Hyster F187 (S40-70FT, S55FTS ) Service Manual – PDF DOWNLOAD
DESCRIPTION:
Hyster F187 (S40-70FT, S55FTS ) Service Manual – PDF DOWNLOAD
SAFETY PRECAUTIONS MAINTENANCE AND REPAIR :
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly
fastened, and that the load being lifted is balanced. Make sure the crane, cables, and
chains have the capacity to support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair
on electric lift trucks.
• Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT
THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance
section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts
must meet or exceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before
using force to remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit whenmaking repairs,
or if the unit needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel
are flammable. Be sure to follow the necessary safety precautions when handling these
fuels and when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks
away from the area. Make sure the area is well ventilated.
TABLE OF CONTENTS:
Hyster F187 (S40-70FT, S55FTS ) Service Manual – PDF DOWNLOAD
Alternator 2200SRM0002-(12-2004)-US-EN.............................................. 1 toc............................................................................. 1 Alternator with Regulator................................................... 1 Safety Precautions Maintenance and Repair................................... 2 General..................................................................... 5 Description................................................................. 5 Alternator Repair........................................................... 7 Alternator Type A....................................................... 7 Remove and Disassemble.............................................. 7 Clean............................................................... 8 Assemble............................................................ 9 Install............................................................. 9 Alternator Type B....................................................... 12 Remove and Disassemble.............................................. 12 Clean............................................................... 12 Assemble............................................................ 13 Install............................................................. 14 General Check and Adjustment................................................ 15 Low Output Check (Type A or Type B)......................................... 15 High Output Check (Type A or Type B)........................................ 17 Brushes Circuit Check....................................................... 18 Delco Alternators....................................................... 18 Motorola Alternators.................................................... 19 Diodes Check................................................................ 20 Diode Bridge Check.......................................................... 20 Delco and Leece-Neville Alternators..................................... 20 Motorola Alternators.................................................... 20 Rotor Field Winding Check................................................... 21 Stator Windings Check....................................................... 22 Voltage Regulator Check..................................................... 22 Troubleshooting............................................................. 22 Brakes (S Model)-1800SRM1135-(05-2005)-US-EN........................................ 27 toc............................................................................. 27 Brake System................................................................ 27 Safety Precautions Maintenance and Repair................................... 28 General..................................................................... 31 Service Brakes.......................................................... 31 Master Cylinder......................................................... 31 Brake Position Sensor................................................... 31 Parking Brake........................................................... 32 Service Brakes Repair....................................................... 32 Remove and Disassemble.................................................. 32 Clean................................................................... 38 Inspect................................................................. 39 Assemble and Install.................................................... 39 Adjust.................................................................. 44 Parking Brake Repair........................................................ 45 Remove and Disassemble.................................................. 45 Assemble and Install.................................................... 46 Adjust.................................................................. 47 Master Cylinder Repair...................................................... 47 Remove.................................................................. 47 Disassemble............................................................. 47 Clean and Inspect....................................................... 47 Assemble................................................................ 47 Bench Bleed Master Cylinder............................................. 50 Install and Adjust...................................................... 50 Service Brakes Adjustment................................................... 50 Brake System Air Removal.................................................... 51 Using Pressure Bleed System............................................. 51 Using Brake Pedal Pressure.............................................. 51 Brake Pedal Adjustment...................................................... 52 Free Pedal Adjustment....................................................... 53 Torque Specifications....................................................... 54 Calibrations-8000SRM1134-(05-2005)-US-EN............................................ 57 toc............................................................................. 57 Calibration Procedures...................................................... 57 Safety Precautions Maintenance and Repair................................... 58 Description................................................................. 61 Proc_Cal_001: Service Password Entry........................................ 63 When to Perform......................................................... 63 Why Perform............................................................. 63 How to Perform.......................................................... 63 Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed............. 64 When to Perform......................................................... 64 Calibration Order....................................................... 64 Why Perform............................................................. 64 How to Perform.......................................................... 64 Proc_Cal_003: Save and Exit................................................. 66 When to Perform......................................................... 66 Why Perform............................................................. 66 How to Perform.......................................................... 66 Proc_Cal_004: Lift Valve Output Threshold................................... 68 When to Perform......................................................... 68 Calibration Order....................................................... 68 Why Perform............................................................. 68 How to Perform.......................................................... 68 Proc_Cal_005: Lower Valve Output Threshold.................................. 71 When to Perform......................................................... 71 Calibration Order....................................................... 71 Why Perform............................................................. 71 How to Perform.......................................................... 71 Proc_Cal_006: Tilt Back Valve Output Threshold.............................. 74 When to Perform......................................................... 74 Calibration Order....................................................... 74 Why Perform............................................................. 74 How to Perform.......................................................... 74 Proc_Cal_007: Tilt Forward Valve Output Threshold........................... 77 When to Perform......................................................... 77 Calibration Order....................................................... 77 Why Perform............................................................. 77 How to Perform.......................................................... 77 Proc_Cal_008: Aux 1 Dir A Valve Output Threshold............................ 80 When to Perform......................................................... 80 Calibration Order....................................................... 80 Why Perform............................................................. 80 How to Perform.......................................................... 80 Proc_Cal_009: Aux 1 Dir B Valve Output Threshold............................ 83 When to Perform......................................................... 83 Calibration Order....................................................... 83 Why Perform............................................................. 83 How to Perform.......................................................... 83 Proc_Cal_010: Aux 2 Dir A Valve Output Threshold............................ 86 When to Perform......................................................... 86 Calibration Order....................................................... 86 Why Perform............................................................. 86 How to Perform.......................................................... 86 Proc_Cal_011: Aux 2 Dir B Valve Output Threshold............................ 89 When to Perform......................................................... 89 Calibration Order....................................................... 89 Why Perform............................................................. 89 How to Perform.......................................................... 89 Proc_Cal_012: Aux 3 Dir A Valve Output Threshold............................ 92 When to Perform......................................................... 92 Calibration Order....................................................... 92 Why Perform............................................................. 92 How to Perform.......................................................... 92 Proc_Cal_013: Aux 3 Dir B Valve Output Threshold............................ 95 When to Perform......................................................... 95 Calibration Order....................................................... 95 Why Perform............................................................. 95 How to Perform.......................................................... 95 Proc_Cal_014: Load Weight Zero Point........................................ 98 When to Perform......................................................... 98 Calibration Order....................................................... 98 Why Perform............................................................. 98 How to Perform.......................................................... 98 Proc_Cal_015: Loaded Weight Calibration..................................... 100 When to Perform......................................................... 100 Calibration Order....................................................... 100 Why Perform............................................................. 100 How to Perform.......................................................... 100 Proc_Cal_016: Transmission Valve Calibration................................ 102 Applicable System/Option................................................ 102 When to Perform......................................................... 102 Calibration Order....................................................... 102 Why Perform............................................................. 102 How to Perform.......................................................... 102 Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment................. 104 Required Tools.......................................................... 104 When to Perform......................................................... 104 Calibration Order....................................................... 104 Why Perform............................................................. 104 How to Perform.......................................................... 104 Proc_Cal_025: Hydraulic Valve Pressure Gage Installation.................... 106 When to Perform......................................................... 106 Why Perform............................................................. 106 How to Perform.......................................................... 106 tables.......................................................................... 57 Table 1. Calibration Procedures............................................. 61 Table 2. How to Read Calibration Procedure.................................. 62 Table 3. Proc_Cal_001: Service Password Entry............................... 63 Table 4. Proc_Cal_002: Hydraulic Valve Calibration Warm Up and A............ 64 Table 5. Proc_Cal_003: Save and Exit........................................ 67 Table 6. Proc_Cal_004: Lift Valve Output Threshold.......................... 68 Table 7. Proc_Cal_005: Lower Valve Output Threshold......................... 71 Table 8. Proc_Cal_006: Tilt Back Valve Output Threshold..................... 74 Table 9. Proc_Cal_007: Tilt Forward Valve Output Threshold.................. 77 Table 10. Proc_Cal_008: Aux 1 Dir A Valve Output Threshold.................. 80 Table 11. Proc_Cal_009: Aux 1 Dir B Valve Output Threshold.................. 83 Table 12. Proc_Cal_010: Aux 2 Dir A Valve Output Threshold.................. 86 Table 13. Proc_Cal_011: Aux 2 Dir B Valve Output Threshold.................. 89 Table 14. Proc_Cal_012: Aux 3 Dir A Valve Output Threshold.................. 92 Table 15. Proc_Cal_013: Aux 3 Dir B Valve Output Threshold.................. 95 Table 16. Proc_Cal_014: Load Weight Zero Point.............................. 98 Table 17. Proc_Cal_015: Loaded Weight Calibration........................... 100 Table 18. Proc_Cal_016: Transmission Valve Calibration...................... 102 Table 19. Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjus............ 105 Table 20. Proc_Cal_025: Hydraulic Valve Pressure Gage Installati............ 107 Capacity and Spec-8000SRM1151-(05-2005)-US-EN....................................... 111 toc............................................................................. 111 Capacities and Specifications............................................... 111 Safety Precautions Maintenance and Repair................................... 112 Lift Truck Lifting Capacity................................................. 115 Counterweight Weights....................................................... 115 Tire Sizes.................................................................. 115 Capacities.................................................................. 116 Electrical System........................................................... 119 Transmission Oil Pressures.................................................. 120 Hydraulic System Relief Pressures........................................... 122 Steering System............................................................. 122 Stall Speeds (in RPM ±100 rpm).............................................. 123 Mazda 2.0L.............................................................. 123 Mazda 2.2L.............................................................. 123 GM 2.4L................................................................. 123 Yanmar 2.6L............................................................. 123 Yanmar 3.3L............................................................. 123 Mast Speeds................................................................. 123 Tilt Angles................................................................. 127 Front End Equipment - Mast Creep............................................ 127 Mast Creep.............................................................. 127 Engine Specifications....................................................... 128 Torque Specifications....................................................... 130 Frame................................................................... 130 Mast.................................................................... 130 Steering System, Cushioned Tire Trucks.................................. 130 Steering System, Pneumatic Tire Trucks.................................. 130 Drive Axle.............................................................. 130 Transmission............................................................ 131 Engine - Mazda 2.0L and 2.2L............................................ 131 Engine - GM 2.4L........................................................ 132 Engine - Yanmar 2.6L and 3.3L Diesel.................................... 134 tables.......................................................................... 111 Table 1. Lift Truck Models S2.0-3.5FT (S40-70FT, S55FTS) (F187)............. 124 Table 2. Lift Truck Models H2.0-3.5FT (H40-70FT) (L177)..................... 125 Table 3. S2.0-3.5FT (S40-70FT, S55FTS) (F187) Lift Truck Models............. 127 Table 4. H2.0-3.5FT (H40-70FT) (L177) Lift Truck Models..................... 127 Table 5. S2.0-3.5FT (S40-70FT, S55FTS) (F187) Lift Truck Models............. 127 Table 6. H2.0-3.5FT (H40-70FT) (L177) Lift Truck Models..................... 128 Cooling-0700SRM1123-(05-2005)-US-EN................................................. 137 toc............................................................................. 137 Cooling System.............................................................. 137 Safety Precautions Maintenance and Repair................................... 138 General..................................................................... 141 Cooling System Checks....................................................... 141 Exhaust Leaks Into Cooling System....................................... 141 Water Flow Restrictions in Radiator..................................... 141 Radiator Hoses.......................................................... 141 Water Pump.............................................................. 141 Radiator Replacement........................................................ 142 Cooling System, Clean................................................... 142 Radiator, Remove........................................................ 143 Radiator, Install....................................................... 143 Fan Assembly Replacement.................................................... 146 Remove.................................................................. 146 Inspect................................................................. 149 Install................................................................. 149 Cylinder Repair-2100SRM1139-(05-2005)-US-EN......................................... 153 toc............................................................................. 153 Cylinder Repair............................................................. 153 Safety Precautions Maintenance and Repair................................... 154 General..................................................................... 157 Description................................................................. 157 Safety Procedures When Working Near Mast.................................... 157 Tilt Cylinder Repair........................................................ 160 Remove.................................................................. 160 Disassemble............................................................. 161 Inspect................................................................. 162 Clean................................................................... 162 Assemble................................................................ 162 Install................................................................. 162 Tilt Cylinders, Adjust.................................................. 163 Tilt Cylinder Leak Check for Two-Stage LFL, Two-Stage FFL, and T........ 164 Tilt Cylinder Leak Check for the Four-Stage Full Free-Lift.............. 164 Torque Specifications................................................... 165 Piston Rod.......................................................... 165 Gland............................................................... 165 Tilt Cylinder Mounting Capscrew..................................... 165 Tilt Cylinder Rod End Capscrew...................................... 165 Lift Cylinder Repair........................................................ 165 Main Lift Cylinders, Remove............................................. 165 Free-Lift Cylinder, Remove.............................................. 166 Free-Lift and Main Lift Cylinders, Disassemble.......................... 171 Two-Stage FFL Cylinder, Disassemble..................................... 172 Inspect................................................................. 172 Clean................................................................... 172 Full Free-Lift and Main Lift Cylinders, Assemble........................ 174 Two-Stage FFL and Main Lift Cylinders, Assemble......................... 174 Main Lift Cylinders, Install............................................ 175 Free-Lift Cylinder, Install............................................. 176 Torque Specifications................................................... 177 Lift Cylinders Leak Check............................................... 177 tables.......................................................................... 153 Table 1. Movement Rates (Maximum) for Tilt Cylinders........................ 164 Diagnostics 9000SRM1112-(12-2004)-US-EN............................................. 181 toc............................................................................. 181 Diagnostic Troubleshooting Manual........................................... 181 Safety Precautions TROUBLESHOOTING PROCEDURES............................... 182 How To Use This Troubleshooting Manual...................................... 184 General Instructions and Safety Information............................. 184 How to Use Diagnostic Troubleshooting Manual............................ 184 General Instructions.................................................... 184 Operational Diagnostic Procedures........................................... 187 Operational Checkout Procedures......................................... 189 DTC Check........................................................... 190 Horn Circuit Check.................................................. 190 Light Circuit Check................................................. 190 Windshield Wiper/Washer Check (If equipped)......................... 190 Indicator Light Power Check......................................... 191 Seat Occupancy Check................................................ 192 Engine Malfunction Indicator Check.................................. 192 Brake Pedal Check................................................... 193 Backup Alarm Check (If equipped).................................... 193 Armrest Hydraulic Interlock Check (If equipped)..................... 193 Engine Cover Latch Sensor Check (If equipped)....................... 194 Brake and Inching Pedal Check....................................... 194 Park Brake Sensor Check............................................. 194 Park Brake Check.................................................... 195 Transmission Anti-Rollback Check (Electronic Transmission Only)..... 195 Engine Speed Check.................................................. 195 Engine Power Check.................................................. 196 Transmission Clutch Check........................................... 196 Transmission Check.................................................. 197 Transmission Speed Selection Check (If equipped).................... 197 Brake and Axle Drag Check........................................... 