Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
Sale!
Hyster N005 Service Manual – PDF DOWNLOAD
Original price was: $89.95.$36.95Current price is: $36.95.
Hyster N005 Service Manual – PDF DOWNLOAD
PART NO. 1579259
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
Hyster N005 Service Manual – PDF DOWNLOAD
DESCRIPTION:
Hyster N005 Service Manual – PDF DOWNLOAD
PART NO. 1579259
SAFETY PRECAUTIONS TROUBLESHOOTING PROCEDURES
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and
that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to
support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift
trucks. Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT
TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or exceed
the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to
remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit
needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are
flammable. Be sure to follow the necessary safety precautions when handling these fuels and when
working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the
area. Make sure the area is well ventilated.
TABLE OF CONTENTS:
Hyster N005 Service Manual – PDF DOWNLOAD
1579259-9000SRM1112-(07-2008)-US-EN....................................................... 1 toc................................................................................... 1 Diagnostic Troubleshooting Manual................................................. 1 Safety Precautions TROUBLESHOOTING PROCEDURES..................................... 2 How To Use This Troubleshooting Manual............................................ 4 General Instructions and Safety Information................................... 4 How to Use Diagnostic Troubleshooting Manual.................................. 4 General Instructions.......................................................... 5 Operational Diagnostic Procedures................................................. 7 Operational Checkout Procedures............................................... 9 DTC Check................................................................. 10 Horn Circuit Check........................................................ 10 Light Circuit Check....................................................... 10 Windshield Washer Wiper Check (If equipped)............................... 10 Heater Check (If equipped)................................................ 11 Dome Light Check (If equipped)............................................ 11 Circulating (Accessory) Fan Check (If equipped)........................... 12 Indicator Light Power Check............................................... 13 Operator Presence System Check............................................ 14 Engine Malfunction Indicator Check........................................ 14 Cold Start Check (Cummins and Yanmar)..................................... 14 Brake Pedal Check......................................................... 15 Backup Alarm Check (If equipped).......................................... 15 Armrest Hydraulic Interlock Check (If equipped and with original.......... 15 Engine Cover Latch Sensor Check (If equipped)............................. 16 Brake and Inching Pedal Check............................................. 16 Park Brake Sensor Check................................................... 16 Park Brake Check.......................................................... 17 Engine Speed Check (All Cummins, Yanmar, and Mazda Engines Excep.......... 17 Engine Power Check........................................................ 18 Transmission Clutch Check................................................. 18 Transmission Check........................................................ 19 Transmission Speed Selection Check (If equipped).......................... 19 Brake and Axle Drag Check................................................. 19 Hydraulic Pump Flow Check................................................. 20 Priority Flow Divider Valve Check......................................... 21 Steering Relief Valve Low Pressure Check.................................. 21 Steering Relief Valve High Pressure Check................................. 22 Control Valve Load Check Valve (Manual Valve)............................. 22 Lift E-Valve Check............................................................ 22 Lift Check (E-Valve)...................................................... 22 Tilt Function Counterbalance Check........................................ 23 Lift Drift Check.......................................................... 23 Tilt Function Drift Check................................................. 24 Mast Cushion Check (All Except 2-Stage Mast).............................. 24 Lift/Tilt Mast Adjustment Check........................................... 24 Tilt Racking Check........................................................ 25 Chain and Header Hose Adjustment Check.................................... 25 Mast Mounting Check....................................................... 26 Mast Channel Check........................................................ 26 Carriage Adjustment Check................................................. 27 Chain Sheave Check........................................................ 27 Carriage Adjustment Check (Standard and Integral Side Shift).............. 27 Engine............................................................................ 29 Engine Basics................................................................. 35 General Terminology....................................................... 35 Combustion Theory......................................................... 35 Engine Components – Cylinder Block........................................ 36 Camshaft and Timing Set................................................... 37 Cylinder Head Assembly.................................................... 37 Valve Train Assembly...................................................... 37 Air Cleaner/Filter........................................................ 37 Carburetion............................................................... 37 Electronic Fuel Injection (EFI)........................................... 37 Positive Crankcase Ventilation (PCV)...................................... 38 Engine Electrical............................................................. 38 Introduction.............................................................. 38 Battery Construction...................................................... 38 Conventional Standard Battery............................................. 39 Maintenance-Free Battery.................................................. 39 Battery Charging.......................................................... 39 Battery Fast Charging..................................................... 40 Battery Slow Charging..................................................... 40 Starting System Principles of Operation................................... 40 Starting System Components - Ignition Switch.............................. 41 Starting System Components - Starter Solenoid............................. 41 Starting System Components - Flywheel and Ring Gear....................... 41 Starting System Components - Starter Motor and Drive...................... 41 Charging System - General................................................. 42 Charging System - Regulator............................................... 42 Charging System - Theory.................................................. 42 Engine Fuel System/Exhaust and Emissions...................................... 43 Introduction.............................................................. 43 Gasoline System Components - Fuel Tank.................................... 43 Electronic Fuel Injector (EFI) - General Description...................... 43 Port Fuel System Components - ECU......................................... 43 Port Fuel System Components - Fuel Pump/Filter............................ 43 Port Fuel System Components - Fuel Rail................................... 43 Port Fuel System Components - Pressure Regulator.......................... 43 Port Fuel System Components - Fuel Injectors.............................. 44 LPG Systems General Information........................................... 44 LPG Fuel Properties....................................................... 44 LPG Fuel Tank............................................................. 44 AISAN Closed-Loop System.................................................. 45 Filter/Lockoff and Regulator.......................................... 45 Carburetor............................................................ 45 Start Mode............................................................ 45 Idle Mode............................................................. 46 Run Mode.............................................................. 46 Main Fuel Lockoff Solenoid................................................ 46 Injector Fuel Lockoff Solenoid............................................ 46 Oxygen (O 2 ) Sensor.................................................. 46 Electronic Control Unit (ECU)............................................. 46 Catalytic Converter/Muffler............................................... 46 Engine Management............................................................. 46 Introduction.............................................................. 46 Ignition and Timing - Conventional Spark.................................. 46 Components - Ignition Coil................................................ 47 Components - Distributor.................................................. 47 Spark Timing.............................................................. 47 Components - Ignition Wires............................................... 47 Components - Spark Plugs.................................................. 47 Faulty or Fouled Spark Plugs.............................................. 48 Electric Controlled Governing System - Mazda LPG.......................... 48 Engine Identification......................................................... 49 Cummins (Diesel) Engine....................................................... 51 Description............................................................... 51 Diesel Fuel System........................................................ 52 Principle of Operation................................................ 52 Fuel Injection Pump and Governor.......................................... 53 Description........................................................... 53 Principles of Operation............................................... 54 Cummins Engine Control.................................................... 55 Engine Speed (RPM) Sensor............................................. 56 Throttle Position Sensor.............................................. 57 Electronic Throttle Actuator.......................................... 58 Engine Oil Pressure Sensor............................................ 58 Coolant Temperature Sensor............................................ 58 Air Restriction Switch................................................ 59 Fuel Filter/Water Separator........................................... 59 Fuel Level Sensor (In Tank)........................................... 59 Engine Electrical System.................................................. 60 Magnetic Valve (Engine Stop Solenoid)................................. 60 Alternator............................................................ 60 Grid Heater........................................................... 60 Cold Start Timing Advance (Fuel Injection Pump)....................... 60 Cummins QSB 3.3L (Diesel) Engine.............................................. 61 Description............................................................... 61 Diesel Fuel System........................................................ 62 Electronics System........................................................ 65 Engine Protection..................................................... 66 Diagnostics........................................................... 66 Grid Heater........................................................... 66 Turbocharger and Charge Air Cooler........................................ 66 Cooling System............................................................ 68 Crankcase Oil Separator................................................... 69 Lubrication System........................................................ 70 Mazda Engine Overview......................................................... 71 Description............................................................... 71 Fuel System............................................................... 71 Engine Controls Unit (ECU) and Emissions.................................. 71 Cooling System............................................................ 71 Ignition System........................................................... 71 Mazda (LPG) Engine Controls................................................... 72 LPG System (Aisan/E-Controls-Mechanical).................................. 72 Description........................................................... 72 Principles of Operation............................................... 73 Control System........................................................ 76 Oxygen (O 2 ) Sensor.................................................. 77 Fuel Tank............................................................. 77 Regulator............................................................. 78 Start Mode........................................................ 79 Idle Mode......................................................... 79 Run Mode.......................................................... 80 Resonator............................................................. 80 Carburetor............................................................ 80 Start Mode........................................................ 80 Idle Mode......................................................... 81 Run Mode.......................................................... 81 Governor.............................................................. 82 LPG System (E-Controls)................................................... 82 Description........................................................... 82 Principles of Operation............................................... 83 Manifold Absolute Pressure Sensor..................................... 83 Throttle Position Sensor.............................................. 83 Oxygen (O 2 ) Sensor.................................................. 84 Engine Coolant Temperature Sensor..................................... 84 Intake Air Temperature Sensor......................................... 84 Engine Control Unit................................................... 84 Accelerator Pedal Position Sensor..................................... 84 Three-Way Catalytic Converter......................................... 84 Camshaft Position Sensor.............................................. 84 Electric Controlled Governing System.................................. 85 Electronic Governor Sensor............................................ 86 Mazda (Gasoline) Engine Controls.............................................. 87 Gasoline System........................................................... 87 Description........................................................... 87 Principles of Operation............................................... 88 Control System............................................................ 90 Camshaft Position Sensor.............................................. 91 Intake Air Temperature Sensor......................................... 92 Mass Air Flow Sensor.................................................. 93 Throttle Position Sensor.............................................. 94 Electronic Governor Sensor............................................ 95 Electronic Governing System........................................... 96 Manifold Absolute Pressure Sensor/Boost Sensor........................ 96 Engine Coolant Temperature Sensor..................................... 97 Intake Air System......................................................... 98 Throttle Body......................................................... 98 Idle Air Control Valve................................................ 99 Fuel System............................................................... 100 Fuel Injector......................................................... 100 Pressure Regulator.................................................... 101 Exhaust System............................................................ 102 Heated Oxygen (O 2 ) Sensor........................................... 102 Three-Way Catalytic Converter......................................... 103 GM (LPG) Engine Controls...................................................... 104 Engine Control System .................................................... 104 Engine Control System Overview........................................ 105 Principles of Operation............................................... 105 Control System............................................................ 106 GM/TGFI 2.4L (Four Cylinder) Control System Component Location........ 106 GM/TGFI 4.3L (Six Cylinder) Control System Component Location......... 107 GM/TGFI 2.4L (Four-Cylinder) LPG System............................... 108 GM/TGFI 4.3L (Six-Cylinder) LPG System................................ 110 Fuel Tank............................................................. 112 Engine Control Unit................................................... 112 Electronic Throttle Body/Throttle Position Sensor..................... 113 Manifold Absolute Pressure/Manifold Air Temperature Sensor............ 113 Propane Injectors..................................................... 114 Engine Coolant Temperature Sensor..................................... 116 Oxygen (O 2 ) Sensor.................................................. 116 Crankshaft Position Sensor (Engine Speed Sensor)...................... 117 Oil Pressure Sensor................................................... 117 Power Latch Relay..................................................... 117 GM 2.4L Camshaft Position Sensor...................................... 117 GM 4.3L Camshaft Position Sensor...................................... 118 Injector Driver Module................................................ 119 Vaporizer/Regulator................................................... 119 Accelerator Pedal Position Sensor..................................... 122 Three-Way Catalytic Converter......................................... 122 Ignition System........................................................... 123 Ignition Coils........................................................ 123 Distributorless Ignition System Module................................ 123 Electronic Ignition Signals........................................... 124 Distributor Ignition (DI) System...................................... 124 Camshaft Position (CMP) Sensor........................................ 125 Ignition Coil and Ignition Control Module (ICM)....................... 125 Secondary Ignition Components......................................... 125 GM (Gasoline) Engine Controls................................................. 126 Engine Control System..................................................... 126 GM 2.4L (Four Cylinder) Engine Control System......................... 126 GM 4.3L (Six Cylinder) Engine Control System.......................... 127 Engine Control System Overview........................................ 128 Principles of Operation............................................... 128 Control System............................................................ 128 GM/TGFI 2.4L (Four Cylinder) Control System Component Location........ 128 GM/TGFI 4.3L (Six Cylinder) Control System Component Location......... 130 GM/TGFI 2.4L (Four-Cylinder) Gasoline System Components............... 131 GM/TGFI 4.3L (Six Cylinder) Gasoline System Components................ 133 Engine Control Unit................................................... 135 Electronic Throttle Body/Throttle Position Sensor..................... 135 Manifold Absolute Pressure/Manifold Air Temperature Sensor ........... 136 Fuel Injector......................................................... 137 Engine Coolant Temperature Sensor..................................... 138 Oxygen (O 2 ) Sensor.................................................. 139 Crankshaft Position Sensor (Engine Speed Sensor)...................... 139 Oil Pressure Sensor................................................... 139 Power Latch Relay..................................................... 139 Camshaft Position Sensor.............................................. 140 Accelerator Pedal Position Sensor..................................... 141 Three-Way Catalytic Converter......................................... 142 Ignition System........................................................... 142 Ignition Coils........................................................ 142 Distributorless Ignition System Module................................ 142 Electronic Ignition Signals........................................... 143 Yanmar (Diesel) Engine........................................................ 144 Description............................................................... 144 Diesel Fuel System........................................................ 145 Principles of Operation............................................... 145 Fuel Injection Pump and Governor.......................................... 146 Description........................................................... 146 Principles of Operation............................................... 148 Timer................................................................. 149 Feed Pump (Vane Type)................................................. 149 Regulating Valve...................................................... 150 Injection Pump Plunger................................................ 151 Suction Process................................................... 152 Injection Process................................................. 152 End of Injection.................................................. 153 Uniform Pressure Process.......................................... 153 Reverse Rotation Prevention Mechanism................................. 154 Fuel Injection Volume Adjustment Mechanism............................ 154 Delivery Valve Assembly............................................... 154 Delivery Valve Holder with Damping Valve.............................. 155 All - Speed Governor.................................................. 156 At Start of Engine.................................................... 158 During Idle........................................................... 159 At Full - Load Maximum Speed Control.................................. 160 At No-Load Maximum Speed Control...................................... 161 Full-Load Position Adjustment Mechanism............................... 162 Structure and Operation of Timer.......................................... 163 Standard Type Automatic Timer......................................... 163 Yanmar Engine Controls.................................................... 164 Engine Speed (RPM) Sensor............................................. 165 Throttle Position Sensor.............................................. 165 Electronic Throttle Actuator.......................................... 166 Engine Oil Pressure Sensor............................................ 166 Coolant Temperature Sensor............................................ 167 Air Filter Restriction Switch......................................... 167 Fuel Filter/Water Separator and Strainer.............................. 168 Fuel Level Sensor..................................................... 168 Engine Electrical System.................................................. 168 Magnetic Valve (Engine Stop Solenoid)................................. 168 Alternator............................................................ 169 Glow Plugs............................................................ 169 Cold Start Timing Advance (Fuel Injection Pump)....................... 