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Hyster Fortis H40-70FT S40-70FT Forklift Complete Service Repair Manual PDF

Original price was: $49.95.Current price is: $29.95.

Full 2,938-page Hyster Fortis service manual compilation for H40-70FT and S40-70FT series forklifts — engine, transmission, brake, hydraulic, mast, and electrical repair across all covered models and engines.

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Description

Hyster Fortis H40-70FT & S40-70FT Forklift Service Manual — Full PDF Compilation

This is the complete Hyster Fortis service manual compilation for the H40-70FT and S40-70FT series lift trucks, delivered as a single 2,938-page PDF. It gathers the individual SRM sections that a technician needs to service, diagnose, disassemble, and rebuild these machines — from the frame and counterweight through engine, transmission, brakes, hydraulics, steering axle, mast, cylinders, and the operator cab. Every procedure is written for the specific covered models and engines, not a generic reference.

File Details

  • Manual type: Service / repair manual compilation (SRM sections)
  • Brand: Hyster
  • Series: Fortis H40-70FT, S40-70FT and related model codes
  • Language: English
  • Page count: 2,938 pages
  • File format: PDF
  • Document numbers: 100 SRM 1120, 600 SRM 1121, 600 SRM 1122, 700 SRM 1123, 900 SRM 1124, 900 SRM 1125, 900 SRM 1126, 900 SRM 1127, 1300 SRM 1129, 1600 SRM 1133, 1800 SRM 1135, 1900 SRM 1136, 2000 SRM 1137, 2100 SRM 1139, 4000 SRM 1148, 2200 SRM 1143, 600 SRM 1205, 1400 SRM 1214, 1400 SRM 1215, 100 SRM 1290, 900 SRM 1325, 900 SRM 1326, 2200 SRM 1327, 1300 SRM 1421, 1300 SRM 1447, 1300 SRM 1529 and related bulletins

Chapters Covered

  • Frame (100 SRM 1120) — hood, seat and side covers, steering column, counterweight, overhead guard, operator restraint system, engine and transmission replacement, throttle pedal and cable adjustment, exhaust system, cooling system, hydraulic filter assembly, fuel and hydraulic tank repair, safety labels
  • GM 2.4L Engine Repair (600 SRM 1121) — intake and exhaust manifolds, camshaft and cylinder head, timing belt, lubrication system, pistons and rods, crankshaft and main bearings, flywheel and flywheel housing, cooling system repair, sensors and switches, ignition system, alternator, starter
  • Mazda 2.0L & 2.2L Engine (600 SRM 1122) — cylinder head, camshaft and valve mechanism, crankshaft and main bearings, pistons and connecting rods, cylinder block, oil pump, cooling system, flywheel and ring gear, valve adjustment, compression check, engine timing
  • Cooling System (700 SRM 1123) — cooling system checks, flushing, radiator replacement for all covered models, fan assembly replacement and inspection
  • LPG Fuel System — GM 2.4L (900 SRM 1124) — LPG tank and bracket, fuel filter unit, electronic throttle body, fuel injectors, LPG regulator, control system, exhaust system
  • LPG Fuel System — Mazda 2.0L & 2.2L (900 SRM 1125) — LPG tank, fuel filter, relief valve, carburetor, fuel injector, governor, regulator, control system
  • Gasoline Fuel System — GM 2.4L (900 SRM 1126) — electronic throttle body, fuel system repair, fuel injectors, pressure regulator, control system, exhaust system
  • Gasoline Fuel System — Mazda 2.0L & 2.2L (900 SRM 1127) — engine tune-up, intake-air system, fuel system, exhaust system, PCV valve, control system
  • Powershift Transmission Repair (1300 SRM 1129) — charge pump, torque converter, front cover housing and chain drive, clutch packs, control valve, MONOTROL pedal, direction control lever
  • Steering Axle (1600 SRM 1133) — steering axle assembly, spindles, bearings, tie rods, steering cylinder
  • Brake System (1800 SRM 1135) — dry brake service repair, parking brake, master cylinder, brake system air removal, brake pedal and free pedal adjustment
  • Hydraulic Gear Pump (1900 SRM 1136) — single gear pump, tandem gear pump, variable displacement pump, gear pump specifications, VDP checks and adjustments
  • Main Control Valve (2000 SRM 1137) — electro-hydraulic main control valve, manual main control valve, pressure relief valve check and adjustment, steering control unit repair
  • Cylinder Repair (2100 SRM 1139) — tilt cylinders, lift cylinders, free-lift cylinders, fork positioner cylinders, seal kit installation
  • Mast Repairs, 2-, 3-, and 4-Stage Masts (4000 SRM 1148) — fork replacement, carriage repair, fork positioner, mast removal and disassembly, mast assembly, header hose arrangement, lift chain adjustment, carriage and mast adjustments, load roller adjustment, mast side kicking adjustment
  • Electrical System — Mazda 2.0L & 2.2L (2200 SRM 1143) — ignition system, distributor, igniter, ignition coil, starter repair, alternator repair
  • Yanmar Diesel Engines 2.6L, 3.0L, 3.3L (600 SRM 1205) — cylinder head assembly, timing gear case and timing gears, drive train, camshaft, cylinder block, lubrication system, fuel system, electronic throttle, cooling system, flywheel, electrical equipment, engine specifications, special tools
  • Drive Axle and Differential — Dry Brake (1400 SRM 1214) — drive axle repair, differential repair, ring gear backlash and runout, gear tooth contact pattern
  • Drive Axle Repair — Wet Brake (1400 SRM 1215) — reduction gear assembly, wet disc brake, parking brake control lever, differential repair, drive axle installation, special tools
  • Operator’s Cab (100 SRM 1290) — cab replacement, door assemblies, window wipers, window replacement, heater replacement, heater and air conditioner assembly, light replacement, display switches, electrical schematics, optional equipment
  • Gasoline Fuel System — Mazda Emission Compliant (900 SRM 1325) — intake-air system, fuel system, exhaust system, PCV valve, oxygen sensor, control system
  • LPG Fuel System — Mazda Emission Compliant (900 SRM 1326) — LPG tank and bracket, fuel filter unit, electronic throttle body, electronic pressure regulator, LPG shutoff valve, fuel mixer, control system, exhaust system
  • Electrical System — Mazda Emission Compliant (2200 SRM 1327) — ignition system, coil replacement, starter, alternator, engine sensors and switches
  • Single Speed Powershift Aluminum Transmission (1300 SRM 1421) — hydraulic gear pump, charge pump, torque converter, stator support, clutch packs, proportional and enable solenoid valves, MONOTROL pedal
  • Single Speed Powershift Aluminum Chain Drive Transmission (1300 SRM 1447) — hydraulic gear pump, housing fittings, charge pump, torque converter, stator support, clutch packs, drive chains and sprockets, proportional and enable solenoid valves, MONOTROL pedal
  • Powershift Transmission Repair (1300 SRM 1529) — charge pump, torque converter, housings and chain drive, clutch packs, control valve, MONOTROL pedal, direction control lever

The Hyster Fortis H40-70FT and S40-70FT service manual compilation is more than a stack of pages — it is a complete workshop library in one file. Each SRM section was originally issued as its own standalone repair guide, and here they are bound together so a technician can move from frame to engine to transmission to mast without switching documents. Torque values, clearances, seal arrangements, tightening sequences, and adjustment procedures are printed alongside the exploded illustrations that show exactly how the parts fit. Whether you are rebuilding a GM 2.4L, diagnosing a wet disc brake, setting ring gear backlash, or re-shimming a mast, the procedure is in this PDF.

Complete PDF Bookmark Tree

Complete Bookmarks

The complete bookmarks in the “Hyster Fortis H40-70FT S40-70FT Forklift Complete Service Repair Manual PDF” are as follows:

