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Hyster L177 (S2.0-3.5FT S40FT-70FT, S55FTS H2.0-3.5FT H40-70FT) Service Manual – PDF DOWNLOAD
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Hyster L177 (S2.0-3.5FT S40FT-70FT, S55FTS H2.0-3.5FT H40-70FT) Service Manual – PDF DOWNLOAD
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Hyster L177 (S2.0-3.5FT S40FT-70FT, S55FTS H2.0-3.5FT H40-70FT) Service Manual – PDF DOWNLOAD
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Hyster L177 (S2.0-3.5FT S40FT-70FT, S55FTS H2.0-3.5FT H40-70FT) Service Manual – PDF DOWNLOAD
Language : English
Pages : 2694
Downloadable : Yes
File Type : PDF
Size: 98.1 MB
PART NO. 1580513
TABLE OF CONTENTS:
Hyster L177 (S2.0-3.5FT S40FT-70FT, S55FTS H2.0-3.5FT H40-70FT) Service Manual – PDF DOWNLOAD
Brake System.............................................................................. 1 toc................................................................................... 1 Brake System...................................................................... 1 General........................................................................... 3 Dry Brake System.............................................................. 3 Wet Brake System.............................................................. 3 Service Brakes Repair (Dry Brake)................................................. 4 Remove and Disassemble........................................................ 4 Clean......................................................................... 9 Inspect....................................................................... 10 Assemble and Install.......................................................... 10 Adjust........................................................................ 17 Parking Brake Repair.............................................................. 18 Remove and Disassemble........................................................ 18 Assemble and Install.......................................................... 18 Adjust........................................................................ 21 Master Cylinder Repair............................................................ 21 Remove (Dry Brake)............................................................ 21 Disassemble (Dry Brake)....................................................... 22 Clean and Inspect (Dry Brake)................................................. 24 Assemble (Dry Brake).......................................................... 24 Bench Bleed Master Cylinder (Dry Brake)....................................... 24 Install and Adjust (Dry Brake)................................................ 24 Remove (Wet Brake)............................................................ 25 Disassemble (Wet Brake)....................................................... 26 Clean and Inspect (Wet Brake)................................................. 27 Assemble (Wet Brake).......................................................... 27 Install and Adjust (Wet Brake)................................................ 27 Service Brakes Adjustment (Dry Brake)............................................. 28 Brake System Air Removal.......................................................... 29 Using Pressure Bleed System................................................... 29 Using Brake Pedal Pressure.................................................... 29 Brake Pedal Adjustment............................................................ 30 Free Pedal Adjustment............................................................. 31 Torque Specifications............................................................. 32 Calibration Procedures.................................................................... 34 toc................................................................................... 37 Description....................................................................... 37 Proc_Cal_001: Service Password Entry.............................................. 40 When to Perform............................................................... 40 Why Perform................................................................... 40 How to Perform................................................................ 40 Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed................... 42 When to Perform............................................................... 42 Calibration Order............................................................. 42 Why Perform................................................................... 42 How to Perform................................................................ 42 Proc_Cal_003: Save and Exit....................................................... 44 When to Perform............................................................... 44 Why Perform................................................................... 44 How to Perform................................................................ 44 Proc_Cal_004: Lift Valve Output Threshold......................................... 46 When to Perform............................................................... 46 Calibration Order............................................................. 46 Why Perform................................................................... 46 How to Perform................................................................ 46 Proc_Cal_005: Lower Valve Output Threshold........................................ 48 When to Perform............................................................... 48 Calibration Order............................................................. 48 Why Perform................................................................... 48 How to Perform................................................................ 48 Proc_Cal_006: Tilt Back Valve Output Threshold.................................... 52 When to Perform............................................................... 52 Calibration Order............................................................. 52 Why Perform................................................................... 52 How to Perform................................................................ 52 Proc_Cal_007: Tilt Forward Valve Output Threshold................................. 54 When to Perform............................................................... 54 Calibration Order............................................................. 54 Why Perform................................................................... 54 How to Perform................................................................ 55 Proc_Cal_008: Aux 1 Dir A Valve Output Threshold.................................. 58 When to Perform............................................................... 58 Calibration Order............................................................. 58 Why Perform................................................................... 58 How to Perform................................................................ 58 Proc_Cal_009: Aux 1 Dir B Valve Output Threshold.................................. 60 When to Perform............................................................... 60 Calibration Order............................................................. 60 Why Perform................................................................... 60 How to Perform................................................................ 60 Proc_Cal_010: Aux 2 Dir A Valve Output Threshold.................................. 64 When to Perform............................................................... 64 Calibration Order............................................................. 64 Why Perform................................................................... 64 How to Perform................................................................ 64 Proc_Cal_011: Aux 2 Dir B Valve Output Threshold.................................. 66 When to Perform............................................................... 66 Calibration Order............................................................. 66 Why Perform................................................................... 66 How to Perform................................................................ 67 Proc_Cal_012: Aux 3 Dir A Valve Output Threshold.................................. 70 When to Perform............................................................... 70 Calibration Order............................................................. 70 Why Perform................................................................... 70 How to Perform................................................................ 70 Proc_Cal_013: Aux 3 Dir B Valve Output Threshold.................................. 72 When to Perform............................................................... 72 Calibration Order............................................................. 72 Why Perform................................................................... 72 How to Perform................................................................ 73 Proc_Cal_014: Load Weight Zero Point.............................................. 76 When to Perform............................................................... 76 Calibration Order............................................................. 76 Why Perform................................................................... 76 How to Perform................................................................ 76 Proc_Cal_015: Loaded Weight Calibration........................................... 78 When to Perform............................................................... 78 Calibration Order............................................................. 78 Why Perform................................................................... 78 How to Perform................................................................ 78 Proc_Cal_016: Transmission Valve Calibration...................................... 80 Applicable System/Option...................................................... 80 When to Perform............................................................... 80 Calibration Order............................................................. 80 Why Perform................................................................... 81 How to Perform................................................................ 81 Applicable System/Option...................................................... 82 When to Perform............................................................... 82 Calibration Order............................................................. 82 Why Perform................................................................... 82 How to Perform................................................................ 82 Proc_Cal_016A: Transmission Valve Calibration-Electronic Extende.................. 84 Applicable System/Option...................................................... 84 When to Perform............................................................... 84 Calibration Order............................................................. 84 Why Perform................................................................... 84 How to Perform................................................................ 84 Proc_Cal_016B: Trans. Valve Calibration-Electronic and Electroni.................. 86 Applicable System/Option...................................................... 86 When to Perform............................................................... 86 Calibration Order............................................................. 86 Why Perform................................................................... 86 How to Perform................................................................ 86 Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment....................... 88 Required Tools................................................................ 88 When to Perform............................................................... 88 Calibration Order............................................................. 88 Why Perform................................................................... 88 How to Perform................................................................ 88 Proc_Cal_025: Hydraulic Valve Pressure Gage Installation.......................... 90 When to Perform............................................................... 90 Why Perform................................................................... 90 How to Perform................................................................ 90 Proc_Cal_026: Travel Speed Calibration............................................ 92 When to Perform............................................................... 92 Calibration Order............................................................. 92 Why Perform................................................................... 92 How to Perform................................................................ 92 tables................................................................................ 37 Table 1. Calibration Procedures................................................... 37 Table 2. How to Read Calibration Procedure........................................ 38 Table 3. Proc_Cal_001: Service Password Entry..................................... 41 Table 4. Proc_Cal_002: Hydraulic Valve Calibration Warm Up and A.................. 42 Table 5. Proc_Cal_003: Save and Exit.............................................. 45 Table 6. Proc_Cal_004: Lift Valve Output Threshold................................ 46 Table 7. Proc_Cal_005: Lower Valve Output Threshold............................... 49 Table 8. Proc_Cal_006: Tilt Back Valve Output Threshold........................... 52 Table 9. Proc_Cal_007: Tilt Forward Valve Output Threshold........................ 55 Table 10. Proc_Cal_008: Aux 1 Dir A Valve Output Threshold........................ 58 Table 11. Proc_Cal_009: Aux 1 Dir B Valve Output Threshold........................ 61 Table 12. Proc_Cal_010: Aux 2 Dir A Valve Output Threshold........................ 64 Table 13. Proc_Cal_011: Aux 2 Dir B Valve Output Threshold........................ 67 Table 14. Proc_Cal_012: Aux 3 Dir A Valve Output Threshold........................ 70 Table 15. Proc_Cal_013: Aux 3 Dir B Valve Output Threshold........................ 73 Table 16. Proc_Cal_014: Load Weight Zero Point.................................... 76 Table 17. Proc_Cal_015: Loaded Weight Calibration................................. 78 Table 18. Proc_Cal_016: Transmission Valve Calibration............................ 81 Table 19. Proc_Cal_016: Transmission Valve Calibration ( S6.0FT,.................. 83 Table 20. Proc_Cal_016A: Transmission Valve Calibration........................... 85 Table 21. Proc_Cal_016B: Transmission Valve Calibration........................... 87 Table 22. Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjus.................. 89 Table 23. Proc_Cal_025: Hydraulic Valve Pressure Gage Installati.................. 91 Table 24. Proc_Cal_026: Travel Speed Calibration.................................. 92 Capacities and Specifications............................................................. 96 toc................................................................................... 96 Capacities and Specifications..................................................... 96 Lift Truck Lifting Capacity....................................................... 98 Counterweight Weights............................................................. 98 Tire Sizes........................................................................ 98 Capacities........................................................................ 99 Electrical System................................................................. 102 Transmission Oil Pressures........................................................ 104 Hydraulic System Relief Pressures................................................. 106 Steering System................................................................... 106 Stall Speeds (in RPM ±100 rpm).................................................... 107 Mazda 2.0L (Except 2007 Emission Compliant Engines)........................... 107 Mazda 2.0L (2007 Emission Compliant Engines Only)............................. 107 Mazda 2.2L (Except 2007 Emission Compliant Engines)........................... 107 Mazda 2.2L (2007 Emission Compliant Engines Only)............................. 107 GM 2.4L....................................................................... 107 Yanmar 2.6L................................................................... 107 Yanmar 3.3L................................................................... 108 Mast Speeds....................................................................... 108 Tilt Angles....................................................................... 111 Front End Equipment - Mast Creep.................................................. 112 Mast Creep.................................................................... 112 Engine Specifications............................................................. 113 Torque Specifications............................................................. 115 Frame......................................................................... 115 Mast.......................................................................... 115 Steering System, Cushioned Tire Trucks........................................ 115 Steering System, Pneumatic Tire Trucks........................................ 115 Drive Axle (Dry Brake)........................................................ 115 Drive Axle (Wet Brake)........................................................ 116 Transmission.................................................................. 116 Engine - Mazda 2.0L and 2.2L.................................................. 117 Engine - GM 2.4L.............................................................. 117 Engine - Yanmar 2.6L and 3.3L Diesel.......................................... 119 tables................................................................................ 96 Table 1. Lift Truck Models S2.0-3.5FT (S40-70FT, S55FTS) (F187)................... 108 Table 2. Lift Truck Models H2.0-3.5FT (H40-70FT) (L177)........................... 109 Table 3. S2.0-3.5FT (S40-70FT, S55FTS) (F187) Lift Truck Models................... 111 Table 4. H2.0-3.5FT (H40-70FT) (L177) Lift Truck Models........................... 111 Table 5. S2.0-3.5FT (S40-70FT, S55FTS) (F187) Lift Truck Models................... 112 Table 6. H2.0-3.5FT (H40-70FT) (L177) Lift Truck Models........................... 112 Cooling System............................................................................ 121 toc................................................................................... 121 Cooling System.................................................................... 121 General........................................................................... 123 Cooling System Checks............................................................. 123 Exhaust Leaks Into Cooling System............................................. 123 Water Flow Restrictions in Radiator........................................... 123 Radiator Hoses................................................................ 123 Water Pump.................................................................... 123 Flushing the Cooling System....................................................... 124 Cooling System, Clean......................................................... 124 Radiator Replacement.............................................................. 125 Radiator, Remove for Lift Trucks Models S30FT, S35FT, S40FTS (E0.............. 125 Radiator, Remove for Lift Truck Models S6.0FT, S7.0FT (S135FT, S.............. 133 Radiator, Remove for Lift Truck Models H6.0FT, H7.0FT (H135FT, H.............. 134 Radiator, Install for Lift Truck Models S30FT, S35FT, S40FTS (E0.............. 136 Radiator, Install for Lift Truck Models S6.0FT, S7.0FT (S135FT, .............. 138 Radiator, Install for Lift Truck Models H6.0FT, H7.0FT (H135FT, .............. 140 Fan Assembly Replacement.......................................................... 144 Fan Removal................................................................... 144 Inspect....................................................................... 148 Fan Installation.............................................................. 150 Cummins QSB 3.3L Fault Codes.............................................................. 154 Cummins QSB 3.3L Fault Codes-2............................................................ 155 Cylinder Repair........................................................................... 156 toc................................................................................... 156 Cylinder Repair................................................................... 156 General........................................................................... 159 Description....................................................................... 159 Safety Procedures When Working Near Mast.......................................... 160 Tilt Cylinder Repair.............................................................. 162 Remove........................................................................ 162 Disassemble................................................................... 162 Inspect....................................................................... 163 Clean......................................................................... 163 Assemble...................................................................... 163 Install....................................................................... 166 Tilt Cylinders, Adjust........................................................ 166 Tilt Cylinder Leak Check...................................................... 168 Torque Specifications......................................................... 169 Piston Rod Nut............................................................ 169 Gland..................................................................... 169 Tilt Cylinder Mounting Capscrew........................................... 170 Tilt Cylinder Rod End Capscrew............................................ 170 Lift Cylinder Repair.............................................................. 170 Main Lift Cylinders........................................................... 170 Remove.................................................................... 170 Disassemble............................................................... 171 Clean..................................................................... 172 Inspect................................................................... 172 Assemble.................................................................. 172 Install................................................................... 173 Two-Stage FFL Left Side Main Lift Cylinder.................................... 174 Disassemble............................................................... 174 Clean..................................................................... 176 Inspect................................................................... 176 Assemble.................................................................. 176 Install................................................................... 176 Free-Lift Cylinder............................................................ 176 Remove.................................................................... 176 Disassemble............................................................... 179 Clean..................................................................... 180 Inspect................................................................... 180 Assemble.................................................................. 180 Install................................................................... 181 Torque Specifications......................................................... 181 Lift Cylinders Leak Check..................................................... 182 tables................................................................................ 156 Table 1. Movement Rates (Maximum) for Tilt Cylinders.............................. 169 Diagnostic Trouble Codes.................................................................. 184 toc................................................................................... 184 522155-2.......................................................................... 184 522157-2.......................................................................... 184 Diagnostic Trouble Codes-2................................................................ 191 Diagnostic Trouble Codes-3................................................................ 192 toc................................................................................... 192 Electrical System................................................................. 192 2802-12....................................................................... 192 628-12........................................................................ 192 523261-3...................................................................... 192 523261-4...................................................................... 192 523257-3...................................................................... 192 523257-4...................................................................... 192 523253-3...................................................................... 192 523253-4...................................................................... 192 523249-3...................................................................... 192 523249-4...................................................................... 192 630-12........................................................................ 192 Diagnostic Troubleshooting Manual......................................................... 194 toc................................................................................... 195 How To Use This Troubleshooting Manual............................................ 195 General Instructions and Safety Information................................... 195 How to Use Diagnostic Troubleshooting Manual.................................. 195 General Instructions.......................................................... 196 Operational Diagnostic Procedures................................................. 197 Operational Checkout Procedures............................................... 199 DTC Check................................................................. 200 Horn Circuit Check........................................................ 200 Light Circuit Check....................................................... 200 Windshield Washer Wiper Check (If equipped)............................... 200 Heater Check (If equipped)................................................ 201 Dome Light Check (If equipped)............................................ 201 Circulating (Accessory) Fan Check (If equipped)........................... 202 Indicator Light Power Check............................................... 203 Operator Presence System Check............................................ 204 Engine Malfunction Indicator Check........................................ 204 Cold Start Check (Cummins and Yanmar)..................................... 204 Brake Pedal Check......................................................... 205 Backup Alarm Check (If equipped).......................................... 205 Armrest Hydraulic Interlock Check (If equipped and with original.......... 205 Engine Cover Latch Sensor Check (If equipped)............................. 206 Brake and Inching Pedal Check............................................. 206 Park Brake Sensor Check................................................... 206 Park Brake Check.......................................................... 207 Engine Speed Check (All Cummins, Yanmar, and Mazda Engines Excep.......... 207 Engine Power Check........................................................ 208 Transmission Clutch Check................................................. 208 Transmission Check........................................................ 209 Transmission Speed Selection Check (If equipped).......................... 209 Brake and Axle Drag Check................................................. 209 Hydraulic Pump Flow Check................................................. 210 Priority Flow Divider Valve Check......................................... 211 Steering Relief Valve Low Pressure Check.................................. 211 Steering Relief Valve High Pressure Check................................. 212 Control Valve Load Check Valve (Manual Valve)............................. 212 Lift E-Valve Check............................................................ 212 Lift Check (E-Valve)...................................................... 212 Tilt Function Counterbalance Check........................................ 213 Lift Drift Check.......................................................... 213 Tilt Function Drift Check................................................. 214 Mast Cushion Check (All Except 2-Stage Mast).............................. 214 Lift/Tilt Mast Adjustment Check........................................... 214 Tilt Racking Check........................................................ 215 Chain and Header Hose Adjustment Check.................................... 215 Mast Mounting Check....................................................... 216 Mast Channel Check........................................................ 216 Carriage Adjustment Check................................................. 217 Chain Sheave Check........................................................ 217 Carriage Adjustment Check (Standard and Integral Side Shift).............. 217 Engine............................................................................ 219 Engine Basics................................................................. 225 General Terminology....................................................... 225 Combustion Theory......................................................... 225 Engine Components – Cylinder Block........................................ 226 Camshaft and Timing Set................................................... 227 Cylinder Head Assembly.................................................... 227 Valve Train Assembly...................................................... 227 Air Cleaner/Filter........................................................ 227 Carburetion............................................................... 227 Electronic Fuel Injection (EFI)........................................... 227 Positive Crankcase Ventilation (PCV)...................................... 228 Engine Electrical............................................................. 228 Introduction.............................................................. 228 Battery Construction...................................................... 228 Conventional Standard Battery............................................. 229 Maintenance-Free Battery.................................................. 229 Battery Charging.......................................................... 229 Battery Fast Charging..................................................... 230 Battery Slow Charging..................................................... 230 Starting System Principles of Operation................................... 230 Starting System Components - Ignition Switch.............................. 231 Starting System Components - Starter Solenoid............................. 231 Starting System Components - Flywheel and Ring Gear....................... 231 Starting System Components - Starter Motor and Drive...................... 231 Charging System - General................................................. 232 Charging System - Regulator............................................... 232 Charging System - Theory.................................................. 232 Engine Fuel System/Exhaust and Emissions...................................... 233 Introduction.............................................................. 233 Gasoline System Components - Fuel Tank.................................... 233 Electronic Fuel Injector (EFI) - General Description...................... 233 Port Fuel System Components - ECU......................................... 233 Port Fuel System Components - Fuel Pump/Filter............................ 233 Port Fuel System Components - Fuel Rail................................... 233 Port Fuel System Components - Pressure Regulator.......................... 233 Port Fuel System Components - Fuel Injectors.............................. 234 LPG Systems General Information........................................... 234 LPG Fuel Properties....................................................... 234 LPG Fuel Tank............................................................. 234 AISAN Closed-Loop System.................................................. 235 Filter/Lockoff and Regulator.......................................... 235 Carburetor............................................................ 235 Start Mode............................................................ 235 Idle Mode............................................................. 236 Run Mode.............................................................. 236 Main Fuel Lockoff Solenoid................................................ 236 Injector Fuel Lockoff Solenoid............................................ 236 Oxygen (O 2 ) Sensor.................................................. 236 Electronic Control Unit (ECU)............................................. 236 Catalytic Converter/Muffler............................................... 236 Engine Management............................................................. 236 Introduction.............................................................. 236 Ignition and Timing - Conventional Spark.................................. 236 Components - Ignition Coil................................................ 237 Components - Distributor.................................................. 237 Spark Timing.............................................................. 237 Components - Ignition Wires............................................... 237 Components - Spark Plugs.................................................. 237 Faulty or Fouled Spark Plugs.............................................. 238 Electric Controlled Governing System - Mazda LPG.......................... 238 Engine Identification......................................................... 239 Cummins (Diesel) Engine....................................................... 241 Description............................................................... 241 Diesel Fuel System........................................................ 242 Principle of Operation................................................ 242 Fuel Injection Pump and Governor.......................................... 243 Description........................................................... 243 Principles of Operation............................................... 244 Cummins Engine Control.................................................... 245 Engine Speed (RPM) Sensor............................................. 246 Throttle Position Sensor.............................................. 247 Electronic Throttle Actuator.......................................... 248 Engine Oil Pressure Sensor............................................ 248 Coolant Temperature Sensor............................................ 248 Air Restriction Switch................................................ 249 Fuel Filter/Water Separator........................................... 249 Fuel Level Sensor (In Tank)........................................... 