - Soft Impact Settings.......................................... 362 Impact Sensor - Hard Impact Settings.......................................... 363 Impact Sensor - Impact Alarm/Shutdown Reset................................... 363 Impact Sensor - Time Duration and Deactivation................................ 364 Impact Sensor - View Impact Event Log......................................... 364 tables................................................................................ 345 Table 1. Password Screen.......................................................... 349 Table 2. Exit Options Menu........................................................ 350 Table 3. Add Password Menu........................................................ 351 Table 4. Delete Password Menu..................................................... 351 Table 5. Edit Password Menu....................................................... 352 Table 6. Operator Passwords Menu.................................................. 352 Table 7. Password Time-Out Delay Menu............................................. 353 Table 8. Passwords - Number Wrong to Disable Menu................................. 353 Table 9. View Password Log Menu................................................... 354 Table 10. Set Language Menu....................................................... 355 Table 11. Set Units Menu.......................................................... 355 Table 12. Set Time Format Menu.................................................... 356 Table 13. Set Daylight Saving Time Menu........................................... 356 Table 14. Set Time Menu........................................................... 358 Table 15. Set Date Format Menu.................................................... 358 Table 16. Set Date Menu........................................................... 359 Table 17. Checklist Off-On Mode Menu.............................................. 359 Table 18. Edit Checklist Menu..................................................... 360 Table 19. Checklist Expiration Menu............................................... 360 Table 20. View Checklist Log Menu................................................. 361 Table 21. Clear Checklist Log Menu................................................ 361 Table 22. Clear Checklist Fault Menu.............................................. 362 Table 23. Soft Impact Settings Menu............................................... 362 Table 24. Hard Impact Settings Menu............................................... 363 Table 25. Shutdown Reset Menu..................................................... 363 Table 26. Alarm Duration Menu..................................................... 364 Table 27. View Event Log Menu..................................................... 364 2200SRM1131............................................................................... 369 toc................................................................................... 369 User Interface.................................................................... 369 Safety Precautions Maintenance and Repair......................................... 370 General........................................................................... 373 Description................................................................... 373 Dash Display Menu Access...................................................... 373 Menu Navigation................................................................... 374 Main Menu......................................................................... 374 Passwords......................................................................... 374 Adding Passwords.............................................................. 375 Hourmeters........................................................................ 376 View Versions..................................................................... 376 VSM Versions.................................................................. 377 Dash Display Versions......................................................... 377 Engine Controller Version..................................................... 378 Transmission Controller Version............................................... 379 Truck Serial Number........................................................... 379 Truck Configuration........................................................... 380 Diagnostics....................................................................... 380 Clear Fault Log............................................................... 381 View Fault Log................................................................ 381 No-Run Data Display........................................................... 382 Engine Accelerator and Throttle Data Display.................................. 383 Engine Speeds and Governor Data Display....................................... 384 Engine Fuel and Emissions Data Display........................................ 384 Engine General Data Display................................................... 386 XMSN/Brake Data Display....................................................... 387 Hydraulic Data Display........................................................ 388 General Truck Data Display.................................................... 390 Set Travel and Braking............................................................ 391 Speed Limit................................................................... 392 Acceleration Rate............................................................. 392 Auto-Deceleration Rate........................................................ 393 Set Power Reversal Rate....................................................... 393 Set Inching/Brake Overlap..................................................... 394 Setup Hydraulics.................................................................. 394 Lift Maximum Speed............................................................ 395 Lower Maximum Speed........................................................... 395 Tilt Maximum Speed............................................................ 395 Auxiliary Function One, Direction A, Maximum Speed............................ 396 Auxiliary Function One, Direction B, Maximum Speed............................ 396 Auxiliary Function Two, Direction A, Maximum Speed............................ 397 Auxiliary Function Two, Direction B, Maximum Speed............................ 398 Auxiliary Function Three, Direction A, Maximum Speed.......................... 398 Auxiliary Function Three, Direction B, Maximum Speed.......................... 399 Lift/Lower Ramp Rate.......................................................... 399 Auxiliary Function Ramp Rate.................................................. 400 Return to Set Tilt Delay/On/Off............................................... 400 Setup Display..................................................................... 401 Set Service Language.......................................................... 401 Setup General Items............................................................... 401 Motion Alarm Activation Type.................................................. 402 Light Shutdown Time-Out....................................................... 402 Restore Default Settings...................................................... 403 Restore Engine Controller Default Calibration................................. 403 Impact Sensor - Enable/Disable................................................ 404 Calibrations...................................................................... 404 Calibrate Electro-Hydraulic Valve Output Thresholds........................... 404 Calibrate Transmission Valve.................................................. 406 Set Tilt Stop Point........................................................... 407 Calibrate Loaded Weight....................................................... 407 Calibrate Travel Speed Sensor................................................. 407 tables................................................................................ 369 Table 1. Password Screen.......................................................... 373 Table 2. Exit Menu................................................................ 374 Table 3. Add Password Menu........................................................ 375 Table 4. Hourmeters Menu.......................................................... 376 Table 5. View VSM Versions Menu................................................... 377 Table 6. View Dash Display Versions Menu.......................................... 377 Table 7. View Engine Controller Versions Menu..................................... 378 Table 8. View Transmission Controller Versions Menu............................... 379 Table 9. View Truck Serial Number Menu............................................ 379 Table 10. View Truck Configuration Menu........................................... 380 Table 11. Clear Fault Log......................................................... 381 Table 12. View Fault Log.......................................................... 381 Table 13. No-Run Data Display..................................................... 382 Table 14. Engine Accelerator and Throttle Data Display............................ 383 Table 15. Engine Speeds and Governor Data Display................................. 384 Table 16. Engine Fuel and Emissions Data Display.................................. 385 Table 17. Engine General Data Display............................................. 386 Table 18. XMSN Brake Data Display................................................. 387 Table 19. Hydraulic Data Display.................................................. 388 Table 20. General Truck Data Display.............................................. 390 Table 21. Speed Limit Menu........................................................ 392 Table 22. Acceleration Rate Menu.................................................. 392 Table 23. Auto-Decel Menu......................................................... 393 Table 24. Power Reversal Menu..................................................... 393 Table 25. Inch/Brake Overlap Menu................................................. 394 Table 26. Lift Speed Menu......................................................... 395 Table 27. Lower Speed Menu........................................................ 395 Table 28. Tilt Speed Menu......................................................... 396 Table 29. Auxiliary Function Speed Menu........................................... 396 Table 30. Auxiliary Function Speed Menu........................................... 397 Table 31. Auxiliary Function Speed Menu........................................... 397 Table 32. Auxiliary Function Speed Menu........................................... 398 Table 33. Auxiliary Function Speed Menu........................................... 398 Table 34. Auxiliary Function Speed Menu........................................... 399 Table 35. Lift/Lower Ramp Rate Menu............................................... 399 Table 36. Auxiliary Ramp Rate Menu................................................ 400 Table 37. Tilt Delay Menu......................................................... 400 Table 38. Service Language Menu................................................... 401 Table 39. Alarm Type Menu......................................................... 402 Table 40. Light Time-Out Menu..................................................... 403 Table 41. Restore Defaults Menu................................................... 403 Table 42. Restore Settings Menu................................................... 404 Table 43. Impact Sensor Enable/Disable............................................ 404 Table 44. Calibrate Electro-Hydraulic Valve Menu.................................. 405 Table 45. Calibrate Transmission Valve Menu....................................... 406 Table 46. Tilt Stop Point Menu.................................................... 407 Table 47. Calibrate Loaded Weight................................................. 407 Table 48. Travel Speed Menu....................................................... 408 2200SRM1142-(06-2006)-US-EN............................................................... 411 toc................................................................................... 411 Electrical System................................................................. 411 Safety Precautions Maintenance and Repair......................................... 412 General........................................................................... 419 Display Switch Cluster............................................................ 420 Remove........................................................................ 420 Install....................................................................... 420 Direction Control and Turn Signal Levers...................................... 421 Remove.................................................................... 421 Install................................................................... 422 Key Switch.................................................................... 423 Remove.................................................................... 423 Install................................................................... 423 Display Switch Cluster Panel Bezel and Overlay................................ 424 Remove.................................................................... 424 Install................................................................... 424 Steering Column Repair............................................................ 424 Remove........................................................................ 424 Disassemble................................................................... 425 Assemble...................................................................... 425 Install....................................................................... 425 Sensors and Switches.............................................................. 427 General....................................................................... 427 Accelerator Pedal Position Sensor............................................. 427 Remove.................................................................... 427 Install................................................................... 429 Brake Fluid Level Switch...................................................... 431 Remove.................................................................... 431 Install................................................................... 431 Service Brake Pedal Position Sensor........................................... 432 Remove.................................................................... 432 Install................................................................... 432 Parking Brake Sensor.......................................................... 433 Remove.................................................................... 433 Install................................................................... 433 Service Brake Pressure Sensor................................................. 433 Remove.................................................................... 433 Install................................................................... 433 MONOTROL® Sensor Microswitch.................................................. 434 Remove.................................................................... 434 Install................................................................... 434 Low Coolant Level Sensor...................................................... 436 Remove.................................................................... 436 Install................................................................... 436 Fuel Level Sensor, Gas and Diesel Engines Only................................ 438 Remove.................................................................... 438 Install................................................................... 438 Armrest Switch................................................................ 438 Remove.................................................................... 438 Install................................................................... 438 Seat Sensor (Operator Presence System)........................................ 440 Non-Suspension and Semi-Suspension Seats.................................. 440 Remove................................................................ 440 Install............................................................... 440 Full Suspension Seats..................................................... 441 Remove................................................................ 441 Install............................................................... 441 Hood Switch................................................................... 441 Remove.................................................................... 441 Install................................................................... 441 Hydraulic Filter Pressure Switch.............................................. 443 Remove.................................................................... 443 Install................................................................... 443 Transmission Speed Sensor..................................................... 444 Remove.................................................................... 444 Install................................................................... 444 Transmission Pressure Sensors................................................. 444 Remove.................................................................... 444 Install................................................................... 444 Transmission Temperature Sensor............................................... 444 Remove.................................................................... 444 Install................................................................... 445 Return to Set Tilt (Tilt Angle) Sensor........................................ 445 Remove.................................................................... 445 Install................................................................... 446 Rear Horn Button Switch....................................................... 446 Remove.................................................................... 446 Install................................................................... 446 Impact Sensor................................................................. 446 Remove.................................................................... 446 Install................................................................... 446 Load Weight Sensor............................................................ 448 Remove.................................................................... 448 Install................................................................... 449 Engine and Fuel Sensors - Mazda 2.0L and 2.2L Gas and LPG Engine.............. 449 Oxygen Sensor............................................................. 449 Remove................................................................ 449 Install............................................................... 449 Intake Air Temperature (IAT) Sensor....................................... 449 Remove................................................................ 449 Install............................................................... 449 Manifold Absolute Pressure (MAP)/Boost Sensor............................. 450 Remove................................................................ 450 Install............................................................... 450 Throttle Position (TPS) Sensor............................................ 450 Remove................................................................ 450 Install............................................................... 450 Engine and Fuel Sensors and Switches - Mazda 2.0L and 2.2L LPG E.............. 451 Oil Pressure Sensor....................................................... 451 Remove................................................................ 451 Install............................................................... 451 Low LPG Pressure Switch................................................... 452 Remove................................................................ 452 Install............................................................... 452 Air Filter Restriction Switch............................................. 452 Remove................................................................ 452 Install............................................................... 452 Engine Coolant Temperature (ECT) Sensor................................... 452 Remove................................................................ 452 Install............................................................... 453 Engine and Fuel Sensors and Switches- Mazda 2.0L and 2.2L Gas En.............. 453 Oil Pressure Sensor....................................................... 453 Remove................................................................ 453 Install............................................................... 453 Mass Air Flow (MAF) Sensor................................................ 454 Remove................................................................ 454 Install............................................................... 454 Air Filter Restriction Switch............................................. 454 Remove................................................................ 454 Install............................................................... 454 Engine Coolant Temperature (ECT) Sensor................................... 454 Remove................................................................ 454 Install............................................................... 455 Engine and Fuel Sensors and Switches, GM 2.4L and 4.3L Gas and L.............. 455 Crankshaft Sensor......................................................... 455 Remove................................................................ 455 Install............................................................... 455 Camshaft Position (CMP) Sensor............................................ 456 Remove................................................................ 456 Install............................................................... 456 Camshaft Position (CMP) Sensor Assembly................................... 457 Remove................................................................ 457 Install............................................................... 457 Oil Pressure Sensor....................................................... 457 Remove................................................................ 457 Install............................................................... 458 Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) .......... 458 Remove................................................................ 458 Install............................................................... 459 Engine Coolant Temperature (ECT) Sensor................................... 459 Remove................................................................ 459 Install............................................................... 459 Air Flow Restriction Switch............................................... 459 Remove................................................................ 459 Install............................................................... 459 Oxygen Sensor............................................................. 460 Remove................................................................ 460 Install............................................................... 462 Engine and Fuel Switches, GM 2.4L and GM 4.3L LPG Trucks Only................. 463 Low LPG Pressure Switch................................................... 463 Remove................................................................ 463 Install............................................................... 463 LPG Pressure Sensor, GM 4.3L Engine Only.................................. 464 Remove................................................................ 