169 Cooling System - All Engines.................................................. 170 Description............................................................... 170 Radiator.................................................................. 170 Combination Cooler/Standard Radiator.................................. 171 Radiator Cap.............................................................. 171 Thermostat................................................................ 171 Engine Coolant Pump....................................................... 172 Fan....................................................................... 172 GM Engine Coolant Flow Diagram............................................ 172 Yanmar Diesel Engine Coolant Flow Diagram................................. 173 Engine Does Not Crank......................................................... 175 Engine Does Not Start/Engine is Hard to Start................................. 178 Engine Idle Speed Incorrect................................................... 184 Engine Idle Speed is Unstable or Engine Stalls at Idle........................ 187 Engine Cuts Out, Misses, Hesitates, Sags, or Stumbles......................... 192 Engine Lack of Power.......................................................... 198 Engine Speed Surge Or Engine Speed Unstable................................... 205 Engine Backfires.............................................................. 209 Engine Is Knocking or Pinging................................................. 212 Excessive Engine Vibrations................................................... 216 Abnormal Engine and Exhaust Noises............................................ 221 Fan or Alternator Bearing Noise............................................... 225 Abnormal Engine and Exhaust Smells............................................ 227 High Engine Fuel Consumption.................................................. 229 Fuel Leaks.................................................................... 232 High Engine Oil Consumption................................................... 235 Engine Oil Leaks.............................................................. 237 Engine Oil is Discolored...................................................... 242 Engine Coolant Leaks.......................................................... 244 Engine Coolant is Discolored.................................................. 247 Engine Exhaust is Discolored.................................................. 248 Engine Fails Emission Compliance Check........................................ 252 Alternator Light is Illuminated............................................... 256 Engine is Overheating......................................................... 257 Air Intake Manifold Temperature too High (Cummins QSB 3.3L Only).............. 260 Air Intake Manifold Pressure (Boost) is Below Normal (Cummins QS.............. 261 Engine Coolant Temperature is Low............................................. 262 Engine Oil Pressure is Low.................................................... 263 Radiator Bubble Test.......................................................... 265 Engine Compression Test (GM and Mazda)........................................ 266 Engine Compression Test (Yanmar Diesel)....................................... 267 Engine Oil Pressure Test...................................................... 268 Fuel System Pressure Test (Gasoline Engines Only)............................. 270 Fuel Injection Nozzle Test (Yanmar Diesel).................................... 272 Vacuum Leak................................................................... 273 Vacuum Leak Detection..................................................... 273 Vacuum Leak Repairs....................................................... 273 Coolant System Test........................................................... 274 Electrical System................................................................. 275 Troubleshooting Guidelines and Procedures..................................... 289 Troubleshooting Guidelines................................................ 289 Troubleshooting Procedures................................................ 292 Troubleshooting Procedures, Identification............................ 292 Troubleshooting Procedures, Location.................................. 292 Troubleshooting Procedures, Structure................................. 292 Troubleshooting Procedures, Performance............................... 293 Diagnostic Trouble Codes...................................................... 294 Diagnostic Trouble Codes.................................................. 294 Wiring Reference Data......................................................... 308 Post 2007 Engine Connections.................................................. 312 Cummins 4.5L.............................................................. 312 GM 2.4L (GAS/LPG)......................................................... 313 GM 4.3L (GAS/LPG)......................................................... 314 Mazda 2.0/2.2L (GAS/LPG).................................................. 315 Yanmar 2.6/3.3L........................................................... 316 Harness Assembly Data......................................................... 317 Electrical System............................................................. 363 General Description....................................................... 363 Description............................................................... 364 Principles of Operation, Components....................................... 368 Principles Of Operation, System........................................... 376 100-2......................................................................... 383 100-2......................................................................... 383 100-3......................................................................... 383 523859-3...................................................................... 383 524223-3...................................................................... 383 524224-3...................................................................... 383 524225-3...................................................................... 383 524282-3...................................................................... 383 523958-3...................................................................... 383 523959-3...................................................................... 383 100-4......................................................................... 391 523859-4...................................................................... 391 523958-4...................................................................... 391 523959-4...................................................................... 391 524223-4...................................................................... 391 524224-4...................................................................... 391 524225-4...................................................................... 391 524282-4...................................................................... 391 524223-0...................................................................... 399 524224-0...................................................................... 399 524225-0...................................................................... 399 524229-0...................................................................... 399 524270-0...................................................................... 399 524276-0...................................................................... 399 524223-1...................................................................... 403 524224-1...................................................................... 403 524225-1...................................................................... 403 524229-1...................................................................... 403 524270-1...................................................................... 403 524276-1...................................................................... 403 110-3......................................................................... 407 110-3......................................................................... 407 110-5......................................................................... 407 177-3......................................................................... 407 522231-3...................................................................... 407 522555-3...................................................................... 407 522603-3...................................................................... 407 524235-3...................................................................... 407 110-4......................................................................... 415 110-4......................................................................... 415 177-4......................................................................... 415 522231-4...................................................................... 415 522555-4...................................................................... 415 522603-4...................................................................... 415 524235-4...................................................................... 415 110-2......................................................................... 423 110-2......................................................................... 423 110-10........................................................................ 426 522712-3...................................................................... 431 522713-3...................................................................... 431 522712-4...................................................................... 438 522713-4...................................................................... 438 51-2.......................................................................... 445 51-7.......................................................................... 445 91-2.......................................................................... 453 91-2.......................................................................... 453 522708-3...................................................................... 457 522710-3...................................................................... 457 522711-3...................................................................... 457 522714-3...................................................................... 457 522708-4...................................................................... 464 522710-4...................................................................... 464 522711-4...................................................................... 464 522714-4...................................................................... 464 515-0......................................................................... 471 523780-3...................................................................... 473 523860-3...................................................................... 473 524245-3...................................................................... 473 524275-3...................................................................... 473 523780-4...................................................................... 479 523860-4...................................................................... 479 524245-4...................................................................... 479 524275-4...................................................................... 479 677-3......................................................................... 484 2350-3........................................................................ 484 522754-3...................................................................... 484 522755-3...................................................................... 484 522764-3...................................................................... 484 522766-3...................................................................... 484 524230-3...................................................................... 484 SYMPTOMS WARNING.............................................................. 484 677-4......................................................................... 490 2350-4........................................................................ 490 522754-4...................................................................... 490 522755-4...................................................................... 490 522764-4...................................................................... 490 522766-4...................................................................... 490 524230-4...................................................................... 490 676-3......................................................................... 494 524195-3...................................................................... 494 524269-3...................................................................... 494 676-4......................................................................... 500 524195-4...................................................................... 500 524269-4...................................................................... 500 524269-7...................................................................... 506 524215-3...................................................................... 508 524215-6...................................................................... 508 524237-3...................................................................... 512 524238-3...................................................................... 512 524240-3...................................................................... 512 524237-4...................................................................... 517 524238-4...................................................................... 517 524240-4...................................................................... 517 879-3......................................................................... 522 880-3......................................................................... 522 881-3......................................................................... 522 882-3......................................................................... 522 522772-3...................................................................... 522 879-4......................................................................... 526 880-4......................................................................... 526 881-4......................................................................... 526 882-4......................................................................... 526 522772-4...................................................................... 526 168-0......................................................................... 530 168-3......................................................................... 530 521982-3...................................................................... 533 522760-3...................................................................... 533 522761-3...................................................................... 533 522762-3...................................................................... 533 522128-3...................................................................... 542 524251-0...................................................................... 542 524260-0...................................................................... 542 524260-3...................................................................... 542 524261-0...................................................................... 542 524261-3...................................................................... 542 168-1......................................................................... 551 168-4......................................................................... 551 521982-4...................................................................... 554 522760-4...................................................................... 554 522761-4...................................................................... 554 522761-6...................................................................... 554 522762-4...................................................................... 554 522128-4...................................................................... 561 524251-1...................................................................... 561 524260-1...................................................................... 561 524260-4...................................................................... 561 524261-1...................................................................... 561 524261-4...................................................................... 561 524260-2...................................................................... 571 524260-11..................................................................... 571 524261-2...................................................................... 571 524261-11..................................................................... 571 96-3.......................................................................... 575 96-4.......................................................................... 575 522810-4...................................................................... 579 524213-1...................................................................... 583 524213-3...................................................................... 583 524213-4...................................................................... 583 523920-3...................................................................... 586 523925-3...................................................................... 586 523930-3...................................................................... 586 523977-3...................................................................... 586 523978-3...................................................................... 586 523986-3...................................................................... 586 524284-3...................................................................... 586 524285-3...................................................................... 586 523920-4...................................................................... 592 523925-4...................................................................... 592 523930-4...................................................................... 592 523977-4...................................................................... 592 523978-4...................................................................... 592 523986-4...................................................................... 592 524284-4...................................................................... 592 524285-4...................................................................... 592 523920-6...................................................................... 597 523925-6...................................................................... 597 523930-6...................................................................... 597 523977-6...................................................................... 597 523978-6...................................................................... 597 523986-6...................................................................... 597 524284-6...................................................................... 597 524285-6...................................................................... 597 105-3......................................................................... 601 105-3......................................................................... 601 522570-3...................................................................... 601 105-4......................................................................... 606 105-4......................................................................... 606 522570-4...................................................................... 606 105-5......................................................................... 610 106-3......................................................................... 613 106-4......................................................................... 617 106-0......................................................................... 621 106-1......................................................................... 621 106-2......................................................................... 621 106-14........................................................................ 621 522739-3...................................................................... 624 522740-3...................................................................... 624 522739-5...................................................................... 629 522740-5...................................................................... 629 522739-6...................................................................... 633 522740-6...................................................................... 633 522735-2...................................................................... 637 522735-4...................................................................... 640 522735-5...................................................................... 643 522735-6...................................................................... 646 522630-2...................................................................... 650 522631-2...................................................................... 650 522632-2...................................................................... 650 522633-2...................................................................... 650 522635-3...................................................................... 650 522636-4...................................................................... 650 522637-3...................................................................... 650 522638-4...................................................................... 650 522606-10..................................................................... 654 522737-10..................................................................... 654 651-3......................................................................... 657 652-3......................................................................... 657 653-3......................................................................... 657 654-3......................................................................... 657 655-3......................................................................... 657 656-3......................................................................... 657 522599-3...................................................................... 657 522600-3...................................................................... 657 522601-3...................................................................... 657 522602-3...................................................................... 657 522721-3...................................................................... 657 522722-3...................................................................... 657 522723-3...................................................................... 657 522724-3...................................................................... 657 522725-3...................................................................... 657 522726-3...................................................................... 657 522599-3...................................................................... 657 522600-3...................................................................... 657 522601-3...................................................................... 657 522602-3...................................................................... 657 651-5......................................................................... 665 651-5......................................................................... 665 652-5......................................................................... 