249 Engine Electrical System.................................................. 250 Magnetic Valve (Engine Stop Solenoid)................................. 250 Alternator............................................................ 250 Grid Heater........................................................... 250 Cold Start Timing Advance (Fuel Injection Pump)....................... 250 Cummins QSB 3.3L (Diesel) Engine.............................................. 251 Description............................................................... 251 Diesel Fuel System........................................................ 252 Electronics System........................................................ 255 Engine Protection..................................................... 256 Diagnostics........................................................... 256 Grid Heater........................................................... 256 Turbocharger and Charge Air Cooler........................................ 256 Cooling System............................................................ 258 Crankcase Oil Separator................................................... 259 Lubrication System........................................................ 260 Mazda Engine Overview......................................................... 261 Description............................................................... 261 Fuel System............................................................... 261 Engine Controls Unit (ECU) and Emissions.................................. 261 Cooling System............................................................ 261 Ignition System........................................................... 261 Mazda (LPG) Engine Controls................................................... 262 LPG System (Aisan/E-Controls-Mechanical).................................. 262 Description........................................................... 262 Principles of Operation............................................... 263 Control System........................................................ 266 Oxygen (O 2 ) Sensor.................................................. 267 Fuel Tank............................................................. 267 Regulator............................................................. 268 Start Mode........................................................ 269 Idle Mode......................................................... 269 Run Mode.......................................................... 270 Resonator............................................................. 270 Carburetor............................................................ 270 Start Mode........................................................ 270 Idle Mode......................................................... 271 Run Mode.......................................................... 271 Governor.............................................................. 272 LPG System (E-Controls)................................................... 272 Description........................................................... 272 Principles of Operation............................................... 273 Manifold Absolute Pressure Sensor..................................... 273 Throttle Position Sensor.............................................. 273 Oxygen (O 2 ) Sensor.................................................. 274 Engine Coolant Temperature Sensor..................................... 274 Intake Air Temperature Sensor......................................... 274 Engine Control Unit................................................... 274 Accelerator Pedal Position Sensor..................................... 274 Three-Way Catalytic Converter......................................... 274 Camshaft Position Sensor.............................................. 274 Electric Controlled Governing System.................................. 275 Electronic Governor Sensor............................................ 276 Mazda (Gasoline) Engine Controls.............................................. 277 Gasoline System........................................................... 277 Description........................................................... 277 Principles of Operation............................................... 278 Control System............................................................ 280 Camshaft Position Sensor.............................................. 281 Intake Air Temperature Sensor......................................... 282 Mass Air Flow Sensor.................................................. 283 Throttle Position Sensor.............................................. 284 Electronic Governor Sensor............................................ 285 Electronic Governing System........................................... 286 Manifold Absolute Pressure Sensor/Boost Sensor........................ 286 Engine Coolant Temperature Sensor..................................... 287 Intake Air System......................................................... 288 Throttle Body......................................................... 288 Idle Air Control Valve................................................ 289 Fuel System............................................................... 290 Fuel Injector......................................................... 290 Pressure Regulator.................................................... 291 Exhaust System............................................................ 292 Heated Oxygen (O 2 ) Sensor........................................... 292 Three-Way Catalytic Converter......................................... 293 GM (LPG) Engine Controls...................................................... 294 Engine Control System .................................................... 294 Engine Control System Overview........................................ 295 Principles of Operation............................................... 295 Control System............................................................ 296 GM/TGFI 2.4L (Four Cylinder) Control System Component Location........ 296 GM/TGFI 4.3L (Six Cylinder) Control System Component Location......... 297 GM/TGFI 2.4L (Four-Cylinder) LPG System............................... 298 GM/TGFI 4.3L (Six-Cylinder) LPG System................................ 300 Fuel Tank............................................................. 302 Engine Control Unit................................................... 302 Electronic Throttle Body/Throttle Position Sensor..................... 303 Manifold Absolute Pressure/Manifold Air Temperature Sensor............ 303 Propane Injectors..................................................... 304 Engine Coolant Temperature Sensor..................................... 306 Oxygen (O 2 ) Sensor.................................................. 306 Crankshaft Position Sensor (Engine Speed Sensor)...................... 307 Oil Pressure Sensor................................................... 307 Power Latch Relay..................................................... 307 GM 2.4L Camshaft Position Sensor...................................... 307 GM 4.3L Camshaft Position Sensor...................................... 308 Injector Driver Module................................................ 309 Vaporizer/Regulator................................................... 309 Accelerator Pedal Position Sensor..................................... 312 Three-Way Catalytic Converter......................................... 312 Ignition System........................................................... 313 Ignition Coils........................................................ 313 Distributorless Ignition System Module................................ 313 Electronic Ignition Signals........................................... 314 Distributor Ignition (DI) System...................................... 314 Camshaft Position (CMP) Sensor........................................ 315 Ignition Coil and Ignition Control Module (ICM)....................... 315 Secondary Ignition Components......................................... 315 GM (Gasoline) Engine Controls................................................. 316 Engine Control System..................................................... 316 GM 2.4L (Four Cylinder) Engine Control System......................... 316 GM 4.3L (Six Cylinder) Engine Control System.......................... 317 Engine Control System Overview........................................ 318 Principles of Operation............................................... 318 Control System............................................................ 318 GM/TGFI 2.4L (Four Cylinder) Control System Component Location........ 318 GM/TGFI 4.3L (Six Cylinder) Control System Component Location......... 320 GM/TGFI 2.4L (Four-Cylinder) Gasoline System Components............... 321 GM/TGFI 4.3L (Six Cylinder) Gasoline System Components................ 323 Engine Control Unit................................................... 325 Electronic Throttle Body/Throttle Position Sensor..................... 325 Manifold Absolute Pressure/Manifold Air Temperature Sensor ........... 326 Fuel Injector......................................................... 327 Engine Coolant Temperature Sensor..................................... 328 Oxygen (O 2 ) Sensor.................................................. 329 Crankshaft Position Sensor (Engine Speed Sensor)...................... 329 Oil Pressure Sensor................................................... 329 Power Latch Relay..................................................... 329 Camshaft Position Sensor.............................................. 330 Accelerator Pedal Position Sensor..................................... 331 Three-Way Catalytic Converter......................................... 332 Ignition System........................................................... 332 Ignition Coils........................................................ 332 Distributorless Ignition System Module................................ 332 Electronic Ignition Signals........................................... 333 Yanmar (Diesel) Engine........................................................ 334 Description............................................................... 334 Diesel Fuel System........................................................ 335 Principles of Operation............................................... 335 Fuel Injection Pump and Governor.......................................... 336 Description........................................................... 336 Principles of Operation............................................... 338 Timer................................................................. 339 Feed Pump (Vane Type)................................................. 339 Regulating Valve...................................................... 340 Injection Pump Plunger................................................ 341 Suction Process................................................... 342 Injection Process................................................. 342 End of Injection.................................................. 343 Uniform Pressure Process.......................................... 343 Reverse Rotation Prevention Mechanism................................. 344 Fuel Injection Volume Adjustment Mechanism............................ 344 Delivery Valve Assembly............................................... 344 Delivery Valve Holder with Damping Valve.............................. 345 All - Speed Governor.................................................. 346 At Start of Engine.................................................... 348 During Idle........................................................... 349 At Full - Load Maximum Speed Control.................................. 350 At No-Load Maximum Speed Control...................................... 351 Full-Load Position Adjustment Mechanism............................... 352 Structure and Operation of Timer.......................................... 353 Standard Type Automatic Timer......................................... 353 Yanmar Engine Controls.................................................... 354 Engine Speed (RPM) Sensor............................................. 355 Throttle Position Sensor.............................................. 355 Electronic Throttle Actuator.......................................... 356 Engine Oil Pressure Sensor............................................ 356 Coolant Temperature Sensor............................................ 357 Air Filter Restriction Switch......................................... 357 Fuel Filter/Water Separator and Strainer.............................. 358 Fuel Level Sensor..................................................... 358 Engine Electrical System.................................................. 358 Magnetic Valve (Engine Stop Solenoid)................................. 358 Alternator............................................................ 359 Glow Plugs............................................................ 359 Cold Start Timing Advance (Fuel Injection Pump)....................... 359 Cooling System - All Engines.................................................. 360 Description............................................................... 360 Radiator.................................................................. 360 Combination Cooler/Standard Radiator.................................. 361 Radiator Cap.............................................................. 361 Thermostat................................................................ 361 Engine Coolant Pump....................................................... 362 Fan....................................................................... 362 GM Engine Coolant Flow Diagram............................................ 362 Yanmar Diesel Engine Coolant Flow Diagram................................. 363 Engine Does Not Crank......................................................... 365 Engine Does Not Start/Engine is Hard to Start................................. 368 Engine Idle Speed Incorrect................................................... 374 Engine Idle Speed is Unstable or Engine Stalls at Idle........................ 377 Engine Cuts Out, Misses, Hesitates, Sags, or Stumbles......................... 382 Engine Lack of Power.......................................................... 388 Engine Speed Surge Or Engine Speed Unstable................................... 395 Engine Backfires.............................................................. 399 Engine Is Knocking or Pinging................................................. 402 Excessive Engine Vibrations................................................... 406 Abnormal Engine and Exhaust Noises............................................ 411 Fan or Alternator Bearing Noise............................................... 415 Abnormal Engine and Exhaust Smells............................................ 417 High Engine Fuel Consumption.................................................. 419 Fuel Leaks.................................................................... 422 High Engine Oil Consumption................................................... 425 Engine Oil Leaks.............................................................. 427 Engine Oil is Discolored...................................................... 432 Engine Coolant Leaks.......................................................... 434 Engine Coolant is Discolored.................................................. 437 Engine Exhaust is Discolored.................................................. 438 Engine Fails Emission Compliance Check........................................ 442 Alternator Light is Illuminated............................................... 446 Engine is Overheating......................................................... 447 Air Intake Manifold Temperature too High (Cummins QSB 3.3L Only).............. 450 Air Intake Manifold Pressure (Boost) is Below Normal (Cummins QS.............. 451 Engine Coolant Temperature is Low............................................. 452 Engine Oil Pressure is Low.................................................... 453 Radiator Bubble Test.......................................................... 455 Engine Compression Test (GM and Mazda)........................................ 456 Engine Compression Test (Yanmar Diesel)....................................... 457 Engine Oil Pressure Test...................................................... 458 Fuel System Pressure Test (Gasoline Engines Only)............................. 460 Fuel Injection Nozzle Test (Yanmar Diesel).................................... 462 Vacuum Leak................................................................... 463 Vacuum Leak Detection..................................................... 463 Vacuum Leak Repairs....................................................... 463 Coolant System Test........................................................... 464 Electrical System................................................................. 465 Troubleshooting Guidelines and Procedures..................................... 479 Troubleshooting Guidelines................................................ 479 Troubleshooting Procedures................................................ 482 Troubleshooting Procedures, Identification............................ 482 Troubleshooting Procedures, Location.................................. 482 Troubleshooting Procedures, Structure................................. 482 Troubleshooting Procedures, Performance............................... 483 Diagnostic Trouble Codes...................................................... 484 Diagnostic Trouble Codes.................................................. 484 Wiring Reference Data......................................................... 498 Post 2007 Engine Connections.................................................. 502 Cummins 4.5L.............................................................. 502 GM 2.4L (GAS/LPG)......................................................... 503 GM 4.3L (GAS/LPG)......................................................... 504 Mazda 2.0/2.2L (GAS/LPG).................................................. 505 Yanmar 2.6/3.3L........................................................... 506 Harness Assembly Data......................................................... 507 Electrical System............................................................. 553 General Description....................................................... 553 Description............................................................... 554 Principles of Operation, Components....................................... 558 Principles Of Operation, System........................................... 566 100-2......................................................................... 573 100-2......................................................................... 573 100-3......................................................................... 573 523859-3...................................................................... 573 524223-3...................................................................... 573 524224-3...................................................................... 573 524225-3...................................................................... 573 524282-3...................................................................... 573 523958-3...................................................................... 573 523959-3...................................................................... 573 100-4......................................................................... 581 523859-4...................................................................... 581 523958-4...................................................................... 581 523959-4...................................................................... 581 524223-4...................................................................... 581 524224-4...................................................................... 581 524225-4...................................................................... 581 524282-4...................................................................... 581 524223-0...................................................................... 589 524224-0...................................................................... 589 524225-0...................................................................... 589 524229-0...................................................................... 589 524270-0...................................................................... 589 524276-0...................................................................... 589 524223-1...................................................................... 593 524224-1...................................................................... 593 524225-1...................................................................... 593 524229-1...................................................................... 593 524270-1...................................................................... 593 524276-1...................................................................... 593 110-3......................................................................... 597 110-3......................................................................... 597 110-5......................................................................... 597 177-3......................................................................... 597 522231-3...................................................................... 597 522555-3...................................................................... 597 522603-3...................................................................... 597 524235-3...................................................................... 597 110-4......................................................................... 605 110-4......................................................................... 605 177-4......................................................................... 605 522231-4...................................................................... 605 522555-4...................................................................... 605 522603-4...................................................................... 605 524235-4...................................................................... 605 110-2......................................................................... 613 110-2......................................................................... 613 110-10........................................................................ 616 522712-3...................................................................... 621 522713-3...................................................................... 621 522712-4...................................................................... 628 522713-4...................................................................... 628 51-2.......................................................................... 635 51-7.......................................................................... 635 91-2.......................................................................... 643 91-2.......................................................................... 643 522708-3...................................................................... 647 522710-3...................................................................... 647 522711-3...................................................................... 647 522714-3...................................................................... 647 522708-4...................................................................... 654 522710-4...................................................................... 654 522711-4...................................................................... 654 522714-4...................................................................... 654 515-0......................................................................... 661 523780-3...................................................................... 663 523860-3...................................................................... 663 524245-3...................................................................... 663 524275-3...................................................................... 663 523780-4...................................................................... 669 523860-4...................................................................... 669 524245-4...................................................................... 669 524275-4...................................................................... 669 677-3......................................................................... 674 2350-3........................................................................ 674 522754-3...................................................................... 674 522755-3...................................................................... 674 522764-3...................................................................... 674 522766-3...................................................................... 674 524230-3...................................................................... 674 SYMPTOMS WARNING.............................................................. 674 677-4......................................................................... 680 2350-4........................................................................ 680 522754-4...................................................................... 680 522755-4...................................................................... 680 522764-4...................................................................... 680 522766-4...................................................................... 680 524230-4...................................................................... 680 676-3......................................................................... 684 524195-3...................................................................... 684 524269-3...................................................................... 684 676-4......................................................................... 690 524195-4...................................................................... 690 524269-4...................................................................... 690 524269-7...................................................................... 696 524215-3...................................................................... 698 524215-6...................................................................... 698 524237-3...................................................................... 702 524238-3...................................................................... 702 524240-3...................................................................... 702 524237-4...................................................................... 707 524238-4...................................................................... 707 524240-4...................................................................... 707 879-3......................................................................... 712 880-3......................................................................... 712 881-3......................................................................... 712 882-3......................................................................... 712 522772-3...................................................................... 712 879-4......................................................................... 716 880-4......................................................................... 716 881-4......................................................................... 716 882-4......................................................................... 716 522772-4...................................................................... 716 168-0......................................................................... 720 168-3......................................................................... 720 521982-3...................................................................... 723 522760-3...................................................................... 723 522761-3...................................................................... 723 522762-3...................................................................... 723 522128-3...................................................................... 732 524251-0...................................................................... 732 524260-0...................................................................... 732 524260-3...................................................................... 732 524261-0...................................................................... 732 524261-3...................................................................... 732 168-1......................................................................... 741 168-4......................................................................... 741 521982-4...................................................................... 744 522760-4...................................................................... 744 522761-4...................................................................... 744 522761-6...................................................................... 744 522762-4...................................................................... 744 522128-4...................................................................... 751 524251-1...................................................................... 751 524260-1...................................................................... 751 524260-4...................................................................... 751 524261-1...................................................................... 751 524261-4...................................................................... 751 524260-2...................................................................... 761 524260-11..................................................................... 761 524261-2...................................................................... 761 524261-11..................................................................... 761 96-3.......................................................................... 765 96-4.......................................................................... 765 522810-4...................................................................... 769 524213-1...................................................................... 773 524213-3...................................................................... 773 524213-4...................................................................... 773 523920-3...................................................................... 776 523925-3...................................................................... 776 523930-3...................................................................... 776 523977-3...................................................................... 776 523978-3...................................................................... 776 523986-3...................................................................... 776 524284-3...................................................................... 776 524285-3...................................................................... 776 523920-4...................................................................... 782 523925-4...................................................................... 782 523930-4...................................................................... 782 523977-4...................................................................... 782 523978-4...................................................................... 782 523986-4...................................................................... 782 524284-4...................................................................... 782 524285-4...................................................................... 782 523920-6...................................................................... 787 523925-6...................................................................... 787 523930-6...................................................................... 787 523977-6...................................................................... 787 523978-6...................................................................... 787 523986-6...................................................................... 787 524284-6...................................................................... 787 524285-6...................................................................... 787 105-3......................................................................... 791 105-3......................................................................... 791 522570-3...................................................................... 791 105-4......................................................................... 796 105-4......................................................................... 796 522570-4...................................................................... 796 105-5......................................................................... 800 106-3......................................................................... 803 106-4......................................................................... 807 106-0......................................................................... 811 106-1......................................................................... 811 106-2......................................................................... 811 106-14........................................................................ 811 522739-3...................................................................... 814 522740-3...................................................................... 814 522739-5...................................................................... 819 522740-5...................................................................... 819 522739-6...................................................................... 823 522740-6...................................................................... 823 522735-2...................................................................... 827 522735-4...................................................................... 830 522735-5...................................................................... 833 522735-6...................................................................... 836 522630-2...................................................................... 840 522631-2...................................................................... 840 522632-2...................................................................... 840 522633-2...................................................................... 840 522635-3...................................................................... 840 522636-4...................................................................... 840 522637-3...................................................................... 840 522638-4...................................................................... 840 522606-10..................................................................... 844 522737-10..................................................................... 844 651-3......................................................................... 847 652-3......................................................................... 847 653-3......................................................................... 847 654-3......................................................................... 847 655-3......................................................................... 