464 Install............................................................... 464 Engine and Fuel Sensors and Switches, Yanmar Diesel Trucks.................... 464 Air Filter Restriction Switch............................................. 464 Remove................................................................ 464 Install............................................................... 464 Oil Pressure Sensor....................................................... 464 Remove................................................................ 464 Install............................................................... 464 Engine Speed Sensor....................................................... 464 Remove................................................................ 464 Install............................................................... 464 Engine Coolant Temperature (ECT) Sensor................................... 466 Remove................................................................ 466 Install............................................................... 466 Throttle Position Sensor (TPS)............................................ 466 Remove................................................................ 466 Install............................................................... 466 Fuel/Water Separator Sensor............................................... 467 Remove................................................................ 467 Install............................................................... 467 Glow Plug Relay........................................................... 468 Remove................................................................ 468 Install............................................................... 468 Engine and Fuel Sensors and Switches, Cummins 4.5L Diesel Engine.............. 470 Air Filter Restriction Switch............................................. 470 Remove................................................................ 470 Install............................................................... 470 Oil Pressure Sensor....................................................... 472 Remove................................................................ 472 Install............................................................... 472 Engine Speed Sensor....................................................... 472 Remove................................................................ 472 Install............................................................... 472 Engine Coolant Temperature (ECT) Sensor................................... 472 Remove................................................................ 472 Install............................................................... 472 Throttle Position Sensor (TPS)............................................ 473 Remove................................................................ 473 Install............................................................... 473 Fuel/Water Separator Sensor............................................... 473 Remove................................................................ 473 Install............................................................... 473 Vehicle System Manager (VSM)...................................................... 474 General....................................................................... 474 VSM Replacement............................................................... 474 Remove.................................................................... 474 Install................................................................... 475 Programming a New VSM and/or Display Switch Cluster........................... 476 General................................................................... 476 PC Service Tool Software.................................................. 476 Data Transferring......................................................... 477 New or Used VSM....................................................... 477 New (Blank) Display Switch Cluster.................................... 477 Used (Non-Blank) Display Switch Cluster............................... 477 Power Distribution Module (PDM) and Component Parts............................... 478 Remove........................................................................ 478 PDM as a Unit............................................................. 478 Install....................................................................... 480 PDM as a Unit............................................................. 480 Remove and Install............................................................ 480 PDM Component Parts....................................................... 480 Battery........................................................................... 480 Remove........................................................................ 480 Install....................................................................... 480 Lights............................................................................ 481 Work Lights (Front and Rear).................................................. 481 Remove.................................................................... 481 Install................................................................... 481 Strobe Light.................................................................. 481 Remove.................................................................... 481 Install................................................................... 481 LED Tail, Backup, and Brake Lights............................................ 482 Remove.................................................................... 482 Install................................................................... 482 Electronic-Hydraulic Controls..................................................... 483 General....................................................................... 483 Mini-Levers................................................................... 483 Remove.................................................................... 483 Install................................................................... 484 Joystick...................................................................... 484 Remove and Disassemble.................................................... 484 Inspect................................................................... 484 Assemble and Install...................................................... 484 tables................................................................................ 411 Table 1. VSM and Display Switch Cluster Replacement............................... 478 2200SRM1142............................................................................... 487 toc................................................................................... 487 Electrical System................................................................. 487 Safety Precautions Maintenance and Repair......................................... 488 General........................................................................... 495 Display Switch Cluster............................................................ 495 Remove........................................................................ 495 Replace....................................................................... 497 Direction Control and Turn Signal Levers...................................... 497 Remove.................................................................... 497 Replace................................................................... 498 Key Switch.................................................................... 499 Remove.................................................................... 499 Replace................................................................... 499 Display Switch Cluster Panel Bezel and Overlay................................ 499 Remove.................................................................... 499 Replace................................................................... 500 Steering Column Repair............................................................ 500 Remove........................................................................ 500 Disassemble................................................................... 501 Assemble...................................................................... 502 Install....................................................................... 502 Sensors And Switches.............................................................. 502 General....................................................................... 502 Accelerator Pedal Position Sensor............................................. 504 Remove.................................................................... 504 Replace................................................................... 505 Brake Fluid Level Switch...................................................... 506 Remove.................................................................... 506 Replace................................................................... 506 Service Brake Pedal Position Sensor........................................... 507 Remove.................................................................... 507 Replace................................................................... 507 Parking Brake Sensor.......................................................... 507 Remove.................................................................... 507 Replace................................................................... 508 Service Brake Pressure Sensor................................................. 508 Remove.................................................................... 508 Replace................................................................... 508 MONOTROL® Sensor Microswitch.................................................. 508 Remove.................................................................... 508 Replace................................................................... 509 Low Coolant Level Sensor...................................................... 510 Remove.................................................................... 510 Replace................................................................... 511 Fuel Level Sensor, Gas and Diesel Engines Only................................ 511 Remove.................................................................... 511 Replace................................................................... 512 Armrest Switch................................................................ 512 Remove.................................................................... 512 Replace................................................................... 514 Seat Sensor................................................................... 514 Non-Suspension and Semi-Suspension Seats.................................. 514 Remove................................................................ 514 Replace............................................................... 515 Full Suspension Seats..................................................... 515 Remove................................................................ 515 Replace............................................................... 515 Hood Switch................................................................... 515 Remove.................................................................... 515 Replace................................................................... 516 Hydraulic Filter Pressure Switch.............................................. 516 Remove.................................................................... 516 Replace................................................................... 517 Transmission Speed Sensor..................................................... 517 Remove.................................................................... 517 Replace................................................................... 517 Transmission Pressure Sensors................................................. 518 Remove.................................................................... 518 Replace................................................................... 518 Transmission Temperature Sensor............................................... 518 Remove.................................................................... 518 Replace................................................................... 518 Return to Set Tilt (Tilt Angle) Sensor........................................ 518 Remove.................................................................... 518 Replace................................................................... 519 Rear Horn Button Switch....................................................... 519 Remove.................................................................... 519 Replace................................................................... 519 Engine and Fuel Sensors - Mazda 2.0L and 2.2L Gas and LPG Engine.............. 520 Oxygen Sensor............................................................. 520 Remove................................................................ 520 Replace............................................................... 520 Intake Air Temperature (IAT) Sensor....................................... 520 Remove................................................................ 520 Replace............................................................... 520 Manifold Absolute Pressure (MAP)/Boost Sensor............................. 520 Remove................................................................ 520 Replace............................................................... 521 Throttle Position (TPS) Sensor............................................ 521 Remove................................................................ 521 Replace............................................................... 521 Engine and Fuel Sensors and Switches - Mazda 2.0L and 2.2L LPG E.............. 521 Oil Pressure Sensor....................................................... 521 Remove................................................................ 521 Replace............................................................... 522 Low LPG Pressure Switch................................................... 522 Remove................................................................ 522 Replace............................................................... 522 Air Filter Restriction Switch............................................. 522 Remove................................................................ 522 Replace............................................................... 522 Engine Coolant Temperature (ECT) Sensor................................... 523 Remove................................................................ 523 Replace............................................................... 523 Engine and Fuel Sensors and Switches- Mazda 2.0L and 2.2L Gas En.............. 523 Oil Pressure Sensor....................................................... 523 Remove................................................................ 523 Replace............................................................... 523 Mass Air Flow (MAF) Sensor................................................ 524 Remove................................................................ 524 Replace............................................................... 524 Air Filter Restriction Switch............................................. 524 Remove................................................................ 524 Replace............................................................... 524 Engine Coolant Temperature (ECT) Sensor................................... 524 Remove................................................................ 525 Replace............................................................... 525 Engine and Fuel Sensors and Switches, GM 2.4L Gas and LPG Trucks.............. 525 Crankshaft Sensor......................................................... 525 Remove................................................................ 525 Replace............................................................... 525 Camshaft Position (CMP) Sensor............................................ 526 Remove................................................................ 526 Replace............................................................... 526 Camshaft Position (CMP) Sensor Assembly................................... 527 Remove................................................................ 527 Install............................................................... 527 Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) .......... 527 Remove................................................................ 527 Replace............................................................... 527 Engine Coolant Temperature (ECT) Sensor................................... 528 Remove................................................................ 528 Replace............................................................... 528 Air Flow Restriction Switch............................................... 528 Remove................................................................ 528 Replace............................................................... 528 Oil Pressure Sensor....................................................... 528 Remove................................................................ 528 Replace............................................................... 529 Oxygen Sensor............................................................. 529 Remove................................................................ 529 Replace............................................................... 530 Engine and Fuel Switches, GM 2.4L LPG Trucks Only............................. 530 Low LPG Pressure Switch................................................... 530 Remove................................................................ 530 Replace............................................................... 530 Engine and Fuel Sensors and Switches, Yanmar Diesel Trucks.................... 530 Air Filter Restriction Switch............................................. 530 Remove................................................................ 530 Replace............................................................... 530 Oil Pressure Sensor....................................................... 530 Remove................................................................ 530 Replace............................................................... 530 Engine Speed Sensor....................................................... 531 Remove................................................................ 531 Replace............................................................... 531 Engine Coolant Temperature (ECT) Sensor................................... 531 Remove................................................................ 531 Replace............................................................... 531 Throttle Position Sensor (TPS)............................................ 533 Remove................................................................ 533 Replace............................................................... 533 Vehicle System Manager (VSM)...................................................... 534 General....................................................................... 534 VSM Replacement............................................................... 534 Remove.................................................................... 534 Replace................................................................... 535 Programming a New VSM and/or Display Switch Cluster........................... 535 General................................................................... 535 PC Service Tool Software.................................................. 536 Data Transferring......................................................... 536 New or Used VSM....................................................... 536 New (Blank) Display Switch Cluster.................................... 537 Used (Non-Blank) Display Switch Cluster............................... 537 Power Distribution Module (PDM) And Component Parts............................... 538 Remove........................................................................ 538 PDM as a Unit............................................................. 538 Replace....................................................................... 540 PDM as a Unit............................................................. 540 Remove and Replace............................................................ 540 PDM Component Parts....................................................... 540 Battery........................................................................... 541 Remove........................................................................ 541 Replace....................................................................... 541 Lights............................................................................ 541 Work Lights (Front and Rear).................................................. 541 Remove.................................................................... 541 Replace................................................................... 541 Strobe Light.................................................................. 541 Remove.................................................................... 541 Replace................................................................... 542 LED Tail, Backup, and Brake Lights............................................ 542 Remove.................................................................... 542 Replace................................................................... 542 Electronic-Hydraulic Controls..................................................... 543 General....................................................................... 543 Mini-Levers................................................................... 543 Remove.................................................................... 543 Replace................................................................... 544 Joystick...................................................................... 544 Remove and Disassemble.................................................... 544 Inspect................................................................... 544 Assemble and Replace...................................................... 544 tables................................................................................ 487 Table 1. VSM and Display Switch Cluster Replacement............................... 538 2200SRM1143-(05-2005)-US-EN............................................................... 547 toc................................................................................... 547 Electrical System................................................................. 547 Safety Precautions Maintenance and Repair......................................... 548 Ignition System................................................................... 551 General....................................................................... 551 Ignition Timing Adjustment, Gasoline and LPG.................................. 551 Spark Plugs Check............................................................. 551 Spark Plug Wires Check........................................................ 551 Distributor Repair................................................................ 554 Remove........................................................................ 554 Disassemble................................................................... 555 Inspect....................................................................... 555 Assemble...................................................................... 556 Install....................................................................... 556 Igniter....................................................................... 557 Remove.................................................................... 557 Test...................................................................... 557 Install................................................................... 557 Camshaft Position (CMP) Sensor................................................ 