665 652-5......................................................................... 665 653-5......................................................................... 665 653-5......................................................................... 665 654-5......................................................................... 665 654-5......................................................................... 665 655-5......................................................................... 665 656-5......................................................................... 665 522721-5...................................................................... 665 522722-5...................................................................... 665 522723-5...................................................................... 665 522724-5...................................................................... 665 522725-5...................................................................... 665 522726-5...................................................................... 665 651-6......................................................................... 670 652-6......................................................................... 670 653-6......................................................................... 670 654-6......................................................................... 670 655-6......................................................................... 670 656-6......................................................................... 670 522599-4...................................................................... 670 522600-4...................................................................... 670 522601-4...................................................................... 670 522602-4...................................................................... 670 522721-6...................................................................... 670 522722-6...................................................................... 670 522723-6...................................................................... 670 522724-6...................................................................... 670 522725-6...................................................................... 670 522726-6...................................................................... 670 2000-9........................................................................ 678 2000-12....................................................................... 678 2000-12....................................................................... 678 2000-12....................................................................... 678 2000-12....................................................................... 678 2000-14....................................................................... 678 2003-12....................................................................... 678 2023-12....................................................................... 678 2039-2........................................................................ 678 2039-12....................................................................... 678 2235-12....................................................................... 678 2236-12....................................................................... 678 2238-12....................................................................... 678 521670-12..................................................................... 678 524258-2...................................................................... 678 522215-12..................................................................... 686 522215-14..................................................................... 686 524236-14..................................................................... 686 524262-12..................................................................... 686 524262-14..................................................................... 686 524263-1...................................................................... 686 524268-12..................................................................... 686 628-12........................................................................ 688 630-12........................................................................ 688 522690-2...................................................................... 688 522690-12..................................................................... 688 522691-2...................................................................... 688 522691-12..................................................................... 688 522692-2...................................................................... 688 522693-12..................................................................... 688 522694-12..................................................................... 688 522695-2...................................................................... 688 522696-2...................................................................... 688 522697-12..................................................................... 688 522698-2...................................................................... 688 522699-2...................................................................... 688 522700-2...................................................................... 688 190-2......................................................................... 690 190-2......................................................................... 690 190-7......................................................................... 690 522120-1...................................................................... 690 522585-2...................................................................... 690 522752-9...................................................................... 696 524249-2...................................................................... 700 524250-2...................................................................... 700 524264-2...................................................................... 700 524264-14..................................................................... 700 524265-2...................................................................... 700 524271-2...................................................................... 700 524225-14..................................................................... 700 628-12........................................................................ 705 630-12........................................................................ 705 2660-3........................................................................ 705 2660-4........................................................................ 705 2661-3........................................................................ 705 2661-4........................................................................ 705 2802-12....................................................................... 705 523510-12..................................................................... 705 523511-12..................................................................... 705 523515-3...................................................................... 705 523515-4...................................................................... 705 523519-3...................................................................... 705 523519-4...................................................................... 705 2802-12....................................................................... 707 628-12........................................................................ 707 630-12........................................................................ 707 523261-3...................................................................... 707 523261-4...................................................................... 707 523257-3...................................................................... 707 523257-4...................................................................... 707 523253-3...................................................................... 707 523253-4...................................................................... 707 523249-3...................................................................... 707 523249-4...................................................................... 707 522780-3...................................................................... 709 522781-3...................................................................... 709 522780-4...................................................................... 713 522781-4...................................................................... 713 522780-2...................................................................... 716 522781-2...................................................................... 716 111-1......................................................................... 719 524252-2...................................................................... 723 524253-14..................................................................... 725 524255-2...................................................................... 726 108-0......................................................................... 727 108-1......................................................................... 727 522655-0...................................................................... 730 522655-1...................................................................... 730 522660-0...................................................................... 730 522660-1...................................................................... 730 524212-2...................................................................... 734 524211-2...................................................................... 734 524210-2...................................................................... 734 524209-2...................................................................... 734 524208-2...................................................................... 734 524207-2...................................................................... 734 524206-2...................................................................... 734 524205-2...................................................................... 734 524204-2...................................................................... 734 524203-2...................................................................... 734 524202-2...................................................................... 734 524201-2...................................................................... 734 524200-2...................................................................... 734 524199-2...................................................................... 734 524198-2...................................................................... 734 524197-2...................................................................... 734 522800-13..................................................................... 736 522801-13..................................................................... 738 522130-0...................................................................... 739 522131-0...................................................................... 739 522132-0...................................................................... 739 522133-0...................................................................... 739 522134-0...................................................................... 739 522130-1...................................................................... 743 522131-1...................................................................... 743 522132-1...................................................................... 743 522133-1...................................................................... 743 522134-1...................................................................... 743 522130-3...................................................................... 748 522131-3...................................................................... 748 522132-3...................................................................... 748 522133-3...................................................................... 748 522134-3...................................................................... 748 522130-4...................................................................... 753 522131-4...................................................................... 753 522132-4...................................................................... 753 522133-4...................................................................... 753 522134-4...................................................................... 753 522135-0...................................................................... 757 522137-0...................................................................... 757 522138-0...................................................................... 757 522135-1...................................................................... 761 522137-1...................................................................... 761 522138-1...................................................................... 761 522135-3...................................................................... 765 522137-3...................................................................... 765 522138-3...................................................................... 765 522135-4...................................................................... 769 522137-4...................................................................... 769 522138-4...................................................................... 769 522155-2...................................................................... 773 522157-2...................................................................... 773 522122-0...................................................................... 780 522124-0...................................................................... 780 522125-0...................................................................... 780 522126-0...................................................................... 780 522127-0...................................................................... 780 522122-1...................................................................... 784 522124-1...................................................................... 784 522125-1...................................................................... 784 522126-1...................................................................... 784 522127-1...................................................................... 784 522122-6...................................................................... 788 522124-6...................................................................... 788 522125-6...................................................................... 788 522126-6...................................................................... 788 522127-6...................................................................... 788 522122-8...................................................................... 793 522124-8...................................................................... 793 522125-8...................................................................... 793 522126-8...................................................................... 793 522127-8...................................................................... 793 522129-3...................................................................... 797 522129-4...................................................................... 797 522197-0...................................................................... 799 522198-0...................................................................... 799 522199-0...................................................................... 799 522200-0...................................................................... 799 522201-0...................................................................... 799 522197-1...................................................................... 802 522198-1...................................................................... 802 522199-1...................................................................... 802 522200-1...................................................................... 802 522201-1...................................................................... 802 522197-6...................................................................... 803 522198-6...................................................................... 803 522199-6...................................................................... 803 522200-6...................................................................... 803 522201-6...................................................................... 803 522197-7...................................................................... 804 522198-7...................................................................... 804 522199-7...................................................................... 804 522200-7...................................................................... 804 522201-7...................................................................... 804 522197-8...................................................................... 805 522198-8...................................................................... 805 522199-8...................................................................... 805 522200-8...................................................................... 805 522201-8...................................................................... 805 522197-14..................................................................... 807 522198-14..................................................................... 807 522199-14..................................................................... 807 522200-14..................................................................... 807 522201-14..................................................................... 807 522197-27..................................................................... 808 522198-27..................................................................... 808 522199-27..................................................................... 808 522200-27..................................................................... 808 522201-27..................................................................... 808 2039-2........................................................................ 811 522540-3...................................................................... 814 522540-4...................................................................... 818 522604-3...................................................................... 823 522604-4...................................................................... 827 522604-5...................................................................... 831 522697-12..................................................................... 836 190-2......................................................................... 837 190-4......................................................................... 837 190-8......................................................................... 837 522752-2...................................................................... 837 522752-4...................................................................... 837 522752-5...................................................................... 843 522598-3...................................................................... 846 522598-4...................................................................... 850 522592-0...................................................................... 854 522592-1...................................................................... 856 522593-12..................................................................... 858 522594-12..................................................................... 862 522595-12..................................................................... 862 522596-12..................................................................... 862 522597-12..................................................................... 862 522614-7...................................................................... 865 522616-8...................................................................... 865 522617-5...................................................................... 865 524226-3...................................................................... 866 524226-4...................................................................... 868 524239........................................................................ 870 524241........................................................................ 870 524246........................................................................ 870 524267........................................................................ 870 524248........................................................................ 870 524746-2...................................................................... 873 Engine Continues to Run When Engine Cover is Raised........................... 875 Engine Stops or Fails to Start................................................ 877 Electrical Functions Do Not Operate........................................... 879 Electrical Function Does Not Turn Off......................................... 884 Electro-Hydraulics Do Not Function With Armrest Down ......................... 890 Electro-Hydraulics Can Still Function With Armrest Raised..................... 893 Vehicle Does Not Power On..................................................... 896 Heater Fan Does Not Operate Properly.......................................... 901 Heater Airflow Does Not Reach Desired Temperature............................. 904 Heater Output Has Insufficient Airflow........................................ 905 Circulating (Accessory) Fan Inoperative....................................... 906 Dome Light Inoperative........................................................ 909 Horn Failure.................................................................. 912 Drive Train....................................................................... 915 Mechanical Overview........................................................... 919 Engine........................................................................ 919 Description............................................................... 919 Torque Converter.............................................................. 919 Description............................................................... 919 Stator................................................................ 920 Turbine............................................................... 920 Pump PTO...................................................................... 921 Chain Drive PTO........................................................... 921 Spur Gear PTO............................................................. 922 Transmission.................................................................. 923 Description............................................................... 923 1.0-5.5 Ton Lift Truck Transmissions...................................... 926 Description........................................................... 926 Single-Speed...................................................... 926 Two-Speed......................................................... 927 Clutch Pack........................................................... 928 Power Flow............................................................ 930 Single-Speed...................................................... 930 Two-Speed......................................................... 931 Transmission Hydraulic Schematic...................................... 933 Transmission Oil Flow................................................. 934 Control Valve Oil Flow................................................ 934 6.0-7.0 Ton Lift Truck Transmissions...................................... 