1p. 1
tocp. 1
Framep. 1
Safety Precautions Maintenance and Repairp. 2
Generalp. 5
Descriptionp. 5
Hood, Seat, and Side Covers Replacementp. 6
Removep. 6
Installp. 12
Steering Columnp. 17
Descriptionp. 17
Steering Column Repairp. 17
Removep. 17
Disassemblep. 19
Cleanp. 19
Inspectp. 19
Assemblep. 22
Installp. 22
LPG Tank and Bracket Assemblyp. 23
Counterweight Replacementp. 23
Removep. 23
Installp. 26
Tow Pin, Remove and Installp. 27
Overhead Guard Replacementp. 27
Remove and Installp. 27
LED Tail, Backup, and Brake Lights, Replacep. 28
Operator Restraint System Replacementp. 29
Descriptionp. 29
Automatic Locking Retractor (ALR)p. 29
Emergency Locking Retractor (ELR)p. 29
Engine Replacementp. 31
Removep. 31
Installp. 36
Transmission Replacementp. 38
Remove Transmission with Iron Housingp. 38
Install Transmission with Iron Housingp. 39
Remove Transmission with Aluminum Housingp. 40
Install Transmission with Aluminum Housingp. 45
Throttle Pedal and Cable Adjustmentp. 47
Mazda Gas/LPG Engines With Basic Power Shift Transmission and Elp. 47
Mazda Gasoline Engine With Electronic Transmissionp. 50
Throttle Pedal Stop Adjustmentp. 51
Yanmar Diesel Engine With Basic Power Shift Transmissionp. 51
Yanmar Diesel Engine With Electronic Throttlep. 51
Exhaust System Repairp. 53
Lift Trucks With Counterweight Exhaust Systemp. 53
Mazda Gas and LPG Enginesp. 53
Remove and Disassemblep. 53
Inspectp. 53
Assemble and Installp. 53
Yanmar Diesel Enginep. 55
Remove and Disassemblep. 55
Inspectp. 55
Assemble and Installp. 55
Lift Trucks With Overhead Exhaust Systemp. 57
Yanmar Diesel Enginep. 57
Remove and Disassemblep. 57
Inspectp. 57
Assemble and Installp. 59
Mazda Gas and LPG Enginesp. 59
Remove and Disassemblep. 59
Inspectp. 61
Assemble and Installp. 61
Cooling Systemp. 62
Descriptionp. 62
Hydraulic Filter Assembly Repairp. 62
Removep. 62
Clean and Inspectp. 62
Installp. 62
Fuel and Hydraulic Tanks Repairp. 64
Inspectp. 64
Cleanp. 64
Steam Method of Cleaningp. 64
Chemical Solution Method of Cleaningp. 65
Additional Preparations for Repairp. 65
Small Leaks, Repairp. 65
Large Leaks, Repairp. 65
Preparations for Use After Repairp. 66
Safety Labelsp. 66
tablesp. 1
Table 1. Gas Spring Installation, Lift Truck Models H1.6FT, H1.8p. 13
Table 2. Gas Spring Installation, Lift Truck Models H2.0-3.5FT (p. 15
Table 3. Weight of Counterweights, Lift Truck Models S2.0-3.5FTp. 25
Table 4. Weight of Counterweights, Lift Truck Models S30FT, S35Fp. 25
Table 5. Weight of Counterweights, Lift Truck Models H1.6FT, H1.p. 25
Table 6. Weight of Counterweights, Lift Truck Models H2.0-3.5FTp. 25
2p. 73
tocp. 73
Operator's Cabp. 73
Safety Precautions Maintenance and Repairp. 74
Generalp. 79
Cab Replacementp. 80
Remove, for Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F001); H2.p. 80
Install, for Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F001); H2p. 94
Remove, for Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (Hp. 96
Install, for Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (p. 102
Door Assembliesp. 103
Right Side Door Assembly, Lift Truck Models H1.6FT, H1.8FT, 2.0Fp. 103
Removep. 103
Disassemblep. 111
Door Cover With Heater Unitp. 111
Door Cover With Air Conditioner/Heater Unitp. 111
Heater Assemblyp. 111
Air Conditioner and Heater Unit Assemblyp. 115
Door Lock Assemblyp. 116
Windowsp. 117
Cleanp. 117
Inspectp. 117
Assemblep. 117
Windowsp. 117
Door Lock Assemblyp. 117
Heater Assemblyp. 117
Air Conditioner and Heater Unit Assemblyp. 118
Door Cover With Heater Unitp. 118
Door Cover With Air Conditioner and Heater Unitp. 118
Installp. 118
Left Side Door Assembly, Lift Truck Models H1.6FT, H1.8FT, 2.0FTp. 119
Removep. 119
Disassemblep. 119
Door Coverp. 119
Door Lock Assemblyp. 119
Windowsp. 119
Cleanp. 119
Inspectp. 119
Assemblep. 119
Windowsp. 119
Door Lock Assemblyp. 119
Door Coverp. 120
Installp. 120
Right and Left Side Door Assemblies, Lift Truck Models H6.0FT, Hp. 121
Removep. 121
Disassemblep. 122
Door Coverp. 122
Door Lock Assemblyp. 122
Windowsp. 122
Cleanp. 123
Inspectp. 123
Assemblep. 124
Windowsp. 124
Door Lock Assemblyp. 124
Door Coverp. 124
Installp. 125
Window Wipers Replacementp. 125
Generalp. 125
Front Wiper Assembly and Motorp. 125
Remove, Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F001) and H2.0p. 125
Install, Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F001) and H2.p. 125
Remove, Lift Truck Models H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-5p. 127
Install, Lift Truck Models H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-p. 127
Rear Wiper Assembly and Motorp. 132
Remove, Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F001)p. 132
Install, Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F001)p. 132
Remove, Lift Truck Models H2.0-3.5FT (H40-70FT) (L177)p. 134
Install, Lift Truck Models H2.0-3.5FT (H40-70FT) (L177)p. 134
Remove, Lift Truck Models H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-5p. 137
Install, Lift Truck Models H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-p. 137
Remove, Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (H006,p. 139
Install, Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (H006p. 139
Window Replacementp. 141
Generalp. 141
Remove Door Window, Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F0p. 141
Install Door Windows, Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (p. 142
Remove Door Window, Lift Truck Models H6.0FT, H7.0FT (H135FT, H1p. 142
Install Door Window, Lift Truck Models H6.0FT, H7.0FT (H135FT, Hp. 144
Heater Replacementp. 144
Remove, for Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (Hp. 144
Install, for Lift truck Models H6.0FT, H7.0FT (H135FT, H155FT) (p. 147
Heater and Air Conditioner Assemblyp. 148
Air Conditioner Condenser Unitp. 148
Removep. 148
Installp. 149
Air Conditioner Receiver/Drier Unitp. 150
Removep. 150
Installp. 150
Air Conditioner Compressorp. 151
Light Replacementp. 152
Work Lights (Front and Rear)p. 152
Removep. 152
Installp. 152
Strobe Lightp. 153
Removep. 153
Installp. 153
Turn, Stop, Tail, and Backup Lightp. 153
Removep. 153
Installp. 153
Front Marker/Turn Signal Lightsp. 155
Removep. 155
Installp. 156
Display Switchesp. 156
Electrical Schematicsp. 156
Optional Equipmentp. 159
Heavy Duty Pre-Cleanerp. 159
Removep. 159
Cleanp. 159
Inspectp. 159
Installp. 159
Fanp. 162
Removep. 162
Installp. 162
Mirrorp. 162
Removep. 162
Installp. 162
Label Replacementp. 164
3p. 167
tocp. 167
GM Engine Repairp. 167
Safety Precautions Maintenance and Repairp. 168
Generalp. 173
Engine Serial Numberp. 173
Engine Removal and Installationp. 175
Intake Manifoldp. 175
Removep. 175
Clean and Inspectp. 176
Installp. 176
Exhaust Manifoldp. 177
Removep. 177
Clean and Inspectp. 177
Installp. 177
Camshaft and Cylinder Head Repairp. 178
Rocker Arm Coverp. 178
Removep. 178
Installp. 178
Camshaft Timing Pulley and/or Front Sealp. 179
Removep. 179
Installp. 179
Camshaft Carrier and Cylinder Headp. 180
Removep. 180
Disassemblep. 181
Camshaft Carrierp. 181
Cylinder Headp. 182
Clean and Inspectp. 183
Camshaft Carrierp. 183
Cylinder Headp. 184
Valve and Valve Seatp. 186
Assemblep. 186
Cylinder Headp. 186
Camshaft Carrierp. 187
Installp. 187
Timing Beltp. 188
Timing Belt Front Coverp. 188
Removep. 188
Installp. 189
Timing Belt and Timing Belt Tensionerp. 189
Removep. 189
Installp. 191
Timing Belt Rear Coverp. 191
Removep. 191
Installp. 191
Lubrication System Repairp. 192
Oil Panp. 192
Removep. 192
Installp. 192
Oil Pumpp. 194
Removep. 194
Clean and Inspectp. 195
Installp. 196
Piston and Piston Rod Assemblies Repairp. 197
Piston Rod Bearings, Replacep. 197
Piston and Piston Rod Assembliesp. 199
Removep. 199
Disassemblep. 200
Pistons, Clean and Inspectp. 200
Cylinder Bores, Inspect and Repairp. 201
Piston Rings, Inspectp. 202
Assemblep. 203
Installp. 203
Crankshaft and Main Bearingsp. 204
Crankshaft Timing Pulley and/or Front Sealp. 204
Removep. 204
Installp. 205
Crankshaft Rear Main Oil Sealp. 206
Removep. 206
Installp. 206
Crankshaft/RPM Sensorp. 206
Removep. 206
Installp. 207
Crankshaft Reluctor Wheelp. 207
Remove and Installp. 207
Crankshaft and Main Bearingsp. 207
Removep. 207
Inspect and Repairp. 208
Bearing Selectionp. 209
Main Bearings and Journal Clearance, Checkp. 210
Installp. 211
Flywheel and Flywheel Housingp. 213
Removep. 213
Installp. 213
Cooling System Repairp. 214
Serpentine Beltp. 214
Removep. 214
Inspectp. 214
Installp. 214
Water Pumpp. 215
Removep. 215
Inspectp. 217
Installp. 217
Thermostatp. 218
Removep. 218
Checkp. 219
Installp. 219
Thermostat Housingp. 220
Removep. 220
Clean and Inspectp. 220
Installp. 220
Sensors and Switchesp. 222
Crankshaft Position (CKP) Sensorp. 222
Removep. 222
Installp. 222
Camshaft Position (CMP) Sensorp. 222
Remove for Lift Trucks Built Before January, 2010p. 222
Assemblyp. 222
Sensor Onlyp. 223
Install for Lift Trucks Built Before January, 2010p. 223
Assemblyp. 223
Sensor Onlyp. 224
Remove for Lift Trucks Built After January, 2010p. 224
Install for Lift Trucks Built After January, 2010p. 224
Oil Pressure Sensorp. 224
Removep. 224
Installp. 225
Ignition Systemp. 225
Spark Plug Wire Inspectionp. 225
Spark Plug Wire Replacementp. 225
Removep. 225
Installp. 226
Spark Plug Replacementp. 226
Removep. 226
Installp. 226
Spark Plug Inspectionp. 227
Usagep. 227
Inspectp. 227
Visual Inspectionp. 229
Coil Packp. 229
Removep. 229
Installp. 229
Alternator Repairp. 230
Alternatorp. 230
Removep. 230
Installp. 230
Alternator Fuse, Replacep. 230
Starter Repairp. 231
Removep. 231
Installp. 231
Engine Specificationsp. 232
Engine Datap. 232
Cylinder Borep. 232
Pistonp. 232
Piston Ringsp. 232
Wrist Pinp. 233
Crankshaftp. 233
Piston Rodp. 233
Camshaft and Camshaft Carrierp. 234
Valve Systemp. 234
Cylinder Head Warpagep. 235
Lubrication Systemp. 235
Cooling Systemp. 235
Torque Specificationsp. 235
Special Toolsp. 237
4p. 243
tocp. 243
Cooling Systemp. 243
Safety Precautions Maintenance and Repairp. 244
Generalp. 247
Cooling System Checksp. 247
Exhaust Leaks Into Cooling Systemp. 247
Water Flow Restrictions in Radiatorp. 247
Radiator Hosesp. 247
Water Pumpp. 247
Flushing the Cooling Systemp. 248
Cooling System, Cleanp. 248
Radiator Replacementp. 249
Radiator, Remove for Lift Trucks Models S30FT, S35FT, S40FTS (E0p. 249
Radiator, Remove for Lift Trucks Models S30FT, S35FT, S40FTS (E0p. 265
Radiator, Remove for Lift Truck Models S6.0FT, S7.0FT (S135FT, Sp. 267
Radiator, Remove for Lift Truck Models H6.0FT, H7.0FT (H135FT, Hp. 270
Radiator, Install for Lift Truck Models S30FT, S35FT, S40FTS (E0p. 276
Radiator, Install for Lift Truck Models S30FT, S35FT, S40FTS (E0p. 279
Radiator, Install for Lift Truck Models S6.0FT, S7.0FT (S135FT,p. 280
Radiator, Install for Lift Truck Models H6.0FT, H7.0FT (H135FT,p. 283
Fan Assembly Replacementp. 293
Fan Removalp. 293
Inspectp. 307
Fan Installationp. 307
5p. 313
tocp. 313
LPG Fuel Systemp. 313
Safety Precautions Maintenance and Repairp. 314
Generalp. 317
Hoses Replacementp. 317
LPG Tank and Bracket Replacementp. 317
Remove LPG Tankp. 317
Install LPG Tankp. 319
Remove LPG Bracketp. 320
Install LPG Bracketp. 320
Remove LPG Tank Bracket Alignment Pinp. 322
Install LPG Tank Bracket Alignment Pinp. 322
Fuel Filter Unit Repairp. 324
Fuel Filter Elementp. 324
Removep. 324
Clean/Inspectp. 324
Installp. 324
Fuel Filter Housingp. 325
Removep. 325
Disassemblep. 325
Assemblep. 326
Installp. 326
Electronic Throttle Body Repairp. 326
Electronic Throttle Bodyp. 326
Removep. 326
Installp. 326
Electronic Throttle Body Adapter Platep. 327
Removep. 327
Installp. 327
Fuel Injector Repairp. 328
Fuel Railp. 328
Remove for Lift Trucks Built Before January, 2010p. 328
Install for Lift Trucks Built Before January, 2010p. 329
Remove for Lift Trucks Built After January, 2010p. 329
Install for Lift Trucks Built After January, 2010p. 330
Fuel Injector for Lift Trucks Built Before January, 2010p. 331
Removep. 331
Cleanp. 331
Installp. 331
Fuel Injector Adapters for Lift Trucks Built Before January, 201p. 332
Removep. 332
Installp. 333
Fuel Injectors and Adapters for Lift Trucks Built After January,p. 334
Removep. 334
Cleanp. 334
Installp. 334
LPG Regulator Repairp. 335
LPG Regulatorp. 335
Removep. 335
Installp. 335
LPG Regulator Fuel Filterp. 336
Removep. 336
Installp. 336
Lock-Off Solenoid and Cartridgep. 337
Removep. 337
Installp. 337
Control Systemp. 338
Electronic Control Unit (ECU)p. 338
Removep. 338
Installp. 339
Fuel Pump Relayp. 339
Removep. 339
Installp. 340
Injector Driver Modulep. 340
Removep. 340
Installp. 341
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT)p. 341
Removep. 341
Installp. 341
Engine Coolant Temperature (ECT) Sensorp. 342
Removep. 342
Installp. 342
Oxygen Sensorp. 342
Removep. 342
Installp. 343
Low LPG Pressure Switchp. 343
Removep. 343
Installp. 343
Exhaust System Repairp. 344
Remove and Disassemblep. 344
Inspectp. 345
Assemble and Installp. 346
6p. 349
tocp. 349
Gasoline Fuel Systemp. 349
Safety Precautions Maintenance and Repairp. 350
Generalp. 353
Electronic Throttle Body Repairp. 353
Electronic Throttle Bodyp. 353
Removep. 353
Installp. 353
Fuel System Repairp. 354
Before Repair Procedurep. 354
After Repair Procedurep. 354
Fuel Leakage Check for Lift Trucks Built Before January, 2010p. 354
Fuel Leakage Check for Lift Trucks Built After January, 2010p. 355
Fuel Line Pressure Checkp. 356
Fuel Injectorsp. 357
Removep. 357
Installp. 360
Pressure Regulatorp. 360
Removep. 360
Installp. 360
Control Systemp. 361
Electronic Control Unit (ECU)p. 361
Removep. 361
Installp. 362
Power Latch Relayp. 362
Removep. 362
Installp. 363
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT)p. 363
Removep. 363
Installp. 363
Engine Coolant Temperature (ECT) Sensorp. 364
Removep. 364
Installp. 364
Oxygen Sensorp. 364
Removep. 364
Installp. 365
Exhaust System Repairp. 365
Remove and Disassemblep. 365
Inspectp. 367
Assemble and Installp. 367
7p. 371
tocp. 371
Framep. 371
Safety Precautions Maintenance and Repairp. 372
Generalp. 375
Descriptionp. 375
Hood, Seat, and Side Covers Replacementp. 376
Removep. 376
Installp. 382
Steering Columnp. 387
Descriptionp. 387
Steering Column Repairp. 387
Removep. 387
Disassemblep. 389
Cleanp. 389
Inspectp. 389