558 Voltage Check............................................................. 558 Ignition Coil Check............................................................... 559 Primary Coil Winding.......................................................... 559 Secondary Coil Winding........................................................ 559 Starter Repair.................................................................... 560 General....................................................................... 560 Remove........................................................................ 560 No-Load Test.................................................................. 561 Magnetic Switch Test.......................................................... 561 Pull-Out Test............................................................. 561 Holding Coil Test......................................................... 562 Return Test............................................................... 562 Pinion Movement Inspection................................................ 562 Install....................................................................... 562 Alternator Repair................................................................. 563 General....................................................................... 563 Charging System Inspection.................................................... 563 Output Current Check.......................................................... 564 No-Load Adjusted Voltage Check................................................ 564 Remove........................................................................ 565 Inspect....................................................................... 565 Rectifier Check........................................................... 565 Install....................................................................... 566 tables................................................................................ 547 Table 1. Spark Plug Wire.......................................................... 551 Table 2. Starter Specifications................................................... 560 Table 3. Problem Diagnosis Chart.................................................. 561 Table 4. Specifications........................................................... 564 Table 5. Rectifier Check Table.................................................... 565 8000SRM1134............................................................................... 569 toc................................................................................... 569 Calibration Procedures............................................................ 569 Safety Precautions Maintenance and Repair......................................... 570 Description....................................................................... 573 Proc_Cal_001: Service Password Entry.............................................. 574 When to Perform............................................................... 574 Why Perform................................................................... 574 How to Perform................................................................ 575 Proc_Cal_002: Hydraulic Valve Calibration Warm Up................................. 575 When to Perform............................................................... 575 Calibration Order............................................................. 575 Why Perform................................................................... 576 How to Perform................................................................ 576 Proc_Cal_003: Save and Exit....................................................... 577 When to Perform............................................................... 577 Why Perform................................................................... 577 How to Perform................................................................ 577 Proc_Cal_004: Lift Valve Output Threshold......................................... 578 When to Perform............................................................... 578 Calibration Order............................................................. 578 Why Perform................................................................... 578 How to Perform................................................................ 579 Proc_Cal_005: Lower Valve Output Threshold........................................ 581 When to Perform............................................................... 581 Calibration Order............................................................. 581 Why Perform................................................................... 581 How to Perform................................................................ 581 Proc_Cal_006: Tilt Back Valve Output Threshold.................................... 583 When to Perform............................................................... 583 Calibration Order............................................................. 583 Why Perform................................................................... 583 How to Perform................................................................ 583 Proc_Cal_007: Tilt Forward Valve Output Threshold................................. 585 When to Perform............................................................... 585 Calibration Order............................................................. 585 Why Perform................................................................... 585 How to Perform................................................................ 585 Proc_Cal_008: Aux 1 Dir A Valve Output Threshold.................................. 587 When to Perform............................................................... 587 Calibration Order............................................................. 587 Why Perform................................................................... 587 How to Perform................................................................ 587 Proc_Cal_009: Aux 1 Dir B Valve Output Threshold.................................. 589 When to Perform............................................................... 589 Calibration Order............................................................. 589 Why Perform................................................................... 589 How to Perform................................................................ 589 Proc_Cal_010: Aux 2 Dir A Valve Output Threshold.................................. 591 When to Perform............................................................... 591 Calibration Order............................................................. 591 Why Perform................................................................... 591 How to Perform................................................................ 591 Proc_Cal_011: Aux 2 Dir B Valve Output Threshold.................................. 593 When to Perform............................................................... 593 Calibration Order............................................................. 593 Why Perform................................................................... 593 How to Perform................................................................ 593 Proc_Cal_012: Aux 3 Dir A Valve Output Threshold.................................. 595 When to Perform............................................................... 595 Calibration Order............................................................. 595 Why Perform................................................................... 595 How to Perform................................................................ 596 Proc_Cal_013: Aux 3 Dir B Valve Output Threshold.................................. 598 When to Perform............................................................... 598 Calibration Order............................................................. 598 Why Perform................................................................... 598 How to Perform................................................................ 598 Proc_Cal_016: Transmission Valve Calibration...................................... 599 Applicable System/Option...................................................... 599 When to Perform............................................................... 600 Calibration Order............................................................. 600 Why Perform................................................................... 600 How to Perform................................................................ 600 Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment....................... 601 Required Tools................................................................ 601 When to Perform............................................................... 601 Calibration Order............................................................. 601 Why Perform................................................................... 601 How to Perform................................................................ 602 tables................................................................................ 569 Table 1. Calibration Procedures................................................... 573 Table 2. How to Read Calibration Procedure........................................ 573 Table 3. Proc_Cal_001: Service Password Entry..................................... 575 Table 4. Proc_Cal_002: Hydraulic Valve Calibration Warm Up........................ 576 Table 5. Proc_Cal_003: Save and Exit.............................................. 578 Table 6. Proc_Cal_004: Lift Valve Output Threshold................................ 579 Table 7. Proc_Cal_005: Lower Valve Output Threshold............................... 581 Table 8. Proc_Cal_006: Tilt Back Valve Output Threshold........................... 583 Table 9. Proc_Cal_007: Tilt Forward Valve Output Threshold........................ 585 Table 10. Proc_Cal_008: Aux 1 Dir A Valve Output Threshold........................ 587 Table 11. Proc_Cal_009: Aux 1 Dir B Valve Output Threshold........................ 589 Table 12. Proc_Cal_010: Aux 2 Dir A Valve Output Threshold........................ 591 Table 13. Proc_Cal_011: Aux 2 Dir B Valve Output Threshold........................ 594 Table 14. Proc_Cal_012: Aux 3 Dir A Valve Output Threshold........................ 596 Table 15. Proc_Cal_013: Aux 3 Dir B Valve Output Threshold........................ 598 Table 16. Proc_Cal_016: Transmission Valve Calibration............................ 600 Table 17. Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjus.................. 602 8000SRM1150............................................................................... 607 toc................................................................................... 607 Periodic Maintenance.............................................................. 607 Safety Precautions Maintenance and Repair......................................... 608 General........................................................................... 613 Serial Number Data............................................................ 613 How to Move Disabled Lift Truck............................................... 613 How to Tow Lift Truck..................................................... 613 How to Put Lift Truck on Blocks............................................... 614 How to Raise Drive Tires.................................................. 614 How to Raise Steering Tires............................................... 614 Maintenance Schedule.............................................................. 616 Maintenance Procedures Every 8 Hours or Daily..................................... 629 How To Make Checks With Engine Stopped........................................ 629 Tires and Wheels.......................................................... 629 Safety Labels............................................................. 630 Inspection of Mast, and Lift Chains....................................... 630 Operator Restraint System................................................. 631 Hood and Seat Latches..................................................... 632 Engine Compartment........................................................ 632 Fuel, Oil, and Coolant Leaks, Check....................................... 633 Hydraulic Hoses........................................................... 633 Coolant Hoses............................................................. 633 Steering Column Gas Cylinder.............................................. 633 Transmission.............................................................. 633 Hydraulic System Oil...................................................... 633 Engine Oil................................................................ 633 Forks..................................................................... 638 Remove................................................................ 638 Inspect............................................................... 638 Install............................................................... 639 Adjust................................................................ 639 How To Make Checks With Engine Running........................................ 639 Indicator Lights, Horn, Fuses and Relays.................................. 639 Service Brakes............................................................ 640 Brake Fluid Level..................................................... 640 Operation, Check...................................................... 640 Parking Brake............................................................. 641 Engine Oil Pressure....................................................... 641 Cooling System............................................................ 641 Steering System........................................................... 642 Control Levers and Pedals................................................. 642 Lift System, Operate...................................................... 643 Maintenance Procedures Every 250 Hours or 6 Weeks................................. 643 Hydraulic System Oil.......................................................... 643 Hydraulic Tank Breather....................................................... 643 Battery....................................................................... 644 Mazda and GM Engine Oil and Filter............................................ 644 Air Filter.................................................................... 644 Drive Belt.................................................................... 645 Mazda 2.0L and 2.2L Engines............................................... 645 Fan and Alternator Drive Belt......................................... 645 GM 2.4L Engine............................................................ 646 Fan and Alternator Drive Belt......................................... 646 Drain Tar From LPG Regulator.................................................. 646 Cooling System................................................................ 647 Clean Debris From Radiator Core........................................... 647 Transmission Oil Level and Filter............................................. 647 Forks......................................................................... 647 Brake Fluid................................................................... 647 Differential and Drive Axle Oil............................................... 647 Maintenance Procedures Every 500 Hours or 3 Months................................ 648 Yanmar Engine Oil and Filter.................................................. 648 Drive Belt.................................................................... 649 Yanmar Diesel Engine...................................................... 649 Fan and Alternator Drive Belt......................................... 649 PCV Valve..................................................................... 650 Mast Lubrication.............................................................. 650 Lift Chain Lubrication........................................................ 651 Tilt Cylinder Lubrication..................................................... 651 Master Brake Cylinder Rod End Pin Lubrication................................. 652 Manual Hydraulic Levers Lubrication........................................... 653 Maintenance Procedures Every 1000 Hours or 6 Months............................... 654 Valve Clearance, Check and Adjust............................................. 654 Ignition System............................................................... 654 GM 2.4L Engine............................................................ 654 Mazda 2.0L and 2.2L Engines............................................... 654 LPG Fuel Filter Element Replace, GM 2.4L Engine............................... 654 Remove.................................................................... 654 Install................................................................... 655 LPG Vapor Fuel Filter Replace, Mazda Engines.................................. 655 Fuel Filter Replacement, Yanmar Engine........................................ 656 Priming the Fuel System....................................................... 657 In-Line Fuel Filter Replacement............................................... 657 Removal................................................................... 657 Installation.............................................................. 658 Lift Chains Wear Check........................................................ 658 Integral Sideshift Carriage, Check Bearings................................... 658 Steering Axle................................................................. 659 Control Levers and Pedals..................................................... 659 Maintenance Procedures Every 2000 Hours or Annually............................... 659 Hydraulic System.............................................................. 659 Hydraulic Filter, Replace................................................. 660 Hydraulic Tank Breather, Replace.......................................... 661 Air Filter Element............................................................ 661 PCV Valve..................................................................... 662 LPG Regulator Fuel Filter, Mazda Engines...................................... 662 Remove and Replace........................................................ 662 Gasoline Fuel Filter.......................................................... 662 Remove and Replace........................................................ 662 Timing Belt................................................................... 663 Mazda Engines............................................................. 663 GM 2.4L Engine............................................................ 663 LPG Fuel Injector, Mazda Engines.............................................. 663 Gasoline Fuel Injector, Mazda Engines......................................... 663 LPG Fuel Injector, GM Engines................................................. 663 Gasoline Fuel Injector, GM Engines............................................ 663 Fuel Injector, Yanmar Engines................................................. 663 Powershift Transmission....................................................... 664 Transmission Oil and Filter, Replace...................................... 664 Forks......................................................................... 665 Integral Sideshift Carriage................................................... 665 Bearings, Replace......................................................... 665 Brake Fluid Change............................................................ 665 Brake Fluid, Remove........................................................... 666 Wheel Bearings................................................................ 667 Steer and Drive Wheel Bearings, Lubricate................................. 667 Service Brakes................................................................ 667 Differential.................................................................. 667 Maintenance Procedures Every 4000 Hours or 2 Years................................ 668 Hydraulic Oil, Replace........................................................ 668 Cooling System................................................................ 669 Safety Procedures When Working Near Mast.......................................... 670 Hood Latch Check.................................................................. 672 Lift Chain Adjustments............................................................ 673 Jump-Starting the Lift Truck...................................................... 674 Welding Repairs................................................................... 674 Overhead Guard Changes............................................................ 675 Wheel and Tire Replacement........................................................ 675 General....................................................................... 675 Solid Rubber Tire, Change..................................................... 675 Remove and Install Tire on Wheel.......................................... 675 Pneumatic Tire, Repair ....................................................... 676 Remove Wheels From Lift Truck............................................. 676 Remove Wheel From Tire.................................................... 677 Remove Tire From Two-Piece Wheel...................................... 677 Remove Tire From Three- and Four-Piece Wheels......................... 678 Install Wheel on Tire..................................................... 679 Install Tire on Three- or Four-Piece Wheels........................... 679 Install Three-Piece or Four-Piece Wheel in Tire....................... 680 Install Tire on Two-Piece Wheel....................................... 681 Install Two-Piece Wheel in Tire....................................... 681 Add Air to Pneumatic Tires.................................................... 682 Wheels, Install........................................................... 682 Dual Drive Wheels, Install................................................ 682 Solid Rubber Tire, Change..................................................... 683 Remove Wheel From Tire.................................................... 683 Install Wheel in Tire..................................................... 684 Adhesives and Sealants............................................................ 686 tables................................................................................ 607 Table 1. Maintenance Schedule..................................................... 621 Table 2. V-Belt Deflection Table.................................................. 649 Table 3. Carriage Chain Adjustment, Forks Not Installed........................... 674 8000SRM1151-(09-2006)-US-EN............................................................... 691 toc................................................................................... 691 Capacities and Specifications..................................................... 691 Safety Precautions Maintenance and Repair......................................... 692 Lift Truck Lifting Capacity....................................................... 695 Counterweight Weights............................................................. 695 Tire Sizes........................................................................ 695 Capacities........................................................................ 696 Electrical System................................................................. 700 Transmission Oil Pressures........................................................ 701 Hydraulic System Relief Pressures................................................. 703 Steering System................................................................... 703 Stall Speeds (in RPM ±100 rpm).................................................... 704 Mazda 2.0L.................................................................... 704 Mazda 2.2L.................................................................... 704 GM 2.4L....................................................................... 704 Yanmar 2.6L................................................................... 704 Yanmar 3.3L................................................................... 704 Mast Speeds....................................................................... 