847 656-3......................................................................... 847 522599-3...................................................................... 847 522600-3...................................................................... 847 522601-3...................................................................... 847 522602-3...................................................................... 847 522721-3...................................................................... 847 522722-3...................................................................... 847 522723-3...................................................................... 847 522724-3...................................................................... 847 522725-3...................................................................... 847 522726-3...................................................................... 847 522599-3...................................................................... 847 522600-3...................................................................... 847 522601-3...................................................................... 847 522602-3...................................................................... 847 651-5......................................................................... 855 651-5......................................................................... 855 652-5......................................................................... 855 652-5......................................................................... 855 653-5......................................................................... 855 653-5......................................................................... 855 654-5......................................................................... 855 654-5......................................................................... 855 655-5......................................................................... 855 656-5......................................................................... 855 522721-5...................................................................... 855 522722-5...................................................................... 855 522723-5...................................................................... 855 522724-5...................................................................... 855 522725-5...................................................................... 855 522726-5...................................................................... 855 651-6......................................................................... 860 652-6......................................................................... 860 653-6......................................................................... 860 654-6......................................................................... 860 655-6......................................................................... 860 656-6......................................................................... 860 522599-4...................................................................... 860 522600-4...................................................................... 860 522601-4...................................................................... 860 522602-4...................................................................... 860 522721-6...................................................................... 860 522722-6...................................................................... 860 522723-6...................................................................... 860 522724-6...................................................................... 860 522725-6...................................................................... 860 522726-6...................................................................... 860 2000-9........................................................................ 868 2000-12....................................................................... 868 2000-12....................................................................... 868 2000-12....................................................................... 868 2000-12....................................................................... 868 2000-14....................................................................... 868 2003-12....................................................................... 868 2023-12....................................................................... 868 2039-2........................................................................ 868 2039-12....................................................................... 868 2235-12....................................................................... 868 2236-12....................................................................... 868 2238-12....................................................................... 868 521670-12..................................................................... 868 524258-2...................................................................... 868 522215-12..................................................................... 876 522215-14..................................................................... 876 524236-14..................................................................... 876 524262-12..................................................................... 876 524262-14..................................................................... 876 524263-1...................................................................... 876 524268-12..................................................................... 876 628-12........................................................................ 878 630-12........................................................................ 878 522690-2...................................................................... 878 522690-12..................................................................... 878 522691-2...................................................................... 878 522691-12..................................................................... 878 522692-2...................................................................... 878 522693-12..................................................................... 878 522694-12..................................................................... 878 522695-2...................................................................... 878 522696-2...................................................................... 878 522697-12..................................................................... 878 522698-2...................................................................... 878 522699-2...................................................................... 878 522700-2...................................................................... 878 190-2......................................................................... 880 190-2......................................................................... 880 190-7......................................................................... 880 522120-1...................................................................... 880 522585-2...................................................................... 880 522752-9...................................................................... 886 524249-2...................................................................... 890 524250-2...................................................................... 890 524264-2...................................................................... 890 524264-14..................................................................... 890 524265-2...................................................................... 890 524271-2...................................................................... 890 524225-14..................................................................... 890 628-12........................................................................ 895 630-12........................................................................ 895 2660-3........................................................................ 895 2660-4........................................................................ 895 2661-3........................................................................ 895 2661-4........................................................................ 895 2802-12....................................................................... 895 523510-12..................................................................... 895 523511-12..................................................................... 895 523515-3...................................................................... 895 523515-4...................................................................... 895 523519-3...................................................................... 895 523519-4...................................................................... 895 2802-12....................................................................... 897 628-12........................................................................ 897 630-12........................................................................ 897 523261-3...................................................................... 897 523261-4...................................................................... 897 523257-3...................................................................... 897 523257-4...................................................................... 897 523253-3...................................................................... 897 523253-4...................................................................... 897 523249-3...................................................................... 897 523249-4...................................................................... 897 522780-3...................................................................... 899 522781-3...................................................................... 899 522780-4...................................................................... 903 522781-4...................................................................... 903 522780-2...................................................................... 906 522781-2...................................................................... 906 111-1......................................................................... 909 524252-2...................................................................... 913 524253-14..................................................................... 915 524255-2...................................................................... 916 108-0......................................................................... 917 108-1......................................................................... 917 522655-0...................................................................... 920 522655-1...................................................................... 920 522660-0...................................................................... 920 522660-1...................................................................... 920 524212-2...................................................................... 924 524211-2...................................................................... 924 524210-2...................................................................... 924 524209-2...................................................................... 924 524208-2...................................................................... 924 524207-2...................................................................... 924 524206-2...................................................................... 924 524205-2...................................................................... 924 524204-2...................................................................... 924 524203-2...................................................................... 924 524202-2...................................................................... 924 524201-2...................................................................... 924 524200-2...................................................................... 924 524199-2...................................................................... 924 524198-2...................................................................... 924 524197-2...................................................................... 924 522800-13..................................................................... 926 522801-13..................................................................... 928 522130-0...................................................................... 929 522131-0...................................................................... 929 522132-0...................................................................... 929 522133-0...................................................................... 929 522134-0...................................................................... 929 522130-1...................................................................... 933 522131-1...................................................................... 933 522132-1...................................................................... 933 522133-1...................................................................... 933 522134-1...................................................................... 933 522130-3...................................................................... 938 522131-3...................................................................... 938 522132-3...................................................................... 938 522133-3...................................................................... 938 522134-3...................................................................... 938 522130-4...................................................................... 943 522131-4...................................................................... 943 522132-4...................................................................... 943 522133-4...................................................................... 943 522134-4...................................................................... 943 522135-0...................................................................... 947 522137-0...................................................................... 947 522138-0...................................................................... 947 522135-1...................................................................... 951 522137-1...................................................................... 951 522138-1...................................................................... 951 522135-3...................................................................... 955 522137-3...................................................................... 955 522138-3...................................................................... 955 522135-4...................................................................... 959 522137-4...................................................................... 959 522138-4...................................................................... 959 522155-2...................................................................... 963 522157-2...................................................................... 963 522122-0...................................................................... 970 522124-0...................................................................... 970 522125-0...................................................................... 970 522126-0...................................................................... 970 522127-0...................................................................... 970 522122-1...................................................................... 974 522124-1...................................................................... 974 522125-1...................................................................... 974 522126-1...................................................................... 974 522127-1...................................................................... 974 522122-6...................................................................... 978 522124-6...................................................................... 978 522125-6...................................................................... 978 522126-6...................................................................... 978 522127-6...................................................................... 978 522122-8...................................................................... 983 522124-8...................................................................... 983 522125-8...................................................................... 983 522126-8...................................................................... 983 522127-8...................................................................... 983 522129-3...................................................................... 987 522129-4...................................................................... 987 522197-0...................................................................... 989 522198-0...................................................................... 989 522199-0...................................................................... 989 522200-0...................................................................... 989 522201-0...................................................................... 989 522197-1...................................................................... 992 522198-1...................................................................... 992 522199-1...................................................................... 992 522200-1...................................................................... 992 522201-1...................................................................... 992 522197-6...................................................................... 993 522198-6...................................................................... 993 522199-6...................................................................... 993 522200-6...................................................................... 993 522201-6...................................................................... 993 522197-7...................................................................... 994 522198-7...................................................................... 994 522199-7...................................................................... 994 522200-7...................................................................... 994 522201-7...................................................................... 994 522197-8...................................................................... 995 522198-8...................................................................... 995 522199-8...................................................................... 995 522200-8...................................................................... 995 522201-8...................................................................... 995 522197-14..................................................................... 997 522198-14..................................................................... 997 522199-14..................................................................... 997 522200-14..................................................................... 997 522201-14..................................................................... 997 522197-27..................................................................... 998 522198-27..................................................................... 998 522199-27..................................................................... 998 522200-27..................................................................... 998 522201-27..................................................................... 998 2039-2........................................................................1001 522540-3......................................................................1004 522540-4......................................................................1008 522604-3......................................................................1013 522604-4......................................................................1017 522604-5......................................................................1021 522697-12.....................................................................1026 190-2.........................................................................1027 190-4.........................................................................1027 190-8.........................................................................1027 522752-2......................................................................1027 522752-4......................................................................1027 522752-5......................................................................1033 522598-3......................................................................1036 522598-4......................................................................1040 522592-0......................................................................1044 522592-1......................................................................1046 522593-12.....................................................................1048 522594-12.....................................................................1052 522595-12.....................................................................1052 522596-12.....................................................................1052 522597-12.....................................................................1052 522614-7......................................................................1055 522616-8......................................................................1055 522617-5......................................................................1055 524226-3......................................................................1056 524226-4......................................................................1058 524239........................................................................1060 524241........................................................................1060 524246........................................................................1060 524267........................................................................1060 524248........................................................................1060 524746-2......................................................................1063 Engine Continues to Run When Engine Cover is Raised...........................1065 Engine Stops or Fails to Start................................................1067 Electrical Functions Do Not Operate...........................................1069 Electrical Function Does Not Turn Off.........................................1074 Electro-Hydraulics Do Not Function With Armrest Down .........................1080 Electro-Hydraulics Can Still Function With Armrest Raised.....................1083 Vehicle Does Not Power On.....................................................1086 Heater Fan Does Not Operate Properly..........................................1091 Heater Airflow Does Not Reach Desired Temperature.............................1094 Heater Output Has Insufficient Airflow........................................1095 Circulating (Accessory) Fan Inoperative.......................................1096 Dome Light Inoperative........................................................1099 Horn Failure..................................................................1102 Drive Train.......................................................................1105 Mechanical Overview...........................................................1109 Engine........................................................................1109 Description...............................................................1109 Torque Converter..............................................................1109 Description...............................................................1109 Stator................................................................1110 Turbine...............................................................1110 Pump PTO......................................................................1111 Chain Drive PTO...........................................................1111 Spur Gear PTO.............................................................1112 Transmission..................................................................1113 Description...............................................................1113 1.0-5.5 Ton Lift Truck Transmissions......................................1116 Description...........................................................1116 Single-Speed......................................................1116 Two-Speed.........................................................1117 Clutch Pack...........................................................1118 Power Flow............................................................1120 Single-Speed......................................................1120 Two-Speed.........................................................1121 Transmission Hydraulic Schematic......................................1123 Transmission Oil Flow.................................................1124 Control Valve Oil Flow................................................1124 6.0-7.0 Ton Lift Truck Transmissions......................................1126 Description...........................................................1126 Two-Speed.........................................................1126 Three-Speed.......................................................1126 Clutch Pack...........................................................1128 Input Shaft and Range Clutches....................................1128 Directional Clutches..............................................1128 Output Section....................................................1129 Power Flow............................................................1130 Two-Speed and Three-Speed.........................................1130 Transmission Hydraulic Schematic......................................1134 Two-Speed.........................................................1134 Three-Speed.......................................................1135 Transmission Control System Overview..........................................1137 Transmission Control System...............................................1137 Transmission Control Software.................................................1140 Transmission Control Modes................................................1140 Neutral...............................................................1140 Gear Engagement Control...............................................1140 Basic Powershift Gear Engagement Mode.............................1140 DuraMatch™ and Electronic Extended Features Gear Engagement Mo....1140 Normal Forward or Reverse.............................................1140 Basic Powershift..................................................1140 DuraMatch™ and Electronic Extended Features Transmission..........1140 Auto-Shift............................................................1140 1st Gear Lock.........................................................1141 Inching...............................................................1141 Basic Powershift Inching Mode.....................................1141 DuraMatch™ Inching Mode...........................................1141 Electronic Extended Features Inching Mode.........................1141 Inch/Brake Overlap Adjustment.........................................1141 Brake Wear Compensation...............................................1141 Auto Decel............................................................1142 Controlled Power Reversal.............................................1142 Basic Multi-Speed.................................................1142 Electronic Extended Features......................................1142 Controlled Creep......................................................1142 Basic Powershift..................................................1142 DuraMatch™ and Electronic Extended Features.......................1143 Controlled Roll Back..................................................1143 DuraMatch™ .......................................................1143 Electronic Extended Features......................................1143 Travel Speed Limit (Optional).........................................1143 Extended Drawbar Pull ( Electronic Extended Features Multi-Speed......1143 Auto-Speed Hydraulics ( Electronic Extended Features Transmissio......1143 Throttle Response Management ( Electronic Extended Features Tran......1144 Steady Travel Speed...............................................1144 Transmission Control Hardware.................................................1144 Control Valve and Sensors.................................................1144 Description...........................................................1144 Principles of Operation...............................................1146 Transmission Proportional Valve...........................................1147 Description...........................................................1147 Neutral...............................................................1147 Proportional Control..................................................1147 MONOTROL® Pedal...........................................................1148 Description...........................................................1148 Principles of Operation...............................................1148 Directional Control Lever.................................................1148 Principles of Operation...............................................1148 Driveshaft, Differential, Drive Axle, and Brakes (Dry Brake Only..............1149 Driveshaft................................................................1149 Differential and Drive Axle...............................................1149 Brake System..............................................................1151 Description...........................................................1151 Service Brakes........................................................1151 Master Cylinder.......................................................1151 Brake Position Sensor.................................................1152 Parking Brake.........................................................1152 Driveshaft, Differential, Drive Axle, and Brakes (Wet Brake Only..............1152 Driveshaft................................................................1152 Differential..............................................................1153 Brake System..............................................................1155 Description...........................................................1155 Service Brakes, 2.0-3.5 Ton Only......................................1155 Service Brakes, 4.0-7.0 Ton...........................................1157 Brake Adjustment and Service..........................................1157 Parking Brake.........................................................1157 Overheating Brakes (Dry Brake Axle Only)......................................1161 Overheating Brakes (Wet Brake Axle Only)......................................1163 Poor Brake Performance (Dry Brake Axle Only)..................................1166 Poor Brake Performance (Wet Brake Axle Only)..................................1169 Brakes Make Too Much Noise (Dry Brake Axle Only)..............................1171 Brakes Pull To One Side (Dry Brake Axle Only).................................1172 Parking Brake Will Not Release................................................1175 Parking Brake Will Not Hold Lift Truck (Dry Brake Axle Only)..................1176 Parking Brake Will Not Hold Lift Truck (Wet Brake Axle Only)..................1177 Abnormal Drive Axle Noise.....................................................1178 Discolored Drive Axle Oil.....................................................1181 Lift Truck Does Not Move (Drive Axle).........................................1183 Abnormal Transmission Noise...................................................1186 Bubbles or Foaming In Transmission Dipstick Tube..............................1188 Inching Operation Is Not Smooth or Chatters...................................1190 Lift Truck Does Not Move In One or Both Directions (Transmission..............1192 Loss of Power/Drivetrain Performance..........................................1195 Transmission Is Too Hot.......................................................1198 Transmission Will Not Shift To Forward High Range.............................1201 Transmission Warmup Procedure.................................................1203 Transmission Pressure Test....................................................1203 Transmission Charge Pump Pressure Test....................................1205 Clutch Pack Pressure Test (Proportional Solenoid Valves)..................1205 Torque Converter Pressure Test............................................1206 Lubrication Pressure Test.................................................1206 Transmission Clutch Drag Test (1.0-5.5 Ton Trucks Only).......................1207 Torque Converter Stall Test...................................................1207 Hydraulic Systems.................................................................1211 Main Hydraulic System.........................................................1215 Description...............................................................1215 Principles of Operation...................................................1218 Hydraulic Schematics......................................................1219 Manual Control Valve Schematics.......................................1219 Electro-Hydraulic Control Valve Schematics............................1224 Manual Hydraulic Control Valve................................................1228 Description...............................................................1228 Principles of Operation...................................................1230 Lift Section..........................................................1230 Lift Operation....................................................1230 Lower Operation...................................................1230 Tilt Section..........................................................1231 Tilt Backward.....................................................1231 Tilt Forward......................................................1231 Auxiliary Section.....................................................1233 Anti-stall Feature....................................................1234 Relief Valves.........................................................1234 Main Relief Valve.................................................1234 Secondary Relief Valve............................................1234 Electro-Hydraulic Control Valve...............................................1235 Description...............................................................1235 Principles of Operation...................................................1236 Inlet Pressure Compensator/Unloader...................................1236 Lift/Lower EHPVs......................................................1238 EHPV Operation....................................................1239 Tilt and Auxiliary Spool Functions....................................1240 Tilt Forward Function.................................................1242 Main Relief Valve ....................................................1243 Secondary Relief Valve................................................1243 Secondary