197 Hydraulic Pump Flow Check........................................... 198 Priority Flow Divider Valve Check................................... 198 Steering Relief Valve Low Pressure Check............................ 199 Steering Relief Valve High Pressure Check........................... 199 Control Valve Load Check Valve (Manual Valve)....................... 199 Tilt Function Counterbalance Check.................................. 200 Lift Drift Check.................................................... 200 Tilt Function Drift Check........................................... 201 Mast Cushion Check (All Except 2-Stage Mast)........................ 201 Lift/Tilt Mast Adjustment Check..................................... 201 Tilt Racking Check.................................................. 202 Chain and Header Hose Adjustment Check.............................. 202 Mast Mounting Check................................................. 202 Mast Channel Check.................................................. 203 Carriage Adjustment Check........................................... 203 Chain Sheave Check.................................................. 203 Carriage Stop Check................................................. 203 Engine...................................................................... 205 Engine Basics........................................................... 211 General Terminology................................................. 211 Combustion Theory................................................... 211 Engine Components – Cylinder Block.................................. 212 Camshaft and Timing Set............................................. 213 Cylinder Head Assembly.............................................. 213 Valve Train Assembly................................................ 213 Manifolds........................................................... 213 Air Cleaner/Filter.................................................. 214 Carburetion......................................................... 214 Electronic Fuel Injection (EFI)..................................... 214 Positive Crankcase Ventilation (PCV)................................ 214 Engine Electrical....................................................... 215 Introduction........................................................ 215 Battery Construction................................................ 215 Conventional Standard Battery....................................... 215 Maintenance-Free Battery............................................ 216 Battery Charging.................................................... 216 Battery Fast Charging............................................... 216 Battery Slow Charging............................................... 217 Starting System Principles of Operation............................. 217 Starting System Components - Ignition Switch........................ 217 Starting System Components - Starter Solenoid....................... 217 Starting System Components - Flywheel and Ring Gear................. 217 Starting System Components - Starter Motor and Drive................ 218 Charging System - General........................................... 218 Charging System - Regulator......................................... 218 Charging System - Theory............................................ 218 Engine Fuel System/Exhaust and Emissions................................ 219 Introduction........................................................ 219 Gasoline System Components - Fuel Tank.............................. 219 Electronic Fuel Injector (EFI) - General Description................ 219 Port Fuel System Components - ECU................................... 220 Port Fuel System Components - Fuel Pump/Filter...................... 220 Port Fuel System Components - Fuel Rail............................. 220 Port Fuel System Components - Pressure Regulator.................... 220 Port Fuel System Components - Fuel Injectors........................ 220 LP Systems General Information...................................... 220 LP Fuel Properties.................................................. 220 LP Fuel Tank........................................................ 220 AISAN Closed-Loop System............................................ 221 Filter/Lockoff and Regulator.................................... 221 Carburetor...................................................... 222 Start Mode...................................................... 222 Idle Mode....................................................... 222 Run Mode........................................................ 222 Main Fuel Lockoff Solenoid.......................................... 222 Injector Fuel Lockoff Solenoid...................................... 222 Oxygen Sensor................................................... 222 Electronic Control Unit (ECU)....................................... 223 Catalytic Converter/Muffler......................................... 223 Engine Management....................................................... 223 Introduction........................................................ 223 Ignition and Timing - Conventional Spark............................ 223 Components - Ignition Coil.......................................... 223 Components - Distributor............................................ 223 Spark Timing........................................................ 224 Components - Ignition Wires......................................... 224 Components - Spark Plugs............................................ 224 Faulty or Fouled Spark Plugs........................................ 224 Electric Controlled Governing System - Mazda LPG.................... 224 Engine Identification................................................... 225 GM and Mazda Engines................................................ 225 Mazda Engine Overview................................................... 226 Description......................................................... 226 Fuel System......................................................... 226 Engine Controls (ECU) and Emissions................................. 226 Cooling System...................................................... 226 Ignition System..................................................... 226 Mazda (LPG) Engine Controls............................................. 227 LPG System (Aisan/E-Controls-Mechanical)............................ 227 Description..................................................... 227 Principles of Operation......................................... 228 Control System.................................................. 230 Oxygen Sensor................................................... 231 Fuel Tank....................................................... 231 Regulator....................................................... 232 Start Mode.................................................. 233 Idle Mode................................................... 233 Run Mode.................................................... 234 Resonator....................................................... 234 Carburetor...................................................... 234 Start Mode.................................................. 234 Idle Mode................................................... 235 Run Mode.................................................... 235 Governor........................................................ 235 LPG System (E-Controls)............................................. 236 Description..................................................... 236 Principles of Operation......................................... 237 Manifold Absolute Pressure Sensor............................... 237 Throttle Position Sensor........................................ 238 Oxygen Sensor................................................... 238 Engine Coolant Temperature Sensor............................... 238 Intake Air Temperature Sensor................................... 238 Engine Control Unit............................................. 238 Accelerator Pedal Position Sensor............................... 238 Three-Way Catalytic Converter................................... 238 Camshaft Position Sensor........................................ 239 Electric Controlled Governing System............................ 240 Electronic Governor Sensor...................................... 240 Mazda (Gasoline) Engine Controls........................................ 241 Gasoline System..................................................... 241 Description..................................................... 241 Principles of Operation......................................... 242 Control System...................................................... 244 Camshaft Position Sensor........................................ 245 Intake Air Temperature Sensor................................... 246 Mass Air Flow Sensor............................................ 247 Throttle Position Sensor........................................ 248 Electronic Governor Sensor...................................... 249 Electronic Governing System..................................... 250 Manifold Absolute Pressure Sensor/Boost Sensor.................. 250 Engine Coolant Temperature Sensor............................... 251 Intake Air System................................................... 252 Throttle Body................................................... 252 Idle Air Control Valve.......................................... 253 Fuel System......................................................... 254 Fuel Injector................................................... 254 Pressure Regulator.............................................. 255 Exhaust System...................................................... 256 Heated Oxygen Sensor............................................ 256 Three-Way Catalytic Converter................................... 257 GM (LPG) Engine Controls................................................ 258 Engine Control System .............................................. 258 Engine Control System Overview.................................. 259 Principles of Operation......................................... 259 Control System...................................................... 260 Control System Component Location............................... 260 GM/TGFI Four-Cylinder LPG System................................ 261 Fuel Tank....................................................... 263 Engine Control Unit............................................. 263 Electronic Throttle Body/Throttle Position Sensor............... 264 Manifold Absolute Pressure/Manifold Air Temperature Sensor...... 264 Propane Injectors............................................... 265 Engine Coolant Temperature Sensor............................... 266 Oxygen Sensor................................................... 267 Crankshaft Position Sensor (Engine Speed Sensor)................ 268 Oil Pressure Sensor............................................. 268 Power Latch Relay............................................... 268 Camshaft Position Sensor........................................ 269 Injector Driver Module.......................................... 269 Vaporizer/Regulator............................................. 270 Accelerator Pedal Position Sensor............................... 273 Three-Way Catalytic Converter................................... 273 Ignition System..................................................... 274 Ignition Coils.................................................. 274 Distributorless Ignition System Module.......................... 274 Electronic Ignition Signals..................................... 275 GM (Gasoline) Engine Controls........................................... 276 Engine Control System............................................... 276 Engine Control System Overview.................................. 277 Principles of Operation......................................... 277 Control System...................................................... 278 Control System Component Location............................... 278 GM/TGFI Four Cylinder Gasoline System Components................ 279 Engine Control Unit............................................. 281 Electronic Throttle Body/Throttle Position Sensor............... 281 Manifold Absolute Pressure/Manifold Air Temperature Sensor ..... 282 Fuel Injector................................................... 283 Engine Coolant Temperature Sensor............................... 284 Oxygen Sensor................................................... 284 Crankshaft Position Sensor (Engine Speed Sensor)................ 285 Oil Pressure Sensor............................................. 285 Power Latch Relay............................................... 285 Camshaft Position Sensor........................................ 285 Accelerator Pedal Position Sensor............................... 286 Three-Way Catalytic Converter................................... 286 Ignition System..................................................... 287 Ignition Coils.................................................. 287 Distributorless Ignition System Module.......................... 287 Electronic Ignition Signals..................................... 288 Cooling System.......................................................... 288 Description......................................................... 288 Radiator............................................................ 288 Radiator Cap........................................................ 288 Thermostat.......................................................... 289 Water Pump.......................................................... 289 Fan................................................................. 289 GM Engine Coolant Flow Diagram...................................... 290 Engine Does Not Crank................................................... 291 Engine Does Not Start / Engine is Hard to Start......................... 294 Engine Idle Speed Incorrect............................................. 298 Engine Idle Speed is Unstable or Engine Stalls at Idle.................. 300 Engine Cuts Out, Misses, Hesitates, Sags, or Stumbles................... 304 Engine Lack of Power.................................................... 308 Engine Surges and Chuggles.............................................. 312 Engine Backfires........................................................ 316 Engine Is Knocking or Pinging........................................... 319 Excessive Engine Vibrations............................................. 323 Abnormal Engine and Exhaust Noises...................................... 326 Fan or Alternator Bearing Noise......................................... 329 Abnormal Engine and Exhaust Smells...................................... 331 High Engine Fuel Consumption............................................ 333 Fuel Leaks.............................................................. 335 High Engine Oil Consumption............................................. 337 Engine Oil Leaks........................................................ 339 Engine Oil is Discolored................................................ 343 Engine Coolant Leaks.................................................... 344 Engine Coolant is Discolored............................................ 347 Engine Exhaust is Discolored............................................ 348 Engine Fails Emission Compliance Check.................................. 350 Alternator Light is Illuminated......................................... 354 Engine is Overheating................................................... 355 Radiator Bubble Test.................................................... 357 Engine Compression Test................................................. 358 Engine Oil Pressure Test................................................ 359 Fuel System Pressure Test (Gas)......................................... 360 Electrical System........................................................... 363 Troubleshooting Guidelines and Procedures............................... 371 Troubleshooting Guidelines.......................................... 371 Troubleshooting Procedures.......................................... 374 Troubleshooting Procedures, Identification...................... 374 Troubleshooting Procedures, Location............................ 374 Troubleshooting Procedures, Structure........................... 374 Troubleshooting Procedures, Performance......................... 375 Diagnostic Trouble Codes................................................ 376 Diagnostic Trouble Codes............................................ 376 Wiring Reference Data................................................... 381 Harness Assembly Data............................................... 384 Electrical System....................................................... 419 General Description................................................. 419 Description......................................................... 420 Principles of Operation, Components................................. 424 Principles Of Operation, System..................................... 430 100-3................................................................... 439 523859-3................................................................ 439 524223-3................................................................ 439 524224-3................................................................ 439 524225-3................................................................ 439 100-4................................................................... 445 523859-4................................................................ 445 524223-4................................................................ 445 524224-4................................................................ 445 524225-4................................................................ 445 524223-0................................................................ 451 524224-0................................................................ 451 524225-0................................................................ 451 524229-0................................................................ 451 524270-0................................................................ 451 524276-0................................................................ 451 524223-1................................................................ 455 524224-1................................................................ 455 524225-1................................................................ 455 524229-1................................................................ 455 524270-1................................................................ 455 524276-1................................................................ 455 110-3................................................................... 459 110-5................................................................... 459 177-3................................................................... 459 524235-3................................................................ 459 110-4................................................................... 465 177-4................................................................... 465 524235-4................................................................ 465 110-2................................................................... 470 110-10.................................................................. 473 522712-3................................................................ 477 522713-3................................................................ 477 522712-4................................................................ 482 522713-4................................................................ 482 51-2.................................................................... 487 51-7.................................................................... 487 91-2.................................................................... 491 522710-3................................................................ 494 522711-3................................................................ 494 522714-3................................................................ 494 522710-4................................................................ 500 522711-4................................................................ 500 522714-4................................................................ 500 515-0................................................................... 506 523780-3................................................................ 507 523860-3................................................................ 507 524245-3................................................................ 507 524275-3................................................................ 507 523780-4................................................................ 512 523860-4................................................................ 512 524245-4................................................................ 512 524275-4................................................................ 512 677-3................................................................... 517 2350-3.................................................................. 517 522754-3................................................................ 517 522755-3................................................................ 517 522764-3................................................................ 517 522766-3................................................................ 517 524230-3................................................................ 517 SYMPTOMS WARNING........................................................ 517 677-4................................................................... 523 2350-4.................................................................. 523 522754-4................................................................ 523 522755-4................................................................ 523 522764-4................................................................ 523 522766-4................................................................ 523 524230-4................................................................ 523 676-3................................................................... 527 524195-3................................................................ 527 524269-3................................................................ 527 676-4................................................................... 532 524195-4................................................................ 532 524269-4................................................................ 532 524269-7................................................................ 536 879-3................................................................... 538 880-3................................................................... 538 881-3................................................................... 538 882-3................................................................... 538 522772-3................................................................ 538 879-4................................................................... 542 880-4................................................................... 542 881-4................................................................... 542 882-4................................................................... 542 522772-4................................................................ 542 168-3................................................................... 545 522760-3................................................................ 547 522761-3................................................................ 547 522762-3................................................................ 547 524251-0................................................................ 554 524260-0................................................................ 554 524261-0................................................................ 554 524261-3................................................................ 554 168-4................................................................... 561 522760-4................................................................ 563 522761-4................................................................ 563 522762-4................................................................ 563 524251-1................................................................ 