Assemblep. 392
Installp. 392
LPG Tank and Bracket Assemblyp. 393
Counterweight Replacementp. 393
Removep. 393
Installp. 396
Tow Pin, Remove and Installp. 397
Overhead Guard Replacementp. 397
Remove and Installp. 397
LED Tail, Backup, and Brake Lights, Replacep. 398
Operator Restraint System Replacementp. 399
Descriptionp. 399
Automatic Locking Retractor (ALR)p. 399
Emergency Locking Retractor (ELR)p. 399
Engine Replacementp. 401
Removep. 401
Installp. 406
Transmission Replacementp. 408
Remove Transmission with Iron Housingp. 408
Install Transmission with Iron Housingp. 409
Remove Transmission with Aluminum Housingp. 410
Install Transmission with Aluminum Housingp. 415
Throttle Pedal and Cable Adjustmentp. 417
Mazda Gas/LPG Engines With Basic Power Shift Transmission and Elp. 417
Mazda Gasoline Engine With Electronic Transmissionp. 420
Throttle Pedal Stop Adjustmentp. 421
Yanmar Diesel Engine With Basic Power Shift Transmissionp. 421
Yanmar Diesel Engine With Electronic Throttlep. 421
Exhaust System Repairp. 423
Lift Trucks With Counterweight Exhaust Systemp. 423
Mazda Gas and LPG Enginesp. 423
Remove and Disassemblep. 423
Inspectp. 423
Assemble and Installp. 423
Yanmar Diesel Enginep. 425
Remove and Disassemblep. 425
Inspectp. 425
Assemble and Installp. 425
Lift Trucks With Overhead Exhaust Systemp. 427
Yanmar Diesel Enginep. 427
Remove and Disassemblep. 427
Inspectp. 427
Assemble and Installp. 429
Mazda Gas and LPG Enginesp. 429
Remove and Disassemblep. 429
Inspectp. 431
Assemble and Installp. 431
Cooling Systemp. 432
Descriptionp. 432
Hydraulic Filter Assembly Repairp. 432
Removep. 432
Clean and Inspectp. 432
Installp. 432
Fuel and Hydraulic Tanks Repairp. 434
Inspectp. 434
Cleanp. 434
Steam Method of Cleaningp. 434
Chemical Solution Method of Cleaningp. 435
Additional Preparations for Repairp. 435
Small Leaks, Repairp. 435
Large Leaks, Repairp. 435
Preparations for Use After Repairp. 436
Safety Labelsp. 436
tablesp. 371
Table 1. Gas Spring Installation, Lift Truck Models H1.6FT, H1.8p. 383
Table 2. Gas Spring Installation, Lift Truck Models H2.0-3.5FT (p. 385
Table 3. Weight of Counterweights, Lift Truck Models S2.0-3.5FTp. 395
Table 4. Weight of Counterweights, Lift Truck Models S30FT, S35Fp. 395
Table 5. Weight of Counterweights, Lift Truck Models H1.6FT, H1.p. 395
Table 6. Weight of Counterweights, Lift Truck Models H2.0-3.5FTp. 395
8p. 443
tocp. 443
Operator's Cabp. 443
Safety Precautions Maintenance and Repairp. 444
Generalp. 449
Cab Replacementp. 450
Remove, for Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F001); H2.p. 450
Install, for Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F001); H2p. 464
Remove, for Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (Hp. 466
Install, for Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (p. 472
Door Assembliesp. 473
Right Side Door Assembly, Lift Truck Models H1.6FT, H1.8FT, 2.0Fp. 473
Removep. 473
Disassemblep. 481
Door Cover With Heater Unitp. 481
Door Cover With Air Conditioner/Heater Unitp. 481
Heater Assemblyp. 481
Air Conditioner and Heater Unit Assemblyp. 485
Door Lock Assemblyp. 486
Windowsp. 487
Cleanp. 487
Inspectp. 487
Assemblep. 487
Windowsp. 487
Door Lock Assemblyp. 487
Heater Assemblyp. 487
Air Conditioner and Heater Unit Assemblyp. 488
Door Cover With Heater Unitp. 488
Door Cover With Air Conditioner and Heater Unitp. 488
Installp. 488
Left Side Door Assembly, Lift Truck Models H1.6FT, H1.8FT, 2.0FTp. 489
Removep. 489
Disassemblep. 489
Door Coverp. 489
Door Lock Assemblyp. 489
Windowsp. 489
Cleanp. 489
Inspectp. 489
Assemblep. 489
Windowsp. 489
Door Lock Assemblyp. 489
Door Coverp. 490
Installp. 490
Right and Left Side Door Assemblies, Lift Truck Models H6.0FT, Hp. 491
Removep. 491
Disassemblep. 492
Door Coverp. 492
Door Lock Assemblyp. 492
Windowsp. 492
Cleanp. 493
Inspectp. 493
Assemblep. 494
Windowsp. 494
Door Lock Assemblyp. 494
Door Coverp. 494
Installp. 495
Window Wipers Replacementp. 495
Generalp. 495
Front Wiper Assembly and Motorp. 495
Remove, Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F001) and H2.0p. 495
Install, Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F001) and H2.p. 495
Remove, Lift Truck Models H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-5p. 497
Install, Lift Truck Models H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-p. 497
Rear Wiper Assembly and Motorp. 502
Remove, Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F001)p. 502
Install, Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F001)p. 502
Remove, Lift Truck Models H2.0-3.5FT (H40-70FT) (L177)p. 504
Install, Lift Truck Models H2.0-3.5FT (H40-70FT) (L177)p. 504
Remove, Lift Truck Models H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-5p. 507
Install, Lift Truck Models H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-p. 507
Remove, Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (H006,p. 509
Install, Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (H006p. 509
Window Replacementp. 511
Generalp. 511
Remove Door Window, Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F0p. 511
Install Door Windows, Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (p. 512
Remove Door Window, Lift Truck Models H6.0FT, H7.0FT (H135FT, H1p. 512
Install Door Window, Lift Truck Models H6.0FT, H7.0FT (H135FT, Hp. 514
Heater Replacementp. 514
Remove, for Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (Hp. 514
Install, for Lift truck Models H6.0FT, H7.0FT (H135FT, H155FT) (p. 517
Heater and Air Conditioner Assemblyp. 518
Air Conditioner Condenser Unitp. 518
Removep. 518
Installp. 519
Air Conditioner Receiver/Drier Unitp. 520
Removep. 520
Installp. 520
Air Conditioner Compressorp. 521
Light Replacementp. 522
Work Lights (Front and Rear)p. 522
Removep. 522
Installp. 522
Strobe Lightp. 523
Removep. 523
Installp. 523
Turn, Stop, Tail, and Backup Lightp. 523
Removep. 523
Installp. 523
Front Marker/Turn Signal Lightsp. 525
Removep. 525
Installp. 526
Display Switchesp. 526
Electrical Schematicsp. 526
Optional Equipmentp. 529
Heavy Duty Pre-Cleanerp. 529
Removep. 529
Cleanp. 529
Inspectp. 529
Installp. 529
Fanp. 532
Removep. 532
Installp. 532
Mirrorp. 532
Removep. 532
Installp. 532
Label Replacementp. 534
9p. 537
tocp. 537
Mazda Enginep. 537
Safety Precautions Maintenance and Repairp. 538
Generalp. 541
Serial Numberp. 541
Engine Removal and Installationp. 542
Cylinder Head, Camshaft, and Valve Mechanism Repairp. 542
Removep. 542
Cleanp. 544
Inspect and Repairp. 544
Cylinder Headp. 544
Rocker Shaft Assemblyp. 544
Camshaftp. 545
Valve Guidesp. 546
Valve Seatsp. 546
Valvesp. 546
Valve Springsp. 547
Installp. 548
Crankshaft and Main Bearings Repairp. 552
Removep. 552
Inspect and Repairp. 552
Crankshaftp. 552
Main Bearingsp. 553
Installp. 554
Pistons and Connecting Rods Repairp. 554
Remove and Disassemblep. 554
Cleanp. 554
Inspect and Repairp. 555
Pistonsp. 555
Piston Ringsp. 555
Connecting Rods and Bearingsp. 555
Assemble and Installp. 556
Cylinder Block Repairp. 557
Oil Pump Repairp. 558
Removep. 558
Disassemblep. 559
Cleanp. 559
Inspectp. 559
Assemblep. 560
Installp. 560
Cooling System Repairp. 562
Thermostatp. 562
Replacep. 562
Fan Assemblyp. 562
Remove and Disassemblep. 562
Assemble and Installp. 562
Water Pumpp. 563
Removep. 563
Installp. 564
Flywheel and Ring Gear Repairp. 564
Removep. 564
Installp. 564
Valve Adjustmentp. 565
Compression Pressure Checkp. 566
Engine Timing Adjustmentp. 566
Engine Specificationsp. 567
Engine Datap. 567
Engine Speedsp. 567
2007, and Later, Emission Compliant Enginesp. 567
All Engines Except 2007, and Later, Emission Compliant Enginesp. 567
Thermostatp. 568
Cylinder Headp. 568
Valve Mechanismp. 568
Camshaftp. 569
Crankshaftp. 569
Connecting Rodsp. 570
Cylinder Blockp. 570
Pistonsp. 570
Oil Pumpp. 570
Torque Specificationsp. 571
tablesp. 537
Table 1. Pressure Specificationsp. 566
10p. 575
tocp. 575
Cooling Systemp. 575
Safety Precautions Maintenance and Repairp. 576
Generalp. 579
Cooling System Checksp. 579
Exhaust Leaks Into Cooling Systemp. 579
Water Flow Restrictions in Radiatorp. 579
Radiator Hosesp. 579
Water Pumpp. 579
Flushing the Cooling Systemp. 580
Cooling System, Cleanp. 580
Radiator Replacementp. 581
Radiator, Remove for Lift Trucks Models S30FT, S35FT, S40FTS (E0p. 581
Radiator, Remove for Lift Trucks Models S30FT, S35FT, S40FTS (E0p. 597
Radiator, Remove for Lift Truck Models S6.0FT, S7.0FT (S135FT, Sp. 599
Radiator, Remove for Lift Truck Models H6.0FT, H7.0FT (H135FT, Hp. 602
Radiator, Install for Lift Truck Models S30FT, S35FT, S40FTS (E0p. 608
Radiator, Install for Lift Truck Models S30FT, S35FT, S40FTS (E0p. 611
Radiator, Install for Lift Truck Models S6.0FT, S7.0FT (S135FT,p. 612
Radiator, Install for Lift Truck Models H6.0FT, H7.0FT (H135FT,p. 615
Fan Assembly Replacementp. 625
Fan Removalp. 625
Inspectp. 639
Fan Installationp. 639
11p. 645
tocp. 645
LPG Fuel Systemp. 645
Safety Precautions Maintenance and Repairp. 646
Generalp. 649
Hoses Replacementp. 649
LPG Tank Replacementp. 649
Removep. 649
Installp. 649
Fuel Filterp. 651
Removep. 651
Clean and Inspectp. 652
Installp. 653
Relief Valve Replacementp. 654
Remove and Installp. 654
Carburetor Repairp. 654
Removep. 654
Disassemblep. 654
Cleanp. 656
Assemblep. 656
Installp. 656
Fuel Injector Repairp. 657
Removep. 657
Clean and Inspectp. 657
Installp. 657
Governor Repairp. 657
Removep. 657
Installp. 657
Regulator Repairp. 658
Removep. 658
Installp. 659
Control Systemp. 659
Engine Control Unit (ECU)p. 659
Removep. 659
Installp. 659
Engine Coolant Temperature (ECT) Sensorp. 660
Removep. 660
Installp. 660
Camshaft Position (CMP) Sensorp. 660
Voltage Checkp. 660
Intake Air Temperature (IAT) Sensorp. 661
Removep. 661
Installp. 661
Manifold Absolute Pressure (MAP) Sensorp. 662
Removep. 662
Installp. 662
Oxygen Sensorp. 662
Removep. 662
Installp. 662
Throttle Position (TP) Sensorp. 663
Removep. 663
Installp. 663
12p. 667
tocp. 667
Gasoline Fuel Systemp. 667
Safety Precautions Maintenance and Repairp. 668
Generalp. 671
Abbreviationsp. 671
Engine Tune-upp. 671
Engine Tune-Up Preparationp. 671
Idle Speed Adjustmentp. 671
Idle-Up Speed Checkp. 671
Intake-Air Systemp. 673
Intake-Air System Manifold Vacuum Checkp. 673
Throttle Bodyp. 674
Removep. 674
Installp. 674
Electronic Governorp. 674
Removep. 674
Installp. 674
Intake-Air Control (IAC) Valvep. 674
Removep. 674
Installp. 676
Intake Manifoldp. 676
Removep. 676
Installp. 676
Fuel Systemp. 677
Before Repair Procedurep. 677
Fuel Line Safety Procedurep. 677
After Repair Procedurep. 677
Fuel Hose, Installp. 677
Fuel Leakage Checkp. 678
Fuel Line Pressure Checkp. 678
Fuel Injectorp. 679
Removep. 679
Installp. 679
Pressure Regulatorp. 680
Removep. 680
Installp. 681
Exhaust Systemp. 682
Exhaust System, Inspectp. 682
Three-Way Catalytic (TWC) Converterp. 682
Remove and Installp. 682
Exhaust Manifoldp. 682
Removep. 682
Installp. 682
Positive Crankcase Ventilation (PCV) Valvep. 684
Removep. 684
Inspectp. 684
Installp. 684
Control Systemp. 684
Engine Control Unit (ECU)p. 684
Removep. 684
Installp. 686
Intake Air Temperature (IAT) Sensorp. 687
Removep. 687
Installp. 687
Mass Air Flow (MAF) Sensorp. 687
Removep. 687
Installp. 687
Throttle Position (TP) Sensorp. 688
TP Sensor, Adjustp. 688
Removep. 689
Installp. 689
Engine Coolant Temperature (ECT) Sensorp. 689
Removep. 689
Installp. 690
Camshaft Position (CMP) Sensorp. 690
Voltage Checkp. 690
Oxygen Sensorp. 690
Removep. 690
Installp. 690
Manifold Absolute Pressure (MAP)/Boost Sensorp. 691
Removep. 691
Installp. 691
Technical Datap. 692
tablesp. 667
Table 1. PCV Valve Specificationsp. 684
Table 2. Closed Throttle Position Specificationsp. 689
Table 3. Gasoline Fuel Systems Technical Datap. 692
13p. 695
tocp. 695
Gasoline Fuel Systemp. 695
Safety Precautions Maintenance and Repairp. 696
Generalp. 699
Abbreviationsp. 699
Intake-Air Systemp. 699
Intake-Air System Manifold Vacuum Checkp. 699
Throttle Bodyp. 700
Removep. 700
Installp. 701
Intake Manifoldp. 701
Removep. 701
Installp. 701
Fuel Systemp. 702
Before Repair Procedurep. 702
Fuel Line Safety Procedurep. 702
After Repair Procedurep. 704
Fuel Hose, Installp. 704
Fuel Leakage Checkp. 705
Fuel Line Pressure Checkp. 705
Fuel Injectorsp. 707
Removep. 707
Installp. 708
Pressure Regulatorp. 708
Removep. 708
Installp. 709
Exhaust Systemp. 709
Counterweight Exhaust Systemp. 709
Remove and Disassemblep. 709
Inspectp. 709
Assemble and Installp. 711
Overhead Exhaust Systemp. 711
Remove and Disassemblep. 711
Inspectp. 711
Assemble and Installp. 713
Exhaust Manifoldp. 713
Removep. 713
Installp. 715
Positive Crankcase Ventilation (PCV) Valvep. 715
Removep. 715
Inspectp. 715
Installp. 715
Oxygen Sensorp. 716
Removep. 716
Installp. 716
Control Systemp. 718
Engine Control Unit (ECU)p. 718
Removep. 718
Installp. 719
Fuel Level Sensorp. 720
Removep. 720
Installp. 720
Technical Datap. 721
tablesp. 695
Table 1. PCV Valve Specificationsp. 715
Table 2. Gasoline Fuel Systems Technical Datap. 721
14p. 725
tocp. 725
LPG Fuel Systemp. 725
Safety Precautions Maintenance and Repairp. 726
Generalp. 729
LPG Tank and Bracket Replacementp. 729
Remove LPG Tank for Lift Truck Models S30FT, S35FT, S40FTS (E010p. 729
Install LPG Tank for Lift Truck Models S30FT, S35FT, S40FTS (E01p. 731
Remove LPG Tank for Lift Truck Models S50CT (A267) and H2.0-2.5Cp. 731
LPG Tank Install for Lift Truck Models S50CT (A267) and H2.0-2.5p. 733
Remove LPG Bracket for Lift Truck Models S30FT, S35FT, S40FTS (Ep. 734
Install LPG Bracket for Lift Truck Models S30FT, S35FT, S40FTS (p. 736
Remove LPG Tank Bracket Alignment Pin, Lift Truck Models S30FT,p. 736
Install LPG Tank Bracket Alignment Pin, Lift Truck Models S30FT,p. 738
Remove LPG Bracket for Lift Truck Models S50CT (A267) and H2.0-2p. 738
Install LPG Bracket for Lift Truck Models S50CT (A267) and H2.0-p. 738
Fuel Filter Unit Repairp. 739
Fuel Filter Elementp. 739
Removep. 739
Clean/Inspectp. 739
Installp. 740
Fuel Filter Housingp. 740
Removep. 740
Disassemblep. 742
Assemblep. 744
Installp. 745
Electronic Throttle Body Repairp. 745
Removep. 745
Installp. 746
Electronic Pressure Regulator (EPR) Repairp. 747
Removep. 747
Disassemblep. 751
Assemblep. 752
Installp. 753