704 Tilt Angles....................................................................... 708 Front End Equipment - Mast Creep.................................................. 708 Mast Creep.................................................................... 708 Engine Specifications............................................................. 709 Torque Specifications............................................................. 711 Frame......................................................................... 711 Mast.......................................................................... 711 Steering System, Cushioned Tire Trucks........................................ 711 Steering System, Pneumatic Tire Trucks........................................ 711 Drive Axle (Dry Brake)........................................................ 711 Drive Axle (Wet Brake)........................................................ 712 Transmission.................................................................. 712 Engine - Mazda 2.0L and 2.2L.................................................. 713 Engine - GM 2.4L.............................................................. 713 Engine - Yanmar 2.6L and 3.3L Diesel.......................................... 715 tables................................................................................ 691 Table 1. Lift Truck Models S2.0-3.5FT (S40-70FT, S55FTS) (F187)................... 705 Table 2. Lift Truck Models H2.0-3.5FT (H40-70FT) (L177)........................... 706 Table 3. S2.0-3.5FT (S40-70FT, S55FTS) (F187) Lift Truck Models................... 708 Table 4. H2.0-3.5FT (H40-70FT) (L177) Lift Truck Models........................... 708 Table 5. S2.0-3.5FT (S40-70FT, S55FTS) (F187) Lift Truck Models................... 708 Table 6. H2.0-3.5FT (H40-70FT) (L177) Lift Truck Models........................... 709 8000SRM1151............................................................................... 719 toc................................................................................... 719 Capacities and Specifications..................................................... 719 Safety Precautions Maintenance and Repair......................................... 720 Lift Truck Lifting Capacity....................................................... 723 Counterweight Weights............................................................. 723 Tire Sizes........................................................................ 723 Capacities........................................................................ 724 Electrical System................................................................. 727 Transmission Oil Pressures........................................................ 728 Hydraulic System Relief Pressures................................................. 729 Steering.......................................................................... 730 Specifications................................................................ 730 Stall Speeds (in RPM ±100 rpm).................................................... 731 Mazda 2.0L.................................................................... 731 Mazda 2.2L.................................................................... 731 GM 2.4L....................................................................... 731 Yanmar 2.6L................................................................... 731 Yanmar 3.3L................................................................... 731 Mast Speeds....................................................................... 732 Tilt Angles....................................................................... 735 Front End Equipment - Mast Creep.................................................. 736 Mast Creep.................................................................... 736 Engine Specifications............................................................. 737 Torque Specifications............................................................. 739 Frame......................................................................... 739 Mast.......................................................................... 739 Steering System, Cushioned Tire Trucks........................................ 739 Steering System, Pneumatic Tire Trucks........................................ 739 Drive Axle.................................................................... 739 Transmission.................................................................. 740 Engine - Mazda 2.0L and 2.2L.................................................. 740 Engine - GM 2.4L.............................................................. 741 Engine - Yanmar 2.6L and 3.3L Diesel.......................................... 742 tables................................................................................ 719 Table 1. Lift Truck Models S2.0-3.5FT (S40-70FT, S55FTS) (F187)................... 732 Table 2. Lift Truck Models H2.0-3.5FT (H40-70FT) (L177)........................... 734 Table 3. S2.0-3.5FT (S40-70FT, S55FTS) (F187) Lift Truck Models................... 735 Table 4. H2.0-3.5FT (H40-70FT) (L177) Lift Truck Models........................... 736 Table 5. S2.0-3.5FT (S40-70FT, S55FTS) (F187) Lift Truck Models................... 736 Table 6. H2.0-3.5FT (H40-70FT) (L177) Lift Truck Models........................... 736 1579259-9000SRM1112-(04-2007)-US-EN....................................................... 747 toc................................................................................... 747 Diagnostic Troubleshooting Manual................................................. 747 Safety Precautions TROUBLESHOOTING PROCEDURES..................................... 748 How To Use This Troubleshooting Manual............................................ 750 General Instructions and Safety Information................................... 750 How to Use Diagnostic Troubleshooting Manual.................................. 750 General Instructions.......................................................... 751 Operational Diagnostic Procedures................................................. 753 Operational Checkout Procedures............................................... 755 DTC Check................................................................. 756 Horn Circuit Check........................................................ 756 Light Circuit Check....................................................... 756 Windshield Washer Wiper Check (If equipped)............................... 756 Heater Check (If equipped)................................................ 757 Dome Light Check (If equipped)............................................ 757 Circulating (Accessory) Fan Check (If equipped)........................... 758 Indicator Light Power Check............................................... 759 Operator Presence System Check............................................ 760 Engine Malfunction Indicator Check........................................ 760 Cold Start Check (Cummins and Yanmar)..................................... 760 Brake Pedal Check......................................................... 761 Backup Alarm Check (If equipped).......................................... 761 Armrest Hydraulic Interlock Check (If equipped and with original.......... 761 Engine Cover Latch Sensor Check (If equipped)............................. 762 Brake and Inching Pedal Check............................................. 762 Park Brake Sensor Check................................................... 762 Park Brake Check.......................................................... 763 Engine Speed Check (All Cummins, Yanmar, and Mazda Engines Excep.......... 763 Engine Power Check........................................................ 764 Transmission Clutch Check................................................. 764 Transmission Check........................................................ 765 Transmission Speed Selection Check (If equipped).......................... 765 Brake and Axle Drag Check................................................. 765 Hydraulic Pump Flow Check................................................. 766 Priority Flow Divider Valve Check......................................... 767 Steering Relief Valve Low Pressure Check.................................. 767 Steering Relief Valve High Pressure Check................................. 768 Control Valve Load Check Valve (Manual Valve)............................. 768 Tilt Function Counterbalance Check........................................ 768 Lift Drift Check.......................................................... 769 Tilt Function Drift Check................................................. 769 Mast Cushion Check (All Except 2-Stage Mast).............................. 770 Lift/Tilt Mast Adjustment Check........................................... 770 Tilt Racking Check........................................................ 771 Chain and Header Hose Adjustment Check.................................... 771 Mast Mounting Check....................................................... 772 Mast Channel Check........................................................ 772 Carriage Adjustment Check................................................. 772 Chain Sheave Check........................................................ 773 Carriage Adjustment Check (Standard and Integral Side Shift).............. 773 Engine............................................................................ 775 Engine Basics................................................................. 781 General Terminology....................................................... 781 Combustion Theory......................................................... 781 Engine Components – Cylinder Block........................................ 782 Camshaft and Timing Set................................................... 783 Cylinder Head Assembly.................................................... 783 Valve Train Assembly...................................................... 783 Air Cleaner/Filter........................................................ 783 Carburetion............................................................... 783 Electronic Fuel Injection (EFI)........................................... 783 Positive Crankcase Ventilation (PCV)...................................... 784 Engine Electrical............................................................. 784 Introduction.............................................................. 784 Battery Construction...................................................... 784 Conventional Standard Battery............................................. 785 Maintenance-Free Battery.................................................. 785 Battery Charging.......................................................... 785 Battery Fast Charging..................................................... 786 Battery Slow Charging..................................................... 786 Starting System Principles of Operation................................... 786 Starting System Components - Ignition Switch.............................. 787 Starting System Components - Starter Solenoid............................. 787 Starting System Components - Flywheel and Ring Gear....................... 787 Starting System Components - Starter Motor and Drive...................... 787 Charging System - General................................................. 788 Charging System - Regulator............................................... 788 Charging System - Theory.................................................. 788 Engine Fuel System/Exhaust and Emissions...................................... 789 Introduction.............................................................. 789 Gasoline System Components - Fuel Tank.................................... 789 Electronic Fuel Injector (EFI) - General Description...................... 789 Port Fuel System Components - ECU......................................... 789 Port Fuel System Components - Fuel Pump/Filter............................ 789 Port Fuel System Components - Fuel Rail................................... 789 Port Fuel System Components - Pressure Regulator.......................... 789 Port Fuel System Components - Fuel Injectors.............................. 790 LPG Systems General Information........................................... 790 LPG Fuel Properties....................................................... 790 LPG Fuel Tank............................................................. 790 AISAN Closed-Loop System.................................................. 791 Filter/Lockoff and Regulator.......................................... 791 Carburetor............................................................ 791 Start Mode............................................................ 791 Idle Mode............................................................. 791 Run Mode.............................................................. 792 Main Fuel Lockoff Solenoid................................................ 792 Injector Fuel Lockoff Solenoid............................................ 792 Oxygen (O 2 ) Sensor.................................................. 792 Electronic Control Unit (ECU)............................................. 792 Catalytic Converter/Muffler............................................... 792 Engine Management............................................................. 792 Introduction.............................................................. 792 Ignition and Timing - Conventional Spark.................................. 792 Components - Ignition Coil................................................ 793 Components - Distributor.................................................. 793 Spark Timing.............................................................. 793 Components - Ignition Wires............................................... 793 Components - Spark Plugs.................................................. 793 Faulty or Fouled Spark Plugs.............................................. 794 Electric Controlled Governing System - Mazda LPG.......................... 794 Engine Identification......................................................... 795 Cummins (Diesel) Engine....................................................... 797 Description............................................................... 797 Diesel Fuel System........................................................ 798 Principle of Operation................................................ 798 Fuel Injection Pump and Governor.......................................... 799 Description........................................................... 799 Principles of Operation............................................... 800 Cummins Engine Control.................................................... 801 Engine Speed (RPM) Sensor............................................. 802 Throttle Position Sensor.............................................. 803 Electronic Throttle Actuator.......................................... 804 Engine Oil Pressure Sensor............................................ 804 Coolant Temperature Sensor............................................ 805 Air Restriction Switch................................................ 805 Fuel Filter/Water Separator........................................... 805 Fuel Level Sensor (In Tank)........................................... 806 Engine Electrical System.................................................. 806 Magnetic Valve (Engine Stop Solenoid)................................. 806 Alternator............................................................ 806 Grid Heater........................................................... 807 Cold Start Timing Advance (Fuel Injection Pump)....................... 807 Mazda Engine Overview......................................................... 807 Description............................................................... 807 Fuel System............................................................... 807 Engine Controls Unit (ECU) and Emissions.................................. 807 Cooling System............................................................ 807 Ignition System........................................................... 807 Mazda (LPG) Engine Controls................................................... 808 LPG System (Aisan/E-Controls-Mechanical).................................. 808 Description........................................................... 808 Principles of Operation............................................... 809 Control System........................................................ 812 Oxygen (O 2 ) Sensor.................................................. 813 Fuel Tank............................................................. 813 Regulator............................................................. 814 Start Mode........................................................ 815 Idle Mode......................................................... 815 Run Mode.......................................................... 816 Resonator............................................................. 816 Carburetor............................................................ 816 Start Mode........................................................ 816 Idle Mode......................................................... 817 Run Mode.......................................................... 817 Governor.............................................................. 817 LPG System (E-Controls)................................................... 818 Description........................................................... 818 Principles of Operation............................................... 819 Manifold Absolute Pressure Sensor..................................... 819 Throttle Position Sensor.............................................. 819 Oxygen (O 2 ) Sensor.................................................. 820 Engine Coolant Temperature Sensor..................................... 820 Intake Air Temperature Sensor......................................... 820 Engine Control Unit................................................... 820 Accelerator Pedal Position Sensor..................................... 820 Three-Way Catalytic Converter......................................... 820 Camshaft Position Sensor.............................................. 821 Electric Controlled Governing System.................................. 822 Electronic Governor Sensor............................................ 822 Mazda (Gasoline) Engine Controls.............................................. 823 Gasoline System........................................................... 823 Description........................................................... 823 Principles of Operation............................................... 824 Control System............................................................ 826 Camshaft Position Sensor.............................................. 827 Intake Air Temperature Sensor......................................... 828 Mass Air Flow Sensor.................................................. 829 Throttle Position Sensor.............................................. 830 Electronic Governor Sensor............................................ 831 Electronic Governing System........................................... 832 Manifold Absolute Pressure Sensor/Boost Sensor........................ 832 Engine Coolant Temperature Sensor..................................... 833 Intake Air System......................................................... 834 Throttle Body......................................................... 834 Idle Air Control Valve................................................ 835 Fuel System............................................................... 836 Fuel Injector......................................................... 836 Pressure Regulator.................................................... 837 Exhaust System............................................................ 838 Heated Oxygen (O 2 ) Sensor........................................... 838 Three-Way Catalytic Converter......................................... 839 GM (LPG) Engine Controls...................................................... 840 Engine Control System .................................................... 840 Engine Control System Overview........................................ 840 Principles of Operation............................................... 841 Control System............................................................ 842 GM/TGFI 2.4L (Four Cylinder) Control System Component Location........ 842 GM/TGFI 4.3L (Six Cylinder) Control System Component Location......... 843 GM/TGFI 2.4L (Four-Cylinder) LPG System............................... 844 GM/TGFI 4.3L (Six-Cylinder) LPG System................................ 846 Fuel Tank............................................................. 848 Engine Control Unit................................................... 848 Electronic Throttle Body/Throttle Position Sensor..................... 849 Manifold Absolute Pressure/Manifold Air Temperature Sensor............ 849 Propane Injectors..................................................... 850 Engine Coolant Temperature Sensor..................................... 852 Oxygen (O 2 ) Sensor.................................................. 852 Crankshaft Position Sensor (Engine Speed Sensor)...................... 853 Oil Pressure Sensor................................................... 853 Power Latch Relay..................................................... 853 GM 2.4L Camshaft Position Sensor...................................... 853 GM 4.3L Camshaft Position Sensor...................................... 854 Injector Driver Module................................................ 855 Vaporizer/Regulator................................................... 855 Accelerator Pedal Position Sensor..................................... 858 Three-Way Catalytic Converter......................................... 859 Ignition System........................................................... 859 Ignition Coils........................................................ 859 Distributorless Ignition System Module................................ 859 Electronic Ignition Signals........................................... 860 Distributor Ignition (DI) System...................................... 861 Camshaft Position (CMP) Sensor........................................ 861 Ignition Coil and Ignition Control Module (ICM)....................... 861 Secondary Ignition Components......................................... 861 GM (Gasoline) Engine Controls................................................. 862 Engine Control System..................................................... 862 GM 2.4L (Four Cylinder) Engine Control System......................... 862 GM 4.3L (Six Cylinder) Engine Control System.......................... 863 Engine Control System Overview........................................ 864 Principles of Operation............................................... 864 Control System............................................................ 865 GM/TGFI 2.4L (Four Cylinder) Control System Component Location........ 865 GM/TGFI 4.3L (Six Cylinder) Control System Component Location......... 866 GM/TGFI 2.4L (Four-Cylinder) Gasoline System Components............... 867 GM/TGFI 4.3L (Six Cylinder) Gasoline System Components................ 869 Engine Control Unit................................................... 871 Electronic Throttle Body/Throttle Position Sensor..................... 871 Manifold Absolute Pressure/Manifold Air Temperature Sensor ........... 872 Fuel Injector......................................................... 873 Engine Coolant Temperature Sensor..................................... 874 Oxygen (O 2 ) Sensor.................................................. 875 Crankshaft Position Sensor (Engine Speed Sensor)...................... 875 Oil Pressure Sensor................................................... 875 Power Latch Relay..................................................... 