936 Description........................................................... 936 Two-Speed......................................................... 936 Three-Speed....................................................... 936 Clutch Pack........................................................... 938 Input Shaft and Range Clutches.................................... 938 Directional Clutches.............................................. 938 Output Section.................................................... 939 Power Flow............................................................ 940 Two-Speed and Three-Speed......................................... 940 Transmission Hydraulic Schematic...................................... 944 Two-Speed......................................................... 944 Three-Speed....................................................... 945 Transmission Control System Overview.......................................... 947 Transmission Control System............................................... 947 Transmission Control Software................................................. 950 Transmission Control Modes................................................ 950 Neutral............................................................... 950 Gear Engagement Control............................................... 950 Basic Powershift Gear Engagement Mode............................. 950 DuraMatch™ and Electronic Extended Features Gear Engagement Mo.... 950 Normal Forward or Reverse............................................. 950 Basic Powershift.................................................. 950 DuraMatch™ and Electronic Extended Features Transmission.......... 950 Auto-Shift............................................................ 950 1st Gear Lock......................................................... 951 Inching............................................................... 951 Basic Powershift Inching Mode..................................... 951 DuraMatch™ Inching Mode........................................... 951 Electronic Extended Features Inching Mode......................... 951 Inch/Brake Overlap Adjustment......................................... 951 Brake Wear Compensation............................................... 951 Auto Decel............................................................ 952 Controlled Power Reversal............................................. 952 Basic Multi-Speed................................................. 952 Electronic Extended Features...................................... 952 Controlled Creep...................................................... 952 Basic Powershift.................................................. 952 DuraMatch™ and Electronic Extended Features....................... 953 Controlled Roll Back.................................................. 953 DuraMatch™ ....................................................... 953 Electronic Extended Features...................................... 953 Travel Speed Limit (Optional)......................................... 953 Extended Drawbar Pull ( Electronic Extended Features Multi-Speed...... 953 Auto-Speed Hydraulics ( Electronic Extended Features Transmissio...... 953 Throttle Response Management ( Electronic Extended Features Tran...... 954 Steady Travel Speed............................................... 954 Transmission Control Hardware................................................. 954 Control Valve and Sensors................................................. 954 Description........................................................... 954 Principles of Operation............................................... 956 Transmission Proportional Valve........................................... 957 Description........................................................... 957 Neutral............................................................... 957 Proportional Control.................................................. 957 MONOTROL® Pedal........................................................... 958 Description........................................................... 958 Principles of Operation............................................... 958 Directional Control Lever................................................. 958 Principles of Operation............................................... 958 Driveshaft, Differential, Drive Axle, and Brakes (Dry Brake Only.............. 959 Driveshaft................................................................ 959 Differential and Drive Axle............................................... 959 Brake System.............................................................. 961 Description........................................................... 961 Service Brakes........................................................ 961 Master Cylinder....................................................... 961 Brake Position Sensor................................................. 962 Parking Brake......................................................... 962 Driveshaft, Differential, Drive Axle, and Brakes (Wet Brake Only.............. 962 Driveshaft................................................................ 962 Differential.............................................................. 963 Brake System.............................................................. 965 Description........................................................... 965 Service Brakes, 2.0-3.5 Ton Only...................................... 965 Service Brakes, 4.0-7.0 Ton........................................... 967 Brake Adjustment and Service.......................................... 967 Parking Brake......................................................... 967 Overheating Brakes (Dry Brake Axle Only)...................................... 971 Overheating Brakes (Wet Brake Axle Only)...................................... 973 Poor Brake Performance (Dry Brake Axle Only).................................. 976 Poor Brake Performance (Wet Brake Axle Only).................................. 979 Brakes Make Too Much Noise (Dry Brake Axle Only).............................. 981 Brakes Pull To One Side (Dry Brake Axle Only)................................. 982 Parking Brake Will Not Release................................................ 985 Parking Brake Will Not Hold Lift Truck (Dry Brake Axle Only).................. 986 Parking Brake Will Not Hold Lift Truck (Wet Brake Axle Only).................. 987 Abnormal Drive Axle Noise..................................................... 988 Discolored Drive Axle Oil..................................................... 991 Lift Truck Does Not Move (Drive Axle)......................................... 993 Abnormal Transmission Noise................................................... 996 Bubbles or Foaming In Transmission Dipstick Tube.............................. 998 Inching Operation Is Not Smooth or Chatters...................................1000 Lift Truck Does Not Move In One or Both Directions (Transmission..............1002 Loss of Power/Drivetrain Performance..........................................1005 Transmission Is Too Hot.......................................................1008 Transmission Will Not Shift To Forward High Range.............................1011 Transmission Warmup Procedure.................................................1013 Transmission Pressure Test....................................................1013 Transmission Charge Pump Pressure Test....................................1015 Clutch Pack Pressure Test (Proportional Solenoid Valves)..................1015 Torque Converter Pressure Test............................................1016 Lubrication Pressure Test.................................................1016 Transmission Clutch Drag Test (1.0-5.5 Ton Trucks Only).......................1017 Torque Converter Stall Test...................................................1017 Hydraulic Systems.................................................................1021 Main Hydraulic System.........................................................1025 Description...............................................................1025 Principles of Operation...................................................1028 Hydraulic Schematics......................................................1029 Manual Control Valve Schematics.......................................1029 Electro-Hydraulic Control Valve Schematics............................1034 Manual Hydraulic Control Valve................................................1038 Description...............................................................1038 Principles of Operation...................................................1040 Lift Section..........................................................1040 Lift Operation....................................................1040 Lower Operation...................................................1040 Tilt Section..........................................................1041 Tilt Backward.....................................................1041 Tilt Forward......................................................1041 Auxiliary Section.....................................................1043 Anti-stall Feature....................................................1044 Relief Valves.........................................................1044 Main Relief Valve.................................................1044 Secondary Relief Valve............................................1044 Electro-Hydraulic Control Valve...............................................1045 Description...............................................................1045 Principles of Operation...................................................1046 Inlet Pressure Compensator/Unloader...................................1046 Lift/Lower EHPVs......................................................1048 EHPV Operation....................................................1049 Tilt and Auxiliary Spool Functions....................................1050 Tilt Forward Function.................................................1052 Main Relief Valve ....................................................1053 Secondary Relief Valve................................................1053 Secondary Function Anti-stall Valve...................................1054 Emergency Lowering Valve..............................................1055 Steering System...............................................................1055 Component Locations.......................................................1055 Description...........................................................1055 Steering Axle Assembly................................................1055 Steering Control Unit.................................................1055 Steering Schematic........................................................1057 Principles of Operation...............................................1058 Steering Control Unit.................................................1058 Actuation Functions With Armrest Up (E-Valve).................................1059 Cycle Times Too Fast - Fast Actuation (E-Valve)...............................1060 Jump/Delay In Lift or Lower Activation After Moving Joystick or ..............1062 Jump/Delay In Secondary Function Actuation After Moving Joystick..............1065 Jump/Delay In Tilt Forward Actuation (E-Valve)................................1067 Forks Drop Slightly Before Lifting (E-Valve)..................................1069 Forks Lower Without Command (E-Valve).........................................1070 Forks Raise or Actuate Without Command (E-Valve)..............................1072 Forks Tilt Forward Without Command (E-Valve)..................................1074 Intermittent Activation (E-Valve) While Commanding Function...................1076 Lift/Lower Function Maximum Speed Too Slow (E-Valve)..........................1078 Lift Function Will Not Move With Joystick or MLM Movement (E-Val..............1081 Lift/Lower Continues To Move For Awhile After Joystick or MLM Is..............1085 Lift/Lower/Secondary Function Suddenly Jumps In Middle of Stroke..............1086 Lower Function Will Not Move With Joystick or MLM Movement (E-Va..............1087 Poor Metering on Lift or Lower Functions (E-Valve)............................1089 Secondary Function Continues to Move for Awhile After Joystick o..............1092 Secondary Function Exhibits Slight Movement in Opposite Directio..............1093 Secondary Function Maximum Speed Too Slow (E-Valve)...........................1094 Secondary Function or Tilt Back Moves Without Command (E-Valve)...............1097 Secondary Function and Tilt Back Will Not Move With Joystick or ..............1099 Tilt Forward Function Continues to Move for Awhile When Joystick..............1103 Tilt Forward Will Not Move Upon Joystick or MLM Movement (E-Valv..............1104 Too Much Joystick or MLM Movement (Deadband) to Start Function M..............1106 Wrong Actuation Operates or Actuation is Backward (E-Valve)...................1107 Actuation Exhibits Slight Movement in Opposite Direction Before ..............1108 Auxiliary Function is Slow or Does Not Function (Manual Valve)................1109 Cycle Times Too Fast - Fast Actuation (Manual Valve)..........................1111 Function Continues to Activate After Returning to Neutral.....................1112 Lift Function Is Slow or Does Not Function (Manual Valve).....................1113 Tilt Back Function Will Not Operate (Manual Valve)............................1115 Tilt Forward Functions When Spool is Activated Forward With Engi..............1116 Tilt Forward Will Not Function When Activated (Manual Valve)..................1117 Abnormal Steer Axle Noise.....................................................1118 Abnormal Steering Wheel Vibration.............................................1120 Back Lash/Kick Back in Steering Wheel.........................................1121 No Steering (All Other Hydraulic Functions OK)................................1123 Steering Is Slow or Difficult.................................................1125 Steering Operation Is Not Smooth..............................................1127 Steering Wheel End Lock Position Cannot Be Felt by Operator...................1129 Steering Wheel Turns By Itself or Does Not Return To Neutral..................1130 Steering Wheel Turns the Tires in the Wrong Direction.........................1131 Abnormal Hydraulic Noise and/or Vibration.....................................1132 Abnormal Smell/Discoloration/Foaming of Oil...................................1135 Actuations Do Not Act Simultaneously..........................................1136 Oil Leaking/Component Life Too Short..........................................1137 Hydraulic Warmup Procedure....................................................1141 Main Relief Valve Test and Adjustment.........................................1142 Secondary Relief Valve Test and Adjustment....................................1144 Hydraulic Pump Flow Test......................................................1146 Main Control Valve LS Leakage Test (E-Valve)..................................1148 Main Control Valve Unloader Margin Test.......................................1149 Electro-Hydraulic Poppet Valve (EHPV) Leakage Test............................1150 PPRV Pilot Pressure Test......................................................1153 Steering Relief Pressure Test and Adjustment..................................1154 Steering Control Unit LS Pressure Test........................................1155 Lift Cylinder Leakage Test....................................................1157 Tilt Cylinder Leakage Test....................................................1158 Steering Cylinder Leakage Test................................................1159 Operators Station.................................................................1161 Operator Station General Description and Principles of Operation..............1163 General Description and Location..........................................1163 Display Switch Cluster (DSC)..................................................1165 Detailed Description......................................................1165 Control Inputs, Right Side................................................1166 Right Indicator and Warning Group.........................................1168 LCD Display...............................................................1169 Left Indicator and Warning Group..........................................1170 Control Inputs, Left Side (Cab Option Only)...............................1171 Transmission Control and Braking..............................................1172 Description...............................................................1172 Vehicle System Manager (VSM)..........................................1173 Display Switch Cluster................................................1173 Interlock and Switching Features..................................1173 MONOTROL® Directional Control.........................................1173 Inch Brake/Service Brake Pedal........................................1173 Parking Brake.........................................................1174 Programming - Menus...........................................................1174 Menus.....................................................................1174 Main Menu.............................................................1177 Save and Exit or Exit Without Saving..................................1177 Back One Level........................................................1177 Hourmeters............................................................1177 View Versions.........................................................1178 Passwords.............................................................1178 Diagnostics...........................................................1178 Setup Travel and Braking..............................................1178 Setup Hydraulics......................................................1178 Setup Display.........................................................1178 Setup General Items...................................................1178 Calibrations..........................................................1178 Manual Hydraulic Control Levers...............................................1179 General Description.......................................................1179 System Components.........................................................1179 Lift/Lower............................................................1179 Tilt..................................................................1179 Auxiliary 1...........................................................1179 Auxiliary 2...........................................................1179 E-Hydraulic System Interface..................................................1180 General Description.......................................................1180 System Components.........................................................1180 E-Hydraulic Control Input Device..........................................1180 Joystick..............................................................1180 Lift/Lower........................................................1181 Tilt..............................................................1181 Auxiliary 1.......................................................1181 Auxiliary 2.......................................................1181 Push Button.......................................................1181 Mini Lever Module (MLM)...............................................1182 Lever 1...........................................................1182 Lever 2...........................................................1182 Lever 3...........................................................1183 Lever 4...........................................................1183 System Modes..............................................................1183 Hydraulic Interlock Mode..............................................1183 Fault Mode............................................................1183 Engine Off Mode.......................................................1183 Normal Operation..........................................................1183 Normal Operation Mode.................................................1183 Lifting Control.......................................................1183 Lowering Control......................................................1184 Tilt Control (Forward and Backward)...................................1184 Auxiliary Control.....................................................1184 Lighting Control..............................................................1184 Description...............................................................1184 Front Work Lights.....................................................1187 Front Marker Lights (if equipped).....................................1187 Front/Rear Turn Signal Lights.........................................1187 Rear Tail/Marker Lights...............................................1187 Rear Work Light.......................................................1187 Rear Backup Lights....................................................1187 Rear Stop Lights......................................................1187 Strobe Light(s).......................................................1187 Spot Light (if equipped)..............................................1187 Cab...........................................................................1187 Description...............................................................1187 Component Descriptions....................................................1189 Cab Heating System....................................................1189 Lighting Control System...............................................1189 Wiper/Washer System...................................................1189 Cab Systems Operation.....................................................1190 Front End (Mast) and Chassis......................................................1193 Front End, Mast...............................................................1195 Description...............................................................1195 Carriages.....................................................................1195 Description...............................................................1195 Principles of Operation...................................................1196 Integral Sideshift Carriage...........................................1196 Mast Mounts...................................................................1198 Description...............................................................1198 Principles of Operation...................................................1198 Two-Stage Limited Free-Lift (LFL) Mast........................................1200 Description...............................................................1200 Principles of Operation...................................................1201 Two-Stage Full Free-Lift (FFL) Mast...........................................1202 Description...............................................................1202 Principles of Operation...................................................1203 Three-Stage Full Free-Lift (FFL) Mast.........................................1204 Description...............................................................1204 Principles of Operation...................................................1204 Four-Stage Full Free-Lift (FFL) Mast..........................................1206 Description...............................................................1206 Principles of Operation...................................................1207 Cylinder Cushion During Lifting Sequence......................................1209 Description...............................................................1209 Principles of Operation...................................................1209 Cylinder Cushion During Lowering Sequence.....................................1210 Description...............................................................1210 Principles of Operation...................................................1210 Tilt and Sideshift Cylinders..................................................1210 Description...............................................................1210 Tilt Cylinder.........................................................1210 Sideshift Cylinder....................................................1210 Lowering Control Valves.......................................................1211 Description...............................................................1211 Principles of Operation...................................................1211 Chassis.......................................................................1213 Description...............................................................1213 Abnormal Channel Wear.........................................................1215 Abnormal Hose Wear............................................................1217 Abnormal Mast Noise...........................................................1219 Body Panels Making Noise......................................................1223 External Leakage From Free-Lift or Main Lift Cylinders........................1224 FFL Mast Banging During Phasing...............................................1225 High Tire Wear - Drive Axle...................................................1227 High Tire Wear - Steer Axle...................................................1229 Hoses Not Tracking Correctly..................................................1231 Integral Sideshift Moving Too Fast............................................1232 Integral Sideshift Not Moving or Slow.........................................1233 LP Tank Bracket Disengages....................................................1236 LP Tank Rattles and Does Not Stay Latched.....................................1237 Mast is Loose.................................................................1238 Mast Lift Chains Are Loose....................................................1240 Mast or Carriage Binding......................................................1241 Mast/Carriage Bounces or is Spongy............................................1243 Misphasing of Full Free-Lift Mast.............................................1244 Overhead Guard Loose or Damaged...............................................1246 Racking During Lift...........................................................1247 Racking During Tilt...........................................................1249 Truck Feels Unstable..........................................................1250 Truck Wanders, Does Not Track Straight or Steer Well..........................1252 Wheels Appear Tipped or Misaligned............................................1254 Wheels Spinning On Uneven Floors..............................................1256 Wheel Studs Breaking..........................................................1257 Supplementary Data................................................................1259 Abbreviations and Acronyms....................................................1261 Special Tools List............................................................1269 Fault Mode Indicator (FMI) Reference List.....................................1275 TSP Reference Tables..........................................................1277 tables................................................................................ 