LPG Shutoff Valve Assemblyp. 754
Removep. 754
Installp. 757
Fuel Mixer Repairp. 759
Removep. 759
Installp. 761
Control Systemp. 762
Engine Control Unit (ECU)p. 762
Removep. 762
Installp. 762
Low LPG Pressure Switchp. 764
Removep. 764
Installp. 765
LPG Low Level Sensorp. 765
Removep. 765
Installp. 768
Exhaust Systemp. 768
Counterweight Exhaust Systemp. 768
Remove and Disassemblep. 768
Inspectp. 770
Assemble and Installp. 770
Overhead Exhaust Systemp. 770
Remove and Disassemblep. 770
Inspectp. 772
Assemble and Installp. 772
Exhaust Manifoldp. 772
Removep. 772
Installp. 774
Positive Crankcase Ventilation (PCV) Valvep. 774
Removep. 774
Inspectp. 774
Installp. 774
Oxygen Sensorp. 774
Removep. 774
Installp. 774
tablesp. 725
Table 1. PCV Valve Specificationsp. 774
15p. 779
tocp. 779
Electrical Systemp. 779
Safety Precautions Maintenance and Repairp. 780
Ignition Systemp. 783
Generalp. 783
Ignition Timing Adjustment, Gasoline and LPGp. 783
Spark Plugs Checkp. 783
Spark Plug Wires Checkp. 783
Distributor Repairp. 786
Removep. 786
Disassemblep. 787
Inspectp. 787
Assemblep. 788
Installp. 788
Igniterp. 789
Removep. 789
Testp. 789
Installp. 789
Camshaft Position (CMP) Sensorp. 790
Voltage Checkp. 790
Ignition Coil Checkp. 791
Primary Coil Windingp. 791
Secondary Coil Windingp. 791
Starter Repairp. 792
Generalp. 792
Removep. 792
No-Load Testp. 793
Magnetic Switch Testp. 793
Pull-Out Testp. 793
Holding Coil Testp. 794
Return Testp. 794
Pinion Movement Inspectionp. 794
Installp. 794
Alternator Repairp. 795
Generalp. 795
Charging System Inspectionp. 795
Output Current Checkp. 796
No-Load Adjusted Voltage Checkp. 796
Removep. 797
Inspectp. 797
Rectifier Checkp. 797
Installp. 798
tablesp. 779
Table 1. Spark Plug Wirep. 783
Table 2. Starter Specificationsp. 792
Table 3. Problem Diagnosis Chartp. 793
Table 4. Specificationsp. 796
Table 5. Rectifier Check Tablep. 797
16p. 801
tocp. 801
Electrical Systemp. 801
Safety Precautions Maintenance and Repairp. 802
Generalp. 805
Ignition Systemp. 805
Generalp. 805
Ignition Timing Adjustment, Gasoline and LPGp. 805
Spark Plugs Checkp. 810
Spark Plug Wires Checkp. 810
Coil Replacementp. 811
Removep. 811
Inspectp. 812
Installp. 812
Starter Repairp. 812
Generalp. 812
Removep. 812
No-Load Testp. 814
Magnetic Switch Testp. 814
Pull-Out Testp. 814
Holding Coil Testp. 815
Return Testp. 815
Pinion Movement Inspectionp. 815
Installp. 815
Alternator Repairp. 816
Generalp. 816
Charging System Inspectionp. 817
Output Current Checkp. 818
No-Load Adjusted Voltage Checkp. 819
Removep. 819
Inspectp. 820
Rectifier Checkp. 820
Installp. 821
Engine Sensors and Switchesp. 821
Oil Pressure Sensor, Gas and LPG Enginesp. 821
Removep. 821
Installp. 821
Air Filter Restriction Switch, Gas and LPG Enginesp. 822
Removep. 822
Installp. 822
Cam Angle Sensor, Gas and LPG Enginesp. 823
Removep. 823
Installp. 823
Voltage Checkp. 824
Manifold Absolute Pressure (MAP) Sensor, Gas and LPG Enginesp. 825
Removep. 825
Installp. 825
Intake Air Temperature (IAT) Sensor, LPG Enginesp. 826
Removep. 826
Installp. 826
Intake Air Temperature (IAT) Sensor, Gas Enginesp. 827
Removep. 827
Installp. 827
Fuel Temperature Sensor, LPG Enginesp. 828
Removep. 828
Installp. 829
Engine Coolant Temperature (ECT) Sensorp. 829
2007 Emissions Compliant Gas Enginesp. 829
Removep. 829
Installp. 829
2007 and 2010 Emissions Compliant LPG Enginesp. 830
Removep. 830
Installp. 830
2010 Emissions Compliant Gas and LPG Enginesp. 831
Removep. 831
Installp. 831
tablesp. 801
Table 1. Spark Plug Wiresp. 810
Table 2. Coil Inspectionp. 812
Table 3. Starter Specificationsp. 813
Table 4. Problem Diagnosis Chartp. 814
Table 5. Specifications – 2007 Emissions Compliant Enginesp. 818
Table 6. Specifications – Lift Trucks Built After January, 2010p. 818
Table 7. Rectifier Check Table – 2007 Emissions Compliant Enginep. 820
Table 8. Rectifier Check Table – Lift Trucks Built After Januaryp. 820
17p. 835
tocp. 835
Framep. 835
Safety Precautions Maintenance and Repairp. 836
Generalp. 839
Descriptionp. 839
Hood, Seat, and Side Covers Replacementp. 840
Removep. 840
Installp. 846
Steering Columnp. 851
Descriptionp. 851
Steering Column Repairp. 851
Removep. 851
Disassemblep. 853
Cleanp. 853
Inspectp. 853
Assemblep. 856
Installp. 856
LPG Tank and Bracket Assemblyp. 857
Counterweight Replacementp. 857
Removep. 857
Installp. 860
Tow Pin, Remove and Installp. 861
Overhead Guard Replacementp. 861
Remove and Installp. 861
LED Tail, Backup, and Brake Lights, Replacep. 862
Operator Restraint System Replacementp. 863
Descriptionp. 863
Automatic Locking Retractor (ALR)p. 863
Emergency Locking Retractor (ELR)p. 863
Engine Replacementp. 865
Removep. 865
Installp. 870
Transmission Replacementp. 872
Remove Transmission with Iron Housingp. 872
Install Transmission with Iron Housingp. 873
Remove Transmission with Aluminum Housingp. 874
Install Transmission with Aluminum Housingp. 879
Throttle Pedal and Cable Adjustmentp. 881
Mazda Gas/LPG Engines With Basic Power Shift Transmission and Elp. 881
Mazda Gasoline Engine With Electronic Transmissionp. 884
Throttle Pedal Stop Adjustmentp. 885
Yanmar Diesel Engine With Basic Power Shift Transmissionp. 885
Yanmar Diesel Engine With Electronic Throttlep. 885
Exhaust System Repairp. 887
Lift Trucks With Counterweight Exhaust Systemp. 887
Mazda Gas and LPG Enginesp. 887
Remove and Disassemblep. 887
Inspectp. 887
Assemble and Installp. 887
Yanmar Diesel Enginep. 889
Remove and Disassemblep. 889
Inspectp. 889
Assemble and Installp. 889
Lift Trucks With Overhead Exhaust Systemp. 891
Yanmar Diesel Enginep. 891
Remove and Disassemblep. 891
Inspectp. 891
Assemble and Installp. 893
Mazda Gas and LPG Enginesp. 893
Remove and Disassemblep. 893
Inspectp. 895
Assemble and Installp. 895
Cooling Systemp. 896
Descriptionp. 896
Hydraulic Filter Assembly Repairp. 896
Removep. 896
Clean and Inspectp. 896
Installp. 896
Fuel and Hydraulic Tanks Repairp. 898
Inspectp. 898
Cleanp. 898
Steam Method of Cleaningp. 898
Chemical Solution Method of Cleaningp. 899
Additional Preparations for Repairp. 899
Small Leaks, Repairp. 899
Large Leaks, Repairp. 899
Preparations for Use After Repairp. 900
Safety Labelsp. 900
tablesp. 835
Table 1. Gas Spring Installation, Lift Truck Models H1.6FT, H1.8p. 847
Table 2. Gas Spring Installation, Lift Truck Models H2.0-3.5FT (p. 849
Table 3. Weight of Counterweights, Lift Truck Models S2.0-3.5FTp. 859
Table 4. Weight of Counterweights, Lift Truck Models S30FT, S35Fp. 859
Table 5. Weight of Counterweights, Lift Truck Models H1.6FT, H1.p. 859
Table 6. Weight of Counterweights, Lift Truck Models H2.0-3.5FTp. 859
18p. 907
tocp. 907
Operator's Cabp. 907
Safety Precautions Maintenance and Repairp. 908
Generalp. 913
Cab Replacementp. 914
Remove, for Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F001); H2.p. 914
Install, for Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F001); H2p. 928
Remove, for Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (Hp. 930
Install, for Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (p. 936
Door Assembliesp. 937
Right Side Door Assembly, Lift Truck Models H1.6FT, H1.8FT, 2.0Fp. 937
Removep. 937
Disassemblep. 945
Door Cover With Heater Unitp. 945
Door Cover With Air Conditioner/Heater Unitp. 945
Heater Assemblyp. 945
Air Conditioner and Heater Unit Assemblyp. 949
Door Lock Assemblyp. 950
Windowsp. 951
Cleanp. 951
Inspectp. 951
Assemblep. 951
Windowsp. 951
Door Lock Assemblyp. 951
Heater Assemblyp. 951
Air Conditioner and Heater Unit Assemblyp. 952
Door Cover With Heater Unitp. 952
Door Cover With Air Conditioner and Heater Unitp. 952
Installp. 952
Left Side Door Assembly, Lift Truck Models H1.6FT, H1.8FT, 2.0FTp. 953
Removep. 953
Disassemblep. 953
Door Coverp. 953
Door Lock Assemblyp. 953
Windowsp. 953
Cleanp. 953
Inspectp. 953
Assemblep. 953
Windowsp. 953
Door Lock Assemblyp. 953
Door Coverp. 954
Installp. 954
Right and Left Side Door Assemblies, Lift Truck Models H6.0FT, Hp. 955
Removep. 955
Disassemblep. 956
Door Coverp. 956
Door Lock Assemblyp. 956
Windowsp. 956
Cleanp. 957
Inspectp. 957
Assemblep. 958
Windowsp. 958
Door Lock Assemblyp. 958
Door Coverp. 958
Installp. 959
Window Wipers Replacementp. 959
Generalp. 959
Front Wiper Assembly and Motorp. 959
Remove, Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F001) and H2.0p. 959
Install, Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F001) and H2.p. 959
Remove, Lift Truck Models H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-5p. 961
Install, Lift Truck Models H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-p. 961
Rear Wiper Assembly and Motorp. 966
Remove, Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F001)p. 966
Install, Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F001)p. 966
Remove, Lift Truck Models H2.0-3.5FT (H40-70FT) (L177)p. 968
Install, Lift Truck Models H2.0-3.5FT (H40-70FT) (L177)p. 968
Remove, Lift Truck Models H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-5p. 971
Install, Lift Truck Models H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-p. 971
Remove, Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (H006,p. 973
Install, Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (H006p. 973
Window Replacementp. 975
Generalp. 975
Remove Door Window, Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F0p. 975
Install Door Windows, Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (p. 976
Remove Door Window, Lift Truck Models H6.0FT, H7.0FT (H135FT, H1p. 976
Install Door Window, Lift Truck Models H6.0FT, H7.0FT (H135FT, Hp. 978
Heater Replacementp. 978
Remove, for Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (Hp. 978
Install, for Lift truck Models H6.0FT, H7.0FT (H135FT, H155FT) (p. 981
Heater and Air Conditioner Assemblyp. 982
Air Conditioner Condenser Unitp. 982
Removep. 982
Installp. 983
Air Conditioner Receiver/Drier Unitp. 984
Removep. 984
Installp. 984
Air Conditioner Compressorp. 985
Light Replacementp. 986
Work Lights (Front and Rear)p. 986
Removep. 986
Installp. 986
Strobe Lightp. 987
Removep. 987
Installp. 987
Turn, Stop, Tail, and Backup Lightp. 987
Removep. 987
Installp. 987
Front Marker/Turn Signal Lightsp. 989
Removep. 989
Installp. 990
Display Switchesp. 990
Electrical Schematicsp. 990
Optional Equipmentp. 993
Heavy Duty Pre-Cleanerp. 993
Removep. 993
Cleanp. 993
Inspectp. 993
Installp. 993
Fanp. 996
Removep. 996
Installp. 996
Mirrorp. 996
Removep. 996
Installp. 996
Label Replacementp. 998
19p. 1001
tocp. 1001
Yanmar Diesel Enginesp. 1001
Safety Precautions Maintenance and Repairp. 1002
Generalp. 1007
Engine Identificationp. 1007
Major Engine Component Identificationp. 1007
Location of Labelsp. 1007
Engine Removal and Installationp. 1008
Cylinder Head Assembly Repairp. 1008
Glow Plugsp. 1010
Removep. 1010
Installp. 1010
Valve Coverp. 1010
Removep. 1010
Clean and Inspectp. 1010
Installp. 1011
Rocker Arm Assemblyp. 1011
Removep. 1011
Disassemblep. 1012
Clean and Inspectp. 1012
Push Rodsp. 1012
Rocker Arm Assemblyp. 1012
Assemblep. 1013
Installp. 1013
Valve Clearance Adjustmentsp. 1013
Cylinder Head Assemblyp. 1015
Removep. 1015
Disassemblep. 1018
Valves and Valve Springs, Removep. 1018
Valve Guides, Removep. 1019
Clean and Inspectp. 1019
Cylinder Headp. 1020
Valve Guidesp. 1020
Valvesp. 1020
Valve Sinkp. 1020
Valve Seatp. 1021
Valve Springsp. 1021
Assemblep. 1022
Valve Guides, Installp. 1022
Valves and Valve Springs, Installp. 1022
Installp. 1023
Timing Gear Case and Timing Gears Repairp. 1025
Timing Gear Case Coverp. 1025
Removep. 1025
Clean and Inspectp. 1025
Installp. 1025
Timing Gearsp. 1026
Crankshaft Gearp. 1026
Removep. 1026
Installp. 1027
Idler Gearp. 1027
Removep. 1027
Inspectp. 1027
Installp. 1028
Camshaft Gearp. 1028
Removep. 1028
Installp. 1028
Timing Gear Casep. 1028
Removep. 1028
Clean and Inspectp. 1029
Installp. 1029
Drive Train, Camshaft, and Cylinder Block Repairp. 1030
Removep. 1030
Disassemblep. 1030
Pistons and Connecting Rodsp. 1030
Crankshaftp. 1031
Camshaftp. 1033
Clean and Inspectp. 1034
Cylinder Blockp. 1035
Honing and Boringp. 1037
Pistonsp. 1038
Piston Pinp. 1038
Connecting Rodp. 1038
Tappetsp. 1039
Crankshaftp. 1039
Camshaftp. 1041
Camshaft Bushingp. 1041
Assemblep. 1041
Camshaftp. 1041
Crankshaftp. 1042
Pistons and Connecting Rodsp. 1042
Installp. 1043
Lubrication System Repairp. 1044
Engine Oil and Oil Filter Changep. 1044
Oil Panp. 1044
Removep. 1044
Installp. 1045
Oil Suction Tubep. 1045
Removep. 1045
Cleanp. 1046
Installp. 1046
Oil Pumpp. 1046
Removep. 1046
Clean and Inspectp. 1047
Outer Rotor Outside Clearancep. 1047
Outer Rotor to Inner Rotor Tip Clearancep. 1047
Outer Rotor Side Clearancep. 1047
Rotor Shaft Clearancep. 1048
Installp. 1048
Fuel System Repairp. 1049
Fuel Injectorsp. 1049
Removep. 1049
Inspectp. 1050
Cleanp. 1050
Testp. 1050
Installp. 1053
Electronic Throttle Systemp. 1053
Removep. 1053
Installp. 1056
Inspectp. 1057
Adjustp. 1057
Fuel Injection Pumpp. 1060
Removep. 1060
Clean and Inspectp. 1063
Installp. 1063
Check/Adjust Fuel Injection Timingp. 1064
Cooling System Repairp. 1065
V-Beltp. 1065
Removep. 1065
Inspectp. 1065
Installp. 1065
Adjustp. 1065
Water Pumpp. 1066
4TNE92-NMHA and 4TNE92-NMHA/1688253 Enginesp. 1066
Removep. 1066
Installp. 1068
4TNE92-NMH, 4TNE98-NMH, 4TNE92-NMH/1688273, and 4TNE98-BNMH Engip. 1069
Removep. 1069
Installp. 1070
Thermostatp. 1071
Removep. 1071
Inspectp. 1072
Installp. 1072
Flywheel and Flywheel Housingp. 1073
Flywheelp. 1073
Removep. 1073
Installp. 1073
Flywheel Housingp. 1075
Removep. 1075
Installp. 1075
Electrical Equipment Repairp. 1076
Alternatorp. 1076
Removep. 1076
Bench Testp. 1078
Regulate Voltage Checkp. 1078
No Load Testp. 1080
Output Testp. 1080
Installp. 1080
Starterp. 1081
Removep. 1082
No Load Testp. 1082
Installp. 1082
Engine Specificationsp. 1083
Engine Datap. 1083
Engine Tuningp. 1089
Cylinder Headp. 1090
Intake/Exhaust Valve and Guidep. 1090
Valve Springp. 1091
Rocker Arm and Shaftp. 1091
Push Rodp. 1091
Gear Train and Camshaftp. 1091
Camshaftp. 1091
Idle Gear Shaft and Bushingp. 1092
Backlash of Each Gearp. 1092
Cylinder Blockp. 1093
Crankshaftp. 1093
Thrust Bearingp. 1093
Pistonp. 1094
Piston Ringp. 1094
Connecting Rodp. 1095
Rod Small Endp. 1095
Tappetp. 1095