875 Camshaft Position Sensor.............................................. 876 Accelerator Pedal Position Sensor..................................... 877 Three-Way Catalytic Converter......................................... 877 Ignition System........................................................... 878 Ignition Coils........................................................ 878 Distributorless Ignition System Module................................ 878 Electronic Ignition Signals........................................... 879 Yanmar (Diesel) Engine........................................................ 880 Description............................................................... 880 Diesel Fuel System........................................................ 881 Principles of Operation............................................... 881 Fuel Injection Pump and Governor.......................................... 882 Description........................................................... 882 Principles of Operation............................................... 884 Timer................................................................. 885 Feed Pump (Vane Type)................................................. 885 Regulating Valve...................................................... 886 Injection Pump Plunger................................................ 887 Suction Process................................................... 888 Injection Process................................................. 888 End of Injection.................................................. 889 Uniform Pressure Process.......................................... 889 Reverse Rotation Prevention Mechanism................................. 890 Fuel Injection Volume Adjustment Mechanism............................ 890 Delivery Valve Assembly............................................... 890 Delivery Valve Holder with Damping Valve.............................. 891 All - Speed Governor.................................................. 892 At Start of Engine.................................................... 894 During Idle........................................................... 895 At Full - Load Maximum Speed Control.................................. 896 At No-Load Maximum Speed Control...................................... 897 Full-Load Position Adjustment Mechanism............................... 898 Structure and Operation of Timer.......................................... 899 Standard Type Automatic Timer......................................... 899 Yanmar Engine Controls.................................................... 900 Engine Speed (RPM) Sensor............................................. 901 Throttle Position Sensor.............................................. 901 Electronic Throttle Actuator.......................................... 902 Engine Oil Pressure Sensor............................................ 902 Coolant Temperature Sensor............................................ 903 Air Filter Restriction Switch......................................... 904 Fuel Filter/Water Separator and Strainer.............................. 904 Fuel Level Sensor..................................................... 904 Engine Electrical System.................................................. 905 Magnetic Valve (Engine Stop Solenoid)................................. 905 Alternator............................................................ 905 Glow Plugs............................................................ 905 Cold Start Timing Advance (Fuel Injection Pump)....................... 905 Cooling System - All Engines.................................................. 906 Description............................................................... 906 Radiator.................................................................. 906 Combination Cooler/Standard Radiator.................................. 907 Radiator Cap.............................................................. 907 Thermostat................................................................ 907 Engine Coolant Pump....................................................... 908 Fan....................................................................... 908 GM Engine Coolant Flow Diagram............................................ 909 Yanmar Diesel Engine Coolant Flow Diagram................................. 910 Engine Does Not Crank......................................................... 911 Engine Does Not Start/Engine is Hard to Start................................. 914 Engine Idle Speed Incorrect................................................... 920 Engine Idle Speed is Unstable or Engine Stalls at Idle........................ 923 Engine Cuts Out, Misses, Hesitates, Sags, or Stumbles......................... 928 Engine Lack of Power.......................................................... 933 Engine Speed Surge or Engine Speed Unstable................................... 940 Engine Backfires.............................................................. 944 Engine Is Knocking or Pinging................................................. 947 Excessive Engine Vibrations................................................... 951 Abnormal Engine and Exhaust Noises............................................ 955 Fan or Alternator Bearing Noise............................................... 959 Abnormal Engine and Exhaust Smells............................................ 961 High Engine Fuel Consumption.................................................. 963 Fuel Leaks.................................................................... 966 High Engine Oil Consumption................................................... 969 Engine Oil Leaks.............................................................. 971 Engine Oil is Discolored...................................................... 975 Engine Coolant Leaks.......................................................... 977 Engine Coolant is Discolored.................................................. 980 Engine Exhaust is Discolored.................................................. 981 Engine Fails Emission Compliance Check........................................ 985 Alternator Light is Illuminated............................................... 989 Engine is Overheating......................................................... 990 Engine Coolant Temperature is Low............................................. 993 Engine Oil Pressure is Low.................................................... 994 Radiator Bubble Test.......................................................... 995 Engine Compression Test (GM and Mazda)........................................ 996 Engine Compression Test (Yanmar Diesel)....................................... 997 Engine Oil Pressure Test...................................................... 998 Fuel System Pressure Test (Gasoline Engines Only).............................1000 Fuel Injection Nozzle Test (Yanmar Diesel)....................................1002 Vacuum Leak...................................................................1003 Vacuum Leak Detection.....................................................1003 Vacuum Leak Repairs.......................................................1003 Coolant System Test...........................................................1004 Electrical System.................................................................1005 Troubleshooting Guidelines and Procedures.....................................1019 Troubleshooting Guidelines................................................1019 Troubleshooting Procedures................................................1021 Troubleshooting Procedures, Identification............................1022 Troubleshooting Procedures, Location..................................1022 Troubleshooting Procedures, Structure.................................1022 Troubleshooting Procedures, Performance...............................1023 Diagnostic Trouble Codes......................................................1024 Diagnostic Trouble Codes..................................................1024 Wiring Reference Data.........................................................1034 Harness Assembly Data.........................................................1039 Electrical System.............................................................1085 General Description.......................................................1085 Description...............................................................1086 Principles of Operation, Components.......................................1091 Principles Of Operation, System...........................................1100 100-2.........................................................................1107 100-3.........................................................................1107 523859-3......................................................................1107 523958-3......................................................................1107 523959-3......................................................................1107 524223-3......................................................................1107 524224-3......................................................................1107 524225-3......................................................................1107 524282-3......................................................................1107 100-4.........................................................................1114 523859-4......................................................................1114 523958-4......................................................................1114 523959-4......................................................................1114 524223-4......................................................................1114 524224-4......................................................................1114 524225-4......................................................................1114 524282-4......................................................................1114 524223-0......................................................................1122 524224-0......................................................................1122 524225-0......................................................................1122 524229-0......................................................................1122 524270-0......................................................................1122 524276-0......................................................................1122 524223-1......................................................................1126 524224-1......................................................................1126 524225-1......................................................................1126 524229-1......................................................................1126 524270-1......................................................................1126 524276-1......................................................................1126 110-3.........................................................................1130 110-5.........................................................................1130 177-3.........................................................................1130 522231-3......................................................................1130 522555-3......................................................................1130 522603-3......................................................................1130 524235-3......................................................................1130 110-4.........................................................................1138 177-4.........................................................................1138 522231-4......................................................................1138 522555-4......................................................................1138 522603-4......................................................................1138 524235-4......................................................................1138 110-2.........................................................................1145 110-10........................................................................1148 522712-3......................................................................1152 522713-3......................................................................1152 522712-4......................................................................1158 522713-4......................................................................1158 51-2..........................................................................1164 51-7..........................................................................1164 91-2..........................................................................1169 522708-3......................................................................1174 522710-3......................................................................1174 522711-3......................................................................1174 522714-3......................................................................1174 522708-4......................................................................1180 522710-4......................................................................1180 522711-4......................................................................1180 522714-4......................................................................1180 515-0.........................................................................1186 523780-3......................................................................1188 523860-3......................................................................1188 524245-3......................................................................1188 524275-3......................................................................1188 523780-4......................................................................1193 523860-4......................................................................1193 524245-4......................................................................1193 524275-4......................................................................1193 677-3.........................................................................1198 2350-3........................................................................1198 522754-3......................................................................1198 522755-3......................................................................1198 522764-3......................................................................1198 522766-3......................................................................1198 524230-3......................................................................1198 SYMPTOMS WARNING..............................................................1198 677-4.........................................................................1204 2350-4........................................................................1204 522754-4......................................................................1204 522755-4......................................................................1204 522764-4......................................................................1204 522766-4......................................................................1204 524230-4......................................................................1204 676-3.........................................................................1208 524195-3......................................................................1208 524269-3......................................................................1208 676-4.........................................................................1214 524195-4......................................................................1214 524269-4......................................................................1214 524269-7......................................................................1220 524215-3......................................................................1222 524215-6......................................................................1222 524237-3......................................................................1226 524238-3......................................................................1226 524240-3......................................................................1226 524237-4......................................................................1231 524238-4......................................................................1231 524240-4......................................................................1231 879-3.........................................................................1236 880-3.........................................................................1236 881-3.........................................................................1236 882-3.........................................................................1236 522772-3......................................................................1236 879-4.........................................................................1240 880-4.........................................................................1240 881-4.........................................................................1240 882-4.........................................................................1240 522772-4......................................................................1240 168-0.........................................................................1243 168-3.........................................................................1243 521982-3......................................................................1245 522760-3......................................................................1245 522761-3......................................................................1245 522762-3......................................................................1245 522128-3......................................................................1254 524251-0......................................................................1254 524260-0......................................................................1254 524260-3......................................................................1254 524261-0......................................................................1254 524261-3......................................................................1254 168-1.........................................................................1263 168-4.........................................................................1263 521982-4......................................................................1266 522760-4......................................................................1266 522761-4......................................................................1266 522761-6......................................................................1266 522762-4......................................................................1266 522128-4......................................................................1273 524251-1......................................................................1273 524260-1......................................................................1273 524260-4......................................................................1273 524261-1......................................................................1273 524261-4......................................................................1273 524260-2......................................................................1282 524260-11.....................................................................1282 524261-2......................................................................1282 524261-11.....................................................................1282 96-3..........................................................................1286 96-4..........................................................................1286 522810-4......................................................................1290 524213-1......................................................................1294 524213-3......................................................................1294 524213-4......................................................................1294 523920-3......................................................................1297 523925-3......................................................................1297 523930-3......................................................................1297 523977-3......................................................................1297 523978-3......................................................................1297 523986-3......................................................................1297 524284-3......................................................................1297 524285-3......................................................................1297 523920-4......................................................................1302 523925-4......................................................................1302 523930-4......................................................................1302 523977-4......................................................................1302 523978-4......................................................................1302 523986-4......................................................................1302 524284-4......................................................................1302 524285-4......................................................................1302 523920-6......................................................................1306 523925-6......................................................................1306 523930-6......................................................................1306 523977-6......................................................................1306 523978-6......................................................................1306 523986-6......................................................................1306 524284-6......................................................................1306 524285-6......................................................................1306 105-3.........................................................................1310 522570-3......................................................................1310 105-4.........................................................................1314 522570-4......................................................................1314 105-5.........................................................................1318 106-3.........................................................................1320 106-4.........................................................................1324 106-0.........................................................................1328 106-1.........................................................................1328 106-2.........................................................................1328 106-14........................................................................1328 522739-3......................................................................1331 522739-5......................................................................1335 522739-6......................................................................1339 522735-2......................................................................1342 522735-4......................................................................1345 522735-5......................................................................1348 522735-6......................................................................1351 522630-2......................................................................1354 522631-2......................................................................1354 522632-2......................................................................1354 522633-2......................................................................1354 522635-3......................................................................1354 522636-4......................................................................1354 522637-3......................................................................1354 