569 524260-1................................................................ 569 524261-1................................................................ 569 524261-4................................................................ 569 524260-2................................................................ 576 524260-11............................................................... 576 524261-2................................................................ 576 524261-11............................................................... 576 96-3.................................................................... 580 96-4.................................................................... 580 522810-4................................................................ 584 524213-1................................................................ 588 524213-3................................................................ 588 524213-4................................................................ 588 523920-3................................................................ 591 523925-3................................................................ 591 523930-3................................................................ 591 523977-3................................................................ 591 523978-3................................................................ 591 523986-3................................................................ 591 524284-3................................................................ 591 524285-3................................................................ 591 523978-4................................................................ 596 523977-4................................................................ 596 523986-4................................................................ 596 524284-4................................................................ 596 524285-4................................................................ 596 523930-4................................................................ 596 523920-4................................................................ 596 523925-4................................................................ 596 523920-6................................................................ 600 523925-6................................................................ 600 523930-6................................................................ 600 523977-6................................................................ 600 523978-6................................................................ 600 523986-6................................................................ 600 524284-6................................................................ 600 524285-6................................................................ 600 105-3................................................................... 604 105-4................................................................... 608 105-5................................................................... 611 106-3................................................................... 613 106-4................................................................... 617 106-0................................................................... 621 106-1................................................................... 621 106-2................................................................... 621 106-14.................................................................. 621 522739-3................................................................ 624 522739-5................................................................ 627 522739-6................................................................ 630 522735-2................................................................ 632 522735-4................................................................ 634 522735-5................................................................ 636 522735-6................................................................ 638 522630-2................................................................ 640 522631-2................................................................ 640 522635-3................................................................ 640 522635-4................................................................ 640 522737-10............................................................... 643 651-3................................................................... 645 652-3................................................................... 645 653-3................................................................... 645 654-3................................................................... 645 522721-3................................................................ 645 522722-3................................................................ 645 522723-3................................................................ 645 522724-3................................................................ 645 651-5................................................................... 649 652-5................................................................... 649 653-5................................................................... 649 654-5................................................................... 649 651-6................................................................... 652 652-6................................................................... 652 653-6................................................................... 652 654-6................................................................... 652 522721-6................................................................ 652 522722-6................................................................ 652 522723-6................................................................ 652 522724-6................................................................ 652 2000-9.................................................................. 656 2000-12................................................................. 656 2000-12................................................................. 656 2003-12................................................................. 656 2023-12................................................................. 656 2039-12................................................................. 656 2235-12................................................................. 656 2236-12................................................................. 656 524258-2................................................................ 656 524236-14............................................................... 663 524262-12............................................................... 663 524263-1................................................................ 663 524268-12............................................................... 663 522690-2................................................................ 665 522690-12............................................................... 665 522691-2................................................................ 665 522691-12............................................................... 665 522692-2................................................................ 665 522694-12............................................................... 665 522695-2................................................................ 665 522696-2................................................................ 665 522698-2................................................................ 665 522699-2................................................................ 665 522700-2................................................................ 665 628-12.................................................................. 665 630-12.................................................................. 665 522697-12............................................................... 665 190-2................................................................... 667 190-7................................................................... 667 522752-9................................................................ 671 524264-2................................................................ 674 524264-14............................................................... 674 524265-2................................................................ 674 524271-2................................................................ 674 628-12.................................................................. 679 630-12.................................................................. 679 2660-3.................................................................. 679 2660-4.................................................................. 679 2661-3.................................................................. 679 2661-4.................................................................. 679 2802-12................................................................. 679 523515-3................................................................ 679 523515-4................................................................ 679 523519-3................................................................ 679 523519-4................................................................ 679 2802-12................................................................. 681 628-12.................................................................. 681 630-12.................................................................. 681 523261-3................................................................ 681 523261-4................................................................ 681 523257-3................................................................ 681 523257-4................................................................ 681 523253-3................................................................ 681 523253-4................................................................ 681 523249-3................................................................ 681 523249-4................................................................ 681 522780-3................................................................ 683 522781-3................................................................ 683 522780-4................................................................ 686 522781-4................................................................ 686 522780-2................................................................ 688 111-1................................................................... 690 524252-2................................................................ 694 524253-14............................................................... 695 524255-2................................................................ 696 108-0................................................................... 697 108-1................................................................... 697 522655-0................................................................ 699 522655-1................................................................ 699 522660-0................................................................ 699 522660-1................................................................ 699 Engine Continues to Run When Engine Cover is Raised..................... 703 Engine Stops or Fails to Start.......................................... 705 Electrical Functions Do Not Operate..................................... 707 Electrical Function Does Not Turn Off................................... 712 Electro-Hydraulics Do Not Function With Armrest Down ................... 717 Electro-Hydraulics Can Still Function With Armrest Raised............... 720 Vehicle Does Not Power On............................................... 723 Drive Train................................................................. 729 Transmission............................................................ 731 Description......................................................... 731 Single-Speed Transmission............................................... 731 Description......................................................... 731 Two-Speed Transmission.................................................. 734 Description......................................................... 734 Mechanical Overview..................................................... 735 Engine.................................................................. 735 Description......................................................... 735 Torque Converter........................................................ 735 Description......................................................... 735 Principles of Operation............................................. 736 Stator.......................................................... 736 Turbine......................................................... 736 Chain Drive............................................................. 738 Description......................................................... 738 Clutch Assemblies....................................................... 739 Description......................................................... 739 Single-Speed Power Flow............................................. 740 Two-Speed Power Flow................................................ 741 Driveshaft, Differential, and Drive Axle................................ 743 Driveshaft.......................................................... 743 Differential and Drive Axle......................................... 743 Brake System........................................................ 745 Description..................................................... 745 Service Brakes.................................................. 745 Master Cylinder................................................. 745 Brake Position Sensor........................................... 745 Parking Brake - Dry Brake....................................... 745 Transmission Hydraulic System........................................... 746 Principles of Operation............................................. 746 Transmission Control System Overview.................................... 750 Transmission Control System......................................... 750 Transmission Control Hardware........................................... 752 Control Valve and Sensors........................................... 752 Description..................................................... 752 Principles of Operation......................................... 754 MONOTROL® Pedal..................................................... 754 Description..................................................... 754 Principles of Operation......................................... 754 Directional Control Lever........................................... 755 Principles of Operation......................................... 755 Transmission Control Software........................................... 755 Transmission Control Modes.......................................... 755 Neutral Mode ( Basic Powershift, and Duramatch™ )............... 755 Gear Engagement Mode............................................ 756 Basic Powershift Gear Engagement Mode....................... 756 Duramatch™ Gear Engagement Mode............................. 756 Controlled Creep Mode ( Basic Powershift Transmission Only)..... 756 Normal Mode (Forward or Reverse)................................ 756 Inching Mode.................................................... 756 Basic Powershift Inching Mode............................... 756 Duramatch™ Inching Mode..................................... 756 Controlled Creep Mode - Duramatch™ Transmission................. 757 Roll Back Mode - Duramatch™ Transmission........................ 757 Auto Decel Mode - Duramatch™ Transmission....................... 757 Auto-Shift Mode (Multispeed Only)............................... 757 1st Gear Lock Mode (Multispeed Only)............................ 757 Extended Drawbar Pull (2-Speed Only)............................ 757 Transmission Proportional Valve......................................... 758 Description......................................................... 758 Principles of Operation............................................. 758 Neutral............................................................. 758 Proportional Control................................................ 758 Forward............................................................. 759 Forward-Inching..................................................... 759 Overheating Brakes...................................................... 761 Poor Brake Performance.................................................. 763 Brakes Make Too Much Noise.............................................. 765 Brakes Pull To One Side................................................. 766 Parking Brake Will Not Release.......................................... 768 Parking Brake Will Not Hold Lift Truck.................................. 769 Abnormal Drive Axle Noise............................................... 770 Discolored Drive Axle Oil............................................... 772 Lift Truck Does Not Move (Drive Axle)................................... 773 Abnormal Transmission Noise............................................. 774 Bubbles or Foaming In Transmission Dipstick Tube........................ 776 Inching Operation Is Not Smooth or Chatters............................. 778 Lift Truck Does Not Move In One or Both Directions...................... 780 Loss of Power/Drivetrain Performance.................................... 783 Transmission Is Too Hot................................................. 785 Transmission Will Not Shift To Forward High Range....................... 787 Transmission Warm-Up Procedure.......................................... 789 Transmission Pressure Test.............................................. 789 Transmission Charge Pump Pressure Test.............................. 790 Clutch Pack Pressure Test (Proportional Solenoid Valves)............ 790 Torque Converter Pressure Test...................................... 791 Lubrication Pressure Test........................................... 791 Transmission Clutch Drag Test........................................... 791 Torque Converter Stall Test............................................. 792 Hydraulic Systems........................................................... 795 Main Hydraulic System................................................... 799 Description......................................................... 799 Principles of Operation............................................. 799 Hydraulic Schematics................................................ 801 Manual Control Valve Schematic.................................. 801 Electro-Hydraulic Control Valve Schematic....................... 803 Manual Hydraulic Control Valve.......................................... 805 Description......................................................... 805 Principles of Operation............................................. 806 Lift Section.................................................... 806 Lift Operation.............................................. 806 Lower Operation............................................. 806 Tilt Section.................................................... 806 Tilt Backward............................................... 806 Tilt Forward................................................ 806 Auxiliary Section............................................... 808 Anti-stall Feature.............................................. 809 Relief Valves................................................... 809 Main Relief Valve........................................... 809 Secondary Relief Valve...................................... 810 Electro-Hydraulic Control Valve......................................... 810 Description......................................................... 810 Principles of Operation............................................. 810 Inlet Pressure Compensator/Unloader............................. 810 Lift/Lower EHPVs................................................ 813 EHPV Operation.............................................. 814 Tilt and Auxiliary Spool Functions.............................. 816 Tilt Forward Function........................................... 818 Main Relief Valve .............................................. 819 Secondary Relief Valve.......................................... 819 Secondary Function Anti-stall Valve............................. 819 Manual Lowering Valve........................................... 821 Steering System......................................................... 821 Component Locations................................................. 821 Description..................................................... 821 Steering Axle Assembly.......................................... 821 Steering Control Unit........................................... 821 Steering Schematic.................................................. 823 Principles of Operation......................................... 824 Steering Control Unit........................................... 824 Actuation Functions With Armrest Up (E-Valve)........................... 825 Cycle Times Too Fast - Fast Actuation (E-Valve)......................... 826 Jump/Delay In Lift or Lower Activation After Moving Joystick or ........ 828 Jump/Delay In Secondary Function Actuation After Moving Joystick........ 830 Jump/Delay In Tilt Forward Actuation (E-Valve).......................... 832 Forks Drop Slightly Before Lifting (E-Valve)............................ 834 Forks Lower Without Command (E-Valve)................................... 835 Forks Raise or Actuate Without Command (E-Valve)........................ 837 Forks Tilt Forward Without Command (E-Valve)............................ 839 Intermittent Activation (E-Valve) While Commanding Function............. 841 Lift/Lower Function Maximum Speed Too Slow (E-Valve).................... 843 Lift Function Will Not Move With Joystick or MLM Movement (E-Val........ 846 Lift/Lower Continues To Move For Awhile After Joystick or MLM Is........ 849 Lift/Lower/Secondary Function Suddenly Jumps In Middle Of Stroke........ 850 Lower Function Will Not Move With Joystick or MLM Movement (E-Va........ 851 Poor Metering On Lift or Lower Functions (E-Valve)...................... 852 Secondary Function Continues To Move For Awhile After Joystick O........ 855 Secondary Function Exhibits Slight Movement In Opposite Directio........ 856 Secondary Function Maximum Speed Too Slow (E-Valve)..................... 857 Secondary Function or Tilt Back Moves Without Command (E-Valve)......... 860 Secondary Function and Tilt Back Will Not Move With Joystick or ........ 861 Tilt Forward Function Continues To Move For Awhile When Joystick........ 864 Tilt Forward Will Not Move Upon Joystick or MLM Movement (E-Valv........ 865 Too Much Joystick Or MLM Movement (Deadband) To Start Function M........ 867 Wrong Actuation Operates or Actuation is Backward (E-Valve)............. 868 Actuation Exhibits Slight Movement in Opposite Direction Before ........ 869 Auxiliary Function is Slow or Does Not Function (Manual Valve).......... 870 Cycle Times Too Fast - Fast Actuation (Manual Valve).................... 872 Function Continues to Activate After Returning to Neutral............... 873 Lift Function Is Slow Or Does Not Function (Manual Valve)............... 874 Tilt Back Function Will Not Operate (Manual Valve)...................... 876 Tilt Forward Functions When Spool is Activated Forward With Engi........ 877 Tilt Forward Will Not Function When Activated (Manual Valve)............ 878 Abnormal Steer Axle Noise............................................... 879 Abnormal Steering Wheel Vibration....................................... 881 Back Lash/Kick Back in Steering Wheel................................... 882 No Steering (All Other Hydraulic Functions OK).......................... 884 Steering Is Slow or Difficult........................................... 886 Steering Operation Is Not Smooth........................................ 888 Steering Wheel End Lock Position Cannot Be Felt By Operator............. 890 Steering Wheel Turns By Itself or Does Not Return To Neutral............ 891 Steering Wheel Turns the Tires in the Wrong Direction................... 892 Abnormal Hydraulic Noise and/or Vibration............................... 893 Abnormal Smell/Discoloration/Foaming of Oil............................. 896 Actuations Do Not Act Simultaneously.................................... 