Oil Pumpp. 1095
Engine Oil Pressurep. 1095
Outer Rotor Outside Clearancep. 1095
Outer Rotor Side Clearancep. 1095
Outer Rotor to Inner Rotor Tip Clearancep. 1096
Rotor Shaft Clearancep. 1096
Standard Torque Specificationsp. 1096
Standard Torque Chartp. 1096
Special Torque Specificationsp. 1097
Special Toolsp. 1098
tablesp. 1001
Table 1. Cylinder Measurement Worksheetp. 1036
Table 2. Fuel Injector Spray Patternsp. 1052
Table 3. V-Belt Deflection Tablep. 1066
Table 4. Alternator Specificationsp. 1076
Table 5. Starter Specificationsp. 1081
Table 6. No Load Test Specificationsp. 1082
Table 7. 4TNE92-NMH Enginep. 1083
Table 8. 4TNE92-NMHA Enginep. 1084
Table 9. 4TNE98-NMH Enginep. 1085
Table 10. 4TNE92-NMH Enginep. 1086
Table 11. 4TNE92-NMHA Enginep. 1087
Table 12. 4TNE98-BNMH Enginep. 1088
20p. 1105
tocp. 1105
Cooling Systemp. 1105
Safety Precautions Maintenance and Repairp. 1106
Generalp. 1109
Cooling System Checksp. 1109
Exhaust Leaks Into Cooling Systemp. 1109
Water Flow Restrictions in Radiatorp. 1109
Radiator Hosesp. 1109
Water Pumpp. 1109
Flushing the Cooling Systemp. 1110
Cooling System, Cleanp. 1110
Radiator Replacementp. 1111
Radiator, Remove for Lift Trucks Models S30FT, S35FT, S40FTS (E0p. 1111
Radiator, Remove for Lift Trucks Models S30FT, S35FT, S40FTS (E0p. 1127
Radiator, Remove for Lift Truck Models S6.0FT, S7.0FT (S135FT, Sp. 1129
Radiator, Remove for Lift Truck Models H6.0FT, H7.0FT (H135FT, Hp. 1132
Radiator, Install for Lift Truck Models S30FT, S35FT, S40FTS (E0p. 1138
Radiator, Install for Lift Truck Models S30FT, S35FT, S40FTS (E0p. 1141
Radiator, Install for Lift Truck Models S6.0FT, S7.0FT (S135FT,p. 1142
Radiator, Install for Lift Truck Models H6.0FT, H7.0FT (H135FT,p. 1145
Fan Assembly Replacementp. 1155
Fan Removalp. 1155
Inspectp. 1169
Fan Installationp. 1169
21p. 1175
tocp. 1175
Powershift Transmissionp. 1175
Safety Precautions Maintenance and Repairp. 1176
Generalp. 1179
Serial Numberp. 1179
Charge Pump Repairp. 1180
Removep. 1180
Inspectp. 1180
Installp. 1180
Torque Converter Replacep. 1181
Removep. 1181
Installp. 1188
Front Cover Housing and Chain Drive Repairp. 1194
Removep. 1194
Cleanp. 1200
Inspectp. 1200
Installp. 1200
Clutch Packs Repairp. 1207
Remove and Disassemblep. 1207
Transmission, Remove and Disassemblep. 1207
Clutch Assemblies, Remove and Disassemblep. 1218
Cleanp. 1223
Inspectp. 1223
Assemble and Installp. 1224
Clutch Assemblies, Assemble and Installp. 1224
Transmission, Assemble and Installp. 1231
Control Valve Repairp. 1237
Remove and Disassemblep. 1237
Cleanp. 1240
Inspectp. 1240
Assemble and Installp. 1240
MONOTROL® Pedal Repairp. 1242
Remove and Disassemblep. 1242
Assemble and Installp. 1245
Direction Control Leverp. 1246
Removep. 1246
Installp. 1246
22p. 1251
tocp. 1251
Single Speed PowerShiftp. 1251
Safety Precautions Maintenance and Repairp. 1252
Generalp. 1255
Serial Numberp. 1255
Hydraulic Gear Pumpp. 1256
Removep. 1256
Installp. 1256
Charge Pump Repairp. 1257
Removep. 1257
Disassemblep. 1258
Cleanp. 1258
Inspectp. 1258
Assemblep. 1258
Installp. 1258
Torque Converter Replacementp. 1259
Removep. 1259
Clean and Inspectp. 1260
Installp. 1260
Stator Support Assembly Repairp. 1260
Removep. 1260
Disassemblep. 1266
Cleanp. 1266
Inspectp. 1267
Assemblep. 1268
Installp. 1268
Clutch Packs Repairp. 1269
Removep. 1269
Engine, Torque Converter, and Transmission Assemblyp. 1269
Transmission Componentsp. 1270
Disassemblep. 1272
Transmissionp. 1272
Housingsp. 1272
Forward Clutch Packp. 1275
Reverse Clutch Packp. 1280
Cleanp. 1286
Inspectp. 1286
Assemblep. 1287
Transmissionp. 1287
Reverse Clutch Packp. 1287
Forward Clutch Packp. 1294
Housingsp. 1301
Installp. 1302
Transmission Componentsp. 1302
Engine, Torque Converter, and Transmission Assemblyp. 1305
Inching Overlap Adjustmentp. 1305
Proportional and Enable Solenoid Valvesp. 1306
Proportional Valvesp. 1306
Removep. 1306
Disassemblep. 1307
Clean and Inspectp. 1307
Assemblep. 1307
Installp. 1307
Enable Solenoid Valvep. 1307
Removep. 1307
Disassemblep. 1307
Clean and Inspectp. 1308
Assemblep. 1308
Installp. 1308
MONOTROL® Pedal Repairp. 1308
Remove and Disassemblyp. 1308
Clean and Inspectp. 1309
Assemble and Installp. 1312
23p. 1317
tocp. 1317
Single Speed Powershiftp. 1317
Safety Precautions Maintenance and Repairp. 1318
Generalp. 1321
Serial Numberp. 1321
Hydraulic Gear Pumpp. 1321
Removep. 1321
Installp. 1321
Housing Fittings Replacementp. 1322
Removep. 1322
Disassemblep. 1322
Assemblep. 1322
Installp. 1322
Charge Pump Repairp. 1324
Removep. 1324
Disassemblep. 1325
Cleanp. 1325
Inspectp. 1325
Assemblep. 1325
Installp. 1325
Torque Converter Replacementp. 1327
Removep. 1327
Clean and Inspectp. 1327
Installp. 1327
Stator Support Assembly Repairp. 1329
Removep. 1329
Disassemblep. 1334
Cleanp. 1335
Inspectp. 1335
Assemblep. 1336
Installp. 1336
Clutch Packs Repairp. 1339
Removep. 1339
Disassemblep. 1342
Housingsp. 1342
Clutch Packsp. 1344
Forward Clutch Packp. 1344
Reverse Clutch Packp. 1349
Cleanp. 1355
Inspectp. 1355
Assemblep. 1356
Clutch Packsp. 1356
Reverse Clutch Packp. 1356
Forward Clutch Packp. 1363
Housingsp. 1369
Installp. 1371
Drive Chains and Sprocketsp. 1374
Removep. 1374
Cleanp. 1376
Inspectp. 1376
Installp. 1377
Proportional and Enable Solenoid Valvesp. 1377
Proportional Valvesp. 1377
Removep. 1377
Disassemblep. 1379
Clean and Inspectp. 1379
Assemblep. 1379
Installp. 1379
Enable Solenoid Valvep. 1380
Removep. 1380
Disassemblep. 1380
Clean and Inspectp. 1380
Assemblep. 1380
Installp. 1380
MONOTROL® Pedal Repairp. 1381
Remove and Disassemblep. 1381
Clean and Inspectp. 1385
Assemble and Installp. 1385
24p. 1389
tocp. 1389
Powershift Transmissionp. 1389
Safety Precautions Maintenance and Repairp. 1390
Generalp. 1393
Serial Numberp. 1393
Charge Pump Repairp. 1393
Removep. 1393
Inspectp. 1393
Installp. 1393
Torque Converter Replacep. 1394
Removep. 1394
Installp. 1399
Housings and Chain Drive Repairp. 1405
Removep. 1405
Cleanp. 1412
Inspectp. 1412
Installp. 1412
Clutch Packs Repairp. 1417
Remove and Disassemblep. 1417
Transmission, Remove and Disassemblep. 1417
Clutch Assemblies, Remove and Disassemblep. 1425
Cleanp. 1431
Inspectp. 1431
Assemble and Installp. 1432
Clutch Assemblies, Assemble and Installp. 1432
Transmission, Assemble and Installp. 1441
Control Valve Repairp. 1445
Remove and Disassemblep. 1445
Cleanp. 1446
Inspectp. 1446
Assemble and Installp. 1448
MONOTROL® Pedal Repairp. 1448
Remove and Disassemblep. 1448
Assemble and Installp. 1450
Direction Control Leverp. 1453
Removep. 1453
Installp. 1453
25p. 1457
tocp. 1457
Drive Axle and Differential Assembly Repairp. 1457
Safety Precautions Maintenance and Repairp. 1458
Generalp. 1461
Drive Axle Repairp. 1461
Remove and Disassemblep. 1461
Clean and Inspectp. 1463
Assemble and Installp. 1463
Differential Repairp. 1466
Removep. 1466
Differential Assembly From Center Sectionp. 1466
Drive Pinion, Pinion Gear, and Bearings From Center Sectionp. 1471
Disassemblep. 1476
Differential Assemblyp. 1476
Drop Box Housingp. 1479
Center Sectionp. 1480
Clean and Inspectp. 1482
Assemblep. 1482
Center Sectionp. 1482
Drop Box Housingp. 1486
Differential Assemblyp. 1487
Installp. 1491
Pinion Inner Shim Set, Adjust Thickness (Depth of Pinion)p. 1491
Drive Pinion, Pinion Gear, and Bearings Into Center Sectionp. 1492
Differential Assembly Into Center Sectionp. 1497
Ring Gear Backlash, Adjustp. 1503
Ring Gear, Runout Checkp. 1504
Gear Set, Tooth Contact Pattern Checkp. 1504
Torque Specificationsp. 1507
tablesp. 1457
Table 1. Pinion Variation Numbers Examplesp. 1492
Table 2. Ring and Pinion Tooth Contact Adjustmentp. 1504
Table 3. Correct Tooth Contactp. 1505
Table 4. Incorrect Tooth Contactp. 1506
26p. 1511
tocp. 1511
Drive Axle Repairp. 1511
Safety Precautions Maintenance and Repairp. 1512
Generalp. 1515
Identification Platep. 1515
Drive Axle Removalp. 1515
Reduction Gear Assemblyp. 1521
Reduction Gear Assembly Repairp. 1521
Removep. 1523
Clean and Inspectp. 1530
Installp. 1531
Brake Repairp. 1543
Wet Disc Brakep. 1543
Removep. 1546
Clean and Inspectp. 1552
Installp. 1553
Parking Brake Control Leverp. 1565
Generalp. 1565
Removep. 1566
Clean and Inspectp. 1567
Installp. 1568
Differential Repairp. 1571
Removep. 1571
Flangep. 1571
Differential Assemblyp. 1573
Bevel Pinionp. 1579
Disassemblep. 1584
Differential Assemblyp. 1584
Clean and Inspectp. 1587
Assemblep. 1587
Differential Assemblyp. 1587
Installp. 1592
Determine Bevel Pinion Shim Thicknessp. 1592
Bevel Pinionp. 1594
Differential Assemblyp. 1598
Gear Set, Tooth Contact Pattern Checkp. 1606
Flangep. 1608
Drive Axle Installationp. 1609
Special Toolsp. 1614
Torque Specificationsp. 1616
tablesp. 1511
Table 1. Bevel Gear and Bevel Pinion Tooth Contact Adjustmentp. 1606
Table 2. Correct Tooth Contactp. 1606
Table 3. Incorrect Tooth Contactp. 1607
27p. 1621
tocp. 1621
Brake Systemp. 1621
Safety Precautions Maintenance and Repairp. 1622
Generalp. 1625
Dry Brake Systemp. 1625
Wet Brake Systemp. 1625
Service Brakes Repair (Dry Brake)p. 1626
Remove and Disassemblep. 1626
Cleanp. 1633
Inspectp. 1634
Assemble and Installp. 1634
Adjustp. 1642
Inching Overlap Adjustmentp. 1642
Parking Brake Repairp. 1643
Remove and Disassemblep. 1643
Assemble and Installp. 1643
Adjustp. 1646
Master Cylinder Repairp. 1646
Remove (Dry Brake)p. 1646
Disassemble (Dry Brake)p. 1646
Clean and Inspect (Dry Brake)p. 1649
Assemble (Dry Brake)p. 1649
Bench Bleed Master Cylinder (Dry Brake)p. 1649
Install and Adjust (Dry Brake)p. 1649
Remove (Wet Brake)p. 1650
Disassemble (Wet Brake)p. 1651
Clean and Inspect (Wet Brake)p. 1653
Assemble (Wet Brake)p. 1653
Install and Adjust (Wet Brake)p. 1653
Service Brakes Adjustment (Dry Brake)p. 1654
Brake System Air Removalp. 1655
Using Pressure Bleed Systemp. 1655
Using Brake Pedal Pressurep. 1655
Brake Pedal Adjustmentp. 1656
Free Pedal Adjustmentp. 1657
Torque Specificationsp. 1658
28p. 1661
tocp. 1661
Steering Axlep. 1661
Safety Precautions Maintenance and Repairp. 1662
Generalp. 1665
Steering Axle Assembly Repairp. 1667
Removep. 1667
Disassemblep. 1668
Cleanp. 1668
Inspectp. 1668
Assemblep. 1676
Installp. 1681
Spindles, Bearings, and Tie Rods Repairp. 1682
Spindles and Bearingsp. 1682
S2.0-3.5FT (S40-70FT, S55FTS) (F187), S4.0, 4.5, 5.5FT, S5.5FTS,p. 1682
Removep. 1682
Disassemblep. 1684
Cleanp. 1684
Inspectp. 1684
Assemblep. 1684
Installp. 1686
Spindles and Bearingsp. 1689
S30FT, S35FT, S40FTS (E010), H1.6FT, H1.8FT, H2.0FTS (H30FT, H35p. 1689
Remove and Disassemblep. 1689
Assemble and Installp. 1689
Tie Rodsp. 1690
S2.0-3.5FT (S40-70FT, S55FTS) (F187), and S4.0, 4.5, 5.5FT, S5.5p. 1690
Removep. 1690
Installp. 1691
Tie Rodsp. 1692
S30FT, S35FT, S40FTS (E010), H1.6FT, H1.8FT, H2.0FTS (H30FT, H35p. 1692
Removep. 1692
Installp. 1695
Steering Cylinder Repairp. 1696
Remove and Disassemblep. 1696
Clean and Inspectp. 1696
Assemble and Installp. 1696
Torque Specificationsp. 1697
29p. 1701
tocp. 1701
Hydraulic Gear Pumpp. 1701
Safety Precautions Maintenance and Repairp. 1702
Generalp. 1705
Hydraulic Gear Pump Assemblyp. 1705
Variable Displacement Pump Assemblyp. 1705
Single Gear Pump Assembly Repairp. 1706
Removep. 1706
Disassemblep. 1712
Cleanp. 1713
Inspectp. 1713
Assemblep. 1713
Installp. 1713
Tandem Gear Pump Assemblyp. 1718
Removep. 1718
Disassemblep. 1718
Cleanp. 1720
Inspectp. 1720
Assemblep. 1720
Installp. 1722
Gear Pump Specificationsp. 1723
Variable Displacement Pump Repairp. 1728
Removep. 1728
Disassemblep. 1735
Cleanp. 1738
Inspectp. 1738
Assemblep. 1738
Installp. 1738
Variable Displacement Pump Checks and Adjustmentsp. 1741
Margin Pressure Checkp. 1741
Flow Compensator Adjustmentp. 1742
Pressure Compensator Adjustmentp. 1742
Variable Displacement Pump Specificationsp. 1744
Torque Specificationsp. 1745
Hydraulic Gear Pumpp. 1745
Variable Displacement Pumpp. 1746
tablesp. 1701
Table 1. Hydraulic Gear Pumps for Lift Truck Models S30FT, S35FTp. 1723
Table 2. Hydraulic Gear Pumps for Lift Truck Models S2.0-3.5FT (p. 1724
Table 3. Hydraulic Gear Pumps for Lift Truck Model S4.0, 4.5, 5.p. 1725
Table 4. Hydraulic Gear Pumps for Lift Truck Models H4.0FT5/FT6;p. 1725
Table 5. Hydraulic Gear Pumps for Lift Truck Models S6.0FT, S7.0p. 1726
Table 6. Hydraulic Gear Pumps for Lift Truck Model H8.0FT, H8.0Fp. 1727
Table 7. Margin Pressurep. 1742
Table 8. Pressure Compensator Adjustmentp. 1743
Table 9. Variable Displacement Pump for Lift Truck Models H2.0-3p. 1744
Table 10. Variable Displacement Pump for Lift Truck Models H4.0Fp. 1744
30p. 1749
tocp. 1749
Main Control Valvep. 1749
Safety Precautions Maintenance and Repairp. 1750
Generalp. 1755
Electro-Hydraulic Main Control Valvep. 1756
Descriptionp. 1756
Removep. 1762
Electro-Hydraulic Control Valve Sectionsp. 1768
Generalp. 1768
Outlet Control Valve Sectionp. 1768
Removep. 1768
Disassemblep. 1768
Cleanp. 1770
Inspectp. 1770
Assemblep. 1770
Installp. 1771
Auxiliary Control Valve Sectionsp. 1771
Removep. 1771
Disassemblep. 1775
Cleanp. 1777
Inspectp. 1777
Assemblep. 1777
Installp. 1778
Tilt Control Valve Sectionp. 1779
Removep. 1779
Disassemblep. 1779
Cleanp. 1784
Inspectp. 1784
Assemblep. 1784
Installp. 1785
Lift/Lower Control Valve Sectionp. 1785
Removep. 1785
Disassemblep. 1785
Cleanp. 1792
Inspectp. 1792
Assemblep. 1793
Installp. 1794
Mid-Inlet Sectionp. 1794
Removep. 1794
Cleanp. 1795
Inspectp. 1795
Installp. 1795
Installp. 1795
Electro Hydraulic Poppet Valve (EHPV) Pilot Pin Adjustmentp. 1799
Lift Pilot Pinp. 1799
Lower Pilot Pinp. 1801
Abnormal/Erroneous EHPV Adjustmentp. 1803
Manual Main Control Valvep. 1803
Descriptionp. 1803
Removep. 1807
OPS Solenoid Assemblyp. 1814
Generalp. 1814
Removep. 1814
Clean and Inspectp. 1816
Installp. 1816
Manual Control Valve Sectionsp. 1817
Generalp. 1817
Outlet Control Valve Sectionp. 1817
Removep. 1817
Disassemblep. 1817
Cleanp. 1820
Inspectp. 1820
Assemblep. 1820
Installp. 1821
Auxiliary Control Valve Sectionsp. 1821
Removep. 1821
Disassemblep. 1821
Cleanp. 1824
Inspectp. 1824
Assemblep. 1824
Installp. 1824
Lift/Tilt Control Valve Sectionp. 1825
Removep. 1825
Disassemblep. 1825
Cleanp. 1829
Inspectp. 1829
Assemblep. 1831
Installp. 1832
Mid-Inlet Sectionp. 1832
Removep. 1832
Cleanp. 1833
Inspectp. 1833
Installp. 1833
Installp. 1833