522638-4......................................................................1354 522606-10.....................................................................1358 522737-10.....................................................................1358 651-3.........................................................................1361 652-3.........................................................................1361 653-3.........................................................................1361 654-3.........................................................................1361 655-3.........................................................................1361 656-3.........................................................................1361 522599-3......................................................................1361 522600-3......................................................................1361 522601-3......................................................................1361 522602-3......................................................................1361 522721-3......................................................................1361 522722-3......................................................................1361 522723-3......................................................................1361 522724-3......................................................................1361 522725-3......................................................................1361 522726-3......................................................................1361 522599-3......................................................................1361 522600-3......................................................................1361 522601-3......................................................................1361 522602-3......................................................................1361 651-5.........................................................................1368 652-5.........................................................................1368 653-5.........................................................................1368 654-5.........................................................................1368 655-5.........................................................................1368 656-5.........................................................................1368 522721-5......................................................................1368 522722-5......................................................................1368 522723-5......................................................................1368 522724-5......................................................................1368 522725-5......................................................................1368 522726-5......................................................................1368 651-6.........................................................................1372 652-6.........................................................................1372 653-6.........................................................................1372 654-6.........................................................................1372 655-6.........................................................................1372 656-6.........................................................................1372 522599-4......................................................................1372 522600-4......................................................................1372 522601-4......................................................................1372 522602-4......................................................................1372 522721-6......................................................................1372 522722-6......................................................................1372 522723-6......................................................................1372 522724-6......................................................................1372 522725-6......................................................................1372 522726-6......................................................................1372 2000-9........................................................................1379 2000-12.......................................................................1379 2000-12.......................................................................1379 2000-12.......................................................................1379 2000-12.......................................................................1379 2000-14.......................................................................1379 2003-12.......................................................................1379 2023-12.......................................................................1379 2039-2........................................................................1379 2039-12.......................................................................1379 2235-12.......................................................................1379 2236-12.......................................................................1379 2238-12.......................................................................1379 521670-12.....................................................................1379 524258-2......................................................................1379 522215-12.....................................................................1387 522215-14.....................................................................1387 524236-14.....................................................................1387 524262-12.....................................................................1387 524263-1......................................................................1387 524268-12.....................................................................1387 628-12........................................................................1389 630-12........................................................................1389 522690-2......................................................................1389 522690-12.....................................................................1389 522691-2......................................................................1389 522691-12.....................................................................1389 522692-2......................................................................1389 522693-12.....................................................................1389 522694-12.....................................................................1389 522695-2......................................................................1389 522696-2......................................................................1389 522697-12.....................................................................1389 522698-2......................................................................1389 522699-2......................................................................1389 522700-2......................................................................1389 190-2.........................................................................1391 190-7.........................................................................1391 522120-1......................................................................1391 522585-2......................................................................1391 522752-9......................................................................1397 524249-2......................................................................1400 524250-2......................................................................1400 524264-2......................................................................1400 524264-14.....................................................................1400 524265-2......................................................................1400 524271-2......................................................................1400 524225-14.....................................................................1400 628-12........................................................................1405 630-12........................................................................1405 2660-3........................................................................1405 2660-4........................................................................1405 2661-3........................................................................1405 2661-4........................................................................1405 2802-12.......................................................................1405 523510-12.....................................................................1405 523511-12.....................................................................1405 523515-3......................................................................1405 523515-4......................................................................1405 523519-3......................................................................1405 523519-4......................................................................1405 2802-12.......................................................................1407 628-12........................................................................1407 630-12........................................................................1407 523261-3......................................................................1407 523261-4......................................................................1407 523257-3......................................................................1407 523257-4......................................................................1407 523253-3......................................................................1407 523253-4......................................................................1407 523249-3......................................................................1407 523249-4......................................................................1407 522780-3......................................................................1409 522781-3......................................................................1409 522780-4......................................................................1412 522781-4......................................................................1412 522780-2......................................................................1414 522781-2......................................................................1414 111-1.........................................................................1416 524252-2......................................................................1420 524253-14.....................................................................1421 524255-2......................................................................1422 108-0.........................................................................1423 108-1.........................................................................1423 522655-0......................................................................1425 522655-1......................................................................1425 522660-0......................................................................1425 522660-1......................................................................1425 524212-2......................................................................1429 524211-2......................................................................1429 524210-2......................................................................1429 524209-2......................................................................1429 524208-2......................................................................1429 524207-2......................................................................1429 524206-2......................................................................1429 524205-2......................................................................1429 524204-2......................................................................1429 524203-2......................................................................1429 524202-2......................................................................1429 524201-2......................................................................1429 524200-2......................................................................1429 524199-2......................................................................1429 524198-2......................................................................1429 524197-2......................................................................1429 522800-13.....................................................................1431 522801-13.....................................................................1433 522130-0......................................................................1434 522131-0......................................................................1434 522132-0......................................................................1434 522133-0......................................................................1434 522134-0......................................................................1434 522130-1......................................................................1438 522131-1......................................................................1438 522132-1......................................................................1438 522133-1......................................................................1438 522134-1......................................................................1438 522130-3......................................................................1442 522131-3......................................................................1442 522132-3......................................................................1442 522133-3......................................................................1442 522134-3......................................................................1442 522130-4......................................................................1447 522131-4......................................................................1447 522132-4......................................................................1447 522133-4......................................................................1447 522134-4......................................................................1447 522135-0......................................................................1451 522137-0......................................................................1451 522138-0......................................................................1451 522135-1......................................................................1455 522137-1......................................................................1455 522138-1......................................................................1455 522135-3......................................................................1459 522137-3......................................................................1459 522138-3......................................................................1459 522135-4......................................................................1463 522137-4......................................................................1463 522138-4......................................................................1463 522135-2......................................................................1467 522137-2......................................................................1467 522122-0......................................................................1474 522124-0......................................................................1474 522125-0......................................................................1474 522126-0......................................................................1474 522127-0......................................................................1474 522122-1......................................................................1478 522124-1......................................................................1478 522125-1......................................................................1478 522126-1......................................................................1478 522127-1......................................................................1478 522122-6......................................................................1482 522124-6......................................................................1482 522125-6......................................................................1482 522126-6......................................................................1482 522127-6......................................................................1482 522122-8......................................................................1487 522124-8......................................................................1487 522125-8......................................................................1487 522126-8......................................................................1487 522127-8......................................................................1487 522129-3......................................................................1491 522129-4......................................................................1491 522197-0......................................................................1492 522198-0......................................................................1492 522199-0......................................................................1492 522200-0......................................................................1492 522201-0......................................................................1492 522197-1......................................................................1495 522198-1......................................................................1495 522199-1......................................................................1495 522200-1......................................................................1495 522201-1......................................................................1495 522197-6......................................................................1496 522198-6......................................................................1496 522199-6......................................................................1496 522200-6......................................................................1496 522201-6......................................................................1496 522197-7......................................................................1497 522198-7......................................................................1497 522199-7......................................................................1497 522200-7......................................................................1497 522201-7......................................................................1497 522197-8......................................................................1498 522198-8......................................................................1498 522199-8......................................................................1498 522200-8......................................................................1498 522201-8......................................................................1498 522197-14.....................................................................1500 522198-14.....................................................................1500 522199-14.....................................................................1500 522200-14.....................................................................1500 522201-14.....................................................................1500 522197-27.....................................................................1501 522198-27.....................................................................1501 522199-27.....................................................................1501 522200-27.....................................................................1501 522201-27.....................................................................1501 2039-2........................................................................1504 522540-3......................................................................1507 522540-4......................................................................1510 522604-3......................................................................1514 522604-4......................................................................1518 522604-5......................................................................1522 522697-12.....................................................................1526 190-2.........................................................................1527 190-4.........................................................................1527 190-8.........................................................................1527 522752-2......................................................................1527 522752-4......................................................................1527 522752-5......................................................................1533 522598-3......................................................................1535 522598-4......................................................................1538 522592-0......................................................................1542 522592-1......................................................................1544 522593-12.....................................................................1546 522594-12.....................................................................1550 522595-12.....................................................................1550 522596-12.....................................................................1550 Engine Continues to Run When Engine Cover is Raised...........................1553 Engine Stops or Fails to Start................................................1555 Electrical Functions Do Not Operate...........................................1557 Electrical Function Does Not Turn Off.........................................1562 Electro-Hydraulics Do Not Function With Armrest Down .........................1568 Electro-Hydraulics Can Still Function With Armrest Raised.....................1571 Vehicle Does Not Power On.....................................................1574 Heater Fan Does Not Operate Properly..........................................1579 Heater Airflow Does Not Reach Desired Temperature.............................1582 Heater Output Has Insufficient Airflow........................................1583 Circulating (Accessory) Fan Inoperative.......................................1584 Dome Light Inoperative........................................................1587 Horn Failure..................................................................1590 Drive Train.......................................................................1593 Mechanical Overview...........................................................1597 Engine........................................................................1597 Description...............................................................1597 Torque Converter..............................................................1597 Description...............................................................1597 Stator................................................................1598 Turbine...............................................................1598 Pump PTO......................................................................1599 Chain Drive PTO...........................................................1599 Spur Gear PTO.............................................................1600 Transmission..................................................................1601 Description...............................................................1601 1.0-5.5 Ton Lift Truck Transmissions......................................1604 Description...........................................................1604 Single-Speed......................................................1604 Two-Speed.........................................................1605 