897 Oil Leaking/Component Life Too Short.................................... 898 Hydraulic Warm-up Procedure............................................. 901 Main Relief Valve Test and Adjustment................................... 902 Secondary Relief Valve Test and Adjustment.............................. 904 Hydraulic Pump Flow Test................................................ 906 Main Control Valve LS Leakage Test (E-Valve)............................ 907 Main Control Valve Unloader Margin Test................................. 908 Electro-Hydraulic Poppet Valve (EHPV) Leakage Test...................... 909 PPRV Pilot Pressure Test................................................ 912 Steering Relief Pressure Test and Adjustment............................ 913 Steering Control Unit LS Pressure Test.................................. 914 Lift Cylinder Leakage Test.............................................. 915 Tilt Cylinder Leakage Test.............................................. 917 Steering Cylinder Leakage Test.......................................... 918 Operators Station........................................................... 921 Operators Station General Description and Principles of Operatio........ 923 General Description and Location.................................... 923 Display Switch Cluster (DSC)............................................ 925 Detailed Description................................................ 925 Control Inputs, Right Side.......................................... 927 Right Indicator and Warning Group................................... 928 LCD Display......................................................... 928 Left Indicator and Warning Group.................................... 930 Transmission Control and Braking........................................ 931 Description......................................................... 931 Vehicle System Manager (VSM).................................... 932 Display Switch Cluster.......................................... 932 Interlock and Switching Features............................ 932 MONOTROL® Directional Control................................... 932 Inch Brake/Service Brake Pedal.................................. 932 Parking Brake................................................... 933 Programming - Menus..................................................... 933 Menus............................................................... 933 Main Menu....................................................... 936 Save and Exit or Exit Without Saving............................ 936 Back One Level.................................................. 936 Hourmeters...................................................... 936 View Versions................................................... 936 Passwords....................................................... 936 Diagnostics..................................................... 936 Setup Travel and Braking........................................ 936 Setup Hydraulics................................................ 936 Setup Display................................................... 937 Setup General Items............................................. 937 Calibrations.................................................... 937 Manual Hydraulic Control Levers......................................... 937 General Description................................................. 937 System Components................................................... 937 Lift/Lower...................................................... 938 Tilt............................................................ 938 Auxiliary 1..................................................... 938 Auxiliary 2..................................................... 938 E-Hydraulic System Interface............................................ 938 General Description................................................. 938 System Components................................................... 938 E-Hydraulic Control Input Device.................................... 938 Joystick........................................................ 938 Lift/Lower.................................................. 938 Tilt........................................................ 938 Auxiliary 1................................................. 939 Auxiliary 2................................................. 939 Push Button................................................. 939 Mini Lever Module (MLM)......................................... 939 Lever 1..................................................... 939 Lever 2..................................................... 939 Lever 3..................................................... 941 Lever 4..................................................... 941 System Modes........................................................ 941 Hydraulic Interlock Mode........................................ 941 Fault Mode...................................................... 941 Engine Off Mode................................................. 941 Normal Operation.................................................... 941 Normal Operation Mode........................................... 941 Lifting Control................................................. 941 Lowering Control................................................ 941 Tilt Control (Forward and Backward)............................. 941 Auxiliary Control............................................... 941 Lighting Control........................................................ 942 Description......................................................... 942 Front Work Lights............................................... 943 Front Marker Lights (if equipped)............................... 943 Front/Rear Turn Signal Lights................................... 943 Rear Tail/Marker Lights......................................... 943 Rear Work Light................................................. 943 Rear Backup Lights.............................................. 944 Rear Stop Lights................................................ 944 Strobe Light(s)................................................. 944 Cab Light (if equipped)......................................... 944 Spot Light (if equipped)........................................ 944 Front End (Mast) and Chassis................................................ 945 Front End, Mast......................................................... 947 Description......................................................... 947 Carriages............................................................... 947 Description......................................................... 947 Principles of Operation............................................. 947 Integral Sideshift Carriage..................................... 947 Mast Mounts............................................................. 949 Description......................................................... 949 Principles of Operation............................................. 949 Two-Stage Limited Free-Lift (LFL) Mast.................................. 949 Description......................................................... 949 Principles of Operation............................................. 950 Two-Stage Full Free-Lift (FFL) Mast..................................... 951 Description......................................................... 951 Principles of Operation............................................. 952 Three-Stage Full Free-Lift (FFL) Mast................................... 953 Description......................................................... 953 Principles of Operation............................................. 954 Four-Stage Full Free-Lift (FFL) Mast.................................... 956 Description......................................................... 956 Principles of Operation............................................. 957 Cylinder Cushion During Lifting Sequence................................ 959 Description......................................................... 959 Principles of Operation............................................. 959 Cylinder Cushion During Lowering Sequence............................... 960 Description......................................................... 960 Principles of Operation............................................. 960 Tilt and Sideshift Cylinders............................................ 960 Description......................................................... 960 Tilt Cylinder................................................... 960 Sideshift Cylinder.............................................. 960 Lowering Control Valves................................................. 961 Description......................................................... 961 Principles of Operation............................................. 961 Chassis................................................................. 963 Description......................................................... 963 Abnormal Channel Wear................................................... 965 Abnormal Hose Wear...................................................... 967 Abnormal Mast Noise..................................................... 968 Body Panels Making Noise................................................ 971 External Leakage From Free-Lift or Main Lift Cylinders.................. 972 FFL Mast Banging During Phasing......................................... 973 High Tire Wear - Drive Axle............................................. 974 High Tire Wear - Steer Axle............................................. 975 Hoses Not Tracking Correctly............................................ 976 Integral Sideshift Moving Too Fast...................................... 977 Integral Sideshift Not Moving or Slow................................... 978 LP Tank Bracket Disengages.............................................. 981 LP Tank Rattles and Does Not Stay Latched............................... 982 Mast is Loose........................................................... 983 Mast Lift Chains Are Loose.............................................. 984 Mast or Carriage Binding................................................ 985 Mast/Carriage Bounces or is Spongy...................................... 987 Misphasing of Full Free-Lift Mast....................................... 988 Overhead Guard Loose or Damaged......................................... 990 Racking During Lift..................................................... 991 Racking During Tilt..................................................... 992 Truck Feels Unstable.................................................... 993 Truck Wanders, Does Not Track Straight or Steer Well.................... 995 Wheels Appear Tipped or Misaligned...................................... 997 Wheels Spinning On Uneven Floors........................................ 998 Wheel Studs Breaking.................................................... 999 Supplementary Data..........................................................1001 Abbreviations and Acronyms..............................................1003 Special Tools List......................................................1011 Fault Mode Indicator (FMI) Reference List...............................1013 TSP Reference Tables....................................................1015 tables.......................................................................... 181 Table 9020-40-1. Test Specifications........................................ 357 Table 9020-40-2. Test Specifications........................................ 358 Table 9020-40-3. Service Tools.............................................. 358 Table 9020-40-4. Test Specifications........................................ 359 Table 9020-40-5. Service Tools.............................................. 359 Table 9020-40-6. Test Specifications - Mazda................................ 360 Table 9020-40-7. Test Specifications - GM................................... 360 Table 9020-40-8. Service Tools.............................................. 360 Table 9030-03-1. Circuit Group Identification............................... 382 Table 9030-03-2. NMHG Wiring Color Codes.................................... 383 Table 9040-10-1. Transmission Control Mode.................................. 751 Table 9040-40-1. Test Specifications........................................ 789 Table 9040-40-2. Service Tools.............................................. 789 Table 9040-40-3. Service Tools.............................................. 789 Table 9040-40-4. Test Specifications........................................ 790 Table 9040-40-5. Test Specifications........................................ 790 Table 9040-40-6. Test Specifications........................................ 791 Table 9040-40-7. Test Specifications........................................ 791 Table 9040-40-8. Test Specifications........................................ 791 Table 9040-40-9. Service Tools.............................................. 791 Table 9040-40-10. Stall Speeds.............................................. 792 Table 9050-40-1. Test Specifications........................................ 901 Table 9050-40-2. Service Tools.............................................. 901 Table 9050-40-3. Test Specifications........................................ 902 Table 9050-40-4. Service Tools.............................................. 902 Table 9050-40-5. Test Specifications........................................ 904 Table 9050-40-6. Service Tools.............................................. 904 Table 9050-40-7. Test Specifications........................................ 906 Table 9050-40-8. Service Tools.............................................. 906 Table 9050-40-9. Test Specifications........................................ 907 Table 9050-40-10. Test Specifications....................................... 908 Table 9050-40-11. Service Tools............................................. 908 Table 9050-40-12. Test Specifications....................................... 909 Table 9050-40-13. Service Tools............................................. 909 Table 9050-40-14. Test Specifications....................................... 912 Table 9050-40-15. Service Tools............................................. 912 Table 9050-40-16. Test Specifications....................................... 913 Table 9050-40-17. Service Tools............................................. 913 Table 9050-40-18. Test Specifications....................................... 914 Table 9050-40-19. Service Tools............................................. 914 Table 9050-40-20. Test Specifications....................................... 915 Table 9050-40-21. Service Tools............................................. 915 Table 9050-40-22. Test Specifications....................................... 917 Table 9050-40-23. Service Tools............................................. 917 Table 9050-40-24. Test Specifications....................................... 918 Table 9050-40-25. Service Tools............................................. 918 Table 9080-50-1. Abbreviations and Acronyms.................................1003 Table 9080-60-1. Special Tools..............................................1011 Table 9080-70-1. FMI........................................................1013 Table 9080-80-1. Resistor-Temperature Characteristics ......................1015 Diagrams-8000SRM1152-(05-2005)-US-EN................................................1019 toc.............................................................................1019 Diagrams and Schematics.....................................................1019 Safety Precautions Maintenance and Repair...................................1020 Drive Axle Differential1-1400SRM1132-(05-2005)-US-EN................................1057 toc.............................................................................1057 Drive Axle and Differential Assembly Repair.................................1057 Safety Precautions Maintenance and Repair...................................1058 General.....................................................................1061 Drive Axle Repair...........................................................1061 Remove and Disassemble..................................................1061 Clean and Inspect.......................................................1061 Assemble and Install....................................................1063 Differential Repair.........................................................1065 Remove..................................................................1065 Differential Assembly From Center Section...........................1065 Drive Pinion, Pinion Gear, and Bearings From Center Section.........1068 Disassemble.............................................................1072 Differential Assembly...............................................1072 Drop Box Housing....................................................1075 Center Section......................................................1076 Clean and Inspect.......................................................1078 Assemble................................................................1078 Center Section......................................................1078 Drop Box Housing....................................................1081 Differential Assembly...............................................1082 Install.................................................................1085 Pinion Inner Shim Set, Adjust Thickness (Depth of Pinion)...........1085 Drive Pinion, Pinion Gear, and Bearings Into Center Section.........1088 Differential Assembly Into Center Section...........................1091 Ring Gear Backlash, Adjust..........................................1095 Ring Gear, Runout Check.............................................1096 Gear Set, Tooth Contact Pattern Check...............................1096 Torque Specifications.......................................................1099 tables..........................................................................1057 Table 1. Pinion Variation Numbers Examples..................................1087 Table 2. Ring and Pinion Tooth Contact Adjustment...........................1097 Table 3. Correct Tooth Contact..............................................1097 Table 4. Incorrect Tooth Contact............................................1098 Drive Axle Dry Brakes-1400SRM1214-(05-2005)-US-EN...................................1103 toc.............................................................................1103 Drive Axle and Differential Assembly Repair.................................1103 Safety Precautions Maintenance and Repair...................................1104 General.....................................................................1107 Drive Axle Repair...........................................................1107 Remove and Disassemble..................................................1107 Clean and Inspect.......................................................1109 Assemble and Install....................................................1109 Differential Repair.........................................................1111 Remove..................................................................1111 Differential Assembly From Center Section...........................1111 Drive Pinion, Pinion Gear, and Bearings From Center Section.........1114 Disassemble.............................................................1120 Differential Assembly...............................................1120 Drop Box Housing....................................................1123 Center Section......................................................1124 Clean and Inspect.......................................................1126 Assemble................................................................1127 Center Section......................................................1127 Drop Box Housing....................................................1130 Differential Assembly...............................................1131 Install.................................................................1134 Pinion Inner Shim Set, Adjust Thickness (Depth of Pinion)...........1134 Drive Pinion, Pinion Gear, and Bearings Into Center Section.........1136 Differential Assembly Into Center Section...........................1141 Ring Gear Backlash, Adjust..........................................1146 Ring Gear, Runout Check.............................................1147 Gear Set, Tooth Contact Pattern Check...............................1147 Torque Specifications.......................................................1150 tables..........................................................................1103 Table 1. Pinion Variation Numbers Examples..................................1136 Table 2. Ring and Pinion Tooth Contact Adjustment...........................1147 Table 3. Correct Tooth Contact..............................................1148 Table 4. Incorrect Tooth Contact............................................1149 Electrical System Mazda1-2200SRM1143-(05-2005)-US-EN................................1153 toc.............................................................................1153 Electrical System...........................................................1153 Safety Precautions Maintenance and Repair...................................1154 Ignition System.............................................................1157 General.................................................................1157 Ignition Timing Adjustment, Gasoline and LPG............................1157 Spark Plugs Check.......................................................1157 Spark Plug Wires Check..................................................1157 Distributor Repair..........................................................1160 Remove..................................................................1160 Disassemble.............................................................1161 Inspect.................................................................1161 Assemble................................................................1162 Install.................................................................1162 Igniter.................................................................1163 Remove..............................................................1163 Test................................................................1163 Install.............................................................1163 Camshaft Position (CMP) Sensor..........................................1164 Voltage Check.......................................................1164 Ignition Coil Check.........................................................1165 Primary Coil Winding....................................................1165 Secondary Coil Winding..................................................1165 Starter Repair..............................................................1166 General.................................................................1166 Remove..................................................................1166 No-Load Test............................................................1167 Magnetic Switch Test....................................................1167 Pull-Out Test.......................................................1167 Holding Coil Test...................................................1168 Return Test.........................................................1168 Pinion Movement Inspection..........................................1168 Install.................................................................1168 Alternator Repair...........................................................1169 General.................................................................1169 Charging System Inspection..............................................1169 Output Current Check....................................................1170 No-Load Adjusted Voltage Check..........................................1170 Remove..................................................................1171 Inspect.................................................................1171 Rectifier Check.....................................................1171 Install.................................................................1172 tables..........................................................................1153 Table 1. Spark Plug Wire....................................................1157 Table 2. Starter