Pressure Relief Valve Check and Adjustmentp. 1839
Primary Relief Valvep. 1839
Secondary Relief Valvep. 1840
Steering Control Unit Repairp. 1845
Steering Control Unit, Removep. 1845
Steering Control Unit, Disassemblep. 1848
Steering Control Unit, Cleanp. 1848
Steering Control Unit, Inspectp. 1848
Steering Control Unit, Assemblep. 1848
Relief Valve, Disassemblep. 1850
Relief Valve, Cleanp. 1850
Relief Valve, Inspectp. 1851
Relief Valve, Assemblep. 1851
Steering Control Unit, Installp. 1851
tablesp. 1749
Table 1. Relief Valve Settingsp. 1841
Table 2. Steering Relief Pressuresp. 1852
31p. 1855
tocp. 1855
Cylinder Repairp. 1855
Safety Precautions Maintenance and Repairp. 1856
Generalp. 1859
Descriptionp. 1859
Safety Procedures When Working Near Mastp. 1860
Tilt Cylinder Repairp. 1862
Removep. 1862
Disassemblep. 1863
Inspectp. 1863
Cleanp. 1863
Assemblep. 1866
Installp. 1867
Tilt Cylinders, Adjustp. 1868
Tilt Cylinder Leak Checkp. 1870
Torque Specificationsp. 1871
Piston Rod Nutp. 1871
Glandp. 1871
Tilt Cylinder Mounting Capscrewp. 1871
Tilt Cylinder Rod End Nutp. 1871
Lift Cylinder Repairp. 1872
Main Lift Cylindersp. 1872
Removep. 1872
Disassemblep. 1873
Cleanp. 1874
Inspectp. 1874
Assemblep. 1874
Installp. 1875
System Air Bleed Proceduresp. 1876
Two-Stage FFL Left Side Main Lift Cylinderp. 1877
Disassemblep. 1877
Cleanp. 1877
Inspectp. 1877
Assemblep. 1877
Installp. 1879
Free-Lift Cylinderp. 1879
Removep. 1879
Disassemblep. 1882
Cleanp. 1882
Inspectp. 1882
Assemblep. 1882
Installp. 1883
Torque Specificationsp. 1884
Lift Cylinders Leak Checkp. 1885
Fork Positioner Cylinder Repairp. 1885
Removep. 1885
Disassemblep. 1885
Cleanp. 1888
Inspectp. 1888
Assemblep. 1889
Installp. 1889
Fork Positioner Cylinder Adjustmentp. 1889
Torque Specificationsp. 1889
Seal Kit Installationp. 1890
External Installation (Seal and Back-Up Ring)p. 1890
Internal Installation (Piston Rod Assembly)p. 1890
tablesp. 1855
Table 1. Movement Rates (Maximum) for Tilt Cylindersp. 1870
32p. 1895
tocp. 1895
Mast Repairsp. 1895
Safety Precautions Maintenance and Repairp. 1896
Generalp. 1899
Safety Procedures When Working Near Mastp. 1899
Fork Replacementp. 1901
Removep. 1901
Installp. 1903
Checksp. 1903
Carriages Repairp. 1904
Standard Carriagep. 1904
Removep. 1904
Repairp. 1904
Installp. 1905
Integral Sideshift Carriagep. 1905
Removep. 1905
Clean and Inspectp. 1908
Repairp. 1908
Installp. 1909
Fork Positionerp. 1909
Removep. 1910
Clean and Inspectp. 1912
Disassemble and Assemblep. 1912
Installp. 1913
Fork Positioner Hydraulic Hose Adjustmentp. 1913
Disconnecting Attachment Hydraulic Quick Disconnect Hosesp. 1915
Connecting Attachment Hydraulic Quick Disconnect Hosesp. 1915
Mast Repairp. 1916
Mast, Removep. 1916
Two-Stage LFL and Two-Stage FFL Mastsp. 1918
Disassemblep. 1918
Clean and Inspectp. 1928
Three-Stage FFL Mastp. 1929
Disassemblep. 1929
Clean and Inspectp. 1931
Two-Stage LFL and Two-Stage FFL Mastp. 1935
Assemblep. 1935
Three-Stage FFL Mastp. 1936
Assemblep. 1936
Four-Stage FFL Mast – Manufactured Before July, 2009p. 1937
Disassemblep. 1937
Clean and Inspectp. 1943
Assemblep. 1944
Four-Stage FFL Mast – Manufactured After July, 2009p. 1945
Disassemblep. 1945
Clean and Inspectp. 1952
Assemblep. 1953
Mast, Installp. 1955
Header Hose Arrangementp. 1958
Two-Stage LFLp. 1958
Two-Stage FFLp. 1965
Three-Stage FFLp. 1980
Standardp. 1980
Four-Stage FFL Mast – Manufactured Before July, 2009p. 1997
Four-Stage FFL Mast – Manufactured After July, 2009p. 2005
Adjustmentp. 2009
Lift Chains Adjustmentp. 2013
Carriage Adjustmentsp. 2015
Mast Adjustmentsp. 2016
Load Roller Adjustmentp. 2016
Mast Side Kicking Adjustmentp. 2018
tablesp. 1895
Table 1. Fork Tip Alignmentp. 1903
Table 2. Pneumatic Tire Trucksp. 1961
Table 3. Cushion Tire Trucksp. 1961
Table 4. Standard Two-Stage Hose Dimensionsp. 1964
Table 5. Pneumatic Tire Trucksp. 1969
Table 6. Cushion Tire Trucksp. 1969
Table 7. Pneumatic Tire Trucksp. 1989
Table 8. Cushion Tire Trucksp. 1989
Table 9. Standard Three-Stage Hose Dimensionsp. 1992
Table 10. Standard Four-Stage Hose Dimensionsp. 1998
Table 11. Standard Four-Stage Hose Dimensionsp. 2006
Table 12. Hook-Type Carriage Chain Adjustmentp. 2014
Table 13. Pin-Type Carriage Chain Adjustmentp. 2014
33p. 2023
tocp. 2023
Wire Harness Repairp. 2023
Safety Precautions Maintenance and Repairp. 2024
Generalp. 2029
Deutsch Crimping Toolp. 2029
How to Strip a Wire for Use With Deutsch Crimping Toolp. 2029
How to Crimp With the Deutsch Crimping Toolp. 2030
Calibration Test for the Deutsch Crimping Toolp. 2032
Deutsch Connectorsp. 2033
DT, DTM, and DTP Series Connectorsp. 2033
Connector Receptacle Replacementp. 2042
Connector Plug Replacementp. 2050
Connector Receptacle Pin Replacementp. 2058
Connector Plug Socket Replacementp. 2067
HD Series Connectorsp. 2076
Connector Receptacle Replacementp. 2078
Connector Plug Replacementp. 2082
Connector Receptacle Pin Replacementp. 2086
Connector Plug Socket Replacementp. 2091
Sealing Plugsp. 2096
Metri-Pack Connectorsp. 2098
Remove and Installp. 2098
Micro-Pack Connectorsp. 2100
Weather-Pack Connectorsp. 2101
Weather-Pack Terminal Repairp. 2101
AMPSEAL Crimping Toolsp. 2102
AMP Hand Crimping Tool With Certi-Crimpp. 2102
Descriptionp. 2102
Stripping Wire for Use with AMP Hand Crimping Toolp. 2103
Insulation Crimp Adjustmentp. 2104
Maintenance and Inspection for AMP Hand Crimping Toolp. 2104
AMP Hand Crimping Toolp. 2104
Crimp Height Inspectionp. 2104
How to use AMP Hand Crimping Toolp. 2105
AMP Pro-Crimper II Toolp. 2105
Descriptionp. 2105
Remove and Install Die Set and Locator Assemblyp. 2106
Stripping Wire for Use With AMP PRO-CRIMPER II Toolp. 2107
Contact Support Adjustmentp. 2107
Crimp Height Adjustmentp. 2108
Maintenance and Inspection Proceduresp. 2108
PRO-CRIMPER II Toolp. 2108
Crimp Height Inspectionp. 2108
How to Use AMP PRO-CRIMPER II Toolp. 2109
AMPSEAL Connector Assembliesp. 2109
Description for Plug Connector Assemblyp. 2109
Seal Plugp. 2109
Contact Crimpingp. 2109
Contact Removalp. 2111
Contact Insertionp. 2113
Description for Plug Connector and Header Assemblyp. 2115
Voltage Readingp. 2118
Seal Plugp. 2118
Contact Crimpingp. 2118
Contact Removalp. 2121
Contact Insertionp. 2123
AMP Superseal 1.5 Crimping Toolsp. 2125
Mini Mic Receptacle and Tab Contactsp. 2125
Descriptionp. 2125
Crimping Conditions and Measurementsp. 2125
Insertion of Rubber Seal on Cablep. 2125
Correction or Replacement of Partsp. 2128
AMP Hand Application Toolp. 2132
Descriptionp. 2132
Maintenance and Inspectionp. 2132
Crimp Height Inspectionp. 2132
Crimp Height Adjustmentp. 2133
How to Use AMP Hand Application Toolp. 2133
AMP Pro-Crimper II Toolp. 2134
Descriptionp. 2134
Remove and Install Die Set and Locator Assemblyp. 2135
Adjustmentsp. 2136
Contact Supportp. 2136
Crimp Heightp. 2137
Inspections and Maintenancep. 2137
Crimp Height Inspectionp. 2137
Visual Inspectionp. 2138
Maintenancep. 2138
How to Use Pro-Crimper II Toolp. 2138
AMP Superseal 1.5 Connector Assembliesp. 2139
Descriptionp. 2139
Harness Assemblyp. 2139
Positioning of Anti-Backout Devicep. 2140
Removal of Contactsp. 2142
Repair and Maintenancep. 2146
Panel Mount Optionp. 2146
AMP Fastin-Faston Hand Toolsp. 2146
Description – AMP Double Action Hand Toolp. 2146
Maintenance and Inspection Proceduresp. 2146
Daily Maintenancep. 2146
Periodic Tool Inspectionp. 2146
Lubricationp. 2146
Visual Inspectionp. 2146
Crimp Height Inspectionp. 2148
Certi-Crimp Ratchet Inspectionp. 2149
How to Use AMP Double Action Hand Toolp. 2150
Description – AMP Extraction Toolp. 2150
Maintenance and Inspectionp. 2150
How to Use AMP Extraction Toolp. 2152
AMP Fastin-Faston Receptacles and Housingsp. 2153
Descriptionp. 2153
Wire Repairp. 2160
Wire Splicing Requirementsp. 2160
Deutsch Jiffy Splicep. 2161
Assemblep. 2161
Disassemblep. 2163
Del-City Crimp-Solder-Shrink Splicep. 2165
Twisted/Shielded Cable and Leads Repairp. 2166
Twisted/Shielded Cable Repairp. 2166
Twisted Leads Repairp. 2168
Special Toolsp. 2168
tablesp. 2023
Table 1. Wire Strip Length Specificationsp. 2030
Table 2. Wire Size (AWG)p. 2103
Table 3. Crimp Heightp. 2105
Table 4. Strip Length for PRO-CRIMPER II Toolp. 2107
Table 5. Crimp Measurementp. 2108
Table 6. Current Ratingp. 2109
Table 7. Crimp Conditionsp. 2118
Table 8. Wire Strip Lengthsp. 2132
Table 9. Wire Strip Lengthsp. 2133
Table 10. Crimp Height – Dimensionp. 2137
Table 11. Wire Size and Crimp Heightp. 2149
Table 12. Wire Strip Lengthp. 2150
Table 13. Wire Strip Length and Crimp Measurementsp. 2155
Table 14. Crimp Pull-Out Testp. 2159
Table 15. Wire Strip Length Specificationsp. 2160
Table 16. Wire Splice Sizep. 2165
34p. 2179
tocp. 2179
User Interfacep. 2179
Safety Precautions Maintenance and Repairp. 2180
Generalp. 2183
Descriptionp. 2183
Dash Display Menu Accessp. 2183
Menu Navigationp. 2184
Standard Displayp. 2184
Main Menup. 2185
Passwords Menup. 2185
Password Administrationp. 2186
Add Passwordp. 2186
Delete Passwordp. 2187
Edit Passwordp. 2188
Other Password Functionsp. 2189
Operator Passwords – Enable/Disablep. 2189
Password Time-Out Delayp. 2190
Passwords – Number Wrong to Disablep. 2191
Lockout Reset Passwordp. 2192
View Password Logp. 2192
View Versionsp. 2193
VSM Versionsp. 2193
Dash Display Versionsp. 2194
Engine Controller Versionp. 2195
Transmission (Xmsn) Controller Versionp. 2196
Truck Serial Numberp. 2197
Diagnosticsp. 2198
View Fault Logp. 2198
Set Travel and Brakingp. 2199
Speed Limitp. 2199
Acceleration Ratep. 2200
Auto-Deceleration Ratep. 2201
Set Power Reversal Ratep. 2202
Set Inching/Brake Overlapp. 2203
Setup Display Menup. 2204
Set Operator Languagep. 2204
Set Unitsp. 2205
Set Time Format (12/24 Hour)p. 2206
Set Daylight Saving Timep. 2207
Set Timep. 2209
Set Date Formatp. 2210
Set Datep. 2211
Setup Hydraulicsp. 2212
Return to Set Tilt Delay/On/Offp. 2212
Setup General Itemsp. 2213
Light Shutdown Time-Outp. 2213
Impact Sensor – Enable/Disablep. 2214
Impact Sensor – Soft Impact Settingsp. 2215
Impact Sensor – Hard Impact Settingsp. 2216
Adjust Impact Sensor Settingsp. 2217
Initial Adjustment of Soft and Hard Impact Settingsp. 2219
Readjustment of Soft and Hard Impact Settingsp. 2219
Impact Sensor – Impact Alarm/Shutdown Resetp. 2221
Impact Sensor – Alarm Time Duration and Deactivationp. 2222
Impact Sensor – View Impact Event Logp. 2223
Economy Mode Indicator (ECO-eLo)p. 2224
Operator Checklistp. 2225
Operator Checklist Off-On Modep. 2225
Edit Operator Checklistp. 2226
Set Operator Checklist Expirationp. 2227
View Checklist Logp. 2228
Clear Operator Checklist Logp. 2229
Clear Operator Checklist Faultp. 2230
Calibrationsp. 2231
Set Tilt Stop Pointp. 2231
Calibrate Loaded Weightp. 2232
tablesp. 2179
Table 1. Password Screenp. 2184
Table 2. Exit Options Menup. 2184
Table 3. Add Password Menup. 2186
Table 4. Delete Password Menup. 2187
Table 5. Edit Password Menup. 2188
Table 6. Operator Passwords Menup. 2189
Table 7. Password Time-Out Delay Menup. 2190
Table 8. Passwords – Number Wrong to Disable Menup. 2191
Table 9. View Password Log Menup. 2192
Table 10. View VSM Versions Menup. 2193
Table 11. View Dash Display Versions Menup. 2194
Table 12. View Engine Controller Versions Menup. 2195
Table 13. View Transmission Controller Versions Menup. 2196
Table 14. View Truck Serial Number Menup. 2197
Table 15. View Fault Logp. 2198
Table 16. Speed Limit Menup. 2199
Table 17. Acceleration Rate Menup. 2200
Table 18. Auto-Decel Menup. 2201
Table 19. Power Reversal Menup. 2202
Table 20. Inch/Brake Overlap Menup. 2203
Table 21. Set Language Menup. 2204
Table 22. Set Units Menup. 2205
Table 23. Set Time Format Menup. 2206
Table 24. Set Daylight Saving Time Menup. 2207
Table 25. Set Time Menup. 2209
Table 26. Set Date Format Menup. 2210
Table 27. Set Date Menup. 2211
Table 28. Tilt Delay Menup. 2212
Table 29. Light Time-Out Menup. 2213
Table 30. Impact Sensor Enable/Disablep. 2214
Table 31. Soft Impact Settings Menup. 2215
Table 32. Hard Impact Settings Menup. 2216
Table 33. Impact Sensor Default Settingsp. 2217
Table 34. Recommended Starting Values for Impact Sensor Settingsp. 2220
Table 35. Shutdown Reset Menup. 2221
Table 36. Alarm Duration Menup. 2222
Table 37. View Event Log Menup. 2223
Table 38. ECO-eLo Settings Menup. 2224
Table 39. Checklist Off-On Mode Menup. 2225
Table 40. Edit Checklist Menup. 2226
Table 41. Checklist Expiration Menup. 2227
Table 42. View Checklist Log Menup. 2228
Table 43. Clear Checklist Log Menup. 2229
Table 44. Clear Checklist Fault Menup. 2230
Table 45. Tilt Stop Point Menup. 2231
Table 46. Calibrate Loaded Weightp. 2232
35p. 2235
tocp. 2235
User Interfacep. 2235
Safety Precautions Maintenance and Repairp. 2236
Generalp. 2241
Descriptionp. 2241
Dash Display Menu Accessp. 2241
Menu Navigationp. 2242
Main Menup. 2243
Passwordsp. 2243
Adding Passwordsp. 2243
Hourmetersp. 2245
View Versionsp. 2246
VSM Versionsp. 2246
Dash Display Versionsp. 2247
Engine Controller Versionp. 2248
Transmission (Xmsn) Controller Versionp. 2249
Truck Serial Numberp. 2250
Truck Configurationp. 2251
Diagnosticsp. 2252
Clear Fault Logp. 2252
View Fault Logp. 2253
No-Run Data Displayp. 2254
Engine Accelerator and Throttle Data Displayp. 2255
Engine Speeds and Governor Data Displayp. 2256
Engine Fuel and Emissions Data Displayp. 2257
Engine General Data Displayp. 2259
XMSN/Brake Data Displayp. 2260
Hydraulic Data Displayp. 2262
General Truck Data Displayp. 2264
Set Travel and Brakingp. 2266
Speed Limitp. 2266
Acceleration Ratep. 2267
Auto-Deceleration Ratep. 2268
Set Power Reversal Ratep. 2269
Set Inching/Brake Overlapp. 2270
Setup Hydraulicsp. 2271
Lift Maximum Speedp. 2271
Lower Maximum Speedp. 2272
Tilt Maximum Speedp. 2273
Auxiliary Function One, Direction A, Maximum Speedp. 2275
Auxiliary Function One, Direction B, Maximum Speedp. 2276
Auxiliary Function Two, Direction A, Maximum Speedp. 2277
Auxiliary Function Two, Direction B, Maximum Speedp. 2278
Auxiliary Function Three, Direction A, Maximum Speedp. 2279
Auxiliary Function Three, Direction B, Maximum Speedp. 2280
Lift/Lower Ramp Ratep. 2281
Hydraulic Auxiliary Ramp Ratep. 2282
Return to Set Tilt Delay/On/Offp. 2283
Hydraulic Input Devicep. 2284
Auxiliary Solenoidp. 2285
Dual Functionp. 2286