Clutch Pack...........................................................1606 Power Flow............................................................1608 Single-Speed......................................................1608 Two-Speed.........................................................1609 Transmission Hydraulic Schematic......................................1611 Transmission Oil Flow.................................................1612 Control Valve Oil Flow................................................1612 6.0-7.0 Ton Lift Truck Transmissions......................................1614 Description...........................................................1614 Two-Speed.........................................................1614 Three-Speed.......................................................1614 Clutch Pack...........................................................1616 Input Shaft and Range Clutches....................................1616 Directional Clutches..............................................1616 Output Section....................................................1617 Power Flow............................................................1617 Two-Speed and Three-Speed.........................................1617 Transmission Hydraulic Schematic......................................1621 Two-Speed.........................................................1621 Three-Speed.......................................................1623 Transmission Control System Overview..........................................1625 Transmission Control System...............................................1625 Transmission Control Software.................................................1628 Transmission Control Modes................................................1628 Neutral...............................................................1628 Gear Engagement Control...............................................1628 Basic Powershift Gear Engagement Mode.............................1628 DuraMatch™ and Electronic Extended Features Gear Engagement Mo....1628 Normal Forward or Reverse.............................................1628 Basic Powershift..................................................1628 DuraMatch™ and Electronic Extended Features Transmission..........1628 Auto-Shift............................................................1628 1st Gear Lock.........................................................1629 Inching...............................................................1629 Basic Powershift Inching Mode.....................................1629 DuraMatch™ Inching Mode...........................................1629 Electronic Extended Features Inching Mode.........................1629 Inch/Brake Overlap Adjustment.........................................1629 Brake Wear Compensation...............................................1629 Auto Decel............................................................1630 Controlled Power Reversal.............................................1630 Basic Multi-Speed.................................................1630 Electronic Extended Features......................................1630 Controlled Creep......................................................1630 Basic Powershift..................................................1630 DuraMatch™ and Electronic Extended Features.......................1631 Controlled Roll Back..................................................1631 DuraMatch™ .......................................................1631 Electronic Extended Features......................................1631 Travel Speed Limit (Optional).........................................1631 Extended Drawbar Pull ( Electronic Extended Features Multi-Speed......1631 Auto-Speed Hydraulics ( Electronic Extended Features Transmissio......1631 Throttle Response Management ( Electronic Extended Features Tran......1632 Steady Travel Speed...............................................1632 Transmission Control Hardware.................................................1632 Control Valve and Sensors.................................................1632 Description...........................................................1632 Principles of Operation...............................................1634 Transmission Proportional Valve...........................................1635 Description...........................................................1635 Neutral...............................................................1635 Proportional Control..................................................1635 MONOTROL® Pedal...........................................................1636 Description...........................................................1636 Principles of Operation...............................................1636 Directional Control Lever.................................................1636 Principles of Operation...............................................1636 Driveshaft, Differential, Drive Axle, and Brakes (Dry Brake Only..............1637 Driveshaft................................................................1637 Differential and Drive Axle...............................................1637 Brake System..............................................................1639 Description...........................................................1639 Service Brakes........................................................1639 Master Cylinder.......................................................1640 Brake Position Sensor.................................................1640 Parking Brake.........................................................1640 Driveshaft, Differential, Drive Axle, and Brakes (Wet Brake Only..............1641 Driveshaft................................................................1641 Differential..............................................................1641 Brake System..............................................................1643 Description...........................................................1643 Service Brakes, 2.0-3.5 Ton Only......................................1644 Service Brakes, 4.0-7.0 Ton...........................................1646 Brake Adjustment and Service..........................................1646 Parking Brake.........................................................1646 Overheating Brakes (Dry Brake Axle Only)......................................1649 Overheating Brakes (Wet Brake Axle Only)......................................1651 Poor Brake Performance (Dry Brake Axle Only)..................................1654 Poor Brake Performance (Wet Brake Axle Only)..................................1657 Brakes Make Too Much Noise (Dry Brake Axle Only)..............................1659 Brakes Pull To One Side (Dry Brake Axle Only).................................1660 Parking Brake Will Not Release................................................1663 Parking Brake Will Not Hold Lift Truck (Dry Brake Axle Only)..................1664 Parking Brake Will Not Hold Lift Truck (Wet Brake Axle Only)..................1665 Abnormal Drive Axle Noise.....................................................1666 Discolored Drive Axle Oil.....................................................1669 Lift Truck Does Not Move (Drive Axle).........................................1671 Abnormal Transmission Noise...................................................1673 Bubbles or Foaming In Transmission Dipstick Tube..............................1675 Inching Operation Is Not Smooth or Chatters...................................1677 Lift Truck Does Not Move In One or Both Directions (Transmission..............1679 Loss of Power/Drivetrain Performance..........................................1682 Transmission Is Too Hot.......................................................1685 Transmission Will Not Shift To Forward High Range.............................1688 Transmission Warmup Procedure.................................................1689 Transmission Pressure Test....................................................1689 Transmission Charge Pump Pressure Test....................................1691 Clutch Pack Pressure Test (Proportional Solenoid Valves)..................1691 Torque Converter Pressure Test............................................1692 Lubrication Pressure Test.................................................1692 Transmission Clutch Drag Test (1.0-5.5 Ton Trucks Only).......................1693 Torque Converter Stall Test...................................................1693 Hydraulic Systems.................................................................1697 Main Hydraulic System.........................................................1701 Description...............................................................1701 Principles of Operation...................................................1704 Hydraulic Schematics......................................................1705 Manual Control Valve Schematics.......................................1705 Electro-Hydraulic Control Valve Schematics............................1710 Manual Hydraulic Control Valve................................................1714 Description...............................................................1714 Principles of Operation...................................................1716 Lift Section..........................................................1716 Lift Operation....................................................1716 Lower Operation...................................................1716 Tilt Section..........................................................1717 Tilt Backward.....................................................1717 Tilt Forward......................................................1718 Auxiliary Section.....................................................1719 Anti-stall Feature....................................................1720 Relief Valves.........................................................1720 Main Relief Valve.................................................1720 Secondary Relief Valve............................................1720 Electro-Hydraulic Control Valve...............................................1721 Description...............................................................1721 Principles of Operation...................................................1722 Inlet Pressure Compensator/Unloader...................................1722 Lift/Lower EHPVs......................................................1724 EHPV Operation....................................................1725 Tilt and Auxiliary Spool Functions....................................1727 Tilt Forward Function.................................................1729 Main Relief Valve.....................................................1730 Secondary Relief Valve................................................1730 Secondary Function Anti-stall Valve...................................1731 Emergency Lowering Valve..............................................1732 Steering System...............................................................1732 Component Locations.......................................................1732 Description...........................................................1732 Steering Axle Assembly................................................1732 Steering Control Unit.................................................1732 Steering Schematic........................................................1734 Principles of Operation...............................................1735 Steering Control Unit.................................................1735 Actuation Functions With Armrest Up (E-Valve).................................1737 Cycle Times Too Fast - Fast Actuation (E-Valve)...............................1738 Jump/Delay In Lift or Lower Activation After Moving Joystick or ..............1740 Jump/Delay In Secondary Function Actuation After Moving Joystick..............1742 Jump/Delay In Tilt Forward Actuation (E-Valve)................................1744 Forks Drop Slightly Before Lifting (E-Valve)..................................1746 Forks Lower Without Command (E-Valve).........................................1747 Forks Raise or Actuate Without Command (E-Valve)..............................1749 Forks Tilt Forward Without Command (E-Valve)..................................1751 Intermittent Activation (E-Valve) While Commanding Function...................1753 Lift/Lower Function Maximum Speed Too Slow (E-Valve)..........................1755 Lift Function Will Not Move With Joystick or MLM Movement (E-Val..............1758 Lift/Lower Continues To Move For Awhile After Joystick or MLM Is..............1761 Lift/Lower/Secondary Function Suddenly Jumps In Middle of Stroke..............1762 Lower Function Will Not Move With Joystick or MLM Movement (E-Va..............1763 Poor Metering on Lift or Lower Functions (E-Valve)............................1765 Secondary Function Continues to Move for Awhile After Joystick o..............1768 Secondary Function Exhibits Slight Movement in Opposite Directio..............1769 Secondary Function Maximum Speed Too Slow (E-Valve)...........................1770 Secondary Function or Tilt Back Moves Without Command (E-Valve)...............1773 Secondary Function and Tilt Back Will Not Move With Joystick or ..............1774 Tilt Forward Function Continues to Move for Awhile When Joystick..............1777 Tilt Forward Will Not Move Upon Joystick or MLM Movement (E-Valv..............1778 Too Much Joystick or MLM Movement (Deadband) to Start Function M..............1780 Wrong Actuation Operates or Actuation is Backward (E-Valve)...................1781 Actuation Exhibits Slight Movement in Opposite Direction Before ..............1782 Auxiliary Function is Slow or Does Not Function (Manual Valve)................1783 Cycle Times Too Fast - Fast Actuation (Manual Valve)..........................1785 Function Continues to Activate After Returning to Neutral.....................1786 Lift Function Is Slow or Does Not Function (Manual Valve).....................1787 Tilt Back Function Will Not Operate (Manual Valve)............................1789 Tilt Forward Functions When Spool is Activated Forward With Engi..............1790 Tilt Forward Will Not Function When Activated (Manual Valve)..................1791 Abnormal Steer Axle Noise.....................................................1792 Abnormal Steering Wheel Vibration.............................................1794 Back Lash/Kick Back in Steering Wheel.........................................1795 No Steering (All Other Hydraulic Functions OK)................................1797 Steering Is Slow or Difficult.................................................1799 Steering Operation Is Not Smooth..............................................1801 Steering Wheel End Lock Position Cannot Be Felt by Operator...................1803 Steering Wheel Turns By Itself or Does Not Return To Neutral..................1804 Steering Wheel Turns the Tires in the Wrong Direction.........................1805 Abnormal Hydraulic Noise and/or Vibration.....................................1806 Abnormal Smell/Discoloration/Foaming of Oil...................................1809 Actuations Do Not Act Simultaneously..........................................1810 Oil Leaking/Component Life Too Short..........................................1811 Hydraulic Warmup Procedure....................................................1815 Main Relief Valve Test and Adjustment.........................................1816 Secondary Relief Valve Test and Adjustment....................................1818 Hydraulic Pump Flow Test......................................................1820 Main Control Valve LS Leakage Test (E-Valve)..................................1822 Main Control Valve Unloader Margin Test.......................................1822 Electro-Hydraulic Poppet Valve (EHPV) Leakage Test............................1824 PPRV Pilot Pressure Test......................................................1827 Steering Relief Pressure Test and Adjustment..................................1828 Steering Control Unit LS Pressure Test........................................1829 Lift Cylinder Leakage Test....................................................1830 Tilt Cylinder Leakage Test....................................................1832 Steering Cylinder Leakage Test................................................1833 Operators Station.................................................................1835 Operator Station General Description and Principles of Operation..............1837 General Description and Location..........................................1837 Display Switch Cluster (DSC)..................................................1840 Detailed Description......................................................1840 Control Inputs, Right Side................................................1841 Right Indicator and Warning Group.........................................1842 LCD Display...............................................................1842 Left Indicator and Warning Group..........................................1844 Control Inputs, Left Side (Cab Option Only)...............................1845 Transmission Control and Braking..............................................1846 Description...............................................................1846 Vehicle System Manager (VSM)..........................................1847 Display Switch Cluster................................................1847 Interlock and Switching Features..................................1847 MONOTROL® Directional Control.........................................1847 Inch Brake/Service Brake Pedal........................................1847 Parking Brake.........................................................1848 Programming - Menus...........................................................1848 Menus.....................................................................1848 Main Menu.............................................................1851 Save and Exit or Exit Without Saving..................................1851 Back One Level........................................................1851 Hourmeters............................................................1851 View Versions.........................................................1852 Passwords.............................................................1852 Diagnostics...........................................................1852 Setup Travel and Braking..............................................1852 Setup Hydraulics......................................................1852 Setup Display.........................................................1852 Setup General Items...................................................1852 Calibrations..........................................................1852 Manual Hydraulic Control Levers...............................................1853 General Description.......................................................1853 System Components.........................................................1853 Lift/Lower............................................................1853 Tilt..................................................................1853 Auxiliary 1...........................................................1853 Auxiliary 2...........................................................1853 E-Hydraulic System Interface..................................................1854 General Description.......................................................1854 System Components.........................................................1854 E-Hydraulic Control Input Device..........................................1854 Joystick..............................................................1854 Lift/Lower........................................................1855 Tilt..............................................................1855 Auxiliary 1.......................................................1855 Auxiliary 2.......................................................1855 Push Button.......................................................1855 Mini Lever Module (MLM)...............................................1855 Lever 1...........................................................1856 Lever 2...........................................................1856 Lever 3...........................................................1857 Lever 4...........................................................1857 System Modes..............................................................1857 Hydraulic Interlock Mode..............................................1857 Fault Mode............................................................1857 Engine Off Mode.......................................................1857 Normal Operation..........................................................1857 Normal Operation Mode.................................................1857 Lifting Control.......................................................1857 Lowering Control......................................................1858 Tilt Control (Forward and Backward)...................................1858 Auxiliary Control.....................................................1858 Lighting Control..............................................................1859 Description...............................................................1859 Front Work Lights.....................................................1861 Front Marker Lights (if equipped).....................................1861 Front/Rear Turn Signal Lights.........................................1861 Rear Tail/Marker Lights...............................................1861 Rear Work Light.......................................................1861 Rear Backup Lights....................................................1861 Rear Stop Lights......................................................1861 Strobe Light(s).......................................................1861 Spot Light (if equipped)..............................................1861 Cab...........................................................................1861 Description...............................................................1861 Component Descriptions....................................................1863 Cab Heating System....................................................1863 Lighting Control System...............................................1863 Wiper/Washer System...................................................1863 Cab Systems Operation.....................................................1864 Front End (Mast) and Chassis......................................................1867 Front End, Mast...............................................................1869 Description...............................................................1869 Carriages.....................................................................1869 Description...............................................................1869 Principles of Operation...................................................1870 Integral Sideshift Carriage...........................................1870 Mast Mounts...................................................................1871 Description...............................................................1871 Principles of Operation...................................................1871 Two-Stage Limited Free-Lift (LFL) Mast........................................1872 Description...............................................................1872 Principles of Operation...................................................1873 Two-Stage Full Free-Lift (FFL) Mast...........................................1874 Description...............................................................1874 Principles of Operation...................................................1875 Three-Stage Full Free-Lift (FFL) Mast.........................................1876 Description...............................................................1876 Principles of Operation...................................................1877 Four-Stage Full Free-Lift (FFL) Mast..........................................1878 Description...............................................................1878 Principles of Operation...................................................1880 Cylinder