Function Anti-stall Valve...................................1244 Emergency Lowering Valve..............................................1245 Steering System...............................................................1245 Component Locations.......................................................1245 Description...........................................................1245 Steering Axle Assembly................................................1245 Steering Control Unit.................................................1245 Steering Schematic........................................................1247 Principles of Operation...............................................1248 Steering Control Unit.................................................1248 Actuation Functions With Armrest Up (E-Valve).................................1249 Cycle Times Too Fast - Fast Actuation (E-Valve)...............................1250 Jump/Delay In Lift or Lower Activation After Moving Joystick or ..............1252 Jump/Delay In Secondary Function Actuation After Moving Joystick..............1255 Jump/Delay In Tilt Forward Actuation (E-Valve)................................1257 Forks Drop Slightly Before Lifting (E-Valve)..................................1259 Forks Lower Without Command (E-Valve).........................................1260 Forks Raise or Actuate Without Command (E-Valve)..............................1262 Forks Tilt Forward Without Command (E-Valve)..................................1264 Intermittent Activation (E-Valve) While Commanding Function...................1266 Lift/Lower Function Maximum Speed Too Slow (E-Valve)..........................1268 Lift Function Will Not Move With Joystick or MLM Movement (E-Val..............1271 Lift/Lower Continues To Move For Awhile After Joystick or MLM Is..............1275 Lift/Lower/Secondary Function Suddenly Jumps In Middle of Stroke..............1276 Lower Function Will Not Move With Joystick or MLM Movement (E-Va..............1277 Poor Metering on Lift or Lower Functions (E-Valve)............................1279 Secondary Function Continues to Move for Awhile After Joystick o..............1282 Secondary Function Exhibits Slight Movement in Opposite Directio..............1283 Secondary Function Maximum Speed Too Slow (E-Valve)...........................1284 Secondary Function or Tilt Back Moves Without Command (E-Valve)...............1287 Secondary Function and Tilt Back Will Not Move With Joystick or ..............1289 Tilt Forward Function Continues to Move for Awhile When Joystick..............1293 Tilt Forward Will Not Move Upon Joystick or MLM Movement (E-Valv..............1294 Too Much Joystick or MLM Movement (Deadband) to Start Function M..............1296 Wrong Actuation Operates or Actuation is Backward (E-Valve)...................1297 Actuation Exhibits Slight Movement in Opposite Direction Before ..............1298 Auxiliary Function is Slow or Does Not Function (Manual Valve)................1299 Cycle Times Too Fast - Fast Actuation (Manual Valve)..........................1301 Function Continues to Activate After Returning to Neutral.....................1302 Lift Function Is Slow or Does Not Function (Manual Valve).....................1303 Tilt Back Function Will Not Operate (Manual Valve)............................1305 Tilt Forward Functions When Spool is Activated Forward With Engi..............1306 Tilt Forward Will Not Function When Activated (Manual Valve)..................1307 Abnormal Steer Axle Noise.....................................................1308 Abnormal Steering Wheel Vibration.............................................1310 Back Lash/Kick Back in Steering Wheel.........................................1311 No Steering (All Other Hydraulic Functions OK)................................1313 Steering Is Slow or Difficult.................................................1315 Steering Operation Is Not Smooth..............................................1317 Steering Wheel End Lock Position Cannot Be Felt by Operator...................1319 Steering Wheel Turns By Itself or Does Not Return To Neutral..................1320 Steering Wheel Turns the Tires in the Wrong Direction.........................1321 Abnormal Hydraulic Noise and/or Vibration.....................................1322 Abnormal Smell/Discoloration/Foaming of Oil...................................1325 Actuations Do Not Act Simultaneously..........................................1326 Oil Leaking/Component Life Too Short..........................................1327 Hydraulic Warmup Procedure....................................................1331 Main Relief Valve Test and Adjustment.........................................1332 Secondary Relief Valve Test and Adjustment....................................1334 Hydraulic Pump Flow Test......................................................1336 Main Control Valve LS Leakage Test (E-Valve)..................................1338 Main Control Valve Unloader Margin Test.......................................1339 Electro-Hydraulic Poppet Valve (EHPV) Leakage Test............................1340 PPRV Pilot Pressure Test......................................................1343 Steering Relief Pressure Test and Adjustment..................................1344 Steering Control Unit LS Pressure Test........................................1345 Lift Cylinder Leakage Test....................................................1347 Tilt Cylinder Leakage Test....................................................1348 Steering Cylinder Leakage Test................................................1349 Operators Station.................................................................1351 Operator Station General Description and Principles of Operation..............1353 General Description and Location..........................................1353 Display Switch Cluster (DSC)..................................................1355 Detailed Description......................................................1355 Control Inputs, Right Side................................................1356 Right Indicator and Warning Group.........................................1358 LCD Display...............................................................1359 Left Indicator and Warning Group..........................................1360 Control Inputs, Left Side (Cab Option Only)...............................1361 Transmission Control and Braking..............................................1362 Description...............................................................1362 Vehicle System Manager (VSM)..........................................1363 Display Switch Cluster................................................1363 Interlock and Switching Features..................................1363 MONOTROL® Directional Control.........................................1363 Inch Brake/Service Brake Pedal........................................1363 Parking Brake.........................................................1364 Programming - Menus...........................................................1364 Menus.....................................................................1364 Main Menu.............................................................1367 Save and Exit or Exit Without Saving..................................1367 Back One Level........................................................1367 Hourmeters............................................................1367 View Versions.........................................................1368 Passwords.............................................................1368 Diagnostics...........................................................1368 Setup Travel and Braking..............................................1368 Setup Hydraulics......................................................1368 Setup Display.........................................................1368 Setup General Items...................................................1368 Calibrations..........................................................1368 Manual Hydraulic Control Levers...............................................1369 General Description.......................................................1369 System Components.........................................................1369 Lift/Lower............................................................1369 Tilt..................................................................1369 Auxiliary 1...........................................................1369 Auxiliary 2...........................................................1369 E-Hydraulic System Interface..................................................1370 General Description.......................................................1370 System Components.........................................................1370 E-Hydraulic Control Input Device..........................................1370 Joystick..............................................................1370 Lift/Lower........................................................1371 Tilt..............................................................1371 Auxiliary 1.......................................................1371 Auxiliary 2.......................................................1371 Push Button.......................................................1371 Mini Lever Module (MLM)...............................................1372 Lever 1...........................................................1372 Lever 2...........................................................1372 Lever 3...........................................................1373 Lever 4...........................................................1373 System Modes..............................................................1373 Hydraulic Interlock Mode..............................................1373 Fault Mode............................................................1373 Engine Off Mode.......................................................1373 Normal Operation..........................................................1373 Normal Operation Mode.................................................1373 Lifting Control.......................................................1373 Lowering Control......................................................1374 Tilt Control (Forward and Backward)...................................1374 Auxiliary Control.....................................................1374 Lighting Control..............................................................1374 Description...............................................................1374 Front Work Lights.....................................................1377 Front Marker Lights (if equipped).....................................1377 Front/Rear Turn Signal Lights.........................................1377 Rear Tail/Marker Lights...............................................1377 Rear Work Light.......................................................1377 Rear Backup Lights....................................................1377 Rear Stop Lights......................................................1377 Strobe Light(s).......................................................1377 Spot Light (if equipped)..............................................1377 Cab...........................................................................1377 Description...............................................................1377 Component Descriptions....................................................1379 Cab Heating System....................................................1379 Lighting Control System...............................................1379 Wiper/Washer System...................................................1379 Cab Systems Operation.....................................................1380 Front End (Mast) and Chassis......................................................1383 Front End, Mast...............................................................1385 Description...............................................................1385 Carriages.....................................................................1385 Description...............................................................1385 Principles of Operation...................................................1386 Integral Sideshift Carriage...........................................1386 Mast Mounts...................................................................1388 Description...............................................................1388 Principles of Operation...................................................1388 Two-Stage Limited Free-Lift (LFL) Mast........................................1390 Description...............................................................1390 Principles of Operation...................................................1391 Two-Stage Full Free-Lift (FFL) Mast...........................................1392 Description...............................................................1392 Principles of Operation...................................................1393 Three-Stage Full Free-Lift (FFL) Mast.........................................1394 Description...............................................................1394 Principles of Operation...................................................1394 Four-Stage Full Free-Lift (FFL) Mast..........................................1396 Description...............................................................1396 Principles of Operation...................................................1397 Cylinder Cushion During Lifting Sequence......................................1399 Description...............................................................1399 Principles of Operation...................................................1399 Cylinder Cushion During Lowering Sequence.....................................1400 Description...............................................................1400 Principles of Operation...................................................1400 Tilt and Sideshift Cylinders..................................................1400 Description...............................................................1400 Tilt Cylinder.........................................................1400 Sideshift Cylinder....................................................1400 Lowering Control Valves.......................................................1401 Description...............................................................1401 Principles of Operation...................................................1401 Chassis.......................................................................1403 Description...............................................................1403 Abnormal Channel Wear.........................................................1405 Abnormal Hose Wear............................................................1407 Abnormal Mast Noise...........................................................1409 Body Panels Making Noise......................................................1413 External Leakage From Free-Lift or Main Lift Cylinders........................1414 FFL Mast Banging During Phasing...............................................1415 High Tire Wear - Drive Axle...................................................1417 High Tire Wear - Steer Axle...................................................1419 Hoses Not Tracking Correctly..................................................1421 Integral Sideshift Moving Too Fast............................................1422 Integral Sideshift Not Moving or Slow.........................................1423 LP Tank Bracket Disengages....................................................1426 LP Tank Rattles and Does Not Stay Latched.....................................1427 Mast is Loose.................................................................1428 Mast Lift Chains Are Loose....................................................1430 Mast or Carriage Binding......................................................1431 Mast/Carriage Bounces or is Spongy............................................1433 Misphasing of Full Free-Lift Mast.............................................1434 Overhead Guard Loose or Damaged...............................................1436 Racking During Lift...........................................................1437 Racking During Tilt...........................................................1439 Truck Feels Unstable..........................................................1440 Truck Wanders, Does Not Track Straight or Steer Well..........................1442 Wheels Appear Tipped or Misaligned............................................1444 Wheels Spinning On Uneven Floors..............................................1446 Wheel Studs Breaking..........................................................1447 Supplementary Data................................................................1449 Abbreviations and Acronyms....................................................1451 Special Tools List............................................................1459 Fault Mode Indicator (FMI) Reference List.....................................1465 TSP Reference Tables..........................................................1467 tables................................................................................ 282 Table 9020-10-1. IAT Ambient Temperature.......................................... 282 Table 9020-40-1. Test Specifications.............................................. 455 Table 9020-40-2. Test Specifications.............................................. 456 Table 9020-40-3. Service Tools.................................................... 456 Table 9020-40-4. Test Specifications.............................................. 457 Table 9020-40-5. Service Tools.................................................... 457 Table 9020-40-6. Test Specifications.............................................. 458 Table 9020-40-7. Service Tools.................................................... 459 Table 9020-40-8. Test Specifications - Mazda...................................... 460 Table 9020-40-9. Test Specifications - GM......................................... 460 Table 9020-40-10. Service Tools................................................... 460 Table 9020-40-11. Test Specifications............................................. 462 Table 9020-40-12. Service Tools................................................... 462 Table 9020-40-13. Test Specifications............................................. 464 Table 9020-40-14. Service Tools................................................... 464 Table 9030-03-1. Cummins QSB 3.3L Fault Codes..................................... 495 Table 9030-03-2. Circuit Group Identification..................................... 498 Table 9030-03-3. Hyster Wiring Color Codes........................................ 499 Table 9040-10-1. Two-Speed Transmission Clutch Pack Solenoid Val..................1135 Table 9040-10-2. Three-Speed Transmission Electronic Proportiona..................1136 Table 9040-10-3. Transmission Control Mode........................................1138 Table 9040-40-1. Test Specifications..............................................1203 Table 9040-40-2. Service Tools....................................................1203 Table 9040-40-3. Service Tools....................................................1203 Table 9040-40-4. Test Specifications..............................................1205 Table 9040-40-5. Test Specifications..............................................1205 Table 9040-40-6. Test Specifications..............................................1206 Table 9040-40-7. Test Specifications..............................................1206 Table 9040-40-8. Test Specifications..............................................1207 Table 9040-40-9. Service Tools....................................................1207 Table 9040-40-10. Stall Speeds....................................................1208 Table 9050-10-1. Standby Pressure Table...........................................1237 Table 9050-40-1. Test Specifications..............................................1331 Table 9050-40-2. Service Tools....................................................1331 Table 9050-40-3. Test Specifications..............................................1332 Table 9050-40-4. Service Tools....................................................1332 Table 9050-40-5. Test Specifications..............................................1334 Table 9050-40-6. Service Tools....................................................1334 Table 9050-40-7. Test Specifications..............................................1336 Table 9050-40-8. Service Tools....................................................1337 Table 9050-40-9. Test Specifications..............................................1338 Table 9050-40-10. Test Specifications.............................................1339 Table 9050-40-11. Service Tools...................................................1339 Table 9050-40-12. Test Specifications.............................................1340 Table 9050-40-13. Service Tools...................................................1340 Table 9050-40-14. Test Specifications.............................................1343 Table 9050-40-15. Service Tools...................................................1343 Table 9050-40-16. Test Specifications.............................................1344 Table 9050-40-17. Service Tools...................................................1344 Table 9050-40-18. Test Specifications.............................................1345 Table 9050-40-19. Service Tools...................................................1346 Table 9050-40-20. Test Specifications.............................................1347 Table 9050-40-21. Service Tools...................................................1347 Table 9050-40-22. Test Specifications.............................................1348 Table 9050-40-23. Service Tools...................................................1348 Table 9050-40-24. Test Specifications.............................................1349 Table 9050-40-25. Service Tools...................................................1349 Table 9080-50-1. Abbreviations and Acronyms.......................................1451 Table 9080-60-1. Special Tools....................................................1459 Table 9080-70-1. FMI..............................................................1465 Table 9080-80-1. Resistor-Temperature Characteristics ............................1467 Diagrams and Schematics...................................................................1470 toc...................................................................................1472 General Information About Diagrams and Schematics.................................1472 Symbol Definitions............................................................1472 tables................................................................................1472 Table 1. Wire Colors..............................................................1472 Table 2. Symbol Definitions.......................................................1472 Drive Axle and Differential Assembly Repair...............................................1533 toc...................................................................................1533 Drive Axle and Differential Assembly Repair.......................................1533 General...........................................................................1535 Drive Axle Repair.................................................................1535 Remove and Disassemble........................................................1535 Clean and Inspect.............................................................1535 Assemble and Install..........................................................1537 Differential Repair...............................................................1539 Remove........................................................................1539 Differential Assembly From Center Section.................................1539 Drive Pinion, Pinion Gear, and Bearings From Center Section...............1543 Disassemble...................................................................1547 Differential Assembly.....................................................1547 Drop Box Housing..........................................................1550 Center Section............................................................1551 Clean and Inspect.............................................................1553 Assemble......................................................................1553 Center Section............................................................1553 Drop Box Housing..........................................................1556 Differential Assembly.....................................................1557 Install.......................................................................1561 Pinion Inner Shim Set, Adjust Thickness (Depth of Pinion).................1561 Drive Pinion, Pinion Gear, and Bearings Into Center Section...............1563 Differential Assembly Into Center Section.................................1566 Ring Gear Backlash, Adjust................................................1571 Ring Gear, Runout Check...................................................1573 Gear Set, Tooth Contact Pattern Check.....................................1573 Torque Specifications.............................................................1576 tables................................................................................1533 Table 1. Pinion Variation Numbers Examples........................................1562 Table 2. Ring and Pinion Tooth Contact Adjustment.................................1573 Table 3. Correct Tooth Contact....................................................1574 Table 4. Incorrect Tooth Contact..................................................1575 Electrical System.........................................................................1578 toc...................................................................................1585 General...........................................................................1585 Display Switch Cluster............................................................1586 Remove........................................................................1586 Install.......................................................................1588 Direction Control and Turn Signal Levers......................................1588 Remove....................................................................1588 Install...................................................................1588 Key Switch....................................................................1590 Remove....................................................................1590 Install...................................................................1590 Display Switch Cluster Panel Bezel and Overlay................................1591 Remove....................................................................1591 Install...................................................................1591 Steering Column Repair............................................................1591 Remove........................................................................1591 Disassemble...................................................................1591 Assemble......................................................................1591 Install.......................................................................1592 Sensors and Switches..............................................................1594 General.......................................................................1594 Dash and Kick Panel, Remove and Install...................................1594 Remove................................................................1594 Install...............................................................1594 Accelerator Pedal Position Sensor.............................................1596 Remove....................................................................1596 Install...................................................................1596 Brake Fluid Level Switch......................................................1599 Remove....................................................................1599 Install...................................................................1599 Service Brake Pedal Position Sensor...........................................1600 Remove....................................................................1600 Install...................................................................1600 Parking Brake Sensor..........................................................1601 Remove....................................................................1601 Install...................................................................1601 Service Brake Pressure Sensor.................................................1602 Remove....................................................................1602 Install...................................................................1602 MONOTROL® Sensor Microswitch..................................................1602 Remove....................................................................1602 Install...................................................................1604 Low Coolant Level Sensor......................................................1604 Remove....................................................................1606 Install...................................................................1606 Fuel Level Sensor, Gas and Diesel Engines Only................................1606 Remove....................................................................1606 Install...................................................................1606 Armrest Switch................................................................1607 Remove....................................................................1607 Install...................................................................1607 Seat Sensor (Operator Presence System)........................................1609 Non-Suspension and Semi-Suspension Seats; All Lift truck Models ..........1609 Remove................................................................1609 Install...............................................................1609 Non-Suspension Seats; Lift Truck Models H6.0FT, H7.0FT (H135FT, ..........1610 Remove................................................................1610 Install...............................................................1610 Full Suspension Seats; All Lift Truck Models..............................1611 Remove................................................................1611 Install...............................................................1611 Hood Shut Off Switch..........................................................1611 Remove....................................................................1611 Install...................................................................1611 Hydraulic Filter Pressure Switch..............................................1615 Remove....................................................................1615 Install...................................................................1615 Transmission Speed Sensor.....................................................1615 Remove....................................................................1615 Install...................................................................1616 Transmission Pressure Sensors.................................................1616 Remove....................................................................1616 Install...................................................................1616 Transmission Temperature Sensor...............................................1616 Remove....................................................................1616 Install...................................................................1617 Engine Speed Sensor...........................................................1618 Remove....................................................................1618 Install...................................................................1618 Intermediate Speed Sensor.....................................................1618 Remove....................................................................1618 Install...................................................................1618 Return to Set Tilt (Tilt Angle) Sensor........................................1618 Lift Truck Models S30FT, S35FT, S40FTS (E010); H1.6FT, H1.8FT, H..........1618 Remove................................................................1618 Install...............................................................1619 Lift Truck Models S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024); ..........1619 Remove................................................................1619 Install...............................................................1620 Rear Horn Button Switch.......................................................1620 Remove....................................................................1620 Install...................................................................1620 Impact Sensor.................................................................1621 All Lift Truck Models Except H6.0FT, H7.0FT (H135FT, H155FT) (H0..........1621 Remove................................................................1621 Install...............................................................1621 Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006)............1623 Remove................................................................1623 Install...............................................................1624 Load Weight Sensor............................................................1624 Remove....................................................................1624 Install...................................................................1625 Engine and Fuel Sensors - Mazda 2.0L and 2.2L Gas and LPG Engine..............1625 Oxygen Sensor.............................................................1625 Remove................................................................1625 Install...............................................................1625 Intake Air Temperature (IAT) Sensor.......................................1626 Remove................................................................1626 Install...............................................................1626 Manifold Absolute Pressure (MAP)/Boost Sensor.............................1626 Remove................................................................1626 Install...............................................................1626 Throttle Position (TPS) Sensor............................................1627 Remove................................................................1627 Install...............................................................1627 Engine and Fuel Sensors and Switches - Mazda 2.0L and 2.2L LPG E..............1627 Oil Pressure Sensor.......................................................1627 Remove................................................................1627 Install...............................................................1627 Low LPG Pressure Switch...................................................1628 Remove................................................................1628 Install...............................................................1628 Air Filter Restriction Switch.............................................1628 Remove................................................................1628 Install...............................................................1629 Engine Coolant Temperature (ECT) Sensor...................................1629 Remove................................................................1629 Install...............................................................1629 