Setup Displayp. 2287
Set Service Languagep. 2287
Setup General Itemsp. 2288
Motion Alarm Activation Typep. 2288
Light Shutdown Time-Outp. 2289
Restore Default Settingsp. 2290
Restore Engine Controller Default Calibrationp. 2291
Impact Sensor – Enable/Disablep. 2292
Impact Sensor – Soft Impact Settingsp. 2293
Impact Sensor – Hard Impact Settingsp. 2294
Adjust Impact Sensor Settingsp. 2295
Initial Adjustment of Soft and Hard Impact Settingsp. 2297
Readjustment of Soft and Hard Impact Settingsp. 2297
Impact Sensor – Impact Alarm/Shutdown Resetp. 2299
Impact Sensor – Alarm Time Duration and Deactivationp. 2300
Impact Sensor – View Impact Event Logp. 2301
Economy Mode Indicator (ECO-eLo)p. 2302
Diesel Particulate Filter (DPF) Displayp. 2303
General Descriptionp. 2303
Passive Regeneration Onlyp. 2303
Regeneration Level 0p. 2303
Auto/Active Regeneration Inhibitedp. 2304
Regeneration Level 1p. 2304
Auto/Active Regenerationp. 2304
Regeneration Level 1p. 2304
Parked Regeneration Requestp. 2304
Regeneration Level 2p. 2304
Warning Levelp. 2305
Regeneration Level 3p. 2305
Service Levelp. 2305
Regeneration Level 4p. 2305
Stop Levelp. 2306
Regeneration Level 5p. 2306
Operator Interfacep. 2306
Refer to Operator Manualp. 2306
CAN Communication Lostp. 2306
Calibrationsp. 2307
Calibrate Transmission Valvep. 2309
Set Tilt Stop Pointp. 2310
Calibrate Loaded Weightp. 2311
Calibrate Travel Speed Sensorp. 2312
Calibrate Mazda LP and Gas Accelerator Pedalp. 2313
tablesp. 2235
Table 1. Password Screenp. 2241
Table 2. Exit Menup. 2242
Table 3. Add Password Menup. 2244
Table 4. Hourmeters Menup. 2245
Table 5. View VSM Versions Menup. 2246
Table 6. View Dash Display Versions Menup. 2247
Table 7. View Engine Controller Versions Menup. 2248
Table 8. View Transmission Controller Versions Menup. 2249
Table 9. View Truck Serial Number Menup. 2250
Table 10. View Truck Configuration Menup. 2251
Table 11. Clear Fault Logp. 2252
Table 12. View Fault Logp. 2253
Table 13. No-Run Data Displayp. 2254
Table 14. Engine Accelerator and Throttle Data Displayp. 2255
Table 15. Engine Speeds and Governor Data Displayp. 2256
Table 16. Engine Fuel and Emissions Data Displayp. 2257
Table 17. Engine General Data Displayp. 2259
Table 18. XMSN Brake Data Displayp. 2260
Table 19. Hydraulic Data Displayp. 2262
Table 20. General Truck Data Displayp. 2264
Table 21. Speed Limit Menup. 2266
Table 22. Acceleration Rate Menup. 2267
Table 23. Auto-Decel Menup. 2268
Table 24. Power Reversal Menup. 2269
Table 25. Inch/Brake Overlap Menup. 2270
Table 26. Lift Speed Menup. 2271
Table 27. Lower Speed Menup. 2272
Table 28. Tilt Speed Menup. 2273
Table 29. Auxiliary Function Speed Menup. 2275
Table 30. Auxiliary Function Speed Menup. 2276
Table 31. Auxiliary Function Speed Menup. 2277
Table 32. Auxiliary Function Speed Menup. 2278
Table 33. Auxiliary Function Speed Menup. 2279
Table 34. Auxiliary Function Speed Menup. 2280
Table 35. Lift/Lower Ramp Rate Menup. 2281
Table 36. Hydraulic Auxiliary Ramp Rate Menup. 2282
Table 37. Tilt Delay Menup. 2283
Table 38. Hydraulic Input Device Menup. 2284
Table 39. Auxiliary Solenoid Menup. 2285
Table 40. Dual Function Menup. 2286
Table 41. Service Language Menup. 2287
Table 42. Alarm Type Menup. 2288
Table 43. Light Time-Out Menup. 2289
Table 44. Restore Defaults Menup. 2290
Table 45. Restore Settings Menup. 2291
Table 46. Impact Sensor Enable/Disablep. 2292
Table 47. Soft Impact Settings Menup. 2293
Table 48. Hard Impact Settings Menup. 2294
Table 49. Impact Sensor Default Settingsp. 2295
Table 50. Recommended Starting Values for Impact Sensor Settingsp. 2298
Table 51. Shutdown Reset Menup. 2299
Table 52. Alarm Duration Menup. 2300
Table 53. View Event Log Menup. 2301
Table 54. ECO-eLo Settings Menup. 2302
Table 55. Calibrate Electro-Hydraulic Valve Menup. 2308
Table 56. Calibrate Transmission Valve Menup. 2309
Table 57. Tilt Stop Point Menup. 2310
Table 58. Calibrate Loaded Weightp. 2311
Table 59. Travel Speed Menup. 2312
Table 60. Travel Speed Menup. 2313
36p. 2317
tocp. 2317
Electrical Systemp. 2317
Safety Precautions Maintenance and Repairp. 2318
Generalp. 2327
Display Switch Clusterp. 2329
Removep. 2329
Installp. 2329
Direction Control and Turn Signal Leversp. 2332
Removep. 2332
Installp. 2333
Key Switchp. 2333
Removep. 2333
Installp. 2334
Display Switch Cluster Panel Bezel and Overlayp. 2334
Removep. 2334
Installp. 2334
Steering Column Repairp. 2334
Removep. 2334
Disassemblep. 2335
Assemblep. 2335
Installp. 2335
Sensors and Switchesp. 2337
Generalp. 2337
Dash and Kick Panel, Remove and Installp. 2337
Removep. 2337
Installp. 2337
Accelerator Pedal Position Sensorp. 2339
Removep. 2339
Installp. 2340
Brake Fluid Level Switchp. 2342
Removep. 2342
Installp. 2344
Service Brake Pedal Position Sensorp. 2345
Removep. 2345
Installp. 2345
Parking Brake Sensorp. 2348
Removep. 2348
Installp. 2349
Service Brake Pressure Sensorp. 2350
Removep. 2350
Installp. 2351
Accumulator Pressure Switch For Lift Truck Models H8.0FT, H8.0FTp. 2352
Removep. 2352
Installp. 2352
MONOTROL® Sensor Microswitchp. 2353
Removep. 2353
Installp. 2355
Low Coolant Level Sensorp. 2356
Removep. 2356
Installp. 2357
Fuel Level Sensor, Gas and Diesel Engines Onlyp. 2360
Removep. 2360
Installp. 2360
Armrest Switchp. 2361
Removep. 2361
Installp. 2361
Seat Sensor (Operator Presence System)p. 2361
Non-Suspension and Semi-Suspension Seats; All Lift truck Modelsp. 2361
Removep. 2361
Installp. 2361
Non-Suspension Seats; Lift Truck Models H6.0FT, H7.0FT (H135FT,p. 2361
Removep. 2361
Installp. 2361
Full Suspension Seats; All Lift Truck Modelsp. 2364
Removep. 2364
Installp. 2364
Hood Shut Off Switchp. 2364
Removep. 2364
Installp. 2366
Remote Key Switchp. 2367
Removep. 2367
Installp. 2367
Hydraulic Filter Pressure Switchp. 2368
Removep. 2368
Installp. 2368
Transmission Speed Sensorp. 2370
Removep. 2370
Installp. 2373
Transmission Pressure Sensorsp. 2373
Removep. 2373
Installp. 2374
Transmission Temperature Sensorp. 2375
Removep. 2375
Installp. 2377
Engine Speed Sensorp. 2378
Removep. 2378
Installp. 2378
Intermediate Speed Sensorp. 2378
Removep. 2378
Installp. 2379
Return to Set Tilt (Tilt Angle) Sensorp. 2379
Lift Truck Models S30FT, S35FT, S40FTS (E010); H1.6FT, H1.8FT, Hp. 2379
Removep. 2379
Installp. 2379
Lift Truck Models S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024, Fp. 2380
Removep. 2380
Installp. 2381
Rear Horn Button Switchp. 2382
Removep. 2382
Installp. 2382
Impact Sensorp. 2383
All Lift Truck Models Except H6.0FT, H7.0FT (H135FT, H155FT) (H0p. 2383
Removep. 2383
Installp. 2383
Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006, Kp. 2385
Removep. 2385
Installp. 2386
Load Weight Sensorp. 2386
Removep. 2386
Installp. 2386
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equippep. 2388
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equippep. 2388
Crankshaft Position (CKP) Sensorp. 2388
Camshaft Position (CMP) Sensorp. 2388
Oil Pressure Sensorp. 2388
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT)p. 2388
Engine Coolant Temperature (ECT) Sensorp. 2388
Air Flow Restriction Switchp. 2388
Remove for GM 2.4L Gas and LPG Trucksp. 2389
Install for GM 2.4L Gas and LPG Trucksp. 2389
Oxygen Sensorp. 2389
Removep. 2389
Installp. 2392
Engine and Fuel Switches, GM 2.4L LPG Trucks Onlyp. 2393
Low LPG Pressure Switchp. 2393
Engine and Fuel Sensors and Switches, Yanmar Diesel Trucksp. 2393
Air Filter Restriction Switchp. 2393
Removep. 2393
Installp. 2393
Oil Pressure Sensorp. 2393
Removep. 2393
Installp. 2393
Engine Speed Sensorp. 2393
Removep. 2393
Installp. 2393
Engine Coolant Temperature (ECT) Sensorp. 2394
Removep. 2394
Installp. 2394
Throttle Position Sensor (TPS)p. 2396
Removep. 2396
Installp. 2396
Fuel/Water Separator Sensorp. 2396
Removep. 2396
Installp. 2397
Glow Plug Relayp. 2397
Removep. 2397
Installp. 2399
Engine and Fuel Sensors and Switches, Cummins Diesel Enginesp. 2399
Air Filter Restriction Switchp. 2399
Removep. 2399
Installp. 2399
Engine Oil Pressure Sensorp. 2403
Removep. 2403
Installp. 2403
Engine Speed Sensorp. 2403
Removep. 2403
Installp. 2403
Engine Coolant Temperature (ECT) Sensorp. 2404
Removep. 2404
Installp. 2404
Throttle Position Sensor (TPS) (Cummins 4.5L Only)p. 2405
Removep. 2405
Installp. 2405
Fuel/Water Separator Sensorp. 2406
Removep. 2406
Installp. 2406
Engine and Fuel Sensors and Switches, Kubota 3.8L Diesel Enginep. 2407
Intake Air Temperature Sensorp. 2408
Removep. 2408
Installp. 2408
Intake Air Pressure Sensorp. 2408
Removep. 2408
Installp. 2408
Air Inlet Heaterp. 2408
Removep. 2408
Installp. 2409
Engine Oil Pressure Sensorp. 2409
Removep. 2409
Installp. 2409
Engine Coolant Temperature (ECT) Sensorp. 2409
Removep. 2409
Installp. 2409
Crankshaft Position Sensorp. 2410
Removep. 2410
Installp. 2410
Adjust Shim Procedurep. 2410
Camshaft Position Sensorp. 2412
Removep. 2412
Installp. 2412
Air Flow Restriction Sensorp. 2412
Removep. 2412
Installp. 2412
Fuel/Water Separatorp. 2413
Removep. 2413
Installp. 2413
Engine and Fuel Sensors and Switches, Kubota 3.8L Diesel Enginep. 2414
Intake Air Temperature Sensorp. 2415
Removep. 2415
Installp. 2415
Boost Sensorp. 2415
Removep. 2415
Installp. 2415
Throttle Valve Assembly and Air Intake Heaterp. 2416
Removep. 2416
Installp. 2417
Engine Coolant Temperature (ECT) Sensorp. 2417
Removep. 2417
Installp. 2417
Engine Oil Pressure Sensorp. 2417
Removep. 2417
Installp. 2417
Crankshaft Position Sensorp. 2418
Removep. 2418
Installp. 2418
Adjust Shim Procedurep. 2418
Camshaft Position Sensorp. 2419
Removep. 2419
Installp. 2419
Differential Pressure Sensorp. 2421
Removep. 2421
Installp. 2421
Mass Air Flow Sensorp. 2421
Removep. 2421
Installp. 2421
Fuel/Water Separatorp. 2422
Removep. 2422
Installp. 2422
Engine and Fuel Sensors and Switches, Kubota 3.6L Diesel Enginep. 2423
Engine Coolant Temperature (ECT) Sensorp. 2423
Removep. 2423
Installp. 2423
Engine Oil Pressure Sensorp. 2424
Removep. 2424
Installp. 2424
Engine Speed Sensorp. 2424
Removep. 2424
Installp. 2424
Fuel Shut Off Solenoidp. 2424
Removep. 2424
Installp. 2424
Vehicle System Manager (VSM)p. 2425
Generalp. 2425
VSM Replacementp. 2425
Removep. 2425
Installp. 2427
Programming a New VSM and/or Display Switch Clusterp. 2427
Generalp. 2427
PC Service Tool Softwarep. 2428
Data Transferringp. 2428
New VSMp. 2428
New (Blank) Display Switch Clusterp. 2428
Used (Non-Blank) Display Switch Clusterp. 2428
Power Distribution Module (PDM) and Component Partsp. 2430
Removep. 2430
PDM as a Unitp. 2430
Installp. 2432
PDM as a Unitp. 2432
Remove and Installp. 2433
PDM Component Partsp. 2433
Transmission Control Unitp. 2434
Removep. 2434
Installp. 2434
Batteryp. 2434
Removep. 2434
Installp. 2435
Lightsp. 2436
Work Lights (Front and Rear)p. 2436
Removep. 2436
Installp. 2436
Strobe Lightp. 2437
Removep. 2437
Installp. 2437
LED Tail, Backup, and Brake Lightsp. 2438
Removep. 2438
Installp. 2438
Front Marker/Turn Signal Lightsp. 2440
Replacing Whole Front Marker/Turn Signal Light Assemblyp. 2440
Removep. 2440
Installp. 2440
Replacing Just the Front Marker/Turn Signal Light LED Light Lensp. 2440
Removep. 2440
Installp. 2440
Diesel Particulate Filter (DPF) Displayp. 2441
Removep. 2441
Clean and Inspectp. 2441
Installp. 2441
Electronic-Hydraulic Controls – Generation 1p. 2442
E-Hydraulic Controls – Testp. 2442
Mini-Leversp. 2442
Full Stroke Testp. 2442
Function Returns to Neutral Testp. 2442
Push Button Switchp. 2442
Generalp. 2443
Mini-Lever Replacementp. 2443
Removep. 2443
Clean and Inspectp. 2444
Installp. 2444
Push Button Switch Replacementp. 2445
Removep. 2445
Installp. 2446
Mini-Lever Module (MLM)p. 2447
Removep. 2447
Installp. 2447
Joystickp. 2448
Remove and Disassemblep. 2448
Inspectp. 2448
Assemble and Installp. 2448
Electronic-Hydraulic Controls – Generation 2p. 2448
Generalp. 2448
Mini-levers, Remove and Installp. 2449
Armrest Assemblyp. 2450
Removep. 2450
Installp. 2452
Horn Buttonp. 2452
Removep. 2452
Installp. 2452
Direction Control Switchp. 2453
Removep. 2453
Installp. 2453
Momentary Switches and Function Selection Buttonp. 2453
Removep. 2454
Installp. 2454
Joystickp. 2456
Remove and Disassemblep. 2456
Inspectp. 2456
Assemble and Installp. 2456
Joystick Armrest Slider Assemblyp. 2456
Removep. 2456
Installp. 2456
tablesp. 2317
Table 1. Adjustment Shim Combinationsp. 2411
Table 2. Adjustment Shim Combinationsp. 2420
Table 3. VSM and Display Switch Cluster Replacementp. 2429
37p. 2461
tocp. 2461
Metric and Inch (SAE) Fastenersp. 2461
Safety Precautions Maintenance and Repairp. 2462
Generalp. 2465
Threaded Fastenersp. 2465
Nomenclature, Threadsp. 2465
Strength Identificationp. 2466
Cotter (Split) Pinsp. 2466
Fastener Torque Tablesp. 2471
Conversion Tablep. 2473
tablesp. 2461
Table 1. Bolts and Screwsp. 2467
Table 2. Studs and Nutsp. 2468
Table 3. Torque Nutsp. 2469
Table 4. Torque Nuts With Nylon Insertp. 2470
Table 5. Torque Values for Metric Fasteners*p. 2471
Table 6. Torque Values for Inch Fasteners*p. 2472
Table 7. Conversion Table for Metric and English Unitsp. 2473
Table 8. Cotter Pin Dimensional Datap. 2474
Table 9. Cotter Pin Dimensional Datap. 2475
Table 10. Cotter Pin Dimensional Datap. 2476
Table 11. Cotter Pin Dimensional Datap. 2478
38p. 2483
tocp. 2483
Calibration Proceduresp. 2483
Safety Precautions Maintenance and Repairp. 2484
Descriptionp. 2489
Proc_Cal_001: Service Password Entryp. 2492
When to Performp. 2492
Why Performp. 2492
How to Performp. 2492
Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleedp. 2494
When to Performp. 2494
Calibration Orderp. 2494
Why Performp. 2494
How to Performp. 2494
Proc_Cal_003: Save and Exitp. 2496
When to Performp. 2496
Why Performp. 2496
How to Performp. 2496
Proc_Cal_004: Lift Valve Output Thresholdp. 2498
When to Performp. 2498
Calibration Orderp. 2498
Why Performp. 2498
How to Performp. 2498
Proc_Cal_005: Lower Valve Output Thresholdp. 2502
When to Performp. 2502
Calibration Orderp. 2502
Why Performp. 2502
How to Performp. 2502
Proc_Cal_006: Tilt Back Valve Output Thresholdp. 2506
When to Performp. 2506
Calibration Orderp. 2506
Why Performp. 2506
How to Performp. 2506
Proc_Cal_007: Tilt Forward Valve Output Thresholdp. 2510
When to Performp. 2510
Calibration Orderp. 2510