Specifications.............................................1166 Table 3. Problem Diagnosis Chart............................................1167 Table 4. Specifications.....................................................1170 Table 5. Rectifier Check Table..............................................1171 Electrical Systems-2200SRM1142-(05-2005)-US-EN......................................1175 toc.............................................................................1175 Electrical System...........................................................1175 Safety Precautions Maintenance and Repair...................................1176 General.....................................................................1183 Display Switch Cluster......................................................1184 Remove..................................................................1184 Replace.................................................................1184 Direction Control and Turn Signal Levers................................1185 Remove..............................................................1185 Replace.............................................................1185 Key Switch..............................................................1186 Remove..............................................................1186 Replace.............................................................1187 Display Switch Cluster Panel Bezel and Overlay..........................1187 Remove..............................................................1187 Replace.............................................................1187 Steering Column Repair......................................................1188 Remove..................................................................1188 Disassemble.............................................................1188 Assemble................................................................1188 Install.................................................................1190 Sensors and Switches........................................................1190 General.................................................................1190 Accelerator Pedal Position Sensor.......................................1190 Remove..............................................................1190 Replace.............................................................1192 Brake Fluid Level Switch................................................1194 Remove..............................................................1194 Replace.............................................................1194 Service Brake Pedal Position Sensor.....................................1194 Remove..............................................................1194 Replace.............................................................1194 Parking Brake Sensor....................................................1195 Remove..............................................................1195 Replace.............................................................1195 Service Brake Pressure Sensor...........................................1195 Remove..............................................................1195 Replace.............................................................1195 MONOTROL® Sensor Microswitch............................................1196 Remove..............................................................1196 Replace.............................................................1197 Low Coolant Level Sensor................................................1198 Remove..............................................................1198 Replace.............................................................1198 Fuel Level Sensor, Gas and Diesel Engines Only..........................1198 Remove..............................................................1198 Replace.............................................................1198 Armrest Switch..........................................................1199 Remove..............................................................1199 Replace.............................................................1199 Seat Sensor.............................................................1201 Non-Suspension and Semi-Suspension Seats............................1201 Remove..........................................................1201 Replace.........................................................1201 Full Suspension Seats...............................................1202 Remove..........................................................1202 Replace.........................................................1202 Hood Switch.............................................................1202 Remove..............................................................1202 Replace.............................................................1202 Hydraulic Filter Pressure Switch........................................1204 Remove..............................................................1204 Replace.............................................................1204 Transmission Speed Sensor...............................................1204 Remove..............................................................1204 Replace.............................................................1205 Transmission Pressure Sensors...........................................1205 Remove..............................................................1205 Replace.............................................................1205 Transmission Temperature Sensor.........................................1205 Remove..............................................................1205 Replace.............................................................1205 Return to Set Tilt (Tilt Angle) Sensor..................................1206 Remove..............................................................1206 Replace.............................................................1206 Rear Horn Button Switch.................................................1206 Remove..............................................................1206 Replace.............................................................1206 Engine and Fuel Sensors - Mazda 2.0L and 2.2L Gas and LPG Engine........1207 Oxygen Sensor.......................................................1207 Remove..........................................................1207 Replace.........................................................1207 Intake Air Temperature (IAT) Sensor.................................1207 Remove..........................................................1207 Replace.........................................................1207 Manifold Absolute Pressure (MAP)/Boost Sensor.......................1208 Remove..........................................................1208 Replace.........................................................1208 Throttle Position (TPS) Sensor......................................1208 Remove..........................................................1208 Replace.........................................................1208 Engine and Fuel Sensors and Switches - Mazda 2.0L and 2.2L LPG E........1209 Oil Pressure Sensor.................................................1209 Remove..........................................................1209 Replace.........................................................1209 Low LPG Pressure Switch.............................................1210 Remove..........................................................1210 Replace.........................................................1210 Air Filter Restriction Switch.......................................1210 Remove..........................................................1210 Replace.........................................................1210 Engine Coolant Temperature (ECT) Sensor.............................1210 Remove..........................................................1210 Replace.........................................................1210 Engine and Fuel Sensors and Switches- Mazda 2.0L and 2.2L Gas En........1211 Oil Pressure Sensor.................................................1211 Remove..........................................................1211 Replace.........................................................1211 Mass Air Flow (MAF) Sensor..........................................1211 Remove..........................................................1211 Replace.........................................................1211 Air Filter Restriction Switch.......................................1212 Remove..........................................................1212 Replace.........................................................1212 Engine Coolant Temperature (ECT) Sensor.............................1212 Remove..........................................................1212 Replace.........................................................1212 Engine and Fuel Sensors and Switches, GM 2.4L Gas and LPG Trucks........1213 Crankshaft Sensor...................................................1213 Remove..........................................................1213 Replace.........................................................1213 Camshaft Position (CMP) Sensor......................................1213 Remove..........................................................1213 Replace.........................................................1214 Camshaft Position (CMP) Sensor Assembly.............................1214 Remove..........................................................1214 Install.........................................................1214 Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) ....1214 Remove..........................................................1214 Replace.........................................................1214 Engine Coolant Temperature (ECT) Sensor.............................1215 Remove..........................................................1215 Replace.........................................................1215 Air Flow Restriction Switch.........................................1215 Remove..........................................................1215 Replace.........................................................1215 Oil Pressure Sensor.................................................1216 Remove..........................................................1216 Replace.........................................................1216 Oxygen Sensor.......................................................1216 Remove..........................................................1216 Replace.........................................................1217 Engine and Fuel Switches, GM 2.4L LPG Trucks Only.......................1218 Low LPG Pressure Switch.............................................1218 Remove..........................................................1218 Replace.........................................................1218 Engine and Fuel Sensors and Switches, Yanmar Diesel Trucks..............1218 Air Filter Restriction Switch.......................................1218 Remove..........................................................1218 Replace.........................................................1218 Oil Pressure Sensor.................................................1218 Remove..........................................................1218 Replace.........................................................1218 Engine Speed Sensor.................................................1218 Remove..........................................................1218 Replace.........................................................1218 Engine Coolant Temperature (ECT) Sensor.............................1220 Remove..........................................................1220 Replace.........................................................1220 Throttle Position Sensor (TPS)......................................1220 Remove..........................................................1220 Replace.........................................................1221 Vehicle System Manager (VSM)................................................1221 General.................................................................1221 VSM Replacement.........................................................1221 Remove..............................................................1221 Replace.............................................................1221 Programming a New VSM and/or Display Switch Cluster.....................1222 General.............................................................1222 PC Service Tool Software............................................1223 Data Transferring...................................................1223 New or Used VSM.................................................1223 New (Blank) Display Switch Cluster..............................1223 Used (Non-Blank) Display Switch Cluster.........................1224 Power Distribution Module (PDM) And Component Parts.........................1225 Remove..................................................................1225 PDM as a Unit.......................................................1225 Replace.................................................................1225 PDM as a Unit.......................................................1225 Remove and Replace......................................................1227 PDM Component Parts.................................................1227 Battery.....................................................................1228 Remove..................................................................1228 Replace.................................................................1228 Lights......................................................................1228 Work Lights (Front and Rear)............................................1228 Remove..............................................................1228 Replace.............................................................1228 Strobe Light............................................................1228 Remove..............................................................1228 Replace.............................................................1229 LED Tail, Backup, and Brake Lights......................................1229 Remove..............................................................1229 Replace.............................................................1229 Electronic-Hydraulic Controls...............................................1230 General.................................................................1230 Mini-Levers.............................................................1230 Remove..............................................................1230 Replace.............................................................1231 Joystick................................................................1231 Remove and Disassemble..............................................1231 Inspect.............................................................1231 Assemble and Replace................................................1231 tables..........................................................................1175 Table 1. VSM and Display Switch Cluster Replacement.........................1225 Frame-0100SRM1120-(05-2005)-US-EN...................................................1235 toc.............................................................................1235 Frame.......................................................................1235 Safety Precautions Maintenance and Repair...................................1236 General.....................................................................1239 Description.................................................................1240 Hood, Seat, and Side Covers Replacement.....................................1240 Remove..................................................................1240 Install.................................................................1245 LPG Tank and Bracket Replacement............................................1247 Remove..................................................................1247 LPG Tank............................................................1247 LPG Bracket.........................................................1247 Install.................................................................1250 LPG Bracket.........................................................1250 LPG Tank............................................................1250 Counterweight Replacement...................................................1251 Remove..................................................................1251 Install.................................................................1252 Tow Pin, Remove and Install.............................................1253 Overhead Guard Replacement..................................................1253 Remove and Install......................................................1253 LED Tail, Backup, and Brake Lights, Replace.............................1254 Operator Restraint System Replacement.......................................1255 Engine Replacement..........................................................1256 Remove Engine Only......................................................1256 Remove Engine and Transmission..........................................1258 Install Engine Only.....................................................1258 Install Engine and Transmission.........................................1259 Throttle Pedal and Cable Adjustment.........................................1259 Mazda Gas/LPG Engines...................................................1259 Yanmar Diesel Engine With Basic Power Shift Transmission................1261 Yanmar Diesel Engine With Electronic Throttle...........................1261 Exhaust System Repair.......................................................1262 Lift Trucks With Counterweight Exhaust System...........................1262 Mazda and GM Gas and LPG Engines....................................1262 Remove and Disassemble..........................................1262 Inspect.........................................................1264 Assemble and Install............................................1264 Yanmar Diesel Engine................................................1264 Remove and Disassemble..........................................1264 Inspect.........................................................1266 Assemble and Install............................................1266 Lift Trucks With Overhead Exhaust System................................1266 Yanmar Diesel Engine................................................1267 Remove and Disassemble..........................................1267 Inspect.........................................................1267 Assemble and Install............................................1267 Mazda Gas and LPG Engines...........................................1269 Remove and Disassemble..........................................1269 Inspect.........................................................1269 Assemble and Install............................................1269 Cooling System..............................................................1271 Description.............................................................1271 Fuel and Hydraulic Tanks Repair.............................................1271 Inspect.................................................................1271 Clean...................................................................1272 Steam Method of Cleaning............................................1272 Chemical Solution Method of Cleaning................................1272 Additional Preparations for Repair......................................1273 Small Leaks, Repair.....................................................1273 Large Leaks, Repair.....................................................1273 Preparations for Usage After Repair.....................................1273 Safety Labels...............................................................1273 tables..........................................................................1235 Table 1. Weight of Counterweights, Lift Truck Models S2.0-3.5FT ............1252 Table 2. Weight of Counterweights, Lift Truck Models S30FT, S35F............1252 Table 3. Weight of Counterweights, Lift Truck Models H1.6FT, H1.............1252 Table 4. Weight of Counterweights, Lift Truck Models H2.0-3.5FT ............1252 Gasoline Fuel System GM-0900SRM1126-(05-2005)-US-EN.................................1279 toc.............................................................................1279 Gasoline Fuel System........................................................1279 Safety Precautions Maintenance and Repair...................................1280 General.....................................................................1283 Electronic Throttle Body Repair.............................................1283 Electronic Throttle Body................................................1283 Remove..............................................................1283 Install.............................................................1283 Fuel System Repair..........................................................1284 Before Repair Procedure.................................................1284 After Repair Procedure..................................................1284 Fuel Leakage Check..................................................1284 Fuel Line Pressure Check................................................1285 Fuel Injectors..........................................................1286 Remove..............................................................1286 Install.............................................................1287 Pressure Regulator......................................................1287 Remove..............................................................1287 Install.............................................................1288 Control System..............................................................1288 Electronic Control Unit (ECU)...........................................1288 Remove..............................................................1288 Install.............................................................1289 Power Latch Relay.......................................................1289 Remove..............................................................1289 Install.............................................................1290 Camshaft Position (CMP) Sensor..........................................1290 Remove..............................................................1290 Install.............................................................1290 Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) ........1291 Remove..............................................................1291 Install.............................................................1291 Engine Coolant Temperature (ECT) Sensor.................................1291 Remove..............................................................1291 Install.............................................................1292 Oxygen Sensor...........................................................1292 Remove..............................................................1292 Install.............................................................1293 Gasoline Fuel System Mazda-0900SRM1127-(05-2005)-US-EN..............................1297 toc.............................................................................1297 Gasoline Fuel System........................................................1297 Safety Precautions Maintenance and Repair...................................1298 General.....................................................................1301 Abbreviations...............................................................1301 Engine Tune-up..............................................................1301 Engine Tune-Up Preparation..............................................1301 Idle Speed Adjustment...................................................1301 Idle-Up Speed Check.....................................................1301 Intake-Air System...........................................................1303 Intake-Air System Manifold Vacuum Check.................................1303 Throttle Body...........................................................1304 Remove..............................................................1304 Install.............................................................1304 Electronic Governor.....................................................1304 Remove..............................................................1304 