Engine and Fuel Sensors and Switches- Mazda 2.0L and 2.2L Gas En..............1629 Oil Pressure Sensor.......................................................1629 Remove................................................................1629 Install...............................................................1629 Mass Air Flow (MAF) Sensor................................................1630 Remove................................................................1630 Install...............................................................1630 Air Filter Restriction Switch.............................................1630 Remove................................................................1630 Install...............................................................1630 Engine Coolant Temperature (ECT) Sensor...................................1631 Remove................................................................1631 Install...............................................................1631 Engine and Fuel Sensors and Switches - Mazda 2.0L and 2.2L Gas a..............1631 Oil Pressure Sensor.......................................................1631 Remove................................................................1631 Install...............................................................1631 Air Filter Restriction Switch.............................................1632 Remove................................................................1632 Install...............................................................1632 CAM Angle Sensor..........................................................1633 Voltage Check.........................................................1633 Oxygen Sensor.............................................................1634 Remove................................................................1634 Install...............................................................1634 Engine and Fuel Sensors and Switches - Mazda 2.0L and 2.2L LPG E..............1634 Engine Coolant Temperature (ECT) Sensor...................................1634 Remove................................................................1634 Install...............................................................1635 Manifold Absolute Pressure (MAP) Sensor...................................1636 Remove................................................................1636 Install...............................................................1636 Intake Air Temperature (IAT) Sensor.......................................1636 Remove................................................................1636 Install...............................................................1636 Fuel Temperature Sensor...................................................1637 Remove................................................................1637 Install...............................................................1637 Low LPG Pressure Switch...................................................1638 Remove................................................................1638 Install...............................................................1638 Engine and Fuel Sensors and Switches- Mazda 2.0L and 2.2L Gas En..............1639 Intake Air Temperature (IAT) Sensor.......................................1639 Remove................................................................1639 Install...............................................................1639 Engine Coolant Temperature (ECT) Sensor...................................1640 Remove................................................................1640 Install...............................................................1640 Manifold Absolute Pressure (MAP) Sensor...................................1641 Remove................................................................1641 Install...............................................................1641 Engine and Fuel Sensors and Switches, GM 2.4L and 4.3L Gas and L..............1642 Crankshaft Sensor.........................................................1642 Remove................................................................1642 Install...............................................................1642 Camshaft Position (CMP) Sensor............................................1643 Remove................................................................1643 Install...............................................................1643 Camshaft Position (CMP) Sensor Assembly...................................1644 Remove................................................................1644 Install...............................................................1644 Oil Pressure Sensor.......................................................1644 Remove................................................................1644 Install...............................................................1644 Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) ..........1645 Remove................................................................1645 Install...............................................................1645 Engine Coolant Temperature (ECT) Sensor...................................1646 Remove................................................................1646 Install...............................................................1646 Air Flow Restriction Switch...............................................1646 Remove................................................................1646 Install...............................................................1647 Oxygen Sensor.............................................................1647 Remove................................................................1647 Install...............................................................1650 Engine and Fuel Switches, GM 2.4L and GM 4.3L LPG Trucks Only.................1651 Low LPG Pressure Switch...................................................1651 Remove................................................................1651 Install...............................................................1651 LPG Pressure Sensor, GM 4.3L Engine Only..................................1652 Remove................................................................1652 Install...............................................................1652 Engine and Fuel Sensors and Switches, Yanmar Diesel Trucks....................1652 Air Filter Restriction Switch.............................................1652 Remove................................................................1652 Install...............................................................1652 Oil Pressure Sensor.......................................................1652 Remove................................................................1652 Install...............................................................1652 Engine Speed Sensor.......................................................1652 Remove................................................................1652 Install...............................................................1652 Engine Coolant Temperature (ECT) Sensor...................................1654 Remove................................................................1654 Install...............................................................1654 Throttle Position Sensor (TPS)............................................1654 Remove................................................................1654 Install...............................................................1654 Fuel/Water Separator Sensor...............................................1655 Remove................................................................1655 Install...............................................................1655 Glow Plug Relay...........................................................1656 Remove................................................................1656 Install...............................................................1658 Engine and Fuel Sensors and Switches, Cummins Diesel Engines..................1658 Air Filter Restriction Switch.............................................1658 Remove................................................................1658 Install...............................................................1658 Oil Pressure Sensor.......................................................1660 Remove................................................................1660 Install...............................................................1660 Engine Speed Sensor (Cummins 4.5L Only)...................................1660 Remove................................................................1660 Install...............................................................1660 Engine Coolant Temperature (ECT) Sensor...................................1661 Remove................................................................1661 Install...............................................................1661 Throttle Position Sensor (TPS) (Cummins 4.5L Only)........................1661 Remove................................................................1661 Install...............................................................1662 Fuel/Water Separator Sensor...............................................1662 Remove................................................................1662 Install...............................................................1662 Vehicle System Manager (VSM)......................................................1663 General.......................................................................1663 VSM Replacement...............................................................1663 Remove....................................................................1663 Install...................................................................1664 Programming a New VSM and/or Display Switch Cluster...........................1665 General...................................................................1665 PC Service Tool Software..................................................1665 Data Transferring.........................................................1666 New or Used VSM.......................................................1666 New (Blank) Display Switch Cluster....................................1666 Used (Non-Blank) Display Switch Cluster...............................1666 Power Distribution Module (PDM) and Component Parts...............................1667 Remove........................................................................1667 PDM as a Unit.............................................................1667 Install.......................................................................1670 PDM as a Unit.............................................................1670 Remove and Install............................................................1670 PDM Component Parts.......................................................1670 Transmission Control Unit.........................................................1671 Remove S6.0FT, S7.0FT, (S135FT,S155FT) (D024, E024) and H6.0FT, ..............1671 Install S6.0FT, S7.0FT, (S135FT,S155FT) (D024, E024) and H6.0FT,..............1672 Battery...........................................................................1672 Remove........................................................................1672 Install.......................................................................1672 Lights............................................................................1672 Work Lights (Front and Rear)..................................................1672 Remove....................................................................1672 Install...................................................................1672 Strobe Light..................................................................1673 Remove....................................................................1673 Install...................................................................1674 LED Tail, Backup, and Brake Lights............................................1674 Remove....................................................................1674 Install...................................................................1674 Electronic-Hydraulic Controls.....................................................1676 General.......................................................................1676 Mini-Lever Replacement........................................................1676 Remove....................................................................1676 Clean and Inspect.........................................................1677 Install...................................................................1677 Push Button Switch Replacement................................................1678 Remove....................................................................1678 Install...................................................................1679 Test..........................................................................1680 Mini-Levers...............................................................1680 Full Stroke Test..........................................................1680 Function Returns to Neutral Test..........................................1680 Push Button Switch........................................................1680 Mini-Lever Module (MLM).......................................................1681 Remove....................................................................1681 Install...................................................................1681 tables................................................................................1667 Table 1. VSM and Display Switch Cluster Replacement...............................1667 Electrical System-2.......................................................................1684 toc...................................................................................1684 Electrical System.................................................................1684 Ignition System...................................................................1686 General.......................................................................1686 Ignition Timing Adjustment, Gasoline and LPG..................................1686 Spark Plugs Check.............................................................1686 Spark Plug Wires Check........................................................1686 Distributor Repair................................................................1689 Remove........................................................................1689 Disassemble...................................................................1690 Inspect.......................................................................1690 Assemble......................................................................1691 Install.......................................................................1691 Igniter.......................................................................1692 Remove....................................................................1692 Test......................................................................1692 Install...................................................................1692 Camshaft Position (CMP) Sensor................................................1693 Voltage Check.............................................................1693 Ignition Coil Check...............................................................1694 Primary Coil Winding..........................................................1694 Secondary Coil Winding........................................................1694 Starter Repair....................................................................1695 General.......................................................................1695 Remove........................................................................1695 No-Load Test..................................................................1696 Magnetic Switch Test..........................................................1696 Pull-Out Test.............................................................1696 Holding Coil Test.........................................................1697 Return Test...............................................................1697 Pinion Movement Inspection................................................1697 Install.......................................................................1697 Alternator Repair.................................................................1698 General.......................................................................1698 Charging System Inspection....................................................1698 Output Current Check..........................................................1699 No-Load Adjusted Voltage Check................................................1699 Remove........................................................................1700 Inspect.......................................................................1700 Rectifier Check...........................................................1700 Install.......................................................................1701 tables................................................................................1684 Table 1. Spark Plug Wire..........................................................1686 Table 2. Starter Specifications...................................................1695 Table 3. Problem Diagnosis Chart..................................................1696 Table 4. Specifications...........................................................1699 Table 5. Rectifier Check Table....................................................1700 Electrical System-3.......................................................................1703 toc...................................................................................1703 Electrical System.................................................................1703 Ignition System...................................................................1705 General.......................................................................1705 Ignition Timing Adjustment, Gasoline and LPG..................................1705 Spark Plugs Check.............................................................1708 Spark Plug Wires Check........................................................1708 CAM Angle Sensor Repair...........................................................1708 Remove........................................................................1708 Install.......................................................................1709 Coil Replacement..................................................................1710 Remove........................................................................1710 Inspect.......................................................................1711 Install.......................................................................1711 Starter Repair....................................................................1712 General.......................................................................1712 Remove........................................................................1713 No-Load Test..................................................................1713 Magnetic Switch Test..........................................................1714 Pull-Out Test.............................................................1714 Holding Coil Test.........................................................1714 Return Test...............................................................1714 Pinion Movement Inspection................................................1714 Install.......................................................................1715 Alternator Repair.................................................................1715 General.......................................................................1715 Charging System Inspection....................................................1716 Output Current Check..........................................................1716 No-Load Adjusted Voltage Check................................................1717 Remove........................................................................1717 Inspect.......................................................................1717 Rectifier Check...........................................................1717 Install.......................................................................1718 tables................................................................................1703 Table 1. Spark Plug Wires.........................................................1708 Table 2. Coil Inspection..........................................................1711 Table 3. Starter Specifications...................................................1712 Table 4. Problem Diagnosis Chart..................................................1713 Table 5. Specifications...........................................................1716 Table 6. Rectifier Check Table....................................................1717 Frame.....................................................................................1720 toc...................................................................................1720 Frame.............................................................................1720 General...........................................................................1723 Description.......................................................................1724 Hood, Seat, and Side Covers Replacement...........................................1724 Remove........................................................................1724 Install.......................................................................1729 LPG Tank and Bracket Replacement..................................................1731 Remove........................................................................1731 LPG Tank..................................................................1731 LPG Bracket...............................................................1734 Install.......................................................................1734 LPG Bracket...............................................................1734 LPG Tank..................................................................1735 Counterweight Replacement.........................................................1736 Remove........................................................................1736 Install.......................................................................1737 Tow Pin, Remove and Install...................................................1738 Overhead Guard Replacement........................................................1738 Remove and Install............................................................1738 LED Tail, Backup, and Brake Lights, Replace...................................1739 Operator Restraint System Replacement.............................................1740 Description...................................................................1740 Automatic Locking Retractor (ALR).........................................1740 Emergency Locking Retractor (ELR).........................................1740 Engine Replacement................................................................1741 Remove Engine Only............................................................1741 Remove Engine and Transmission................................................1745 Install Engine Only...........................................................1745 Install Engine and Transmission...............................................1746 Throttle Pedal and Cable Adjustment...............................................1747 Mazda Gas/LPG Engines With Basic Power Shift Transmission and Ma..............1747 Mazda Gasoline Engine With Electronic Transmission............................1750 Throttle Pedal Stop Adjustment, Mazda 2007 Emission Compliant En..............1751 Yanmar Diesel Engine With Basic Power Shift Transmission......................1751 Yanmar Diesel Engine With Electronic Throttle.................................1751 Exhaust System Repair.............................................................1753 Lift Trucks With Counterweight Exhaust System.................................1753 Mazda and GM Gas and LPG Engines..........................................1753 Remove and Disassemble................................................1753 Inspect...............................................................1753 Assemble and Install..................................................1755 Yanmar Diesel Engine......................................................1757 Remove and Disassemble................................................1757 Inspect...............................................................1757 Assemble and Install..................................................1757 Lift Trucks With Overhead Exhaust System......................................1759 Yanmar Diesel Engine......................................................1759 Remove and Disassemble................................................1759 Inspect...............................................................1759 Assemble and Install..................................................1760 Mazda Gas and LPG Engines.................................................1762 Remove and Disassemble................................................1762 Inspect...............................................................1762 Assemble and Install..................................................1762 Cooling System....................................................................1766 Description...................................................................1766 Fuel and Hydraulic Tanks Repair...................................................1766 Inspect.......................................................................1766 Clean.........................................................................1766 Steam Method of Cleaning..................................................1766 Chemical Solution Method of Cleaning......................................1767 Additional Preparations for Repair............................................1767 Small Leaks, Repair...........................................................1768 Large Leaks, Repair...........................................................1768 Preparations for Use After Repair.............................................1768 Safety Labels.....................................................................1768 tables................................................................................1720 Table 1. Weight of Counterweights, Lift Truck Models S2.0-3.5FT ..................1737 Table 2. Weight of Counterweights, Lift Truck Models S30FT, S35F..................1737 Table 3. Weight of Counterweights, Lift Truck Models H1.6FT, H1...................1737 Table 4. Weight of Counterweights, Lift Truck Models H2.0-3.5FT ..................1737 Gasoline Fuel System......................................................................1772 toc...................................................................................1772 Gasoline Fuel System..............................................................1772 General...........................................................................1774 Electronic Throttle Body Repair...................................................1774 Electronic Throttle Body......................................................1774 Remove....................................................................1774 Install...................................................................1774 Fuel System Repair................................................................1775 Before Repair Procedure.......................................................1775 After Repair Procedure........................................................1775 Fuel Leakage Check........................................................1775 Fuel Line Pressure Check......................................................1776 Fuel Injectors................................................................1777 Remove....................................................................1777 Install...................................................................1778 Pressure Regulator............................................................1778 Remove....................................................................1778 Install...................................................................1779 Control System....................................................................1779 Electronic Control Unit (ECU).................................................1779 Remove....................................................................1779 Install...................................................................1780 Power Latch Relay.............................................................1780 Remove....................................................................1780 Install...................................................................1781 Camshaft Position (CMP) Sensor................................................1781 Remove....................................................................1781 Install...................................................................1781 Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) ..............1782 Remove....................................................................1782 Install...................................................................1782 Engine Coolant Temperature (ECT) Sensor.......................................1782 Remove....................................................................1782 Install...................................................................1783 Oxygen Sensor.................................................................1783 Remove....................................................................1783 Install...................................................................1784 Gasoline Fuel System-2....................................................................1787 toc...................................................................................1787 Gasoline Fuel System..............................................................1787 General...........................................................................1790 Abbreviations.....................................................................1790 Engine Tune-up....................................................................1790 Engine Tune-Up Preparation....................................................1790 Idle Speed Adjustment.........................................................1790 Idle-Up Speed Check...........................................................1790 Intake-Air System.................................................................1792 Intake-Air System Manifold Vacuum Check.......................................1792 Throttle Body.................................................................1793 Remove....................................................................1793 Install...................................................................1793 Electronic Governor...........................................................1793 Remove....................................................................1793 Install...................................................................1793 Intake-Air Control (IAC) Valve................................................1793 Remove....................................................................1793 Install...................................................................1795 Intake Manifold...............................................................1795 Remove....................................................................1795 Install...................................................................1795 Fuel System.......................................................................1796 Before Repair Procedure.......................................................1796 Fuel Line Safety Procedure................................................1796 After Repair Procedure........................................................1796 Fuel Hose, Install........................................................1796 Fuel Leakage Check........................................................1797 Fuel Line Pressure Check......................................................1797 Fuel Injector.................................................................1798 Remove....................................................................1798 Install...................................................................1798 Pressure Regulator............................................................1799 Remove....................................................................1799 Install...................................................................1800 Exhaust System....................................................................1801 Exhaust System, Inspect.......................................................1801 Three-Way Catalytic (TWC) Converter...........................................1801 Remove and Install........................................................1801 Exhaust Manifold..............................................................1801 Remove....................................................................1801 Install...................................................................1801 Positive Crankcase Ventilation (PCV) Valve....................................1803 Remove....................................................................1803 Inspect...................................................................1803 Install...................................................................1803 Control System....................................................................1803 Engine Control Unit (ECU).....................................................1803 Remove....................................................................1803 Install...................................................................1805 Intake Air Temperature (IAT) Sensor...........................................1806 Remove....................................................................1806 Install...................................................................1806 Mass Air Flow (MAF) Sensor....................................................1806 Remove....................................................................1806 Install...................................................................1806 Throttle Position (TP) Sensor.................................................1807 TP Sensor, Adjust.........................................................1807 Remove....................................................................1808 Install...................................................................1808 Engine Coolant Temperature (ECT) Sensor.......................................1808 Remove....................................................................1808 Install...................................................................1809 Camshaft Position (CMP) Sensor................................................1809 Voltage Check.............................................................1809 Oxygen Sensor.................................................................1809 Remove....................................................................1809 Install...................................................................1809 Manifold Absolute Pressure (MAP)/Boost Sensor.................................1810 Remove....................................................................1810 Install...................................................................1810 Technical Data....................................................................1811 