Why Performp. 2510
How to Performp. 2510
Proc_Cal_008: Aux 1 Dir A Valve Output Thresholdp. 2514
When to Performp. 2514
Calibration Orderp. 2514
Why Performp. 2514
How to Performp. 2514
Proc_Cal_009: Aux 1 Dir B Valve Output Thresholdp. 2517
When to Performp. 2517
Calibration Orderp. 2517
Why Performp. 2517
How to Performp. 2517
Proc_Cal_010: Aux 2 Dir A Valve Output Thresholdp. 2520
When to Performp. 2520
Calibration Orderp. 2520
Why Performp. 2520
How to Performp. 2520
Proc_Cal_011: Aux 2 Dir B Valve Output Thresholdp. 2523
When to Performp. 2523
Calibration Orderp. 2523
Why Performp. 2523
How to Performp. 2523
Proc_Cal_012: Aux 3 Dir A Valve Output Thresholdp. 2526
When to Performp. 2526
Calibration Orderp. 2526
Why Performp. 2526
How to Performp. 2526
Proc_Cal_013: Aux 3 Dir B Valve Output Thresholdp. 2529
When to Performp. 2529
Calibration Orderp. 2529
Why Performp. 2529
How to Performp. 2529
Proc_Cal_014: Load Weight Zero Pointp. 2532
When to Performp. 2532
Calibration Orderp. 2532
Why Performp. 2532
How to Performp. 2532
Proc_Cal_015: Loaded Weight Calibrationp. 2534
When to Performp. 2534
Calibration Orderp. 2534
Why Performp. 2534
How to Performp. 2534
Proc_Cal_016: Transmission Valve Calibrationp. 2537
Applicable System/Optionp. 2537
When to Performp. 2537
Calibration Orderp. 2537
Why Performp. 2537
How to Performp. 2537
Proc_Cal_016A: Transmission Valve Calibration-Electronic Extendep. 2539
Applicable System/Optionp. 2539
When to Performp. 2539
Calibration Orderp. 2539
Why Performp. 2539
How to Performp. 2539
Proc_Cal_016B: Trans. Valve Calibration-Electronic and Electronip. 2542
Applicable System/Optionp. 2542
When to Performp. 2542
Calibration Orderp. 2542
Why Performp. 2542
How to Performp. 2542
Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustmentp. 2545
Required Toolsp. 2545
When to Performp. 2545
Calibration Orderp. 2545
Why Performp. 2545
How to Performp. 2545
Proc_Cal_025: Hydraulic Valve Pressure Gage Installationp. 2547
When to Performp. 2547
Why Performp. 2547
How to Performp. 2547
Proc_Cal_026: Travel Speed Calibrationp. 2548
When to Performp. 2548
Calibration Orderp. 2548
Why Performp. 2548
How to Performp. 2548
tablesp. 2483
Table 1. Calibration Proceduresp. 2489
Table 2. How to Read Calibration Procedurep. 2491
Table 3. Proc_Cal_001: Service Password Entryp. 2493
Table 4. Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Ap. 2494
Table 5. Proc_Cal_003: Save and Exitp. 2497
Table 6. Proc_Cal_004: Lift Valve Output Thresholdp. 2499
Table 7. Proc_Cal_005: Lower Valve Output Thresholdp. 2503
Table 8. Proc_Cal_006: Tilt Back Valve Output Thresholdp. 2507
Table 9. Proc_Cal_007: Tilt Forward Valve Output Thresholdp. 2511
Table 10. Proc_Cal_008: Aux 1 Dir A Valve Output Thresholdp. 2514
Table 11. Proc_Cal_009: Aux 1 Dir B Valve Output Thresholdp. 2517
Table 12. Proc_Cal_010: Aux 2 Dir A Valve Output Thresholdp. 2520
Table 13. Proc_Cal_011: Aux 2 Dir B Valve Output Thresholdp. 2523
Table 14. Proc_Cal_012: Aux 3 Dir A Valve Output Thresholdp. 2526
Table 15. Proc_Cal_013: Aux 3 Dir B Valve Output Thresholdp. 2529
Table 16. Proc_Cal_014: Load Weight Zero Pointp. 2532
Table 17. Proc_Cal_015: Loaded Weight Calibrationp. 2534
Table 18. Proc_Cal_016: Transmission Valve Calibrationp. 2538
Table 19. Proc_Cal_016A: Transmission Valve Calibrationp. 2540
Table 20. Proc_Cal_016B: Transmission Valve Calibrationp. 2543
Table 21. Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjusp. 2546
Table 22. Proc_Cal_025: Hydraulic Valve Pressure Gage Installatip. 2547
Table 23. Proc_Cal_026: Travel Speed Calibrationp. 2549
39p. 2553
tocp. 2553
Periodic Maintenancep. 2553
Safety Precautions Maintenance and Repairp. 2554
Generalp. 2559
Serial Number Datap. 2559
How to Move Disabled Lift Truckp. 2559
How to Tow Lift Truckp. 2559
How to Put Lift Truck on Blocksp. 2560
How to Raise Drive Tiresp. 2560
How to Raise Steering Tiresp. 2561
How to Clean a Lift Truckp. 2562
Maintenance Schedulep. 2562
Maintenance Procedures Every 8 Hours or Dailyp. 2586
How to Make Checks With Engine Stoppedp. 2586
Tires and Wheelsp. 2587
Safety Labelsp. 2587
Mast, Carriage, Lift Chains, Header Hoses, Attachmentp. 2587
Operator Restraint Systemp. 2588
Automatic Locking Retractor (ALR)p. 2588
Emergency Locking Retractor (ELR)p. 2588
Adjust Seat – Full Suspensionp. 2589
Adjust Seat – Internal Suspensionp. 2590
Hood and Seat Latchesp. 2592
Engine Compartmentp. 2592
Paper Applicationp. 2592
Fuel, Oil, and Coolant Leaks, Checkp. 2593
Hydraulic Hosesp. 2593
Coolant Hosesp. 2593
Steering Column Gas Cylinderp. 2594
Transmissionp. 2594
Hydraulic System Oilp. 2594
Engine Oilp. 2595
Air Filterp. 2601
Forksp. 2601
Removep. 2601
Inspectp. 2602
Installp. 2604
Adjustp. 2604
How to Make Checks With Engine Runningp. 2604
Indicator Lights, Horn, Fuses, and Relaysp. 2606
Service Brakesp. 2607
Brake Fluid Levelp. 2607
Operation, Checkp. 2607
Parking Brakep. 2607
Engine Oil Pressurep. 2608
Cooling Systemp. 2608
Steering Systemp. 2609
Control Levers and Pedalsp. 2609
Lift System, Operatep. 2609
First Service After First 100 Hours of Operationp. 2610
Mazda and GM Engine Oil and Oil Filterp. 2610
Yanmar Engine Oil and Oil Filterp. 2611
Maintenance Procedures Every 250 Hours or 6 Monthsp. 2611
Mazda and GM Engine Oil and Oil Filterp. 2611
Drive Beltp. 2612
Mazda 2.0L and 2.2L Enginesp. 2612
Fan and Alternator Drive Beltp. 2612
GM 2.4L Enginep. 2613
Fan and Alternator Drive Beltp. 2613
Drain Tar From LPG Regulator (Except 2007 Mazda Emission Compliap. 2613
Drain Tar From LPG Regulator (2007 Mazda Emission Compliant Engip. 2614
Maintenance Procedures Every 500 Hours or 6 Monthsp. 2615
Hydraulic System Oilp. 2615
Hydraulic Tank Breatherp. 2615
Inspectp. 2615
Batteryp. 2616
Yanmar Engine Oil and Oil Filterp. 2616
Drive Beltp. 2616
Yanmar Diesel Enginep. 2616
Fan and Alternator Drive Beltp. 2616
PCV Valvep. 2617
Clean Debris From Radiator Corep. 2617
Transmission Oil Levelp. 2617
Wet Brake Planetary Housing Oil Level Checkp. 2619
Forksp. 2620
Mast Lubricationp. 2620
Header Hose Checksp. 2624
Lift Chain Lubricationp. 2624
Tilt Cylinder Lubricationp. 2624
Master Brake Cylinder Rod End Pin Lubricationp. 2625
Manual Hydraulic Levers Lubricationp. 2626
Brake Fluidp. 2627
Tie Rod Lubrication (H40-70FT)p. 2628
Differential and Drive Axle Oil (Dry Brake)p. 2628
Maintenance Procedures Every 1000 Hours or 6 Monthsp. 2628
Valve Clearance, Check and Adjustp. 2628
Ignition Systemp. 2629
GM 2.4L Enginep. 2629
Mazda 2.0L and 2.2L Enginesp. 2629
LPG Fuel Filter Element Replace, GM 2.4L Enginep. 2629
Removep. 2629
Installp. 2629
LPG Vapor Fuel Filter Replace, Mazda Engines (Except 2007 Mazdap. 2630
LPG Fuel Filter Replace, Mazda 2007 Emission Compliant Engines Op. 2630
Removep. 2630
Clean/Inspectp. 2631
Installp. 2631
Gasoline Fuel Filter Replacement, Mazda 2007 Emission Compliantp. 2632
Remove and Replacep. 2632
Fuel Filter Replacement, Yanmar Enginep. 2632
Priming the Fuel System (Yanmar)p. 2634
Lift Chains Wear Checkp. 2634
Lift Chain Lubricationp. 2635
Integral Sideshift Carriage, Check Bearingsp. 2635
Integral Sideshift Carriage, Check Lower Mounting Hooksp. 2636
Steering Axlep. 2636
Control Levers and Pedalsp. 2636
Maintenance Procedures Every 2000 Hours or Annuallyp. 2637
Hydraulic Systemp. 2637
Hydraulic Filter, Replacep. 2637
Hydraulic Tank Breather, Replacep. 2638
Air Filterp. 2639
PCV Valvep. 2640
Oxygen Sensorp. 2641
LPG Regulator Fuel Filter, Mazda Engines (Except 2007 Mazda Emisp. 2642
Remove and Replacep. 2642
LPG Regulator Fuel Filter, GM Enginesp. 2643
Removep. 2643
Installp. 2643
Gasoline Fuel Filterp. 2643
Remove and Replace for Lift Trucks Equipped with GFIp. 2643
Timing Beltp. 2644
Mazda Enginesp. 2644
GM 2.4L Enginep. 2644
LPG Fuel Injector, Mazda Engines (Except 2007 Mazda Emission Comp. 2644
Gasoline Fuel Injector, Mazda Enginesp. 2644
LPG Fuel Injector, GM Enginesp. 2644
Gasoline Fuel Injector, GM Enginesp. 2644
Fuel Injector, Yanmar Enginesp. 2644
Forksp. 2645
Integral Sideshift Carriagep. 2645
Bearings, Replacep. 2645
Transmission Oil and Filter (Dry Brake), Replacep. 2645
Iron Transmission Housingp. 2645
Aluminum Transmission Housingp. 2646
Removep. 2646
Clean and Inspectp. 2647
Installp. 2647
Transmission Oil Change, Wet Brake Drive Axlep. 2648
Iron Transmission Housingp. 2648
Aluminum Transmission Housingp. 2649
Wet Brake Axle Center Section and Planetary Housing, Oil Changep. 2652
Brake Fluid (Master Cylinder), Changep. 2655
Brake Fluid (Dry Brake), Removep. 2656
Service Brakes (Dry Brake)p. 2656
Differential (Dry Brake)p. 2657
Maintenance Procedures Every 4000 Hours or 2 Yearsp. 2658
Hydraulic Oil, Replacep. 2658
Cooling Systemp. 2658
Safety Procedures When Working Near Mastp. 2660
Hood Latch Checkp. 2662
Lift Chain Adjustmentsp. 2663
Jump-Starting the Lift Truckp. 2664
Jump-Starting Using a Battery Chargerp. 2664
Jump-Starting a Lift Truck Using Another Lift Truckp. 2664
Welding Repairsp. 2665
Overhead Guard Changesp. 2665
Wheel and Tire Replacementp. 2665
Generalp. 2665
Solid Rubber Tire, Change ( S Series)p. 2665
Remove and Install Tire on Wheelp. 2666
Pneumatic Tire With Tube, Repairp. 2667
Remove Wheels From Lift Truckp. 2667
Remove Tire From Wheelp. 2667
Remove Tire From Two-Piece Wheelp. 2668
Remove Tire From Three- and Four-Piece Wheelsp. 2669
Install Wheel in Tirep. 2670
Install Three-Piece or Four-Piece Wheel in Tirep. 2670
Install Tire on Two-Piece Wheelp. 2672
Install Two-Piece Wheel in Tirep. 2672
Add Air to Pneumatic Tires With Tubep. 2673
Install the Wheelsp. 2673
Dual Drive Wheels, Installp. 2673
Pneumatic Tubeless Tire, Repairp. 2674
Remove Wheels From Lift Truckp. 2674
Remove Tire From Wheelp. 2675
Install Tire on Wheelp. 2676
Add Air to Pneumatic Tubeless Tirep. 2679
Wheels, Installp. 2679
Solid Rubber Tires on Pneumatic Wheels, Changep. 2679
Remove Tire From Wheelp. 2680
Install Tire on Wheelp. 2681
Adhesives and Sealantsp. 2683
tablesp. 2553
Table 1. Maintenance Schedulep. 2577
Table 2. V-Belt Deflection Tablep. 2616
Table 3. Carriage Chain Adjustment, Forks Not Installedp. 2663
40p. 2687
tocp. 2687
Capacities and Specificationsp. 2687
Safety Precautions Maintenance and Repairp. 2688
Lift Truck Lifting Capacityp. 2691
Counterweight Weightsp. 2691
Tire Sizesp. 2691
Capacitiesp. 2692
Electrical Systemp. 2696
Transmission Oil Pressuresp. 2697
Hydraulic System Relief Pressuresp. 2700
Steering Systemp. 2700
Stall Speeds (in RPM ±100 rpm)p. 2701
Mazda 2.0L (Except 2007 Emission Compliant Engines)p. 2701
Mazda 2.0L (2007 Emission Compliant Engines Only)p. 2701
Mazda 2.2L (Except 2007 Emission Compliant Engines)p. 2701
Mazda 2.2L (2007 Emission Compliant Engines Only)p. 2702
GM 2.4Lp. 2702
Yanmar 2.6Lp. 2702
Yanmar 3.3Lp. 2702
Mast Speedsp. 2703
Tilt Anglesp. 2706
Front End Equipment – Mast Creepp. 2707
Mast Creepp. 2707
Engine Specificationsp. 2708
Torque Specificationsp. 2710
Framep. 2710
Mastp. 2710
Steering System, Cushioned Tire Trucksp. 2710
Steering System, Pneumatic Tire Trucksp. 2710
Drive Axle (Dry Brake)p. 2710
Drive Axle (Wet Brake)p. 2711
Transmission – Iron Housingp. 2711
Transmission – Aluminum Housingp. 2712
Engine – Mazda 2.0L and 2.2Lp. 2712
Engine – GM 2.4Lp. 2713
Engine – Yanmar 2.6L and 3.3L Dieselp. 2714
tablesp. 2687
Table 1. Hydraulic Systems With Hydraulic Gear Pumpp. 2700
Table 2. Hydraulic Systems With Variable Displacement Pumpp. 2700
Table 3. Lift Truck Models S2.0-3.5FT (S40-70FT, S55FTS) (F187)p. 2703
Table 4. Lift Truck Models H2.0-3.5FT (H40-70FT) (L177)p. 2704
Table 5. S2.0-3.5FT (S40-70FT, S55FTS) (F187) Lift Truck Modelsp. 2706
Table 6. H2.0-3.5FT (H40-70FT) (L177) Lift Truck Modelsp. 2706
Table 7. S2.0-3.5FT (S40-70FT, S55FTS) (F187) Lift Truck Modelsp. 2707
Table 8. H2.0-3.5FT (H40-70FT) (L177) Lift Truck Modelsp. 2707
41p. 2719
tocp. 2719
Diagrams and Schematicsp. 2719
Safety Precautions Maintenance and Repairp. 2720
General Information About Diagrams and Schematicsp. 2723
Symbol Definitionsp. 2723
Diagrams Manual Applicationsp. 2724
tablesp. 2719
Table 1. Wire Colorsp. 2723
Table 2. Symbol Definitionsp. 2723
Table 3. 1-9 Ton Diagrams Manual Applicationsp. 2724
42p. 2787
tocp. 2787
Diagrams and Schematicsp. 2787
Safety Precautions Maintenance and Repairp. 2788
General Information About Diagrams and Schematicsp. 2791
Symbol Definitionsp. 2791
Diagrams Manual Applicationsp. 2792
tablesp. 2787
Table 1. Wire Colorsp. 2791
Table 2. Symbol Definitionsp. 2791
Table 3. 1-9 Ton Diagrams Manual Applicationsp. 2792
43p. 2857
tocp. 2857
Diagrams and Schematicsp. 2857
Safety Precautions Maintenance and Repairp. 2858
General Information About Diagrams and Schematicsp. 2861
Symbol Definitionsp. 2861
Diagrams Manual Applicationsp. 2862
tablesp. 2857
Table 1. Wire Colorsp. 2861
Table 2. Symbol Definitionsp. 2861
Table 3. 1-9 Ton Diagrams Manual Applicationsp. 2862

What This Manual Enables You to Do

With this Hyster Fortis service manual you can carry out the full range of field repairs these trucks demand: replace an engine or transmission, rebuild a torque converter, service the powershift clutch packs, adjust a MONOTROL pedal, set tilt cylinder stroke, tension header hoses, replace wet disc brakes, repair the drive axle and differential, service the steering axle, overhaul lift and tilt cylinders, and troubleshoot the electrical and fuel systems of GM, Mazda, Yanmar, Cummins, and Kubota powered units.

Having the correct procedures and specifications matters because these trucks share a common platform but differ in engines, transmissions, brakes, and hydraulic systems. A torque value or seal orientation taken from the wrong section can cost a day of rework or damage a component. This compilation keeps every variant’s data in one place, matched to the correct model codes and SRM numbers.

Delivery is instant — the PDF is available immediately after purchase, no shipping, no waiting. Open it on a laptop, tablet, or phone in the shop, and print only the pages you need for the job in front of you.

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Hyster Fortis H40-70FT S40-70FT Forklift Complete Service Repair Manual PDF — PDF page 1 preview
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