Install.............................................................1304 Intake-Air Control (IAC) Valve..........................................1304 Remove..............................................................1304 Install.............................................................1306 Intake Manifold.........................................................1306 Remove..............................................................1306 Install.............................................................1306 Fuel System.................................................................1307 Before Repair Procedure.................................................1307 Fuel Line Safety Procedure..........................................1307 After Repair Procedure..................................................1307 Fuel Hose, Install..................................................1307 Fuel Leakage Check..................................................1308 Fuel Line Pressure Check................................................1308 Fuel Injector...........................................................1309 Remove..............................................................1309 Install.............................................................1309 Pressure Regulator......................................................1310 Remove..............................................................1310 Install.............................................................1311 Exhaust System..............................................................1312 Exhaust System, Inspect.................................................1312 Three-Way Catalytic (TWC) Converter.....................................1312 Remove and Install..................................................1312 Exhaust Manifold........................................................1312 Remove..............................................................1312 Install.............................................................1312 Positive Crankcase Ventilation (PCV) Valve..............................1314 Remove..............................................................1314 Inspect.............................................................1314 Install.............................................................1314 Control System..............................................................1314 Engine Control Unit (ECU)...............................................1314 Remove..............................................................1314 Install.............................................................1316 Intake Air Temperature (IAT) Sensor.....................................1317 Remove..............................................................1317 Install.............................................................1317 Mass Air Flow (MAF) Sensor..............................................1317 Remove..............................................................1317 Install.............................................................1317 Throttle Position (TP) Sensor...........................................1318 TP Sensor, Adjust...................................................1318 Remove..............................................................1319 Install.............................................................1319 Engine Coolant Temperature (ECT) Sensor.................................1319 Remove..............................................................1319 Install.............................................................1320 Camshaft Position (CMP) Sensor..........................................1320 Voltage Check.......................................................1320 Oxygen Sensor...........................................................1320 Remove..............................................................1320 Install.............................................................1320 Manifold Absolute Pressure (MAP)/Boost Sensor...........................1321 Remove..............................................................1321 Install.............................................................1321 Technical Data..............................................................1322 tables..........................................................................1297 Table 1. PCV Valve Specifications...........................................1314 Table 2. Closed Throttle Position Specifications............................1319 Table 3. Gasoline Fuel Systems Technical Data...............................1322 GM Engine Repair-0600SRM1121-(05-2005)-US-EN........................................1325 toc.............................................................................1325 GM Engine Repair............................................................1325 Safety Precautions Maintenance and Repair...................................1326 General.....................................................................1331 Engine Serial Number........................................................1331 Engine Removal and Installation.............................................1332 Intake Manifold.............................................................1332 Remove..................................................................1332 Clean and Inspect.......................................................1333 Install.................................................................1333 Exhaust Manifold............................................................1334 Remove..................................................................1334 Clean and Inspect.......................................................1335 Install.................................................................1335 Camshaft and Cylinder Head Repair...........................................1335 Rocker Arm Cover........................................................1335 Remove..............................................................1335 Install.............................................................1336 Camshaft Timing Pulley and/or Front Seal................................1336 Remove..............................................................1336 Install.............................................................1336 Camshaft Position (CMP) Sensor Assembly.................................1337 Remove..............................................................1337 Install.............................................................1337 Camshaft Carrier and Cylinder Head......................................1337 Remove..............................................................1337 Disassemble.........................................................1339 Camshaft Carrier................................................1339 Cylinder Head...................................................1340 Clean and Inspect...................................................1341 Camshaft Carrier................................................1341 Cylinder Head...................................................1342 Valve and Valve Seat................................................1344 Assemble............................................................1344 Cylinder Head...................................................1344 Camshaft Carrier................................................1344 Install.............................................................1345 Timing Belt.................................................................1346 Timing Belt Front Cover.................................................1346 Remove..............................................................1346 Install.............................................................1347 Timing Belt and Timing Belt Tensioner...................................1347 Remove..............................................................1347 Install.............................................................1349 Timing Belt Rear Cover..................................................1349 Remove..............................................................1349 Install.............................................................1349 Lubrication System Repair...................................................1350 Oil Pan.................................................................1350 Remove..............................................................1350 Install.............................................................1350 Oil Pump................................................................1352 Remove..............................................................1352 Clean and Inspect...................................................1353 Install.............................................................1354 Piston and Piston Rod Assemblies Repair.....................................1355 Piston Rod Bearings, Replace............................................1355 Piston and Piston Rod Assemblies........................................1357 Remove..............................................................1357 Disassemble.........................................................1358 Pistons, Clean and Inspect..........................................1358 Cylinder Bores, Inspect and Repair..................................1359 Piston Rings, Inspect...............................................1360 Assemble............................................................1361 Install.............................................................1361 Crankshaft and Main Bearings................................................1362 Crankshaft Timing Pulley and/or Front Seal..............................1362 Remove..............................................................1362 Install.............................................................1363 Crankshaft Rear Main Oil Seal...........................................1364 Remove..............................................................1364 Install.............................................................1364 Crankshaft/RPM Sensor...................................................1365 Remove..............................................................1365 Install.............................................................1365 Crankshaft Reluctor Wheel...............................................1365 Remove and Install..................................................1365 Crankshaft and Main Bearings............................................1366 Remove..............................................................1366 Inspect and Repair..................................................1366 Bearing Selection...................................................1367 Main Bearings and Journal Clearance, Check..........................1368 Install.............................................................1369 Flywheel and Flywheel Housing...............................................1371 Remove..................................................................1371 Install.................................................................1371 Cooling System Repair.......................................................1372 Serpentine Belt.........................................................1372 Remove..............................................................1372 Inspect.............................................................1372 Install.............................................................1372 Water Pump..............................................................1373 Remove..............................................................1373 Inspect.............................................................1375 Install.............................................................1375 Thermostat..............................................................1376 Remove..............................................................1376 Check...............................................................1377 Install.............................................................1377 Thermostat Housing......................................................1378 Remove..............................................................1378 Clean and Inspect...................................................1378 Install.............................................................1379 Ignition System.............................................................1380 Spark Plug Wire Inspection..............................................1380 Spark Plug Wire Replacement.............................................1380 Remove..............................................................1380 Install.............................................................1381 Spark Plug Replacement..................................................1381 Remove..............................................................1381 Install.............................................................1381 Spark Plug Inspection...................................................1382 Usage...............................................................1382 Inspect.............................................................1382 Visual Inspection...................................................1383 Coil Pack...............................................................1384 Remove..............................................................1384 Install.............................................................1384 Alternator Repair...........................................................1384 Alternator..............................................................1384 Remove..............................................................1384 Install.............................................................1384 Alternator Fuse, Replace................................................1385 Starter Repair..............................................................1385 Remove..................................................................1385 Install.................................................................1385 Engine Specifications.......................................................1386 Engine Data.............................................................1386 Cylinder Bore...........................................................1386 Piston..................................................................1386 Piston Rings............................................................1386 Wrist Pin...............................................................1387 Crankshaft..............................................................1387 Piston Rod..............................................................1388 Camshaft and Camshaft Carrier...........................................1388 Valve System............................................................1388 Cylinder Head Warpage...................................................1389 Lubrication System......................................................1389 Cooling System..........................................................1389 Torque Specifications.......................................................1390 Special Tools...............................................................1391 Hydraulic Gear Pump-1900SRM1136-(05-2005)-US-EN.....................................1397 toc.............................................................................1397 Hydraulic Gear Pump.........................................................1397 Safety Precautions Maintenance and Repair...................................1398 General.....................................................................1401 Gear Pump Assembly Repair...................................................1401 Remove..................................................................1401 Disassemble.............................................................1401 Inspect.................................................................1404 Clean...................................................................1404 Assemble................................................................1404 Install.................................................................1404 Gear Pump Specifications....................................................1405 Torque Specifications.......................................................1406 tables..........................................................................1397 Table 1. Standard Gear Pump.................................................1405 Table 2. High Pressure Gear Pump............................................1405 LP Fuel System Mazda-0900SRM1125-(05-2005)-US-EN....................................1409 toc.............................................................................1409 LPG Fuel System.............................................................1409 Safety Precautions Maintenance and Repair...................................1410 General.....................................................................1413 Hoses Replacement...........................................................1413 LPG Tank Replacement........................................................1413 Remove..................................................................1413 Install.................................................................1413 Fuel Filter.................................................................1415 Remove..................................................................1415 Clean and Inspect.......................................................1416 Install.................................................................1417 Relief Valve Replacement....................................................1418 Remove and Install......................................................1418 Carburetor Repair...........................................................1418 Remove..................................................................1418 Disassemble.............................................................1418 Clean...................................................................1420 Assemble................................................................1420 Install.................................................................1420 Fuel Injector Repair........................................................1421 Remove..................................................................1421 Clean and Inspect.......................................................1421 Install.................................................................1421 Governor Repair.............................................................1421 Remove..................................................................1421 Install.................................................................1421 Regulator Repair............................................................1422 Remove..................................................................1422 Install.................................................................1423 Control System..............................................................1423 Engine Control Unit (ECU)...............................................1423 Remove..............................................................1423 Install.............................................................1423 Engine Coolant Temperature (ECT) Sensor.................................1424 Remove..............................................................1424 Install.............................................................1424 Camshaft Position (CMP) Sensor..........................................1424 Voltage Check.......................................................1424 Intake Air Temperature (IAT) Sensor.....................................1425 Remove..............................................................1425 Install.............................................................1425 Manifold Absolute Pressure (MAP) Sensor.................................1426 Remove..............................................................1426 Install.............................................................1426 Oxygen Sensor...........................................................1426 Remove..............................................................1426 Install.............................................................1426 Throttle Position (TP) Sensor...........................................1427 Remove..............................................................1427 Install.............................................................1427 LP Fuel Systems GM-0900SRM1124-(05-2005)-US-EN......................................1431 toc.............................................................................1431 LPG Fuel System.............................................................1431 Safety Precautions Maintenance and Repair...................................1432 General.....................................................................1435 Hoses Replacement...........................................................1435 LPG Tank Replacement........................................................1435 Remove..................................................................1435 Install.................................................................1435 Fuel Filter Unit Repair.....................................................1437 Fuel Filter Element.....................................................1437 Remove..............................................................1437 Install.............................................................1438 Fuel Filter Housing.....................................................1438 Remove..............................................................1438 Disassemble.........................................................1439 Assemble............................................................1439 Install.............................................................1439 Electronic Throttle Body Repair.............................................1440 Electronic Throttle Body................................................1440 Remove..............................................................1440 Install.............................................................1440 Electronic Throttle Body Adapter Plate..................................1441 Remove..............................................................1441 Install.............................................................1441 Fuel Injector Repair........................................................1441 Fuel Rail...............................................................1441 Remove..............................................................1441 Install.............................................................1442 Fuel Injector...........................................................1443 Remove..............................................................1443 Clean...............................................................1443 Install.............................................................1443 Fuel Injector Adapters..................................................1444 Remove..............................................................1444 Install.............................................................1445 Vaporizer Repair............................................................1445 Vaporizer...............................................................1445 Remove..............................................................1445 Install.............................................................1446 Vaporizer Fuel Filter...................................................1447 Remove..............................................................1447 Install.............................................................1447 Lock-Off Solenoid and Cartridge.........................................1448 Remove..............................................................1448 Install.............................................................1448 Control System..............................................................1448 Electronic Control Unit (ECU)...........................................1448 Remove..............................................................1448 Install.............................................................1450 Power Latch Relay.......................................................1450 Remove..............................................................1450 Install.............................................................1450 Injector Driver Module..................................................1451 Remove..............................................................1451 Install.............................................................1451 