tables................................................................................1787 Table 1. PCV Valve Specifications.................................................1803 Table 2. Closed Throttle Position Specifications..................................1808 Table 3. Gasoline Fuel Systems Technical Data.....................................1811 Gasoline Fuel System-3....................................................................1813 toc...................................................................................1813 Gasoline Fuel System..............................................................1813 General...........................................................................1816 Abbreviations.....................................................................1816 Intake-Air System.................................................................1816 Intake-Air System Manifold Vacuum Check.......................................1816 Throttle Body.................................................................1817 Remove....................................................................1818 Install...................................................................1818 Intake Manifold...............................................................1818 Remove....................................................................1818 Install...................................................................1819 Fuel System.......................................................................1819 Before Repair Procedure.......................................................1819 Fuel Line Safety Procedure................................................1819 After Repair Procedure........................................................1821 Fuel Hose, Install........................................................1821 Fuel Leakage Check........................................................1821 Fuel Line Pressure Check......................................................1822 Fuel Injectors................................................................1823 Remove....................................................................1823 Install...................................................................1823 Pressure Regulator............................................................1825 Remove....................................................................1825 Install...................................................................1825 Exhaust System....................................................................1826 Exhaust System, Inspect.......................................................1826 Three-Way Catalytic (TWC) Converter...........................................1826 Remove and Install........................................................1826 Exhaust Manifold..............................................................1826 Remove....................................................................1826 Install...................................................................1826 Positive Crankcase Ventilation (PCV) Valve....................................1828 Remove....................................................................1828 Inspect...................................................................1828 Install...................................................................1828 Control System....................................................................1828 Engine Control Unit (ECU).....................................................1828 Remove....................................................................1828 Install...................................................................1828 Intake Air Temperature (IAT) Sensor...........................................1831 Remove....................................................................1831 Install...................................................................1831 Engine Coolant Temperature (ECT) Sensor.......................................1832 Remove....................................................................1832 Install...................................................................1833 CAM Angle Sensor..............................................................1833 Voltage Check.............................................................1833 Manifold Absolute Pressure (MAP) Sensor.......................................1834 Remove....................................................................1834 Install...................................................................1834 Oxygen Sensor.................................................................1835 Remove....................................................................1835 Install...................................................................1835 Technical Data....................................................................1836 tables................................................................................1813 Table 1. PCV Valve Specifications.................................................1828 Table 2. Gasoline Fuel Systems Technical Data.....................................1836 GM Engine Repair..........................................................................1839 toc...................................................................................1839 GM Engine Repair..................................................................1839 General...........................................................................1843 Engine Serial Number..............................................................1843 Engine Removal and Installation...................................................1844 Intake Manifold...................................................................1844 Remove........................................................................1844 Clean and Inspect.............................................................1845 Install.......................................................................1845 Exhaust Manifold..................................................................1846 Remove........................................................................1846 Clean and Inspect.............................................................1846 Install.......................................................................1847 Camshaft and Cylinder Head Repair.................................................1847 Rocker Arm Cover..............................................................1847 Remove....................................................................1847 Install...................................................................1847 Camshaft Timing Pulley and/or Front Seal......................................1848 Remove....................................................................1848 Install...................................................................1848 Camshaft Position (CMP) Sensor Assembly.......................................1849 Remove....................................................................1849 Install...................................................................1849 Camshaft Carrier and Cylinder Head............................................1849 Remove....................................................................1849 Disassemble...............................................................1851 Camshaft Carrier......................................................1851 Cylinder Head.........................................................1852 Clean and Inspect.........................................................1852 Camshaft Carrier......................................................1852 Cylinder Head.........................................................1853 Valve and Valve Seat......................................................1855 Assemble..................................................................1856 Cylinder Head.........................................................1856 Camshaft Carrier......................................................1856 Install...................................................................1856 Timing Belt.......................................................................1858 Timing Belt Front Cover.......................................................1858 Remove....................................................................1858 Install...................................................................1859 Timing Belt and Timing Belt Tensioner.........................................1859 Remove....................................................................1859 Install...................................................................1860 Timing Belt Rear Cover........................................................1861 Remove....................................................................1861 Install...................................................................1861 Lubrication System Repair.........................................................1862 Oil Pan.......................................................................1862 Remove....................................................................1862 Install...................................................................1862 Oil Pump......................................................................1864 Remove....................................................................1864 Clean and Inspect.........................................................1865 Install...................................................................1866 Piston and Piston Rod Assemblies Repair...........................................1867 Piston Rod Bearings, Replace..................................................1867 Piston and Piston Rod Assemblies..............................................1869 Remove....................................................................1869 Disassemble...............................................................1870 Pistons, Clean and Inspect................................................1870 Cylinder Bores, Inspect and Repair........................................1871 Piston Rings, Inspect.....................................................1871 Assemble..................................................................1872 Install...................................................................1873 Crankshaft and Main Bearings......................................................1874 Crankshaft Timing Pulley and/or Front Seal....................................1874 Remove....................................................................1874 Install...................................................................1875 Crankshaft Rear Main Oil Seal.................................................1875 Remove....................................................................1875 Install...................................................................1875 Crankshaft/RPM Sensor.........................................................1876 Remove....................................................................1876 Install...................................................................1876 Crankshaft Reluctor Wheel.....................................................1876 Remove and Install........................................................1876 Crankshaft and Main Bearings..................................................1877 Remove....................................................................1877 Inspect and Repair........................................................1878 Bearing Selection.........................................................1878 Main Bearings and Journal Clearance, Check................................1880 Install...................................................................1881 Flywheel and Flywheel Housing.....................................................1882 Remove........................................................................1882 Install.......................................................................1882 Cooling System Repair.............................................................1883 Serpentine Belt...............................................................1883 Remove....................................................................1883 Inspect...................................................................1883 Install...................................................................1883 Water Pump....................................................................1884 Remove....................................................................1884 Inspect...................................................................1886 Install...................................................................1886 Thermostat....................................................................1887 Remove....................................................................1887 Check.....................................................................1888 Install...................................................................1888 Thermostat Housing............................................................1889 Remove....................................................................1889 Clean and Inspect.........................................................1890 Install...................................................................1890 Ignition System...................................................................1891 Spark Plug Wire Inspection....................................................1891 Spark Plug Wire Replacement...................................................1891 Remove....................................................................1891 Install...................................................................1892 Spark Plug Replacement........................................................1892 Remove....................................................................1892 Install...................................................................1892 Spark Plug Inspection.........................................................1893 Usage.....................................................................1893 Inspect...................................................................1893 Visual Inspection.........................................................1894 Coil Pack.....................................................................1895 Remove....................................................................1895 Install...................................................................1895 Alternator Repair.................................................................1895 Alternator....................................................................1895 Remove....................................................................1895 Install...................................................................1896 Alternator Fuse, Replace......................................................1896 Starter Repair....................................................................1897 Remove........................................................................1897 Install.......................................................................1897 Engine Specifications.............................................................1897 Engine Data...................................................................1897 Cylinder Bore.................................................................1898 Piston........................................................................1898 Piston Rings..................................................................1898 Wrist Pin.....................................................................1898 Crankshaft....................................................................1899 Piston Rod....................................................................1899 Camshaft and Camshaft Carrier.................................................1899 Valve System..................................................................1900 Cylinder Head Warpage.........................................................1900 Lubrication System............................................................1900 Cooling System................................................................1901 Torque Specifications.............................................................1901 Special Tools.....................................................................1902 Hydraulic Gear Pump.......................................................................1908 toc...................................................................................1908 Hydraulic Gear Pump...............................................................1908 General...........................................................................1910 Single Gear Pump Assembly Repair..................................................1910 Remove........................................................................1910 Disassemble...................................................................1911 Clean.........................................................................1911 Inspect.......................................................................1911 Assemble......................................................................1911 Install.......................................................................1915 Tandem Gear Pump Assembly.........................................................1916 Remove........................................................................1916 Disassemble...................................................................1918 Clean.........................................................................1920 Inspect.......................................................................1920 Assemble......................................................................1920 Install.......................................................................1921 Gear Pump Specifications..........................................................1921 Torque Specifications.............................................................1925 tables................................................................................1908 Table 1. Standard Gear Pump for Lift Truck Models S30FT, S35FT, ..................1921 Table 2. High Pressure Gear Pump for Lift Truck Models S30FT, S3..................1922 Table 3. Standard Gear Pump for Lift Truck Models S4.0, 4.5, 5.5..................1923 Table 4. High Pressure Gear Pump for Lift Truck Models S4.0, 4.5..................1923 Table 5. Standard Gear Pump for Lift Truck Models S6.0FT, S7.0FT..................1924 Table 6. High Pressure Gear Pump for Lift Truck Models S6.0FT, S..................1924 LPG Fuel System...........................................................................1927 toc...................................................................................1927 LPG Fuel System...................................................................1927 General...........................................................................1930 Hoses Replacement.................................................................1930 LPG Tank Replacement..............................................................1930 Remove........................................................................1930 Install.......................................................................1932 Fuel Filter Unit Repair...........................................................1933 Fuel Filter Element...........................................................1933 Remove....................................................................1933 Clean/Inspect.............................................................1933 Install...................................................................1933 Fuel Filter Housing...........................................................1934 Remove....................................................................1934 Disassemble...............................................................1934 Assemble..................................................................1935 Install...................................................................1935 Electronic Throttle Body Repair...................................................1935 Electronic Throttle Body......................................................1935 Remove....................................................................1935 Install...................................................................1935 Electronic Throttle Body Adapter Plate........................................1936 Remove....................................................................1936 Install...................................................................1936 Fuel Injector Repair..............................................................1937 Fuel Rail.....................................................................1937 Remove....................................................................1937 Install...................................................................1937 Fuel Injector.................................................................1938 Remove....................................................................1938 Clean.....................................................................1939 Install...................................................................1939 Fuel Injector Adapters........................................................1940 Remove....................................................................1940 Install...................................................................1940 LPG Regulator Repair..............................................................1941 LPG Regulator.................................................................1941 Remove....................................................................1941 Install...................................................................1942 LPG Regulator Fuel Filter.....................................................1943 Remove....................................................................1943 Install...................................................................1943 Lock-Off Solenoid and Cartridge...............................................1944 Remove....................................................................1944 Install...................................................................1944 Control System....................................................................1945 Electronic Control Unit (ECU).................................................1945 Remove....................................................................1945 Install...................................................................1945 Power Latch Relay.............................................................1946 Remove....................................................................1946 Install...................................................................1947 Injector Driver Module........................................................1947 Remove....................................................................1947 Install...................................................................1948 Camshaft Position (CMP) Sensor................................................1948 Remove....................................................................1948 Install...................................................................1948 Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) ..............1949 Remove....................................................................1949 Install...................................................................1949 Engine Coolant Temperature (ECT) Sensor.......................................1949 Remove....................................................................1949 Install...................................................................1949 Oxygen Sensor.................................................................1950 Remove....................................................................1950 Install...................................................................1950 LPG Fuel System-2.........................................................................1953 toc...................................................................................1953 LPG Fuel System...................................................................1953 General...........................................................................1956 Hoses Replacement.................................................................1956 LPG Tank Replacement..............................................................1956 Remove........................................................................1956 Install.......................................................................1956 Fuel Filter.......................................................................1958 Remove........................................................................1958 Clean and Inspect.............................................................1959 Install.......................................................................1960 Relief Valve Replacement..........................................................1961 Remove and Install............................................................1961 Carburetor Repair.................................................................1961 Remove........................................................................1961 Disassemble...................................................................1961 Clean.........................................................................1963 Assemble......................................................................1963 Install.......................................................................1963 Fuel Injector Repair..............................................................1964 Remove........................................................................1964 Clean and Inspect.............................................................1964 Install.......................................................................1964 Governor Repair...................................................................1964 Remove........................................................................1964 Install.......................................................................1964 Regulator Repair..................................................................1965 Remove........................................................................1965 Install.......................................................................1966 Control System....................................................................1966 Engine Control Unit (ECU).....................................................1966 Remove....................................................................1966 Install...................................................................1966 Engine Coolant Temperature (ECT) Sensor.......................................1967 Remove....................................................................1967 Install...................................................................1967 Camshaft Position (CMP) Sensor................................................1967 Voltage Check.............................................................1967 Intake Air Temperature (IAT) Sensor...........................................1968 Remove....................................................................1968 Install...................................................................1968 Manifold Absolute Pressure (MAP) Sensor.......................................1969 Remove....................................................................1969 Install...................................................................1969 Oxygen Sensor.................................................................1969 Remove....................................................................1969 Install...................................................................1969 Throttle Position (TP) Sensor.................................................1970 Remove....................................................................1970 Install...................................................................1970 LPG Fuel System-3.........................................................................1973 toc...................................................................................1973 LPG Fuel System...................................................................1973 General...........................................................................1976 LPG Tank Replacement..............................................................1976 Remove........................................................................1976 Install.......................................................................1978 Fuel Filter Unit Repair...........................................................1979 Fuel Filter Element...........................................................1979 Remove....................................................................1979 Clean/Inspect.............................................................1979 Install...................................................................1979 Fuel Filter Housing...........................................................1980 Remove....................................................................1980 Disassemble...............................................................1981 Assemble..................................................................1981 Install...................................................................1982 Electronic Throttle Body Repair...................................................1982 Remove........................................................................1982 Install.......................................................................1983 Electronic Pressure Regulator (EPR) Repair........................................1984 Remove........................................................................1984 Disassemble...................................................................1985 Assemble......................................................................1987 Install.......................................................................1989 LPG Shutoff Valve Assembly........................................................1990 Remove........................................................................1990 Install.......................................................................1990 Fuel Mixer Repair.................................................................1992 Remove........................................................................1992 Install.......................................................................1993 Control System....................................................................1995 Engine Control Unit (ECU).....................................................1995 Remove....................................................................1995 Install...................................................................1996 Engine Coolant Temperature (ECT) Sensor.......................................1997 Remove....................................................................1997 Install...................................................................1997 CAM Angle Sensor..............................................................1998 Voltage Check.............................................................1998 Manifold Absolute Pressure (MAP) Sensor.......................................1999 Remove....................................................................1999 Install...................................................................1999 Intake Air Temperature (IAT) Sensor...........................................1999 Remove....................................................................1999 Install...................................................................1999 Fuel Temperature Sensor.......................................................2000 Remove....................................................................2000 Install...................................................................2000 Oxygen Sensor.................................................................2001 Remove....................................................................2001 Install...................................................................2001 Exhaust System....................................................................2002 Exhaust System, Inspect.......................................................2002 Three-Way Catalytic (TWC) Converter...........................................2002 Remove and Install........................................................2002 Exhaust Manifold..............................................................2002 Remove....................................................................2002 Install...................................................................2002 Positive Crankcase Ventilation (PCV) Valve....................................2004 Remove....................................................................2004 Inspect...................................................................2004 Install...................................................................2004 tables................................................................................1973 Table 1. PCV Valve Specifications.................................................2004 Main Control Valve........................................................................2007 toc...................................................................................2010 General...........................................................................2010 Electro-Hydraulic Main Control Valve..............................................2011 Description...................................................................2011 Remove........................................................................2014 Electro-Hydraulic Control Valve Sections......................................2018 General...................................................................2018 Outlet Control Valve Section..............................................2018 Remove................................................................2018 Disassemble...........................................................2018 Clean.................................................................2018 Inspect...............................................................2018 Assemble..............................................................2020 Install...............................................................2020 Auxiliary Control Valve Sections..........................................2020 Remove................................................................2020 Disassemble...........................................................2022 Clean.................................................................2023 Inspect...............................................................2023 Assemble..............................................................2023 Install...............................................................2023 Tilt Control Valve Section................................................2024 Remove................................................................2024 Disassemble...........................................................2024 Clean.................................................................2024 Inspect...............................................................2027 Assemble..............................................................2027 Install...............................................................2027 Lift/Lower Control Valve Section..........................................2027 Remove................................................................2027 