1 Table 9020-10-1. IAT Ambient Temperature.......................................... 92 Table 9020-40-1. Test Specifications.............................................. 265 Table 9020-40-2. Test Specifications.............................................. 266 Table 9020-40-3. Service Tools.................................................... 266 Table 9020-40-4. Test Specifications.............................................. 267 Table 9020-40-5. Service Tools.................................................... 267 Table 9020-40-6. Test Specifications.............................................. 268 Table 9020-40-7. Service Tools.................................................... 269 Table 9020-40-8. Test Specifications - Mazda...................................... 270 Table 9020-40-9. Test Specifications - GM......................................... 270 Table 9020-40-10. Service Tools................................................... 270 Table 9020-40-11. Test Specifications............................................. 272 Table 9020-40-12. Service Tools................................................... 272 Table 9020-40-13. Test Specifications............................................. 274 Table 9020-40-14. Service Tools................................................... 274 Table 9030-03-1. Cummins QSB 3.3L Fault Codes..................................... 305 Table 9030-03-2. Circuit Group Identification..................................... 308 Table 9030-03-3. Hyster Wiring Color Codes........................................ 309 Table 9040-10-1. Two-Speed Transmission Clutch Pack Solenoid Val.................. 945 Table 9040-10-2. Three-Speed Transmission Electronic Proportiona.................. 946 Table 9040-10-3. Transmission Control Mode........................................ 948 Table 9040-40-1. Test Specifications..............................................1013 Table 9040-40-2. Service Tools....................................................1013 Table 9040-40-3. Service Tools....................................................1013 Table 9040-40-4. Test Specifications..............................................1015 Table 9040-40-5. Test Specifications..............................................1015 Table 9040-40-6. Test Specifications..............................................1016 Table 9040-40-7. Test Specifications..............................................1016 Table 9040-40-8. Test Specifications..............................................1017 Table 9040-40-9. Service Tools....................................................1017 Table 9040-40-10. Stall Speeds....................................................1018 Table 9050-10-1. Standby Pressure Table...........................................1047 Table 9050-40-1. Test Specifications..............................................1141 Table 9050-40-2. Service Tools....................................................1141 Table 9050-40-3. Test Specifications..............................................1142 Table 9050-40-4. Service Tools....................................................1142 Table 9050-40-5. Test Specifications..............................................1144 Table 9050-40-6. Service Tools....................................................1144 Table 9050-40-7. Test Specifications..............................................1146 Table 9050-40-8. Service Tools....................................................1147 Table 9050-40-9. Test Specifications..............................................1148 Table 9050-40-10. Test Specifications.............................................1149 Table 9050-40-11. Service Tools...................................................1149 Table 9050-40-12. Test Specifications.............................................1150 Table 9050-40-13. Service Tools...................................................1150 Table 9050-40-14. Test Specifications.............................................1153 Table 9050-40-15. Service Tools...................................................1153 Table 9050-40-16. Test Specifications.............................................1154 Table 9050-40-17. Service Tools...................................................1154 Table 9050-40-18. Test Specifications.............................................1155 Table 9050-40-19. Service Tools...................................................1156 Table 9050-40-20. Test Specifications.............................................1157 Table 9050-40-21. Service Tools...................................................1157 Table 9050-40-22. Test Specifications.............................................1158 Table 9050-40-23. Service Tools...................................................1158 Table 9050-40-24. Test Specifications.............................................1159 Table 9050-40-25. Service Tools...................................................1159 Table 9080-50-1. Abbreviations and Acronyms.......................................1261 Table 9080-60-1. Special Tools....................................................1269 Table 9080-70-1. FMI..............................................................1275 Table 9080-80-1. Resistor-Temperature Characteristics ............................1277 1580514-1900SRM1136-(03-2007)-US-EN.......................................................1281 toc...................................................................................1281 Hydraulic Gear Pump...............................................................1281 Safety Precautions Maintenance and Repair.........................................1282 General...........................................................................1285 Single Gear Pump Assembly Repair..................................................1285 Remove........................................................................1285 Disassemble...................................................................1286 Clean.........................................................................1286 Inspect.......................................................................1286 Assemble......................................................................1286 Install.......................................................................1290 Tandem Gear Pump Assembly.........................................................1291 Remove........................................................................1291 Disassemble...................................................................1293 Clean.........................................................................1295 Inspect.......................................................................1295 Assemble......................................................................1295 Install.......................................................................1296 Gear Pump Specifications..........................................................1296 Torque Specifications.............................................................1300 tables................................................................................1281 Table 1. Standard Gear Pump for Lift Truck Models S30FT, S35FT, ..................1296 Table 2. High Pressure Gear Pump for Lift Truck Models S30FT, S3..................1297 Table 3. Standard Gear Pump for Lift Truck Models S4.0, 4.5, 5.5..................1298 Table 4. High Pressure Gear Pump for Lift Truck Models S4.0, 4.5..................1298 Table 5. Standard Gear Pump for Lift Truck Models S6.0FT, S7.0FT..................1299 Table 6. High Pressure Gear Pump for Lift Truck Models S6.0FT, S..................1299 1580515-2000SRM1137-(04-2007)-US-EN.......................................................1303 toc...................................................................................1303 Main Control Valve................................................................1303 Safety Precautions Maintenance and Repair.........................................1304 General...........................................................................1309 Electro-Hydraulic Main Control Valve..............................................1309 Description...................................................................1309 Remove........................................................................1312 Electro-Hydraulic Control Valve Sections......................................1316 General...................................................................1316 Outlet Control Valve Section..............................................1316 Remove................................................................1316 Disassemble...........................................................1316 Clean.................................................................1316 Inspect...............................................................1317 Assemble..............................................................1318 Install...............................................................1318 Auxiliary Control Valve Sections..........................................1318 Remove................................................................1318 Disassemble...........................................................1320 Clean.................................................................1320 Inspect...............................................................1321 Assemble..............................................................1321 Install...............................................................1321 Tilt Control Valve Section................................................1321 Remove................................................................1321 Disassemble...........................................................1322 Clean.................................................................1323 Inspect...............................................................1324 Assemble..............................................................1324 Install...............................................................1324 Lift/Lower Control Valve Section..........................................1324 Remove................................................................1324 Disassemble...........................................................1324 Clean.................................................................1327 Inspect...............................................................1327 Assemble..............................................................1327 Install...............................................................1328 Mid-Inlet Section.........................................................1328 Remove................................................................1328 Clean.................................................................1329 Inspect...............................................................1329 Install...............................................................1329 Install.......................................................................1329 Electro Hydraulic Poppet Valve (EHPV) Pilot Pin Adjustment....................1333 Lift Pilot Pin............................................................1333 Lower Pilot Pin...........................................................1335 Abnormal/Erroneous EHPV Adjustment........................................1337 Manual Main Control Valve.........................................................1337 Description...................................................................1337 Remove........................................................................1338 Manual Control Valve Sections.................................................1343 General...................................................................1343 Outlet Control Valve Section..............................................1343 Remove................................................................1343 Disassemble...........................................................1343 Clean.................................................................1345 Inspect...............................................................1345 Assemble..............................................................1345 Install...............................................................1345 Auxiliary Control Valve Sections..........................................1345 Remove................................................................1345 Disassemble...........................................................1346 Clean.................................................................1346 Inspect...............................................................1346 Assemble..............................................................1346 Install...............................................................1348 Lift/Tilt Control Valve Section...........................................1348 Remove................................................................1348 Disassemble...........................................................1348 Clean.................................................................1351 Inspect...............................................................1351 Assemble..............................................................1351 Install...............................................................1352 Mid-Inlet Section.........................................................1352 Remove................................................................1352 Clean.................................................................1352 Inspect...............................................................1353 Install...............................................................1353 Install.......................................................................1353 Pressure Relief Valve Check and Adjustment........................................1357 Primary Relief Valve..........................................................1357 Secondary Relief Valve........................................................1358 Steering Control Unit Repair......................................................1360 Steering Control Unit, Remove.................................................1360 Steering Control Unit, Disassemble............................................1363 Steering Control Unit, Clean..................................................1364 Steering Control Unit, Inspect................................................1364 Steering Control Unit, Assemble...............................................1364 Relief Valve, Disassemble.....................................................1365 Relief Valve, Clean...........................................................1365 Relief Valve, Inspect.........................................................1366 Relief Valve, Assemble........................................................1366 Steering Control Unit, Install................................................1366 tables................................................................................1303 Table 1. Relief Valve Settings....................................................1357 1580515-2000SRM1137-(06-2007)-US-EN.......................................................1369 toc...................................................................................1369 Main Control Valve................................................................1369 Safety Precautions Maintenance and Repair.........................................1370 General...........................................................................1375 Electro-Hydraulic Main Control Valve..............................................1375 Description...................................................................1375 Remove........................................................................1378 Electro-Hydraulic Control Valve Sections......................................1382 General...................................................................1382 Outlet Control Valve Section..............................................1382 Remove................................................................1382 Disassemble...........................................................1382 Clean.................................................................1382 Inspect...............................................................1383 Assemble..............................................................1384 Install...............................................................1384 Auxiliary Control Valve Sections..........................................1384 Remove................................................................1384 Disassemble...........................................................1386 Clean.................................................................1386 Inspect...............................................................1387 Assemble..............................................................1387 Install...............................................................1387 Tilt Control Valve Section................................................1387 Remove................................................................1387 Disassemble...........................................................1388 Clean.................................................................1389 Inspect...............................................................1390 Assemble..............................................................1390 Install...............................................................1390 Lift/Lower Control Valve Section..........................................1390 Remove................................................................1390 Disassemble...........................................................1390 Clean.................................................................1393 Inspect...............................................................1393 Assemble..............................................................1393 Install...............................................................1394 Mid-Inlet Section.........................................................1394 Remove................................................................1394 Clean.................................................................1395 Inspect...............................................................1395 Install...............................................................1395 Install.......................................................................1395 Electro Hydraulic Poppet Valve (EHPV) Pilot Pin Adjustment....................1399 Lift Pilot Pin............................................................1399 Lower Pilot Pin...........................................................1401 Abnormal/Erroneous EHPV Adjustment........................................1403 Manual Main Control Valve.........................................................1403 Description...................................................................1403 Remove........................................................................1404 Manual Control Valve Sections.................................................1409 General...................................................................1409 Outlet Control Valve Section..............................................1409 Remove................................................................1409 Disassemble...........................................................1409 Clean.................................................................1411 Inspect...............................................................1411 Assemble..............................................................1411 Install...............................................................1411 Auxiliary Control Valve Sections..........................................1411 Remove................................................................1411 Disassemble...........................................................1412 Clean.................................................................1412 Inspect...............................................................1412 Assemble..............................................................1412 Install...............................................................1414 Lift/Tilt Control Valve Section...........................................1414 Remove................................................................1414 Disassemble...........................................................1414 Clean.................................................................1417 Inspect...............................................................1417 Assemble..............................................................1417 Install...............................................................1418 Mid-Inlet Section.........................................................1418 Remove................................................................1418 Clean.................................................................1418 Inspect...............................................................1419 Install...............................................................1419 Install.......................................................................1419 