Cushion During Lifting Sequence......................................1882 Description...............................................................1882 Principles of Operation...................................................1882 Cylinder Cushion During Lowering Sequence.....................................1883 Description...............................................................1883 Principles of Operation...................................................1883 Tilt and Sideshift Cylinders..................................................1883 Description...............................................................1883 Tilt Cylinder.........................................................1883 Sideshift Cylinder....................................................1883 Lowering Control Valves.......................................................1884 Description...............................................................1884 Principles of Operation...................................................1884 Chassis.......................................................................1886 Description...............................................................1886 Abnormal Channel Wear.........................................................1887 Abnormal Hose Wear............................................................1889 Abnormal Mast Noise...........................................................1891 Body Panels Making Noise......................................................1895 External Leakage From Free-Lift or Main Lift Cylinders........................1896 FFL Mast Banging During Phasing...............................................1897 High Tire Wear - Drive Axle...................................................1899 High Tire Wear - Steer Axle...................................................1901 Hoses Not Tracking Correctly..................................................1903 Integral Sideshift Moving Too Fast............................................1904 Integral Sideshift Not Moving or Slow.........................................1905 LP Tank Bracket Disengages....................................................1908 LP Tank Rattles and Does Not Stay Latched.....................................1909 Mast is Loose.................................................................1910 Mast Lift Chains Are Loose....................................................1912 Mast or Carriage Binding......................................................1913 Mast/Carriage Bounces or is Spongy............................................1915 Misphasing of Full Free-Lift Mast.............................................1916 Overhead Guard Loose or Damaged...............................................1918 Racking During Lift...........................................................1919 Racking During Tilt...........................................................1921 Truck Feels Unstable..........................................................1922 Truck Wanders, Does Not Track Straight or Steer Well..........................1924 Wheels Appear Tipped or Misaligned............................................1926 Wheels Spinning On Uneven Floors..............................................1928 Wheel Studs Breaking..........................................................1929 Supplementary Data................................................................1931 Abbreviations and Acronyms....................................................1933 Special Tools List............................................................1941 Fault Mode Indicator (FMI) Reference List.....................................1947 TSP Reference Tables..........................................................1949 tables................................................................................ 747 Table 9020-40-1. Test Specifications.............................................. 995 Table 9020-40-2. Test Specifications.............................................. 996 Table 9020-40-3. Service Tools.................................................... 996 Table 9020-40-4. Test Specifications.............................................. 997 Table 9020-40-5. Service Tools.................................................... 997 Table 9020-40-6. Test Specifications.............................................. 998 Table 9020-40-7. Service Tools.................................................... 999 Table 9020-40-8. Test Specifications - Mazda......................................1000 Table 9020-40-9. Test Specifications - GM.........................................1000 Table 9020-40-10. Service Tools...................................................1000 Table 9020-40-11. Test Specifications.............................................1002 Table 9020-40-12. Service Tools...................................................1002 Table 9020-40-13. Test Specifications.............................................1004 Table 9020-40-14. Service Tools...................................................1004 Table 9030-03-1. Circuit Group Identification.....................................1035 Table 9030-03-2. Hyster Wiring Color Codes........................................1036 Table 9040-10-1. Two-Speed Transmission Clutch Pack Solenoid Val..................1622 Table 9040-10-2. Three-Speed Transmission Electronic Proportiona..................1624 Table 9040-10-3. Transmission Control Mode........................................1626 Table 9040-40-1. Test Specifications..............................................1689 Table 9040-40-2. Service Tools....................................................1689 Table 9040-40-3. Service Tools....................................................1689 Table 9040-40-4. Test Specifications..............................................1691 Table 9040-40-5. Test Specifications..............................................1691 Table 9040-40-6. Test Specifications..............................................1692 Table 9040-40-7. Test Specifications..............................................1692 Table 9040-40-8. Test Specifications..............................................1693 Table 9040-40-9. Service Tools....................................................1693 Table 9040-40-10. Stall Speeds....................................................1694 Table 9050-10-1. Standby Pressure Table...........................................1723 Table 9050-40-1. Test Specifications..............................................1815 Table 9050-40-2. Service Tools....................................................1815 Table 9050-40-3. Test Specifications..............................................1816 Table 9050-40-4. Service Tools....................................................1816 Table 9050-40-5. Test Specifications..............................................1818 Table 9050-40-6. Service Tools....................................................1818 Table 9050-40-7. Test Specifications..............................................1820 Table 9050-40-8. Service Tools....................................................1821 Table 9050-40-9. Test Specifications..............................................1822 Table 9050-40-10. Test Specifications.............................................1822 Table 9050-40-11. Service Tools...................................................1822 Table 9050-40-12. Test Specifications.............................................1824 Table 9050-40-13. Service Tools...................................................1824 Table 9050-40-14. Test Specifications.............................................1827 Table 9050-40-15. Service Tools...................................................1827 Table 9050-40-16. Test Specifications.............................................1828 Table 9050-40-17. Service Tools...................................................1828 Table 9050-40-18. Test Specifications.............................................1829 Table 9050-40-19. Service Tools...................................................1829 Table 9050-40-20. Test Specifications.............................................1830 Table 9050-40-21. Service Tools...................................................1830 Table 9050-40-22. Test Specifications.............................................1832 Table 9050-40-23. Service Tools...................................................1832 Table 9050-40-24. Test Specifications.............................................1833 Table 9050-40-25. Service Tools...................................................1833 Table 9080-50-1. Abbreviations and Acronyms.......................................1933 Table 9080-60-1. Special Tools....................................................1941 Table 9080-70-1. FMI..............................................................1947 Table 9080-80-1. Resistor-Temperature Characteristics.............................1949 Capacities and Specifications 8000SRM1208.................................................1953 toc...................................................................................1953 Capacities and Specifications.....................................................1953 Safety Precautions Maintenance and Repair.........................................1954 Lift Truck Lifting Capacity.......................................................1957 Counterweight Weights.............................................................1957 Tire Sizes........................................................................1957 Capacities........................................................................1957 Electrical System.................................................................1960 Transmission Oil Pressures........................................................1962 Hydraulic System Relief Pressures.................................................1963 Steering System...................................................................1963 Stall Speeds (in RPM ±100 rpm)....................................................1964 Mazda ........................................................................1964 Yanmar 2.6L...................................................................1964 Mast Speeds ......................................................................1964 Tilt Angles.......................................................................1965 Front End Equipment - Mast Creep..................................................1966 Mast Creep....................................................................1966 Engine Specifications.............................................................1967 Torque Specifications.............................................................1968 Frame.........................................................................1968 Mast..........................................................................1968 Steering System, Cushioned Tire Trucks........................................1968 Steering System, Pneumatic Tire Trucks........................................1969 Drive Axle....................................................................1969 Transmission..................................................................1969 Engine - Mazda 2.0L...........................................................1970 Engine - Yanmar 2.6L Diesel...................................................1970 tables................................................................................1953 Table 1. Lift Truck Models S1.5FT, S1.8FT, S2.0FTS (S30FT, S35FT..................1964 Table 2. Lift Truck Models H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT..................1964 Table 3. Lift Truck Models H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT..................1965 Table 4. S1.5FT, S1.8FT, S2.0FTS (S30FT, S35FT, S40FTS) (E010) L..................1965 Table 5. H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) (F001) L..................1966 Table 6. S1.5FT, S1.8FT, S2.0FTS (S30FT, S35FT, S40FTS) (E010) L..................1966 Table 7. H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) (F001) L..................1967 Diagrams and Schematics 8000SRM1152.......................................................1975 toc...................................................................................1975 Diagrams and Schematics...........................................................1975 Safety Precautions Maintenance and Repair.........................................1976 General Information About Diagrams and Schematics.................................1979 Symbol Definitions............................................................1979 tables................................................................................1975 Table 1. Wire Colors..............................................................1979 Table 2. Symbol Definitions.......................................................1979 Periodic Maintenance 8000SRM1207..........................................................2029 toc...................................................................................2029 Periodic Maintenance..............................................................2029 Safety Precautions Maintenance and Repair.........................................2030 General...........................................................................2035 Serial Number Data............................................................2035 How to Move Disabled Lift Truck...............................................2035 How to Tow Lift Truck.....................................................2035 How to Put Lift Truck on Blocks...............................................2036 How to Raise Drive Tires..................................................2036 How to Raise Steering Tires...............................................2036 Maintenance Schedule..............................................................2038 Maintenance Procedures Every 8 Hours or Daily.....................................2047 How To Make Checks With Engine Stopped........................................2047 Tires and Wheels..........................................................2047 Safety Labels.............................................................2048 Inspection of Mast, and Lift Chains.......................................2048 Operator Restraint System.................................................2049 Hood and Seat Latches.....................................................2050 Engine Compartment........................................................2050 Fuel, Oil, and Coolant Leaks, Check.......................................2050 Hydraulic Hoses...........................................................2050 Coolant Hoses.............................................................2050 Steering Column Gas Cylinder..............................................2050 Transmission..............................................................2051 Hydraulic System Oil......................................................2051 Engine Oil................................................................2051 Forks.....................................................................2053 Remove................................................................2053 Inspect...............................................................2053 Install...............................................................2054 Adjust................................................................2054 How To Make Checks With Engine Running........................................2054 Indicator Lights, Horn, Fuses and Relays..................................2054 Service Brakes............................................................2055 Brake Fluid Level.....................................................2055 Operation, Check......................................................2055 Parking Brake.............................................................2056 Engine Oil Pressure.......................................................2056 Cooling System............................................................2056 Steering System...........................................................2057 Control Levers and Pedals.................................................2057 Lift System, Operate......................................................2058 Maintenance Procedures Every 250 Hours or 6 Weeks.................................2058 Hydraulic System Oil..........................................................2058 Hydraulic Tank Breather.......................................................2058 Battery.......................................................................2059 Mazda Engine Oil and Filter...................................................2059 Air Filter....................................................................2059 Drive Belt....................................................................2060 Mazda 2.0L Engines........................................................2060 Fan and Alternator Drive Belt.........................................2060 Drain Tar From LPG Regulator..................................................2060 Cooling System................................................................2061 Clean Debris From Radiator Core...........................................2061 Transmission Oil Level and Filter.............................................2061 Forks.........................................................................2062 Brake Fluid...................................................................2062 Differential and Drive Axle Oil...............................................2062 Maintenance Procedures Every 500 Hours or 3 Months................................2062 Yanmar Engine Oil and Filter..................................................2062 Drive Belt....................................................................2063 Yanmar Diesel Engine......................................................2063 Fan and Alternator Drive Belt.........................................2063 PCV Valve.....................................................................2064 Mast Lubrication..............................................................2064 Lift Chain Lubrication........................................................2066 Tilt Cylinder Lubrication.....................................................2066 Master Brake Cylinder Rod End Pin Lubrication.................................2067 Manual Hydraulic Levers Lubrication...........................................2067 Tie Rod Lubrication...........................................................2067 Maintenance Procedures Every 1000 Hours or 6 Months...............................2069 Valve Clearance, Check and Adjust.............................................2069 Ignition System...............................................................2069 Mazda 2.0L Engines........................................................2069 LPG Vapor Fuel Filter Replace, Mazda Engines..................................2069 Fuel Filter Replacement, Yanmar Engine........................................2070 Priming the Fuel System.......................................................2071 In-Line Fuel Filter Replacement...............................................2071 Removal...................................................................2071 Installation..............................................................2072 Lift Chains Wear Check........................................................2072 Integral Sideshift Carriage, Check Bearings...................................2072 Steering Axle.................................................................2073 Control Levers and Pedals.....................................................2073 Maintenance Procedures Every 2000 Hours or Annually...............................2073 Hydraulic System..............................................................2073 Hydraulic Filter, Replace.................................................2074 Hydraulic Tank Breather, Replace..........................................2075 Air Filter Element............................................................2075 PCV Valve.....................................................................2076 LPG Regulator Fuel Filter, Mazda Engines......................................2076 Remove and Replace........................................................2076 Gasoline Fuel Filter..........................................................2076 Remove and Replace........................................................2076 Timing Belt...................................................................2077 Mazda Engines.............................................................2077 LPG Fuel Injector, Mazda Engines..............................................2077 Gasoline Fuel Injector, Mazda Engines.........................................2077 Fuel Injector, Yanmar Engines.................................................2077 Powershift Transmission.......................................................2077 Transmission Oil and Filter, Replace......................................2077 Forks.........................................................................2078 Integral Sideshift Carriage...................................................2078 Bearings, Replace.........................................................2078 Brake Fluid Change............................................................2078 Brake Fluid, Remove...........................................................2079 Wheel Bearings................................................................2080 Steer and Drive Wheel Bearings, Lubricate.................................2080 Service Brakes................................................................2080 Differential..................................................................2080 Maintenance Procedures Every 4000 Hours or 2 Years................................2081 Hydraulic Oil, Replace........................................................2081 Cooling System................................................................2082 Safety Procedures When Working Near Mast..........................................2083 Hood Latch Check..................................................................2085 Lift Chain Adjustments............................................................2086 Jump-Starting the Lift Truck......................................................2087 Welding Repairs...................................................................2087 Overhead Guard Changes............................................................2088 WHEEL REPAIR......................................................................2088 General.......................................................................2088 How to Change Solid Rubber Tire (S Series) ...................................2088 Remove and Install Tire on Wheel..........................................2088 Pneumatic Tire, Repair........................................................2089 Remove Wheels From Lift Truck.............................................2089 Remove Tire From Wheel....................................................2089 Remove Tire From Two-Piece Wheel......................................2090 Remove Tire From Three- and Four-Piece Wheels.........................2091 Install Wheel in Tire.....................................................2092 Install Two-Piece Wheel in Tire.......................................2093 Install Three- or Four-Piece Wheel in Tire............................2094 Add Air to Pneumatic Tires................................................2095 Wheels, Install...........................................................2095 Solid Rubber Tires on Pneumatic Wheels, Change................................2095 Remove Tire From Wheel....................................................2096 Install Tire on Wheel.....................................................2097 Adhesives and Sealants............................................................2099 tables................................................................................2029 Table 1. Maintenance Schedule.....................................................2041 Table 2. V-Belt Deflection Table..................................................2063 Table 3. Carriage Chain Adjustment, Forks Not Installed...........................2087
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