Disassemble...........................................................2027 Clean.................................................................2030 Inspect...............................................................2030 Assemble..............................................................2030 Install...............................................................2031 Mid-Inlet Section.........................................................2031 Remove................................................................2031 Clean.................................................................2032 Inspect...............................................................2032 Install...............................................................2032 Install.......................................................................2032 Electro Hydraulic Poppet Valve (EHPV) Pilot Pin Adjustment....................2036 Lift Pilot Pin............................................................2036 Lower Pilot Pin...........................................................2038 Abnormal/Erroneous EHPV Adjustment........................................2040 Manual Main Control Valve.........................................................2040 Description...................................................................2040 Remove........................................................................2041 Manual Control Valve Sections.................................................2046 General...................................................................2046 Outlet Control Valve Section..............................................2046 Remove................................................................2046 Disassemble...........................................................2046 Clean.................................................................2048 Inspect...............................................................2048 Assemble..............................................................2048 Install...............................................................2048 Auxiliary Control Valve Sections..........................................2048 Remove................................................................2048 Disassemble...........................................................2049 Clean.................................................................2049 Inspect...............................................................2049 Assemble..............................................................2049 Install...............................................................2051 Lift/Tilt Control Valve Section...........................................2051 Remove................................................................2051 Disassemble...........................................................2051 Clean.................................................................2054 Inspect...............................................................2054 Assemble..............................................................2054 Install...............................................................2055 Mid-Inlet Section.........................................................2055 Remove................................................................2055 Clean.................................................................2056 Inspect...............................................................2056 Install...............................................................2056 Install.......................................................................2056 Pressure Relief Valve Check and Adjustment........................................2060 Primary Relief Valve..........................................................2060 Secondary Relief Valve........................................................2061 Steering Control Unit Repair......................................................2064 Steering Control Unit, Remove.................................................2064 Steering Control Unit, Disassemble............................................2067 Steering Control Unit, Clean..................................................2067 Steering Control Unit, Inspect................................................2067 Steering Control Unit, Assemble...............................................2069 Relief Valve, Disassemble.....................................................2069 Relief Valve, Clean...........................................................2070 Relief Valve, Inspect.........................................................2070 Relief Valve, Assemble........................................................2070 Steering Control Unit, Install................................................2070 tables................................................................................2061 Table 1. Relief Valve Settings....................................................2061 Table 2. Steering Relief Pressures................................................2071 Mast Repairs..............................................................................2073 toc...................................................................................2073 Mast Repairs......................................................................2073 General...........................................................................2076 Safety Procedures When Working Near Mast..........................................2076 Fork Repair.......................................................................2078 Remove........................................................................2078 Install.......................................................................2078 Checks........................................................................2079 Carriages Repair..................................................................2080 Standard Carriage.............................................................2080 Remove....................................................................2080 Repair....................................................................2081 Install...................................................................2081 Integral Sideshift Carriage...................................................2081 Remove....................................................................2081 Clean and Inspect.........................................................2084 Repair....................................................................2085 Install...................................................................2086 Mast Repair.......................................................................2086 Mast, Remove..................................................................2086 Two-Stage LFL and Two-Stage FFL Masts, Disassemble............................2090 Clean and Inspect.............................................................2096 Three-Stage FFL Mast..........................................................2097 Disassemble...............................................................2097 Clean and Inspect.........................................................2101 Two-Stage LFL and Two-Stage FFL Mast, Assemble................................2102 Three-Stage FFL Mast, Assemble................................................2103 Four-Stage FFL, Disassemble...................................................2105 Clean and Inspect.............................................................2109 Four-Stage FFL, Assemble......................................................2111 Mast, Install.................................................................2113 Header Hose Arrangement...........................................................2116 Two-Stage LFL.................................................................2116 Two-Stage FFL.................................................................2123 Three-Stage FFL...............................................................2135 Four-Stage FFL................................................................2150 Adjustment....................................................................2158 Lift Chains Adjustment............................................................2159 Carriage Adjustments..............................................................2161 Tilt Cylinders Adjustment.........................................................2161 Mast Adjustments..................................................................2165 Load Roller Adjustment........................................................2165 Mast Side Kicking Adjustment..................................................2167 tables................................................................................2073 Table 1. Fork Tip Alignment.......................................................2079 Table 2. Pneumatic Tire Trucks....................................................2119 Table 3. Cushion Tire Trucks......................................................2119 Table 4. Standard Two-Stage Hose Dimensions.......................................2122 Table 5. Pneumatic Tire Trucks....................................................2126 Table 6. Cushion Tire Trucks......................................................2126 Table 7. Pneumatic Tire Trucks....................................................2144 Table 8. Cushion Tire Trucks......................................................2144 Table 9. Standard Three-Stage Hose Dimensions.....................................2146 Table 10. Standard Four-Stage Hose Dimensions.....................................2151 Table 11. Hook-Type Carriage Chain Adjustment.....................................2159 Table 12. Pin-Type Carriage Chain Adjustment......................................2160 Mazda Engine..............................................................................2169 toc...................................................................................2169 Mazda Engine......................................................................2169 General...........................................................................2172 Serial Number.................................................................2172 Engine Removal and Installation...................................................2172 Cylinder Head, Camshaft, and Valve Mechanism Repair...............................2173 Remove........................................................................2173 Clean.........................................................................2175 Inspect and Repair............................................................2175 Cylinder Head.............................................................2175 Rocker Shaft Assembly.....................................................2175 Camshaft..................................................................2175 Valve Guides..............................................................2177 Valve Seats...............................................................2177 Valves....................................................................2177 Valve Springs.............................................................2178 Install.......................................................................2178 Crankshaft and Main Bearings Repair...............................................2182 Remove........................................................................2182 Inspect and Repair............................................................2183 Crankshaft................................................................2183 Main Bearings.............................................................2183 Install.......................................................................2184 Pistons and Connecting Rods Repair................................................2185 Remove and Disassemble........................................................2185 Clean.........................................................................2185 Inspect and Repair............................................................2185 Pistons...................................................................2185 Piston Rings..............................................................2185 Connecting Rods and Bearings..............................................2186 Assemble and Install..........................................................2186 Cylinder Block Repair.............................................................2188 Oil Pump Repair...................................................................2188 Remove........................................................................2188 Disassemble...................................................................2190 Clean.........................................................................2190 Inspect.......................................................................2190 Assemble......................................................................2191 Install.......................................................................2191 Cooling System Repair.............................................................2193 Thermostat....................................................................2193 Replace...................................................................2193 Fan Assembly..................................................................2193 Remove and Disassemble....................................................2193 Assemble and Install......................................................2193 Water Pump....................................................................2194 Remove....................................................................2194 Install...................................................................2195 Flywheel and Ring Gear Repair.....................................................2195 Remove........................................................................2195 Install.......................................................................2195 Valve Adjustment..................................................................2196 Compression Pressure Check........................................................2197 Engine Timing Adjustment..........................................................2198 Engine Specifications.............................................................2198 Engine Data...................................................................2198 Engine Speeds.................................................................2198 2007 Emission Compliant Engines...........................................2198 All Engines Except 2007 Emission Compliant Engines........................2199 Thermostat....................................................................2199 Cylinder Head.................................................................2199 Valve Mechanism...............................................................2199 Camshaft......................................................................2200 Crankshaft....................................................................2200 Connecting Rods...............................................................2201 Cylinder Block................................................................2201 Pistons.......................................................................2201 Oil Pump......................................................................2202 Torque Specifications.............................................................2202 tables................................................................................2169 Table 1. Pressure Specifications..................................................2197 Metric and Inch (SAE) Fasteners...........................................................2205 toc...................................................................................2205 Metric and Inch (SAE) Fasteners...................................................2205 General...........................................................................2207 Threaded Fasteners............................................................2207 Nomenclature, Threads.........................................................2207 Strength Identification.......................................................2208 Cotter (Split) Pins...........................................................2208 Fastener Torque Tables........................................................2213 Conversion Table..............................................................2215 tables................................................................................2205 Table 1. Bolts and Screws.........................................................2209 Table 2. Studs and Nuts...........................................................2210 Table 3. Torque Nuts..............................................................2211 Table 4. Torque Nuts With Nylon Insert............................................2212 Table 5. Torque Values for Metric Fasteners*......................................2213 Table 6. Torque Values for Inch Fasteners*........................................2214 Table 7. Conversion Table for Metric and English Units............................2215 Table 8. Cotter Pin Dimensional Data..............................................2216 Table 9. Cotter Pin Dimensional Data..............................................2217 Table 10. Cotter Pin Dimensional Data.............................................2218 Table 11. Cotter Pin Dimensional Data.............................................2220 Operational Checkout......................................................................2224 toc...................................................................................2224 Operational Diagnostic Procedures.................................................2224 Operational Checkout Procedures...............................................2224 DTC Check.................................................................2225 Horn Circuit Check........................................................2225 Light Circuit Check.......................................................2225 Windshield Washer Wiper Check (If equipped)...............................2225 Heater Check (If equipped)................................................2226 Dome Light Check (If equipped)............................................2226 Circulating (Accessory) Fan Check (If equipped)...........................2227 Indicator Light Power Check...............................................2228 Engine Malfunction Indicator Check........................................2229 Cold Start Check (Cummins and Yanmar).....................................2229 Brake Pedal Check.........................................................2229 Backup Alarm Check (If equipped)..........................................2230 Operator Presence System Check............................................2230 Hydraulic Interlock Check.................................................2230 Armrest Hydraulic Interlock Check (If equipped and with original..........2230 Engine Cover Latch Sensor Check (If equipped).............................2231 Brake and Inching Pedal Check.............................................2231 Park Brake Sensor Check...................................................2231 Park Brake Check..........................................................2232 Engine Speed Check (All Cummins, Yanmar, and Mazda Engines Excep..........2232 Engine Power Check........................................................2233 Transmission Clutch Check.................................................2233 Transmission Check........................................................2234 Transmission Speed Selection Check (If equipped)..........................2234 Brake and Axle Drag Check.................................................2234 Hydraulic Pump Flow Check.................................................2235 Priority Flow Divider Valve Check.........................................2236 Steering Relief Valve Low Pressure Check..................................2236 Steering Relief Valve High Pressure Check.................................2237 Control Valve Load Check Valve (Manual Valve).............................2237 Lift E-Valve Check............................................................2237 Lift Check (E-Valve)......................................................2237 Tilt Function Counterbalance Check........................................2238 Lift Drift Check..........................................................2238 Tilt Function Drift Check.................................................2239 Mast Cushion Check (All Except 2-Stage Mast)..............................2239 Lift/Tilt Mast Adjustment Check...........................................2239 Tilt Racking Check........................................................2240 Chain and Header Hose Adjustment Check....................................2240 Mast Mounting Check.......................................................2241 Mast Channel Check........................................................2241 Carriage Adjustment Check.................................................2242 Chain Sheave Check........................................................2242 Carriage Adjustment Check (Standard and Integral Side Shift)..............2242 Periodic Maintenance......................................................................2243 toc...................................................................................2243 Periodic Maintenance..............................................................2243 General...........................................................................2248 Serial Number Data............................................................2248 How to Move Disabled Lift Truck...............................................2248 How to Tow Lift Truck.....................................................2248 How to Put Lift Truck on Blocks...............................................2249 How to Raise Drive Tires..................................................2249 How to Raise Steering Tires...............................................2250 Maintenance Schedule..............................................................2250 Maintenance Procedures Every 8 Hours or Daily.....................................2267 How to Make Checks With Engine Stopped........................................2267 Tires and Wheels..........................................................2267 Safety Labels.............................................................2268 Mast, Carriage, Lift Chains, Header Hoses, Attachment.....................2268 Operator Restraint System.................................................2268 Automatic Locking Retractor (ALR).....................................2268 Emergency Locking Retractor (ELR).....................................2269 Hood and Seat Latches.....................................................2270 Engine Compartment........................................................2270 Paper Application.........................................................2270 Fuel, Oil, and Coolant Leaks, Check.......................................2271 Hydraulic Hoses...........................................................2271 Coolant Hoses.............................................................2271 Steering Column Gas Cylinder..............................................2271 Transmission..............................................................2272 Hydraulic System Oil......................................................2272 Engine Oil................................................................2272 Air Filter................................................................2278 Forks.....................................................................2278 Remove................................................................2278 Inspect...............................................................2278 Install...............................................................2279 Adjust................................................................2279 How to Make Checks With Engine Running........................................2280 Indicator Lights, Horn, Fuses, and Relays.................................2280 Service Brakes............................................................2282 Brake Fluid Level.....................................................2282 Operation, Check......................................................2283 Parking Brake.............................................................2283 Engine Oil Pressure.......................................................2283 Cooling System............................................................2284 Steering System...........................................................2284 Control Levers and Pedals.................................................2285 Lift System, Operate......................................................2285 First Service After First 100 Hours of Operation..................................2286 Mazda and GM Engine Oil Filter................................................2286 Yanmar Engine Oil Filter......................................................2286 Hydraulic System..............................................................2287 Hydraulic Filter, Replace.................................................2287 Transmission Oil Filter, Replace..............................................2288 Maintenance Procedures Every 250 Hours or 6 months................................2288 Mazda and GM Engine Oil and Filter............................................2288 Drive Belt....................................................................2289 Mazda 2.0L and 2.2L Engines...............................................2289 Fan and Alternator Drive Belt.........................................2289 GM 2.4L Engine............................................................2290 Fan and Alternator Drive Belt.........................................2290 Drain Tar From LPG Regulator (Except 2007 Mazda Emission Complia..............2290 Drain Tar From LPG Regulator (2007 Mazda Emission Compliant Engi..............2291 Maintenance Procedures Every 500 Hours or 6 Months................................2292 Hydraulic System Oil..........................................................2292 Hydraulic Tank Breather.......................................................2292 Inspect...................................................................2292 Battery.......................................................................2293 Yanmar Engine Oil and Filter..................................................2293 Drive Belt....................................................................2293 Yanmar Diesel Engine......................................................2293 Fan and Alternator Drive Belt.........................................2293 PCV Valve.....................................................................2294 Clean Debris From Radiator Core...............................................2294 Transmission Oil Level........................................................2294 Wet Brake Planetary Housing Oil Level Check...................................2295 Forks.........................................................................2296 Mast Lubrication..............................................................2297 Header Hose Checks............................................................2299 Lift Chain Lubrication........................................................2300 Tilt Cylinder Lubrication.....................................................2300 Master Brake Cylinder Rod End Pin Lubrication.................................2301 Manual Hydraulic Levers Lubrication...........................................2301 Brake Fluid...................................................................2302 Tie Rod Lubrication (H40-70FT)................................................2303 Differential and Drive Axle Oil (Dry Brake)...................................2303 Maintenance Procedures Every 1000 Hours or 6 Months...............................2303 Valve Clearance, Check and Adjust.............................................2303 Ignition System...............................................................2304 GM 2.4L Engine............................................................2304 Mazda 2.0L and 2.2L Engines...............................................2304 LPG Fuel Filter Element Replace, GM 2.4L Engine...............................2304 Remove....................................................................2304 Install...................................................................2304 LPG Vapor Fuel Filter Replace, Mazda Engines (Except 2007 Mazda ..............2305 LPG Fuel Filter Replace, Mazda 2007 Emission Compliant Engines O..............2305 Remove....................................................................2305 Clean/Inspect.............................................................2306 Install...................................................................2306 Gasoline Fuel Filter Replacement, Mazda 2007 Emission Compliant ..............2306 Remove and Replace........................................................2306 Fuel Filter Replacement, Yanmar Engine........................................2307 Priming the Fuel System (Yanmar)..............................................2308 Lift Chains Wear Check........................................................2309 Lift Chain Lubrication........................................................2310 Integral Sideshift Carriage, Check Bearings...................................2310 Steering Axle.................................................................2311 Control Levers and Pedals.....................................................2311 Maintenance Procedures Every 2000 Hours or Annually...............................2312 Hydraulic System..............................................................2312 Hydraulic Filter, Replace.................................................2312 Hydraulic Tank Breather, Replace..........................................2313 Air Filter....................................................................2313 PCV Valve.....................................................................2315 Oxygen Sensor.................................................................2315 LPG Regulator Fuel Filter, Mazda Engines (Except 2007 Mazda Emis..............2317 Remove and Replace........................................................2317 LPG Regulator Fuel Filter, GM Engine..........................................2318 Remove....................................................................2318 Install...................................................................2318 Gasoline Fuel Filter..........................................................2318 Remove and Replace........................................................2318 Timing Belt...................................................................2319 Mazda Engines.............................................................2319 GM 2.4L Engine............................................................2319 LPG Fuel Injector, Mazda Engines (Except 2007 Mazda Emission Com..............2319 Gasoline Fuel Injector, Mazda Engines.........................................2319 LPG Fuel Injector, GM Engines.................................................2319 Gasoline Fuel Injector, GM Engines............................................2319 Fuel Injector, Yanmar Engines.................................................2319 Forks.........................................................................2320 Integral Sideshift Carriage...................................................2320 Bearings, Replace.........................................................2320 Transmission Oil and Filter (Dry Brake), Replace..............................2320 Transmission and Left Planetary Housing Oil Change, Wet Brake Dr..............2321 Wet Brake Axle Center Section and Right Side Planetary Housing, ..............2323 Brake Fluid (Master Cylinder), Change.........................................2324 Brake Fluid (Dry Brake), Remove...............................................2325 Service Brakes (Dry Brake)....................................................2325 Differential (Dry Brake)......................................................2326 Valve Clearance, Check and Adjust for Cummins QSB 3.3L Diesel En..............2327 Maintenance Procedures Every 4000 Hours or 2 Years................................2328 Hydraulic Oil, Replace........................................................2328 Cooling System................................................................2329 Safety Procedures When Working Near Mast..........................................2329 Hood Latch Check..................................................................2333 Lift Chain Adjustments............................................................2334 Jump-Starting the Lift Truck......................................................2335 Jump-Starting Using a Battery Charger.........................................2335 Jump-Starting a Lift Truck Using Another Lift Truck...........................2335 Welding Repairs...................................................................2336 Overhead Guard Changes............................................................2336 Wheel and Tire Replacement........................................................2337 General.......................................................................2337 Solid Rubber Tire, Change ( S Series).........................................2337 Remove and Install Tire on Wheel..........................................2337 Pneumatic Tire With Tube, Repair..............................................2338 Remove Wheels From Lift Truck.............................................2338 Remove Tire From Wheel....................................................2338 Remove Tire From Two-Piece Wheel......................................2339 Remove Tire From Three- and Four-Piece Wheels.........................2340 Install Wheel in Tire.....................................................2341 Install Three-Piece or Four-Piece Wheel in Tire.......................2341 Install Tire on Two-Piece Wheel.......................................2342 Install Two-Piece Wheel in Tire.......................................2343 Add Air to Pneumatic Tires With Tube..........................................2343 Install the Wheels........................................................2344 Dual Drive Wheels, Install................................................2344 Pneumatic Tubeless Tire, Repair...............................................2345 Remove Wheels From Lift Truck.............................................2345 Remove Tire From Wheel....................................................2345 Install Tire on Wheel.....................................................2347 Add Air to Pneumatic Tubeless Tire........................................2349 Wheels, Install...........................................................2350 Solid Rubber Tires on Pneumatic Wheels, Change................................2350 Remove Wheel From Tire....................................................2350 Install Tire on Wheel.....................................................2352 Adhesives and Sealants............................................................2354 tables................................................................................2243 Table 1. Maintenance Schedule.....................................................2258 Table 2. V-Belt Deflection Table..................................................2293 Table 3. Carriage Chain Adjustment, Forks Not Installed...........................2335 Powershift Transmission...................................................................2357 toc...................................................................................2358 General...........................................................................2358 