Pressure Relief Valve Check and Adjustment........................................1423 Primary Relief Valve..........................................................1423 Secondary Relief Valve........................................................1424 Steering Control Unit Repair......................................................1426 Steering Control Unit, Remove.................................................1426 Steering Control Unit, Disassemble............................................1429 Steering Control Unit, Clean..................................................1430 Steering Control Unit, Inspect................................................1430 Steering Control Unit, Assemble...............................................1430 Relief Valve, Disassemble.....................................................1431 Relief Valve, Clean...........................................................1431 Relief Valve, Inspect.........................................................1432 Relief Valve, Assemble........................................................1432 Steering Control Unit, Install................................................1432 tables................................................................................1369 Table 1. Relief Valve Settings....................................................1423 1580527-8000SRM1152-(04-2007)-US-EN.......................................................1435 toc...................................................................................1435 Diagrams and Schematics...........................................................1435 Safety Precautions Maintenance and Repair.........................................1436 General Information About Diagrams and Schematics.................................1439 Symbol Definitions............................................................1439 tables................................................................................1435 Table 1. Wire Colors..............................................................1439 Table 2. Symbol Definitions.......................................................1439 1580527-8000SRM1152-(07-2007)-US-EN.......................................................1501 toc...................................................................................1501 Diagrams and Schematics...........................................................1501 Safety Precautions Maintenance and Repair.........................................1502 General Information About Diagrams and Schematics.................................1505 Symbol Definitions............................................................1505 tables................................................................................1501 Table 1. Wire Colors..............................................................1505 Table 2. Symbol Definitions.......................................................1505 1624743-8000SRM1249-(10-2007)-US-EN.......................................................1567 toc...................................................................................1567 Capacities and Specifications.....................................................1567 Safety Precautions Maintenance and Repair.........................................1568 Lift Truck Lifting Capacity.......................................................1571 Counterweight Weights.............................................................1571 Tire Sizes........................................................................1572 Capacities........................................................................1573 Electrical System.................................................................1577 Transmission Oil Pressures........................................................1578 Hydraulic System Relief Pressures.................................................1580 Steering System...................................................................1580 Stall Speeds (in RPM ±100 rpm)....................................................1581 GM 4.3L Gas/LPG...............................................................1581 Cummins 4.5L Diesel...........................................................1581 Mast Speeds.......................................................................1581 Tilt Angles.......................................................................1583 Front End Equipment - Mast Creep..................................................1584 Mast Creep....................................................................1584 Engine Specifications.............................................................1585 Torque Specifications.............................................................1586 Frame.........................................................................1586 Mast..........................................................................1586 Steering System...............................................................1586 Drive Axle (Wet Brake)........................................................1586 Drive Axle (Dry Brake)........................................................1587 Transmission..................................................................1587 Engine - GM 4.3L..............................................................1588 Engine - Cummins 4.5L Diesel..................................................1589 tables................................................................................1567 Table 1. S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; S80, 100FT..................1573 Table 2. H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 10..................1574 Table 3. S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; S80, 100FT..................1577 Table 4. H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 10..................1577 Table 5. S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; S80, 100FT..................1580 Table 6. H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 10..................1580 Table 7. Lift Truck Models S4.0, (S80FT, S80FTBCS) (G004).........................1581 Table 8. Lift Truck Models S4.5, 5.5FT; S5.5FTS; (S100, 120FT;) ..................1582 Table 9. Lift Truck Models H4.0FT5, H4.0FT6; (H80FT, H90FT) (N00..................1582 Table 10. Lift Truck Models H4.0FT5, H4.0FT6; (H80FT, H90FT) (N0..................1582 Table 11. Lift Truck Models H4.5FTS5, H4.5FT6; H5.0-5.50FT (H100..................1583 Table 12. Lift Truck Models H4.5FTS5, H4.5FT6; H5.0-5.50FT (H100..................1583 Table 13. S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; S80, 100F..................1583 Table 14. H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 1..................1583 Table 15. S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; S80, 100F..................1584 Table 16. H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 1..................1584 Brake System 1624741-1800SRM1247-(07-2008)-US-EN..........................................1593 toc...................................................................................1593 Brake System......................................................................1593 Safety Precautions Maintenance and Repair.........................................1594 General...........................................................................1597 Dry Brake System..............................................................1597 Wet Brake System..............................................................1597 Service Brakes Repair (Dry Brake).................................................1598 Remove and Disassemble........................................................1599 Clean.........................................................................1601 Inspect.......................................................................1602 Assemble and Install..........................................................1602 Adjust........................................................................1606 Parking Brake Repair..............................................................1606 Remove and Disassemble........................................................1606 Assemble and Install..........................................................1611 Adjust........................................................................1611 Dry Brake System..........................................................1611 Wet Brake System..........................................................1611 Lift Trucks With a MONOTROL® Pedal or Forward Reverse Lever...............1612 Master Cylinder Repair............................................................1612 Remove........................................................................1612 Disassemble...................................................................1615 Clean and Inspect.............................................................1615 Assemble......................................................................1616 Install and Adjust............................................................1617 Accumulator.......................................................................1618 Precharge Check...............................................................1618 Remove........................................................................1618 Install.......................................................................1620 Service Brakes Adjustment (Dry Brake).............................................1621 Service Brakes Adjustment.....................................................1621 Brake System Air Removal..........................................................1621 Using Pressure Bleed System...................................................1621 Using Brake Pedal Pressure....................................................1622 Brake Pedal Adjustment............................................................1623 Free Pedal Adjustment.............................................................1624 Torque Specifications.............................................................1625 Calibration Procedures 1580528-8000SRM1134-(07-2008)-US-EN................................1629 toc...................................................................................1629 Calibration Procedures............................................................1629 Safety Precautions Maintenance and Repair.........................................1630 Description.......................................................................1635 Proc_Cal_001: Service Password Entry..............................................1638 When to Perform...............................................................1638 Why Perform...................................................................1638 How to Perform................................................................1638 Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed...................1640 When to Perform...............................................................1640 Calibration Order.............................................................1640 Why Perform...................................................................1640 How to Perform................................................................1640 Proc_Cal_003: Save and Exit.......................................................1642 When to Perform...............................................................1642 Why Perform...................................................................1642 How to Perform................................................................1642 Proc_Cal_004: Lift Valve Output Threshold.........................................1644 When to Perform...............................................................1644 Calibration Order.............................................................1644 Why Perform...................................................................1644 How to Perform................................................................1644 Proc_Cal_005: Lower Valve Output Threshold........................................1646 When to Perform...............................................................1646 Calibration Order.............................................................1646 Why Perform...................................................................1646 How to Perform................................................................1646 Proc_Cal_006: Tilt Back Valve Output Threshold....................................1650 When to Perform...............................................................1650 Calibration Order.............................................................1650 Why Perform...................................................................1650 How to Perform................................................................1650 Proc_Cal_007: Tilt Forward Valve Output Threshold.................................1652 When to Perform...............................................................1652 Calibration Order.............................................................1652 Why Perform...................................................................1652 How to Perform................................................................1653 Proc_Cal_008: Aux 1 Dir A Valve Output Threshold..................................1656 When to Perform...............................................................1656 Calibration Order.............................................................1656 Why Perform...................................................................1656 How to Perform................................................................1656 Proc_Cal_009: Aux 1 Dir B Valve Output Threshold..................................1658 When to Perform...............................................................1658 Calibration Order.............................................................1658 Why Perform...................................................................1658 How to Perform................................................................1658 Proc_Cal_010: Aux 2 Dir A Valve Output Threshold..................................1662 When to Perform...............................................................1662 Calibration Order.............................................................1662 Why Perform...................................................................1662 How to Perform................................................................1662 Proc_Cal_011: Aux 2 Dir B Valve Output Threshold..................................1664 When to Perform...............................................................1664 Calibration Order.............................................................1664 Why Perform...................................................................1664 How to Perform................................................................1665 Proc_Cal_012: Aux 3 Dir A Valve Output Threshold..................................1668 When to Perform...............................................................1668 Calibration Order.............................................................1668 Why Perform...................................................................1668 How to Perform................................................................1668 Proc_Cal_013: Aux 3 Dir B Valve Output Threshold..................................1670 When to Perform...............................................................1670 Calibration Order.............................................................1670 Why Perform...................................................................1670 How to Perform................................................................1671 Proc_Cal_014: Load Weight Zero Point..............................................1674 When to Perform...............................................................1674 Calibration Order.............................................................1674 Why Perform...................................................................1674 How to Perform................................................................1674 Proc_Cal_015: Loaded Weight Calibration...........................................1676 When to Perform...............................................................1676 Calibration Order.............................................................1676 Why Perform...................................................................1676 How to Perform................................................................1676 Proc_Cal_016: Transmission Valve Calibration......................................1678 Applicable System/Option......................................................1678 When to Perform...............................................................1678 Calibration Order.............................................................1678 Why Perform...................................................................1679 How to Perform................................................................1679 Applicable System/Option......................................................1680 When to Perform...............................................................1680 Calibration Order.............................................................1680 Why Perform...................................................................1680 How to Perform................................................................1680 Proc_Cal_016A: Transmission Valve Calibration-Electronic Extende..................1682 Applicable System/Option......................................................1682 When to Perform...............................................................1682 Calibration Order.............................................................1682 Why Perform...................................................................1682 How to Perform................................................................1682 Proc_Cal_016B: Trans. Valve Calibration-Electronic and Electroni..................1684 Applicable System/Option......................................................1684 When to Perform...............................................................1684 Calibration Order.............................................................1684 Why Perform...................................................................1684 How to Perform................................................................1684 Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment.......................1686 Required Tools................................................................1686 When to Perform...............................................................1686 Calibration Order.............................................................1686 Why Perform...................................................................1686 How to Perform................................................................1686 Proc_Cal_025: Hydraulic Valve Pressure Gage Installation..........................1688 When to Perform...............................................................1688 Why Perform...................................................................1688 How to Perform................................................................1688 Proc_Cal_026: Travel Speed Calibration............................................1690 When to Perform...............................................................1690 Calibration Order.............................................................1690 Why Perform...................................................................1690 How to Perform................................................................1690 tables................................................................................1629 Table 1. Calibration Procedures...................................................1635 Table 2. How to Read Calibration Procedure........................................1636 Table 3. Proc_Cal_001: Service Password Entry.....................................1639 Table 4. Proc_Cal_002: Hydraulic Valve Calibration Warm Up and A..................1640 Table 5. Proc_Cal_003: Save and Exit..............................................1643 Table 6. Proc_Cal_004: Lift Valve Output Threshold................................1644 Table 7. Proc_Cal_005: Lower Valve Output Threshold...............................1647 Table 8. Proc_Cal_006: Tilt Back Valve Output Threshold...........................1650 Table 9. Proc_Cal_007: Tilt Forward Valve Output Threshold........................1653 Table 10. Proc_Cal_008: Aux 1 Dir A Valve Output Threshold........................1656 Table 11. Proc_Cal_009: Aux 1 Dir B Valve Output Threshold........................1659 Table 12. Proc_Cal_010: Aux 2 Dir A Valve Output Threshold........................1662 Table 13. Proc_Cal_011: Aux 2 Dir B Valve Output Threshold........................1665 Table 14. Proc_Cal_012: Aux 3 Dir A Valve Output Threshold........................1668 Table 15. Proc_Cal_013: Aux 3 Dir B Valve Output Threshold........................1671 Table 16. Proc_Cal_014: Load Weight Zero Point....................................1674 Table 17. Proc_Cal_015: Loaded Weight Calibration.................................1676 Table 18. Proc_Cal_016: Transmission Valve Calibration............................1679 Table 19. Proc_Cal_016: Transmission Valve Calibration ( S6.0FT,..................1681 Table 20. Proc_Cal_016A: Transmission Valve Calibration...........................1683 Table 21. Proc_Cal_016B: Transmission Valve Calibration...........................1685 Table 22. Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjus..................1687 Table 23. Proc_Cal_025: Hydraulic Valve Pressure Gage Installati..................1689 Table 24. Proc_Cal_026: Travel Speed Calibration..................................1690 Diagrams and Schematics 1580527-8000SRM1152-(07-2007)-US-EN...............................1695 toc...................................................................................1695 Diagrams and Schematics...........................................................1695 Safety Precautions Maintenance and Repair.........................................1696 General Information About Diagrams and Schematics.................................1699 Symbol Definitions............................................................1699 tables................................................................................1695 Table 1. Wire Colors..............................................................1699 Table 2. Symbol Definitions.......................................................1699 Drive Axle - Dry Brake 1624739-1400SRM1245-(11-2008)-US-EN................................1761 toc...................................................................................1761 Drive Axle and Differential Assembly Repair.......................................1761 Safety Precautions Maintenance and Repair.........................................1762 General...........................................................................1765 Drive Axle Repair.................................................................1765 Remove and Disassemble........................................................1765 Clean and Inspect.............................................................1768 Assemble and Install..........................................................1768 Differential Repair...............................................................1770 Remove........................................................................1770 Support Differential Assembly From Differential Housing Assembly..........1770 Differential Assembly From Differential Assembly Support..................1772 Differential Assembly Support from Drop Box...............................1775 Drive Pinion and Pinion Gear, from Differential Assembly Support..........1777 Disassemble...................................................................1778 Differential Assembly.....................................................1778 Drop Box Housing..........................................................1780 Differential Assembly Support.............................................1781 Differential Housing......................................................1782 Clean and Inspect.............................................................1783 Assemble......................................................................1783 Differential Housing......................................................1783 Differential Assembly Support.............................................1784 Drop Box Housing..........................................................1785 Differential Assembly.....................................................1786 Install.......................................................................1790 Pinion Inner Shim Set, Adjust Thickness (Depth of Pinion).................1790 Drive Pinion and Pinion Gear Into Differential Assembly Support...........1792 Differential Assembly Into Differential Assembly Support..................1794 Ring Gear Backlash, Adjust................................................1797 Gear Set, Tooth Contact Pattern Check.....................................1798 Differential Assembly Support Into Differential Housing...................1802 Torque Specifications.............................................................1803 tables................................................................................1761 Table 1. Pinion Variation Numbers Examples........................................1791 Table 2. Ring and Pinion Tooth Contact Adjustment.................................1799 Table 3. Correct Tooth Contact....................................................1800 Table 4. Incorrect Tooth Contact..................................................1801 Drve Axle - Wet Brake 1624740-1400SRM1246-(08-2008)-US-EN.................................1807 toc...................................................................................1807 Drive Axle and Differential Assembly Repair.......................................1807 Safety Precautions Maintenance and Repair.........................................1808 General...........................................................................1811 Identification Plate..........................................................1811 Drive Axle Removal................................................................1811 Hub Seal Replacement..............................................................1816 Remove........................................................................1816 Install.......................................................................1820 Planetary Reduction Repair........................................................1825 Remove........................................................................1825 Disassemble...................................................................1828 Clean and Inspect.............................................................1834 Assemble......................................................................1834 Install.......................................................................1843 Brake Repair......................................................................1846 Remove and Disassemble........................................................1846 Clean and Inspect.............................................................1857 Assemble and Install..........................................................1857 Bevel Pinion......................................................................1868 Remove........................................................................1868 Disassemble...................................................................1870 Clean and Inspect.............................................................1873 Assemble......................................................................1874 Calculation of Measurement Y..............................................1875 Calculation of Measurement X..............................................1876 Calculation of Measurement S1.............................................1877 Calculation of Measurement S2.............................................1878 Bevel Pinion Housing......................................................1880 Install.......................................................................1882 Differential Unit.................................................................1884 Remove........................................................................1884 Disassemble...................................................................1895 Differential Assembly.....................................................1895 Ring Nuts.................................................................1900 Clean and Inspect.............................................................1901 Assemble......................................................................1902 Ring Nuts.................................................................1902 Differential Assembly.....................................................1905 Install.......................................................................1912 Drive Axle Installation...........................................................1925 Special Tools.....................................................................1930 Torque Specifications.............................................................1930 Electrical System 1580520-2200SRM1142-(09-2008)-US-EN.....................................1933 toc...................................................................................1933 Electrical System.................................................................1933 Safety Precautions Maintenance and Repair.........................................1934 General...........................................................................1943 Display Switch Cluster............................................................1944 Remove........................................................................1944 Install.......................................................................1946 Direction Control and Turn Signal Levers......................................1946 Remove....................................................................1946 Install...................................................................1946 Key Switch....................................................................1948 Remove....................................................................1948 Install...................................................................1948 Display Switch Cluster Panel Bezel and Overlay................................1949 Remove....................................................................1949 Install...................................................................1949 Steering Column Repair............................................................1949 Remove........................................................................1949 Disassemble...................................................................1949 Assemble......................................................................1949 Install.......................................................................1950 Sensors and Switches..............................................................1952 General.......................................................................1952 Dash and Kick Panel, Remove and Install...................................1952 Remove................................................................1952 Install...............................................................1952 Accelerator Pedal Position Sensor.............................................1954 Remove....................................................................1954 Install...................................................................1954 Brake Fluid Level Switch......................................................1957 Remove....................................................................1957 Install...................................................................1957 Service Brake Pedal Position Sensor...........................................1958 Remove....................................................................1958 Install...................................................................1958 Parking Brake Sensor..........................................................1959 Remove....................................................................1959 Install...................................................................1959 Service Brake Pressure Sensor.................................................1960 Remove....................................................................1960 Install...................................................................1960 MONOTROL® Sensor Microswitch..................................................1960 Remove....................................................................1960 Install...................................................................1962 Low Coolant Level Sensor......................................................1962 Remove....................................................................1964 Install...................................................................1964 Fuel Level Sensor, Gas and Diesel Engines Only................................1964 Remove....................................................................1964 Install...................................................................1964 Armrest Switch................................................................1965 Remove....................................................................1965 Install...................................................................1965 Seat Sensor (Operator Presence System)........................................1967 Non-Suspension and Semi-Suspension Seats; All Lift truck Models ..........1967 Remove................................................................1967 Install...............................................................1967 Non-Suspension Seats; Lift Truck Models H6.0FT, H7.0FT (H135FT, ..........1968 Remove................................................................1968 Install...............................................................1968 Full Suspension Seats; All Lift Truck Models..............................1969 Remove................................................................1969 Install...............................................................1969 Hood Shut Off Switch..........................................................1969 Remove....................................................................1969 Install...................................................................1969 Hydraulic Filter Pressure Switch..............................................1973 Remove....................................................................1973 Install...................................................................1973 Transmission Speed Sensor.....................................................1973 Remove....................................................................1973 Install...................................................................1974 Transmission Pressure Sensors.................................................1974 Remove....................................................................1974 Install...................................................................1974 Transmission Temperature Sensor...............................................1974 Remove....................................................................1974 Install...................................................................1975 Engine Speed Sensor...........................................................1976 Remove....................................................................1976 Install...................................................................1976 Intermediate Speed Sensor.....................................................1976 Remove....................................................................1976 Install...................................................................1976 Return to Set Tilt (Tilt Angle) Sensor........................................1976 Lift Truck Models S30FT, S35FT, S40FTS (E010); H1.6FT, H1.8FT, H..........1976 Remove................................................................1976 Install...............................................................1977 Lift Truck Models S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024); ..........1977 Remove................................................................1977 Install...............................................................1978 Rear Horn Button Switch.......................................................1978 Remove....................................................................1978 Install...................................................................1978 Impact Sensor.................................................................1979 All Lift Truck Models Except H6.0FT, H7.0FT (H135FT, H155FT) (H0..........1979 Remove................................................................1979 Install...............................................................1979 Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006)............1981 Remove................................................................1981 Install...............................................................1982 Load Weight Sensor............................................................1982 Remove....................................................................1982 Install...................................................................1983 Engine and Fuel Sensors - Mazda 2.0L and 2.2L Gas and LPG Engine..............1983 Oxygen Sensor.............................................................1983 Remove................................................................1983 Install...............................................................1983 Intake Air Temperature (IAT) Sensor.......................................1984 Remove................................................................1984 Install...............................................................1984 Manifold Absolute Pressure (MAP)/Boost Sensor.............................1984 Remove................................................................1984 Install...............................................................1984 Throttle Position (TPS) Sensor............................................1985 Remove................................................................1985 Install...............................................................1985 Engine and Fuel Sensors and Switches - Mazda 2.0L and 2.2L LPG E..............1985 Oil Pressure Sensor.......................................................1985 Remove................................................................1985 Install...............................................................1985 Low LPG Pressure Switch...................................................1986 Remove................................................................1986 Install...............................................................1986 Air Filter Restriction Switch.............................................1986 Remove................................................................1986 Install...............................................................1987 Engine Coolant Temperature (ECT) Sensor...................................1987 Remove................................................................1987 Install...............................................................1987 Engine and Fuel Sensors and Switches- Mazda 2.0L and 2.2L Gas En..............1987 Oil Pressure Sensor.......................................................1987 Remove................................................................1987 Install...............................................................1987 Mass Air Flow (MAF) Sensor................................................1988 Remove................................................................1988 Install...............................................................1988 Air Filter Restriction Switch.............................................1988 Remove................................................................1988 Install...............................................................1988 Engine Coolant Temperature (ECT) Sensor...................................1989 Remove................................................................1989 Install...............................................................1989 Engine and Fuel Sensors and Switches - Mazda 2.0L and 2.2L Gas a..............1989 Oil Pressure Sensor.......................................................1989 Remove................................................................1989 Install...............................................................1989 Air Filter Restriction Switch.............................................1990 Remove................................................................1990 Install...............................................................1990 CAM Angle Sensor..........................................................1991 Voltage Check.........................................................1991 Oxygen Sensor.............................................................1992 Remove................................................................1992 Install...............................................................1992 Engine and Fuel Sensors and Switches - Mazda 2.0L and 2.2L LPG E..............1992 Engine Coolant Temperature (ECT) Sensor...................................1992 Remove................................................................1992 Install...............................................................1993 Manifold Absolute Pressure (MAP) Sensor...................................1994 Remove................................................................1994 Install...............................................................1994 Intake Air Temperature (IAT) Sensor.......................................1994 Remove................................................................1994 Install...............................................................1994 Fuel Temperature Sensor...................................................1995 Remove................................................................1995 Install...............................................................1995 Low LPG Pressure Switch...................................................1996 Remove................................................................1996 Install...............................................................1996 Engine and Fuel Sensors and Switches- Mazda 2.0L and 2.2L Gas En..............1997 Intake Air Temperature (IAT) Sensor.......................................1997 Remove................................................................1997 Install...............................................................1997 Engine Coolant Temperature (ECT) Sensor...................................1998 Remove................................................................1998 Install...............................................................1998 Manifold Absolute Pressure (MAP) Sensor...................................1999 Remove................................................................1999 Install...............................................................1999 Engine and Fuel Sensors and Switches, GM 2.4L and 4.3L Gas and L..............2000 Crankshaft Sensor.........................................................2000 Remove................................................................2000 Install...............................................................2000 Camshaft Position (CMP) Sensor............................................2001 Remove................................................................2001 Install...............................................................2001 Camshaft Position (CMP) Sensor Assembly...................................2002 Remove................................................................2002 Install...............................................................2002 Oil Pressure Sensor.......................................................2002 Remove................................................................2002 Install...............................................................2002 Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) ..........2003 Remove................................................................2003 Install...............................................................2003 Engine Coolant Temperature (ECT) Sensor...................................2004 Remove................................................................2004 Install...............................................................2004 Air Flow Restriction Switch...............................................2004 Remove................................................................2004 Install...............................................................2005 Oxygen Sensor.............................................................2005 Remove................................................................2005 Install...............................................................2008 Engine and Fuel Switches, GM 2.4L and GM 4.3L LPG Trucks Only.................2009 Low LPG Pressure Switch...................................................2009 Remove................................................................2009 Install...............................................................2009 LPG Pressure Sensor, GM 4.3L Engine Only..................................2010 Remove................................................................2010 Install...............................................................2010 Engine and Fuel Sensors and Switches, Yanmar Diesel Trucks....................2010 Air Filter Restriction Switch.............................................2010 Remove................................................................2010 Install...............................................................2010 Oil Pressure Sensor.......................................................2010 Remove................................................................2010 Install...............................................................2010 Engine Speed Sensor.......................................................2010 Remove................................................................2010 Install...............................................................2010 Engine Coolant Temperature (ECT) Sensor...................................2012 Remove................................................................2012 Install...............................................................2012 Throttle Position Sensor (TPS)............................................2012 Remove................................................................2012 Install...............................................................2012 Fuel/Water Separator Sensor...............................................2013 Remove................................................................2013 Install...............................................................2013 Glow Plug Relay...........................................................2014 Remove................................................................2014 Install...............................................................2016 Engine and Fuel Sensors and Switches, Cummins Diesel Engines..................2016 Air Filter Restriction Switch.............................................2016 Remove................................................................2016 Install...............................................................2016 Oil Pressure Sensor.......................................................2018 Remove................................................................2018 Install...............................................................2018 Engine Speed Sensor (Cummins 4.5L Only)...................................2018 Remove................................................................2018 Install...............................................................2018 Engine Coolant Temperature (ECT) Sensor...................................2019 Remove................................................................2019 Install...............................................................2019 Throttle Position Sensor (TPS) (Cummins 4.5L