Camshaft Position (CMP) Sensor..........................................1452 Remove..............................................................1452 Install.............................................................1452 Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) ........1452 Remove..............................................................1452 Install.............................................................1453 Engine Coolant Temperature (ECT) Sensor.................................1453 Remove..............................................................1453 Install.............................................................1453 Oxygen Sensor...........................................................1453 Remove..............................................................1453 Install.............................................................1454 Main Control Valve-2000SRM1137-(05-2005)-US-EN......................................1457 toc.............................................................................1457 Main Control Valve..........................................................1457 Safety Precautions Maintenance and Repair...................................1458 General.....................................................................1461 Electro-Hydraulic Main Control Valve........................................1461 Description.............................................................1461 Remove..................................................................1462 Electro-Hydraulic Control Valve Sections................................1465 General.............................................................1465 Outlet Control Valve Section........................................1465 Remove..........................................................1465 Disassemble.....................................................1465 Clean...........................................................1466 Inspect.........................................................1467 Assemble........................................................1467 Install.........................................................1467 Auxiliary Control Valve Section.....................................1467 Remove..........................................................1467 Disassemble.....................................................1469 Clean...........................................................1469 Inspect.........................................................1470 Assemble........................................................1470 Install.........................................................1470 Tilt Control Valve Section..........................................1470 Remove..........................................................1470 Disassemble.....................................................1471 Clean...........................................................1472 Inspect.........................................................1472 Assemble........................................................1472 Install.........................................................1472 Lift/Lower Control Valve Section....................................1472 Remove..........................................................1472 Disassemble.....................................................1472 Clean...........................................................1474 Inspect.........................................................1474 Assemble........................................................1475 Install.........................................................1475 Install.................................................................1475 Manual Main Control Valve...................................................1478 Description.............................................................1478 Remove..................................................................1479 Manual Control Valve Sections...........................................1482 General.............................................................1482 Outlet Control Valve Section........................................1482 Remove..........................................................1482 Disassemble.....................................................1482 Clean...........................................................1484 Inspect.........................................................1484 Assemble........................................................1484 Install.........................................................1484 Auxiliary Control Valve Section.....................................1484 Remove..........................................................1484 Disassemble.....................................................1485 Clean...........................................................1486 Inspect.........................................................1486 Assemble........................................................1486 Install.........................................................1486 Lift/Tilt Control Valve Section.....................................1486 Remove..........................................................1486 Disassemble.....................................................1487 Clean...........................................................1487 Inspect.........................................................1487 Assemble........................................................1489 Install.........................................................1489 Install.................................................................1489 Steering Control Unit Repair................................................1492 Steering Control Unit, Remove...........................................1492 Steering Control Unit, Disassemble......................................1494 Steering Control Unit, Clean............................................1494 Steering Control Unit, Inspect..........................................1494 Steering Control Unit, Assemble.........................................1496 Relief Valve, Disassemble...............................................1496 Relief Valve, Clean.....................................................1497 Relief Valve, Inspect...................................................1497 Relief Valve, Assemble..................................................1497 Steering Control Unit, Install..........................................1497 Mast Repair 2 3 4 Stage-4000SRM1148-(05-2005)-US-EN.................................1501 toc.............................................................................1501 Mast Repairs................................................................1501 Safety Precautions Maintenance and Repair...................................1502 General.....................................................................1505 Safety Procedures When Working Near Mast....................................1505 Forks Repair................................................................1507 Remove..................................................................1507 Install.................................................................1507 Checks..................................................................1508 Carriages Repair............................................................1509 Standard Carriage.......................................................1509 Remove..............................................................1509 Repair..............................................................1510 Install.............................................................1510 Integral Sideshift Carriage.............................................1511 Remove..............................................................1511 Clean and Inspect...................................................1513 Repair..............................................................1514 Install.............................................................1515 Mast Repair.................................................................1515 Mast, Remove............................................................1515 Two-Stage LFL and Two-Stage FFL Masts, Disassemble......................1518 Clean and Inspect.......................................................1524 Three-Stage FFL Mast....................................................1525 Disassemble.........................................................1525 Clean and Inspect...................................................1526 Two-Stage LFL and Two-Stage FFL Mast, Assemble..........................1530 Three-Stage FFL Mast, Assemble..........................................1531 Four-Stage FFL, Disassemble.............................................1532 Clean and Inspect.......................................................1536 Four-Stage FFL, Assemble................................................1538 Mast, Install...........................................................1541 Header Hose Arrangement.....................................................1542 Two-Stage LFL...........................................................1542 Two-Stage FFL...........................................................1548 Three-Stage FFL.........................................................1560 Four-Stage FFL..........................................................1575 Adjustment..............................................................1581 Lift Chains Adjustment......................................................1583 Carriage Adjustments........................................................1584 Tilt Cylinders Adjustment...................................................1584 Mast Adjustments............................................................1586 tables..........................................................................1501 Table 1. Fork Tip Alignment.................................................1508 Table 2. Pneumatic Tire Trucks..............................................1545 Table 3. Cushion Tire Trucks................................................1545 Table 4. Standard Two-Stage Hose Dimensions.................................1548 Table 5. Pneumatic Tire Trucks..............................................1551 Table 6. Cushion Tire Trucks................................................1551 Table 7. Pneumatic Tire Trucks..............................................1569 Table 8. Cushion Tire Trucks................................................1569 Table 9. Standard Three-Stage Hose Dimensions...............................1571 Table 10. Standard Four-Stage Hose Dimensions...............................1576 Mazda Engine-0600SRM1122-(05-2005)-US-EN............................................1591 toc.............................................................................1591 Mazda Engine................................................................1591 Safety Precautions Maintenance and Repair...................................1592 General.....................................................................1595 Engine Removal and Installation.............................................1595 Cylinder Head, Camshaft, and Valve Mechanism Repair.........................1595 Remove..................................................................1595 Clean...................................................................1597 Inspect and Repair......................................................1597 Cylinder Head.......................................................1597 Rocker Shaft Assembly...............................................1598 Camshaft............................................................1598 Valve Guides........................................................1599 Valve Seats.........................................................1599 Valves..............................................................1600 Valve Springs.......................................................1600 Install.................................................................1601 Crankshaft and Main Bearings Repair.........................................1605 Remove..................................................................1605 Inspect and Repair......................................................1605 Crankshaft..........................................................1605 Main Bearings.......................................................1606 Install.................................................................1606 Pistons and Connecting Rods Repair..........................................1607 Remove and Disassemble..................................................1607 Clean...................................................................1607 Inspect and Repair......................................................1607 Pistons.............................................................1607 Piston Rings........................................................1608 Connecting Rods and Bearings........................................1608 Assemble and Install....................................................1609 Cylinder Block Repair.......................................................1610 Oil Pump Repair.............................................................1611 Remove..................................................................1611 Disassemble.............................................................1612 Clean...................................................................1612 Inspect.................................................................1612 Assemble................................................................1612 Install.................................................................1613 Cooling System Repair.......................................................1615 Thermostat..............................................................1615 Replace.............................................................1615 Fan Assembly............................................................1615 Remove and Disassemble..............................................1615 Assemble and Install................................................1615 Water Pump..............................................................1616 Remove..............................................................1616 Install.............................................................1617 Distributor Repair..........................................................1618 Remove..................................................................1618 Install.................................................................1618 Flywheel and Ring Gear Repair...............................................1619 Remove..................................................................1619 Install.................................................................1619 Valve Adjustment............................................................1619 Compression Pressure Check..................................................1620 Engine Timing Adjustment....................................................1621 Engine Specifications.......................................................1622 Engine Data.............................................................1622 Thermostat..............................................................1622 Cylinder Head...........................................................1622 Valve Mechanism.........................................................1622 Camshaft................................................................1623 Crankshaft..............................................................1623 Connecting Rods.........................................................1624 Cylinder Block..........................................................1624 Pistons.................................................................1624 Oil Pump................................................................1625 Torque Specifications.......................................................1625 tables..........................................................................1591 Table 1. Pressure Specifications............................................1621 Periodic Maintenance-8000SRM1150-(05-2005)-US-EN....................................1629 toc.............................................................................1629 Periodic Maintenance........................................................1629 Safety Precautions Maintenance and Repair...................................1630 General.....................................................................1635 Serial Number Data......................................................1635 How to Move Disabled Lift Truck.........................................1635 How to Tow Lift Truck...............................................1635 How to Put Lift Truck on Blocks.........................................1636 How to Raise Drive Tires............................................1636 How to Raise Steering Tires.........................................1636 Maintenance Schedule........................................................1638 Maintenance Procedures Every 8 Hours or Daily...............................1650 How To Make Checks With Engine Stopped..................................1650 Tires and Wheels....................................................1650 Safety Labels.......................................................1651 Mast, Carriage, Lift Chains, Attachment.............................1651 Seat Belt, Hip Restraints, and Seat Rails...........................1652 Hood and Seat Latches...............................................1652 Engine Compartment..................................................1652 Fuel, Oil, and Coolant Leaks, Check.................................1654 Hydraulic Hoses.....................................................1654 Coolant Hoses.......................................................1654 Steering Column Gas Cylinder........................................1654 Transmission........................................................1654 Hydraulic System Oil................................................1654 Engine Oil..........................................................1655 Forks...............................................................1659 Remove..........................................................1659 Inspect.........................................................1659 Install.........................................................1660 Adjust..........................................................1660 How To Make Checks With Engine Running..................................1660 Indicator Lights, Horn, Fuses, and Relays...........................1661 Service Brakes......................................................1661 Brake Fluid Level...............................................1661 Operation, Check................................................1662 Parking Brake.......................................................1662 Engine Oil Pressure.................................................1662 Cooling System......................................................1663 Steering System.....................................................1663 Control Levers and Pedals...........................................1664 Lift System, Operate................................................1664 First Service After First 100 Hours of Operation............................1664 Mazda and GM Engine Oil and Filter......................................1664 Yanmar Engine Oil and Filter............................................1664 Hydraulic System........................................................1666 Hydraulic Filter, Replace...........................................1666 Transmission............................................................1667 Transmission Oil Filter, Replace....................................1667 Maintenance Procedures Every 250 Hours or 6 Weeks...........................1668 Hydraulic System Oil....................................................1668 Hydraulic Tank Breather.................................................1668 Battery.................................................................1669 Mazda and GM Engine Oil and Filter......................................1669 Air Filter..............................................................1670 Drive Belt..............................................................1670 Mazda 2.0L and 2.2L Engines.........................................1670 Fan and Alternator Drive Belt...................................1670 GM 2.4L Engine......................................................1671 Fan and Alternator Drive Belt...................................1671 Drain Tar From LPG Regulator............................................1671 Cooling System..........................................................1672 Clean Debris From Radiator Core.....................................1672 Check Transmission Oil Level............................................1672 Forks...................................................................1673 Brake Fluid.............................................................1673 Differential and Drive Axle Oil.........................................1673 Maintenance Procedures Every 500 Hours or 3 Months..........................1674 Yanmar Engine Oil and Filter............................................1674 Drive Belt..............................................................1674 Yanmar Diesel Engine................................................1674 Fan and Alternator Drive Belt...................................1674 PCV Valve...............................................................1674 Mast Lubrication........................................................1675 Lift Chain Lubrication..................................................1677 Tilt Cylinder Lubrication...............................................1677 Master Brake Cylinder Rod End Pin Lubrication...........................1678 Manual Hydraulic Levers Lubrication.....................................1678 Tie Rod Lubrication (H40-70FT)..........................................1678 Maintenance Procedures Every 1000 Hours or 6 Months.........................1679 Valve Clearance, Check and Adjust.......................................1679 Ignition System.........................................................1679 GM 2.4L Engine......................................................1679 Mazda 2.0L and 2.2L Engines.........................................1679 LPG Fuel Filter Element Replace, GM 2.4L Engine.........................1679 Remove..............................................................1679 Install.............................................................1679 LPG Vapor Fuel Filter Replace, Mazda Engines............................1680 Fuel Filter Replacement, Yanmar Engine..................................1681 Fuel Tank In-Line Fuel Filter Replacement...............................1682 Removal.............................................................1682 Installation........................................................1682 Priming the Fuel System.................................................1682 Lift Chains Wear Check..................................................1683 Lift Chain Lubrication..................................................1683 Integral Sideshift Carriage, Check Bearings.............................1683 Steering Axle...........................................................1684 Control Levers and Pedals...............................................1684 Maintenance Procedures Every 2000 Hours or Annually.........................1685 Hydraulic System........................................................1685 Hydraulic Filter, Replace...........................................1685 Hydraulic Tank Breather, Replace....................................1686 Air Filter Element......................................................1686 PCV Valve...............................................................1687 Oxygen Sensor...........................................................1687 LPG Regulator Fuel Filter, Mazda Engines................................1688 Remove and Replace..................................................1688 LPG Regulator Fuel Filter, GM Engine....................................1688 Remove..............................................................1688 Install.............................................................1688 Gasoline Fuel Filter....................................................1689 Remove and Replace..................................................1689 Timing Belt.............................................................1689 Mazda Engines.......................................................1689 