Serial Number.................................................................2358 Charge Pump Repair................................................................2359 Remove........................................................................2359 Inspect.......................................................................2359 Install.......................................................................2359 Torque Converter Replace..........................................................2360 Remove........................................................................2360 Install.......................................................................2364 Front Cover Housing and Chain Drive Repair........................................2370 Remove........................................................................2370 Clean.........................................................................2377 Inspect.......................................................................2377 Install.......................................................................2377 Clutch Packs Repair...............................................................2383 Remove and Disassemble........................................................2383 Transmission, Remove and Disassemble......................................2383 Clutch Assemblies, Remove and Disassemble.................................2394 Clean.........................................................................2400 Inspect.......................................................................2400 Assemble and Install..........................................................2401 Clutch Assemblies, Assemble and Install...................................2401 Transmission, Assemble and Install........................................2409 Control Valve Repair..............................................................2414 Remove and Disassemble........................................................2414 Clean.........................................................................2415 Inspect.......................................................................2415 Assemble and Install..........................................................2417 MONOTROL® Pedal Repair............................................................2418 Remove and Disassemble........................................................2418 Assemble and Install..........................................................2421 Direction Control Lever...........................................................2422 Remove........................................................................2422 Install.......................................................................2422 Steering Axle.............................................................................2425 toc...................................................................................2425 Steering Axle.....................................................................2425 General...........................................................................2428 Steering Axle Assembly Repair.....................................................2429 Remove........................................................................2429 Disassemble...................................................................2430 Clean.........................................................................2430 Inspect.......................................................................2430 Assemble......................................................................2437 Install.......................................................................2442 Spindles, Bearings, and Tie Rods Repair...........................................2443 Spindles and Bearings.........................................................2443 S2.0-3.5FT (S40-70FT, S55FTS) (F187), S4.0, 4.5, 5.5FT, S5.5FTS,..........2443 Remove................................................................2443 Disassemble...........................................................2444 Clean.................................................................2445 Inspect...............................................................2445 Assemble..............................................................2445 Install...............................................................2446 Spindles and Bearings.........................................................2449 S30FT, S35FT, S40FTS (E010), H1.6FT, H1.8FT, H2.0FTS (H30FT, H35..........2449 Remove and Disassemble................................................2449 Assemble and Install..................................................2449 Tie Rods......................................................................2450 S2.0-3.5FT (S40-70FT, S55FTS) (F187), and S4.0, 4.5, 5.5FT, S5.5..........2450 Remove................................................................2450 Install...............................................................2451 Tie Rods......................................................................2452 S30FT, S35FT, S40FTS (E010), H1.6FT, H1.8FT, H2.0FTS (H30FT, H35..........2452 Remove................................................................2452 Install...............................................................2452 Steering Cylinder Repair..........................................................2455 Remove and Disassemble........................................................2455 Clean and Inspect.............................................................2456 Assemble and Install..........................................................2456 Torque Specifications.............................................................2457 User Interface............................................................................2460 toc...................................................................................2462 General...........................................................................2462 Description...................................................................2462 Dash Display Menu Access......................................................2462 Menu Navigation...................................................................2463 Standard Display..............................................................2463 Main Menu.........................................................................2463 Passwords Menu....................................................................2464 Password Administration...........................................................2464 Add Password..................................................................2464 Delete Password...............................................................2465 Edit Password.................................................................2465 Other Password Functions..........................................................2466 Operator Passwords - Enable/Disable...........................................2466 Password Time-Out Delay.......................................................2467 Passwords - Number Wrong to Disable...........................................2467 Lockout Reset Password........................................................2468 View Password Log.............................................................2468 View Versions.....................................................................2469 VSM Versions..................................................................2469 Dash Display Versions.........................................................2470 Engine Controller Version.....................................................2471 Transmission (Xmsn) Controller Version........................................2472 Truck Serial Number...........................................................2473 Diagnostics.......................................................................2474 View Fault Log................................................................2474 Set Travel and Braking............................................................2475 Speed Limit...................................................................2475 Acceleration Rate.............................................................2476 Auto-Deceleration Rate........................................................2476 Set Power Reversal Rate.......................................................2477 Set Inching/Brake Overlap.....................................................2478 Setup Display Menu................................................................2479 Set Operator Language.........................................................2479 Set Units.....................................................................2480 Set Time Format (12/24 Hour)..................................................2480 Set Daylight Saving Time......................................................2481 Set Time......................................................................2483 Set Date Format...............................................................2483 Set Date......................................................................2483 Setup Hydraulics..................................................................2484 Return to Set Tilt Delay/On/Off...............................................2484 Setup General Items...............................................................2485 Light Shutdown Time-Out.......................................................2485 Impact Sensor - Enable/Disable................................................2486 Impact Sensor - Soft Impact Settings..........................................2487 Impact Sensor - Hard Impact Settings..........................................2487 Adjust Impact Sensor Settings.................................................2488 Initial Adjustment of Soft and Hard Impact Settings.......................2490 Readjustment of Soft and Hard Impact Settings.............................2491 Impact Sensor - Impact Alarm/Shutdown Reset...................................2491 Impact Sensor - Alarm Time Duration and Deactivation..........................2492 Impact Sensor - View Impact Event Log.........................................2493 Operator Checklist................................................................2494 Operator Checklist Off-On Mode................................................2494 Edit Operator Checklist.......................................................2494 Set Operator Checklist Expiration.............................................2495 View Checklist Log............................................................2495 Clear Operator Checklist Log..................................................2496 Clear Operator Checklist Fault................................................2496 Calibrations......................................................................2497 Set Tilt Stop Point...........................................................2497 Calibrate Loaded Weight.......................................................2497 tables................................................................................2462 Table 1. Password Screen..........................................................2462 Table 2. Exit Options Menu........................................................2463 Table 3. Add Password Menu........................................................2464 Table 4. Delete Password Menu.....................................................2465 Table 5. Edit Password Menu.......................................................2466 Table 6. Operator Passwords Menu..................................................2466 Table 7. Password Time-Out Delay Menu.............................................2467 Table 8. Passwords - Number Wrong to Disable Menu.................................2467 Table 9. View Password Log Menu...................................................2468 Table 10. View VSM Versions Menu..................................................2469 Table 11. View Dash Display Versions Menu.........................................2470 Table 12. View Engine Controller Versions Menu....................................2471 Table 13. View Transmission Controller Versions Menu..............................2472 Table 14. View Truck Serial Number Menu...........................................2473 Table 15. View Fault Log..........................................................2474 Table 16. Speed Limit Menu........................................................2475 Table 17. Acceleration Rate Menu..................................................2476 Table 18. Auto-Decel Menu.........................................................2476 Table 19. Power Reversal Menu.....................................................2477 Table 20. Inch/Brake Overlap Menu.................................................2478 Table 21. Set Language Menu.......................................................2479 Table 22. Set Units Menu..........................................................2480 Table 23. Set Time Format Menu....................................................2480 Table 24. Set Daylight Saving Time Menu...........................................2481 Table 25. Set Time Menu...........................................................2483 Table 26. Set Date Format Menu....................................................2483 Table 27. Set Date Menu...........................................................2483 Table 28. Tilt Delay Menu.........................................................2484 Table 29. Light Time-Out Menu.....................................................2485 Table 30. Impact Sensor Enable/Disable............................................2486 Table 31. Soft Impact Settings Menu...............................................2487 Table 32. Hard Impact Settings Menu...............................................2488 Table 33. Impact Sensor Default Settings..........................................2488 Table 34. Recommended Starting Values for Impact Sensor Settings..................2490 Table 35. Shutdown Reset Menu.....................................................2491 Table 36. Alarm Duration Menu.....................................................2492 Table 37. View Event Log Menu.....................................................2493 Table 38. Checklist Off-On Mode Menu..............................................2494 Table 39. Edit Checklist Menu.....................................................2494 Table 40. Checklist Expiration Menu...............................................2495 Table 41. View Checklist Log Menu.................................................2495 Table 42. Clear Checklist Log Menu................................................2496 Table 43. Clear Checklist Fault Menu..............................................2496 Table 44. Tilt Stop Point Menu....................................................2497 Table 45. Calibrate Loaded Weight.................................................2497 User Interface-2..........................................................................2499 toc...................................................................................2501 General...........................................................................2501 Description...................................................................2501 Dash Display Menu Access......................................................2501 Menu Navigation...................................................................2502 Main Menu.........................................................................2503 Passwords.........................................................................2503 Adding Passwords..............................................................2504 Hourmeters........................................................................2505 View Versions.....................................................................2506 VSM Versions..................................................................2506 Dash Display Versions.........................................................2507 Engine Controller Version.....................................................2508 Transmission (Xmsn) Controller Version........................................2509 Truck Serial Number...........................................................2510 Truck Configuration...........................................................2511 Diagnostics.......................................................................2512 Clear Fault Log...............................................................2512 View Fault Log................................................................2513 No-Run Data Display...........................................................2514 Engine Accelerator and Throttle Data Display..................................2515 Engine Speeds and Governor Data Display.......................................2516 Engine Fuel and Emissions Data Display........................................2518 Engine General Data Display...................................................2521 XMSN/Brake Data Display.......................................................2522 Hydraulic Data Display........................................................2524 General Truck Data Display....................................................2526 Set Travel and Braking............................................................2528 Speed Limit...................................................................2528 Acceleration Rate.............................................................2529 Auto-Deceleration Rate........................................................2529 Set Power Reversal Rate.......................................................2530 Set Inching/Brake Overlap.....................................................2531 Setup Hydraulics..................................................................2532 Lift Maximum Speed............................................................2532 Lower Maximum Speed...........................................................2533 Tilt Maximum Speed............................................................2533 Auxiliary Function One, Direction A, Maximum Speed............................2535 Auxiliary Function One, Direction B, Maximum Speed............................2535 Auxiliary Function Two, Direction A, Maximum Speed............................2536 Auxiliary Function Two, Direction B, Maximum Speed............................2536 Auxiliary Function Three, Direction A, Maximum Speed..........................2537 Auxiliary Function Three, Direction B, Maximum Speed..........................2537 Lift/Lower Ramp Rate..........................................................2538 Hydraulic Auxiliary Ramp Rate.................................................2539 Return to Set Tilt Delay/On/Off...............................................2540 Setup Display.....................................................................2541 Set Service Language..........................................................2541 Setup General Items...............................................................2542 Motion Alarm Activation Type..................................................2542 Light Shutdown Time-Out.......................................................2543 Restore Default Settings......................................................2544 Restore Engine Controller Default Calibration.................................2544 Impact Sensor - Enable/Disable................................................2545 Impact Sensor - Soft Impact Settings..........................................2546 Impact Sensor - Hard Impact Settings..........................................2546 Adjust Impact Sensor Settings.................................................2547 Initial Adjustment of Soft and Hard Impact Settings.......................2549 Readjustment of Soft and Hard Impact Settings.............................2550 Impact Sensor - Impact Alarm/Shutdown Reset...................................2550 Impact Sensor - Alarm Time Duration and Deactivation..........................2551 Impact Sensor - View Impact Event Log.........................................2552 Calibrations......................................................................2553 Calibrate Transmission Valve..................................................2555 Set Tilt Stop Point...........................................................2555 Calibrate Loaded Weight.......................................................2556 Calibrate Travel Speed Sensor.................................................2556 Calibrate Mazda LP and Gas Accelerator Pedal..................................2557 tables................................................................................2501 Table 1. Password Screen..........................................................2501 Table 2. Exit Menu................................................................2502 Table 3. Add Password Menu........................................................2504 Table 4. Hourmeters Menu..........................................................2505 Table 5. View VSM Versions Menu...................................................2506 Table 6. View Dash Display Versions Menu..........................................2507 Table 7. View Engine Controller Versions Menu.....................................2508 Table 8. View Transmission Controller Versions Menu...............................2509 Table 9. View Truck Serial Number Menu............................................2510 Table 10. View Truck Configuration Menu...........................................2511 Table 11. Clear Fault Log.........................................................2512 Table 12. View Fault Log..........................................................2513 Table 13. No-Run Data Display.....................................................2514 Table 14. Engine Accelerator and Throttle Data Display............................2515 Table 15. Engine Speeds and Governor Data Display.................................2517 Table 16. Engine Fuel and Emissions Data Display..................................2519 Table 17. Engine General Data Display.............................................2521 Table 18. XMSN Brake Data Display.................................................2522 Table 19. Hydraulic Data Display..................................................2524 Table 20. General Truck Data Display..............................................2526 Table 21. Speed Limit Menu........................................................2528 Table 22. Acceleration Rate Menu..................................................2529 Table 23. Auto-Decel Menu.........................................................2529 Table 24. Power Reversal Menu.....................................................2530 Table 25. Inch/Brake Overlap Menu.................................................2531 Table 26. Lift Speed Menu.........................................................2532 Table 27. Lower Speed Menu........................................................2533 Table 28. Tilt Speed Menu.........................................................2533 Table 29. Auxiliary Function Speed Menu...........................................2535 Table 30. Auxiliary Function Speed Menu...........................................2535 Table 31. Auxiliary Function Speed Menu...........................................2536 Table 32. Auxiliary Function Speed Menu...........................................2536 Table 33. Auxiliary Function Speed Menu...........................................2537 Table 34. Auxiliary Function Speed Menu...........................................2537 Table 35. Lift/Lower Ramp Rate Menu...............................................2538 Table 36. Hydraulic Auxiliary Ramp Rate Menu......................................2539 Table 37. Tilt Delay Menu.........................................................2540 Table 38. Service Language Menu...................................................2541 Table 39. Alarm Type Menu.........................................................2542 Table 40. Light Time-Out Menu.....................................................2543 Table 41. Restore Defaults Menu...................................................2544 Table 42. Restore Settings Menu...................................................2544 Table 43. Impact Sensor Enable/Disable............................................2545 Table 44. Soft Impact Settings Menu...............................................2546 Table 45. Hard Impact Settings Menu...............................................2547 Table 46. Impact Sensor Default Settings..........................................2547 Table 47. Recommended Starting Values for Impact Sensor Settings..................2549 Table 48. Shutdown Reset Menu.....................................................2550 Table 49. Alarm Duration Menu.....................................................2551 Table 50. View Event Log Menu.....................................................2552 Table 51. Calibrate Electro-Hydraulic Valve Menu..................................2554 Table 52. Calibrate Transmission Valve Menu.......................................2555 Table 53. Tilt Stop Point Menu....................................................2555 Table 54. Calibrate Loaded Weight.................................................2556 Table 55. Travel Speed Menu.......................................................2556 Table 56. Travel Speed Menu.......................................................2557 Wire Harness Repair.......................................................................2560 toc...................................................................................2560 Wire Harness Repair...............................................................2560 General...........................................................................2564 Deutsch Crimping Tool.............................................................2564 How to Strip a Wire for Use With Deutsch Crimping Tool........................2564 How to Crimp With the Deutsch Crimping Tool...................................2565 Calibration Test for the Deutsch Crimping Tool................................2566 Deutsch Connectors................................................................2568 DT, DTM, and DTP Series Connectors............................................2568 Connector Receptacle Replacement..........................................2576 Connector Plug Replacement................................................2581 Connector Receptacle Pin Replacement......................................2587 Connector Plug Socket Replacement.........................................2593 HD Series Connectors..........................................................2601 Connector Receptacle Replacement..........................................2603 Connector Plug Replacement................................................2606 Connector Receptacle Pin Replacement......................................2609 Connector Plug Socket Replacement.........................................2614 Sealing Plugs.................................................................2618 Metri-Pack Connectors.............................................................2620 Remove and Install............................................................2620 Micro-Pack Connectors.............................................................2622 Weather-Pack Connectors...........................................................2623 Weather-Pack Terminal Repair..................................................2623 AMPSEAL Crimping Tools............................................................2624 AMP Hand Crimping Tool With Certi-Crimp.......................................2624 Description...............................................................2624 Stripping Wire for Use With AMP Hand Crimping Tool........................2625 Insulation Crimp Adjustment...............................................2625 Maintenance and Inspection for AMP Hand Crimping Tool.....................2626 AMP Hand Crimping Tool................................................2626 Crimp Height Inspection...............................................2626 How to Use AMP Hand Crimping Tool.............................................2627 AMP Pro-Crimper II Tool.......................................................2627 Description...............................................................2627 Remove and Install Die Set and Locator Assembly.......................2628 Stripping Wire for Use With AMP PRO-CRIMPER II Tool.......................2629 Contact Support Adjustment................................................2629 Crimp Height Adjustment...................................................2630 Maintenance and Inspection Procedures.....................................2630 PRO-CRIMPER II Tool...................................................2630 Crimp Height Inspection...............................................2630 How to Use AMP PRO-CRIMPER II Tool............................................2631 AMPSEAL Connector Assemblies......................................................2632 Description for Plug Connector Assembly.......................................2632 Seal Plug.................................................................2632 Contact Crimping..........................................................2633 Contact Removal...........................................................2633 Contact Insertion.........................................................2635 Description for Plug Connector and Header Assembly............................2637 Voltage Reading...........................................................2638 Seal Plug.................................................................2638 Contact Crimping..........................................................2639 Contact Removal...........................................................2641 Contact Insertion.........................................................2643 AMP Superseal 1.5 Crimping Tools..................................................2645 Mini Mic Receptacle and Tab Contacts..........................................2645 Description...............................................................2645 Crimping Conditions and Measurements......................................2645 Insertion of Rubber Seal on Cable.........................................2647 Correction or Replacement of Parts........................................2648 AMP Hand Application Tool.....................................................2652 Description...............................................................2652 Maintenance and Inspection................................................2652 Crimp Height Inspection...............................................2652 Crimp Height Adjustment...................................................2653 How to Use AMP Hand Application Tool..........................................2653 AMP Pro-Crimper II Tool.......................................................2654 Description...............................................................2654 Remove and Install Die Set and Locator Assembly.......................2654 Adjustments...............................................................2655 Contact Support.......................................................2655 Crimp Height..........................................................2655 Inspections and Maintenance...............................................2657 Crimp Height Inspection...............................................2657 Visual Inspection.....................................................2657 Maintenance...........................................................2657 How to Use Pro-Crimper II Tool................................................2657 AMP Superseal 1.5 Connector Assemblies............................................2658 Description...................................................................2658 Harness Assembly..........................................................2658 Positioning of anti-backout device....................................2659 Removal of Contacts...................................................2661 Repair and Maintenance........................................................2665 Panel Mount Option............................................................2665 AMP Fastin-Faston Hand Tools......................................................2665 Description - AMP Double Action Hand Tool.....................................2665 Maintenance and Inspection Procedures.........................................2667 Daily Maintenance.........................................................2667 Periodic Tool Inspection..................................................2667 Lubrication...........................................................2667 Visual Inspection.....................................................2667 Crimp Height Inspection...................................................2668 Certi-Crimp Ratchet Inspection............................................2668 How to Use AMP Double Action Hand Tool........................................2669 Description - AMP Extraction Tool.............................................2670 Maintenance and Inspection....................................................2670 How to Use AMP Extraction Tool................................................2671 AMP Fastin-Faston Receptacles and Housings........................................2672 Description...................................................................2672 Wire Repair.......................................................................2678 Wire Splicing Requirements....................................................2678 Deutsch Jiffy Splice..........................................................2679 Assemble..................................................................2679 Disassemble...............................................................2681 Del-City Crimp-Solder-Shrink Splice...........................................2683 Twisted/Shielded Cable and Leads Repair...........................................2684 Twisted/Shielded Cable Repair.................................................2684 Twisted Leads Repair..........................................................2686 Special Tools.....................................................................2687 tables................................................................................2560 Table 1. Wire Strip Length Specifications.........................................2565 Table 2. Wire Size (AWG)..........................................................2626 Table 3. Crimp Height.............................................................2627 Table 4. Strip Length for PRO-CRIMPER II Tool.....................................2629 Table 5. Crimp Measurement........................................................2630 Table 6. Current Rating...........................................................2632 Table 7. Crimp Conditions.........................................................2640 Table 8. Wire Strip Lengths.......................................................2652 Table 9. Wire Strip Lengths.......................................................2653 Table 10. Crimp Height - Dimension ...............................................2657 Table 11. Wire Size and Crimp Height..............................................2668 Table 12. Wire Strip Length.......................................................2669 Table 13. Wire Strip Length and Crimp Measurements................................2674 Table 14. Crimp Pull-Out Test.....................................................2677 Table 15. Wire Strip Length Specifications........................................2678 Table 16. Wire Splice Size........................................................2683
HYSTER L177 (S2.0-3.5FT S40FT-70FT, S55FTS H2.0-3.5FT H40-70FT) SERVICE MANUAL – PDF DOWNLOAD:
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