Only)........................2019 Remove................................................................2019 Install...............................................................2020 Fuel/Water Separator Sensor...............................................2020 Remove................................................................2020 Install...............................................................2020 Vehicle System Manager (VSM)......................................................2021 General.......................................................................2021 VSM Replacement...............................................................2021 Remove....................................................................2021 Install...................................................................2022 Programming a New VSM and/or Display Switch Cluster...........................2023 General...................................................................2023 PC Service Tool Software..................................................2023 Data Transferring.........................................................2024 New or Used VSM.......................................................2024 New (Blank) Display Switch Cluster....................................2024 Used (Non-Blank) Display Switch Cluster...............................2024 Power Distribution Module (PDM) and Component Parts...............................2025 Remove........................................................................2025 PDM as a Unit.............................................................2025 Install.......................................................................2028 PDM as a Unit.............................................................2028 Remove and Install............................................................2028 PDM Component Parts.......................................................2028 Transmission Control Unit.........................................................2029 Remove S6.0FT, S7.0FT, (S135FT,S155FT) (D024, E024) and H6.0FT, ..............2029 Install S6.0FT, S7.0FT, (S135FT,S155FT) (D024, E024) and H6.0FT,..............2030 Battery...........................................................................2030 Remove........................................................................2030 Install.......................................................................2030 Lights............................................................................2030 Work Lights (Front and Rear)..................................................2030 Remove....................................................................2030 Install...................................................................2030 Strobe Light..................................................................2031 Remove....................................................................2031 Install...................................................................2032 LED Tail, Backup, and Brake Lights............................................2032 Remove....................................................................2032 Install...................................................................2032 Electronic-Hydraulic Controls.....................................................2034 General.......................................................................2034 Mini-Lever Replacement........................................................2034 Remove....................................................................2034 Clean and Inspect.........................................................2035 Install...................................................................2035 Push Button Switch Replacement................................................2036 Remove....................................................................2036 Install...................................................................2037 Test..........................................................................2038 Mini-Levers...............................................................2038 Full Stroke Test..........................................................2038 Function Returns to Neutral Test..........................................2038 Push Button Switch........................................................2038 Mini-Lever Module (MLM).......................................................2039 Remove....................................................................2039 Install...................................................................2039 tables................................................................................1933 Table 1. VSM and Display Switch Cluster Replacement...............................2025 Main Control Valve 1580515-2000SRM1137-(06-2007)-US-EN....................................2043 toc...................................................................................2043 Main Control Valve................................................................2043 Safety Precautions Maintenance and Repair.........................................2044 General...........................................................................2049 Electro-Hydraulic Main Control Valve..............................................2049 Description...................................................................2049 Remove........................................................................2052 Electro-Hydraulic Control Valve Sections......................................2056 General...................................................................2056 Outlet Control Valve Section..............................................2056 Remove................................................................2056 Disassemble...........................................................2056 Clean.................................................................2056 Inspect...............................................................2057 Assemble..............................................................2058 Install...............................................................2058 Auxiliary Control Valve Sections..........................................2058 Remove................................................................2058 Disassemble...........................................................2060 Clean.................................................................2060 Inspect...............................................................2061 Assemble..............................................................2061 Install...............................................................2061 Tilt Control Valve Section................................................2061 Remove................................................................2061 Disassemble...........................................................2062 Clean.................................................................2063 Inspect...............................................................2064 Assemble..............................................................2064 Install...............................................................2064 Lift/Lower Control Valve Section..........................................2064 Remove................................................................2064 Disassemble...........................................................2064 Clean.................................................................2067 Inspect...............................................................2067 Assemble..............................................................2067 Install...............................................................2068 Mid-Inlet Section.........................................................2068 Remove................................................................2068 Clean.................................................................2069 Inspect...............................................................2069 Install...............................................................2069 Install.......................................................................2069 Electro Hydraulic Poppet Valve (EHPV) Pilot Pin Adjustment....................2073 Lift Pilot Pin............................................................2073 Lower Pilot Pin...........................................................2075 Abnormal/Erroneous EHPV Adjustment........................................2077 Manual Main Control Valve.........................................................2077 Description...................................................................2077 Remove........................................................................2078 Manual Control Valve Sections.................................................2083 General...................................................................2083 Outlet Control Valve Section..............................................2083 Remove................................................................2083 Disassemble...........................................................2083 Clean.................................................................2085 Inspect...............................................................2085 Assemble..............................................................2085 Install...............................................................2085 Auxiliary Control Valve Sections..........................................2085 Remove................................................................2085 Disassemble...........................................................2086 Clean.................................................................2086 Inspect...............................................................2086 Assemble..............................................................2086 Install...............................................................2088 Lift/Tilt Control Valve Section...........................................2088 Remove................................................................2088 Disassemble...........................................................2088 Clean.................................................................2091 Inspect...............................................................2091 Assemble..............................................................2091 Install...............................................................2092 Mid-Inlet Section.........................................................2092 Remove................................................................2092 Clean.................................................................2092 Inspect...............................................................2093 Install...............................................................2093 Install.......................................................................2093 Pressure Relief Valve Check and Adjustment........................................2097 Primary Relief Valve..........................................................2097 Secondary Relief Valve........................................................2098 Steering Control Unit Repair......................................................2100 Steering Control Unit, Remove.................................................2100 Steering Control Unit, Disassemble............................................2103 Steering Control Unit, Clean..................................................2104 Steering Control Unit, Inspect................................................2104 Steering Control Unit, Assemble...............................................2104 Relief Valve, Disassemble.....................................................2105 Relief Valve, Clean...........................................................2105 Relief Valve, Inspect.........................................................2106 Relief Valve, Assemble........................................................2106 Steering Control Unit, Install................................................2106 tables................................................................................2043 Table 1. Relief Valve Settings....................................................2097 Operators Cab 1673866-0100SRM1290-(07-2008)-US-EN.........................................2109 toc...................................................................................2109 Operator's Cab....................................................................2109 Safety Precautions Maintenance and Repair.........................................2110 General...........................................................................2115 Cab Replacement...................................................................2116 Remove, for Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F001); H2...............2116 Install, for Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F001); H2..............2127 Remove, for Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (H..............2128 Install, for Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (..............2132 Door Assemblies...................................................................2133 Right Side Door Assembly, Lift Truck Models H1.6FT, H1.8FT, 2.0F..............2133 Remove....................................................................2133 Disassemble...............................................................2138 Door Cover............................................................2138 Heater Assembly.......................................................2140 Door Lock Assembly....................................................2141 Windows...............................................................2142 Clean.....................................................................2142 Inspect...................................................................2142 Assemble..................................................................2142 Windows...............................................................2142 Door Lock Assembly....................................................2142 Heater Assembly.......................................................2143 Door Cover............................................................2143 Install...................................................................2143 Left Side Door Assembly, Lift Truck Models H1.6FT, H1.8FT, 2.0FT..............2143 Remove....................................................................2143 Disassemble...............................................................2143 Door Cover............................................................2143 Door Lock Assembly....................................................2145 Windows...............................................................2145 Clean.....................................................................2145 Inspect...................................................................2145 Assemble..................................................................2145 Windows...............................................................2145 Door Lock Assembly....................................................2145 Door Cover............................................................2145 Install...................................................................2145 Right and Left Side Door Assemblies, Lift Truck Models H6.0FT, H..............2146 Remove....................................................................2146 Disassemble...............................................................2146 Door Cover............................................................2146 Door Lock Assembly....................................................2148 Windows...............................................................2148 Clean.....................................................................2148 Inspect...................................................................2148 Assemble..................................................................2149 Windows...............................................................2149 Door Lock Assembly....................................................2149 Door Cover............................................................2149 Install...................................................................2150 Window Wipers Replacement.........................................................2150 General.......................................................................2150 Front Wiper Assembly and Motor................................................2150 Remove, Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F001) and H2.0..........2150 Install, Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F001) and H2...........2150 Remove, Lift Truck Models H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-5..........2152 Install, Lift Truck Models H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-..........2152 Rear Wiper Assembly and Motor.................................................2154 Remove, Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F001)...................2154 Install, Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F001)..................2154 Remove, Lift Truck Models H2.0-3.5FT (H40-70FT) (L177)....................2156 Install, Lift Truck Models H2.0-3.5FT (H40-70FT) (L177)...................2156 Remove, Lift Truck Models H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-5..........2159 Install, Lift Truck Models H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-..........2159 Remove, Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (H006,..........2161 Install, Lift Truck Models H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-..........2161 Window Replacement................................................................2163 General.......................................................................2163 Remove Door Window, Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F0..............2163 Install Door Windows, Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (..............2164 Remove Door Window, Lift Truck Models H6.0FT, H7.0FT (H135FT, H1..............2165 Install Door Window, Lift Truck Models H6.0FT, H7.0FT (H135FT, H..............2166 Heater Replacement................................................................2166 Remove, for Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (H..............2166 Install, for Lift truck Models H6.0FT, H7.0FT (H135FT, H155FT) (..............2169 Light Replacement.................................................................2170 Work Lights (Front and Rear)..................................................2170 Remove....................................................................2170 Install...................................................................2170 Strobe Light..................................................................2172 Remove....................................................................2172 Install...................................................................2172 Turn, Stop, Tail, and Backup Light............................................2173 Remove....................................................................2173 Install...................................................................2173 Front Marker/Turn Signal Lights...............................................2173 Remove....................................................................2173 Install...................................................................2173 Display Switches..................................................................2174 Electrical Schematics.............................................................2178 Optional Equipment................................................................2181 Heavy Duty Pre-Cleaner........................................................2181 Remove....................................................................2181 Clean.....................................................................2182 Inspect...................................................................2182 Install...................................................................2182 Fan...........................................................................2182 Remove....................................................................2182 Install...................................................................2182 Mirror........................................................................2182 Remove....................................................................2182 Install...................................................................2182 Label Replacement.................................................................2182 Powershift Transmission 1580510-1300SRM1129-(07-2008)-US-EN...............................2187 toc...................................................................................2187 Powershift Transmission...........................................................2187 Safety Precautions Maintenance and Repair.........................................2188 General...........................................................................2191 Serial Number.................................................................2191 Charge Pump Repair................................................................2192 Remove........................................................................2192 Inspect.......................................................................2192 Install.......................................................................2192 Torque Converter Replace..........................................................2193 Remove........................................................................2193 Install.......................................................................2197 Front Cover Housing and Chain Drive Repair........................................2203 Remove........................................................................2203 Clean.........................................................................2210 Inspect.......................................................................2210 Install.......................................................................2210 Clutch Packs Repair...............................................................2216 Remove and Disassemble........................................................2216 Transmission, Remove and Disassemble......................................2216 Clutch Assemblies, Remove and Disassemble.................................2227 Clean.........................................................................2233 Inspect.......................................................................2233 Assemble and Install..........................................................2234 Clutch Assemblies, Assemble and Install...................................2234 Transmission, Assemble and Install........................................2242 Control Valve Repair..............................................................2247 Remove and Disassemble........................................................2247 Clean.........................................................................2248 Inspect.......................................................................2248 Assemble and Install..........................................................2250 MONOTROL® Pedal Repair............................................................2251 Remove and Disassemble........................................................2251 Assemble and Install..........................................................2254 Direction Control Lever...........................................................2255 Remove........................................................................2255 Install.......................................................................2255
HYSTER N005 SERVICE MANUAL – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is the SAME MANUAL used by the dealerships to diagnose your vehicle
- No waiting for couriers / posts as this is a PDF manual and you can download it within 2 minutes time once you make the payment.
- Your payment is all safe and the delivery of the manual is INSTANT – You will be taken to the DOWNLOAD PAGE.
- So have no hesitations whatsoever and write to us about any queries you may have : heydownloadss @gmail.com
S.V