GM 2.4L Engine......................................................1689 LPG Fuel Injector, Mazda Engines........................................1689 Gasoline Fuel Injector, Mazda Engines...................................1689 LPG Fuel Injector, GM Engines...........................................1689 Gasoline Fuel Injector, GM Engines......................................1690 Fuel Injector, Yanmar Engines...........................................1690 Transmission............................................................1690 Transmission Oil and Filter, Replace................................1690 Forks...................................................................1691 Integral Sideshift Carriage.............................................1691 Bearings, Replace...................................................1691 Brake Fluid Change......................................................1691 Brake Fluid, Remove.....................................................1691 Wheel Bearings..........................................................1691 Steer and Drive Wheel Bearings, Lubricate...........................1691 Service Brakes..........................................................1691 Differential............................................................1693 Maintenance Procedures Every 4000 Hours or 2 Years..........................1694 Hydraulic Oil, Replace..................................................1694 Cooling System..........................................................1694 Safety Procedures When Working Near Mast....................................1696 Hood Latch Check............................................................1698 Lift Chain Adjustments......................................................1699 Jump-Starting the Lift Truck................................................1700 Jump-Starting Using a Battery Charger...................................1700 Jump-Starting a Lift Truck Using Another Lift Truck.....................1700 Welding Repairs.............................................................1700 Overhead Guard Changes......................................................1701 Wheel and Tire Replacement..................................................1701 General.................................................................1701 Solid Rubber Tire, Change...............................................1701 Remove and Install Tire on Wheel....................................1701 Pneumatic Tire, Repair .................................................1702 Remove Wheels From Lift Truck.......................................1702 Remove Wheel From Tire..............................................1703 Remove Tire From Two-Piece Wheel................................1703 Remove Tire From Three- and Four-Piece Wheels...................1704 Install Wheel on Tire...............................................1705 Install Tire on Three- or Four-Piece Wheels.....................1705 Install Three-Piece or Four-Piece Wheel in Tire.................1706 Install Tire on Two-Piece Wheel.................................1707 Install Two-Piece Wheel in Tire.................................1707 Add Air to Pneumatic Tires..............................................1708 Wheels, Install.....................................................1708 Dual Drive Wheels, Install..........................................1708 Solid Rubber Tire, Change...............................................1709 Remove Wheel From Tire..............................................1709 Install Wheel in Tire...............................................1711 Adhesives and Sealants......................................................1713 tables..........................................................................1629 Table 1. Maintenance Schedule...............................................1643 Table 2. V-Belt Deflection Table............................................1674 Table 3. Carriage Chain Adjustment, Forks Not Installed.....................1700 Powershift Transmission Repair-1300SRM1129-(05-2005)-US-EN..........................1717 toc.............................................................................1717 Powershift Transmission.....................................................1717 Safety Precautions Maintenance and Repair...................................1718 General.....................................................................1721 Charge Pump Repair..........................................................1721 Remove..................................................................1721 Inspect.................................................................1721 Install.................................................................1721 Torque Converter Replace....................................................1721 Remove..................................................................1721 Install.................................................................1726 Front Cover Housing and Chain Drive Repair..................................1730 Remove..................................................................1730 Clean...................................................................1734 Inspect.................................................................1734 Install.................................................................1735 Clutch Packs Repair.........................................................1740 Remove and Disassemble..................................................1740 Transmission, Remove and Disassemble................................1740 Clutch Assemblies, Remove and Disassemble...........................1748 Clean...................................................................1754 Inspect.................................................................1754 Assemble and Install....................................................1755 Clutch Assemblies, Assemble and Install.............................1755 Transmission, Assemble and Install..................................1763 Control Valve Repair........................................................1766 Remove and Disassemble..................................................1766 Clean...................................................................1769 Inspect.................................................................1769 Assemble and Install....................................................1769 MONOTROL® Pedal Repair......................................................1770 Remove and Disassemble..................................................1770 Assemble and Install....................................................1771 Direction Control Lever.....................................................1775 Remove..................................................................1775 Install.................................................................1775 Starter 2200SRM0106-(12-2004)-US-EN.................................................1779 toc.............................................................................1779 Starter.....................................................................1779 Safety Precautions Maintenance and Repair...................................1780 General.....................................................................1783 Description and Operation...................................................1783 Starter Repair..............................................................1785 Remove..................................................................1785 Disassemble.............................................................1785 Clean...................................................................1786 Assemble................................................................1786 Install.................................................................1787 General Checks and Adjustments..............................................1787 Troubleshooting.............................................................1790 Steer Axle-1600SRM1133-(05-2005)-US-EN..............................................1795 toc.............................................................................1795 Steering Axle...............................................................1795 Safety Precautions Maintenance and Repair...................................1796 General.....................................................................1799 Steering Axle Assembly Repair...............................................1800 Remove..................................................................1800 Disassemble.............................................................1800 Clean...................................................................1802 Inspect.................................................................1803 Assemble................................................................1804 Install.................................................................1805 Spindles, Bearings, and Tie Rods Repair.....................................1806 Spindles and Bearings...................................................1806 S2.0-3.5FT (S40-70FT, S55FTS) [F187]................................1806 Remove and Disassemble..........................................1806 Assemble and Install............................................1807 S30FT, S35FT, S40FTS (E010), H1.6FT, H1.8FT, H2.0FTS (H30FT, H35....1808 Remove and Disassemble..........................................1808 Assemble and Install............................................1808 Tie Rods................................................................1809 S2.0-3.5FT (S40-70FT, S55FTS) [F187]................................1809 Remove..........................................................1809 Install.........................................................1810 S30FT, S35FT, S40FTS (E010), H1.6FT, H1.8FT, H2.0FTS (H30FT, H35....1811 Remove..........................................................1811 Install.........................................................1811 Steering Cylinder Repair....................................................1813 Remove and Disassemble..................................................1813 Clean and Inspect.......................................................1813 Assemble and Install....................................................1813 Torque Specifications.......................................................1814 User Interface Service-2200SRM1131-(05-2005)-US-EN..................................1817 toc.............................................................................1817 User Interface..............................................................1817 Safety Precautions Maintenance and Repair...................................1818 General.....................................................................1821 Description.............................................................1821 Dash Display Menu Access................................................1821 Menu Navigation.............................................................1822 Main Menu...................................................................1822 Passwords...................................................................1823 Adding Passwords........................................................1823 Hourmeters..................................................................1824 View Versions...............................................................1825 VSM Versions............................................................1825 Dash Display Versions...................................................1826 Engine Controller Version...............................................1827 Transmission Controller Version.........................................1828 Truck Serial Number.....................................................1828 Truck Configuration.....................................................1829 Diagnostics.................................................................1830 Clear Fault Log.........................................................1830 View Fault Log..........................................................1831 No-Run Data Display.....................................................1832 Engine Accelerator and Throttle Data Display............................1833 Engine Speeds and Governor Data Display.................................1834 Engine Fuel and Emissions Data Display..................................1835 Engine General Data Display.............................................1837 XMSN/Brake Data Display.................................................1838 Hydraulic Data Display..................................................1840 General Truck Data Display..............................................1842 Set Travel and Braking......................................................1844 Speed Limit.............................................................1844 Acceleration Rate.......................................................1845 Auto-Deceleration Rate..................................................1845 Set Power Reversal Rate.................................................1846 Set Inching/Brake Overlap...............................................1847 Setup Hydraulics............................................................1848 Lift Maximum Speed......................................................1848 Lower Maximum Speed.....................................................1848 Tilt Maximum Speed......................................................1849 Auxiliary Function One, Direction A, Maximum Speed......................1850 Auxiliary Function One, Direction B, Maximum Speed......................1850 Auxiliary Function Two, Direction A, Maximum Speed......................1851 Auxiliary Function Two, Direction B, Maximum Speed......................1851 Auxiliary Function Three, Direction A, Maximum Speed....................1852 Auxiliary Function Three, Direction B, Maximum Speed....................1852 Lift/Lower Ramp Rate....................................................1853 Hydraulic Auxiliary Ramp Rate...........................................1853 Return to Set Tilt Delay/On/Off.........................................1854 Setup Display...............................................................1855 Set Service Language....................................................1855 Setup General Items.........................................................1856 Motion Alarm Activation Type............................................1856 Light Shutdown Time-Out.................................................1857 Restore Default Settings................................................1858 Restore Engine Controller Default Calibration...........................1858 Calibrations................................................................1859 Calibrate Transmission Valve............................................1860 Set Tilt Stop Point.....................................................1861 Calibrate Travel Speed Sensor...........................................1862 tables..........................................................................1817 Table 1. Password Screen....................................................1821 Table 2. Exit Menu..........................................................1822 Table 3. Add Password Menu..................................................1823 Table 4. Hourmeters Menu....................................................1824 Table 5. View VSM Versions Menu.............................................1825 Table 6. View Dash Display Versions Menu....................................1826 Table 7. View Engine Controller Versions Menu...............................1827 Table 8. View Transmission Controller Versions Menu.........................1828 Table 9. View Truck Serial Number Menu......................................1829 Table 10. View Truck Configuration Menu.....................................1829 Table 11. Clear Fault Log...................................................1830 Table 12. View Fault Log....................................................1831 Table 13. No-Run Data Display...............................................1832 Table 14. Engine Accelerator and Throttle Data Display......................1833 Table 15. Engine Speeds and Governor Data Display...........................1834 Table 16. Engine Fuel and Emissions Data Display............................1835 Table 17. Engine General Data Display.......................................1837 Table 18. XMSN Brake Data Display...........................................1838 Table 19. Hydraulic Data Display............................................1840 Table 20. General Truck Data Display........................................1842 Table 21. Speed Limit Menu..................................................1844 Table 22. Acceleration Rate Menu............................................1845 Table 23. Auto-Decel Menu...................................................1845 Table 24. Power Reversal Menu...............................................1846 Table 25. Inch/Brake Overlap Menu...........................................1847 Table 26. Lift Speed Menu...................................................1848 Table 27. Lower Speed Menu..................................................1849 Table 28. Tilt Speed Menu...................................................1849 Table 29. Auxiliary Function Speed Menu.....................................1850 Table 30. Auxiliary Function Speed Menu.....................................1850 Table 31. Auxiliary Function Speed Menu.....................................1851 Table 32. Auxiliary Function Speed Menu.....................................1851 Table 33. Auxiliary Function Speed Menu.....................................1852 Table 34. Auxiliary Function Speed Menu.....................................1852 Table 35. Lift/Lower Ramp Rate Menu.........................................1853 Table 36. Hydraulic Auxiliary Ramp Rate Menu................................1853 Table 37. Tilt Delay Menu...................................................1854 Table 38. Service Language Menu.............................................1855 Table 39. Alarm Type Menu...................................................1856 Table 40. Light Time-Out Menu...............................................1857 Table 41. Restore Defaults Menu.............................................1858 Table 42. Restore Settings Menu.............................................1858 Table 43. Calibrate Electro-Hydraulic Valve Menu............................1859 Table 44. Calibrate Transmission Valve Menu.................................1861 Table 45. Tilt Stop Point Menu..............................................1861 Table 46. Travel Speed Menu.................................................1862 User Interface Supervisor-2200SRM1130-(05-2005)-US-EN...............................1865 toc.............................................................................1865 User Interface..............................................................1865 Safety Precautions Maintenance and Repair...................................1866 General.....................................................................1869 Description.............................................................1869 Dash Display Menu Access................................................1869 Menu Navigation.............................................................1870 Standard Display........................................................1870 Main Menu...................................................................1870 Password s Menu.............................................................1870 Password Administration.....................................................1871 Add Password............................................................1871 Delete Password.........................................................1871 Edit Password...........................................................1872 Other Password Functions....................................................1873 Operator Passwords - Enable/Disable.....................................1873 Password Time-Out Delay.................................................1873 Passwords - Number Wrong to Disable.....................................1874 Lockout Reset Password..................................................1874 View Password Log.......................................................1875 Setup Display Menu..........................................................1876 Set Operator Language...................................................1876 Set Units...............................................................1877 Set Time Format (12/24 Hour)............................................1877 Set Daylight Saving Time................................................1878 Set Time................................................................1880 Set Date Format.........................................................1880 Set Date................................................................1881 Operator Checklist..........................................................1881 Operator Checklist Off-On Mode..........................................1881 Edit Operator Checklist.................................................1882 Set Operator Checklist Expiration.......................................1882 View Checklist Log......................................................1883 Clear Operator Checklist Log............................................1883 Clear Operator Checklist Fault..........................................1884 tables..........................................................................1865 Table 1. Password Screen....................................................1869 Table 2. Exit Options Menu..................................................1870 Table 3. Add Password Menu..................................................1871 Table 4. Delete Password Menu...............................................1871 Table 5. Edit Password Menu.................................................1872 Table 6. Operator Passwords Menu............................................1873 Table 7. Password Time-Out Delay Menu.......................................1873 Table 8. Passwords - Number Wrong to Disable Menu...........................1874 Table 9. View Password Log Menu.............................................1875 Table 10. Set Language Menu.................................................1876 Table 11. Set Units Menu....................................................1877 Table 12. Set Time Format Menu..............................................1877 Table 13. Set Daylight Saving Time Menu.....................................1878 Table 14. Set Time Menu.....................................................1880 Table 15. Set Date Format Menu..............................................1880 Table 16. Set Date Menu.....................................................1881 Table 17. Checklist Off-On Mode Menu........................................1881 Table 18. Edit Checklist Menu...............................................1882 Table 19. Checklist Expiration Menu.........................................1882 Table 20. View Checklist Log Menu...........................................1883 Table 21. Clear Checklist Log Menu..........................................1883 Table 22. Clear Checklist Fault Menu........................................1884 Wire Harness Repair-2200SRM1128-(05-2005)-US-EN.....................................1887 toc.............................................................................1887 Wire Harness Repair.........................................................1887 Safety Precautions Maintenance and Repair...................................1888 General.....................................................................1891 Deutsch Crimping Tool.......................................................1891 How to Strip a Wire for Use With Deutsch Crimping Tool..................1891 How to Crimp With the Deutsch Crimping Tool.............................1892 Calibration Test for the Deutsch Crimping Tool..........................1893 Deutsch Connectors..........................................................1895 DT, DTM, and DTP Series Connectors......................................1895 Connector Receptacle Replacement....................................1902 Connector Plug Replacement..........................................1908 Connector Receptacle Pin Replacement................................1913 Connector Plug Socket Replacement...................................1920 HD Series Connectors....................................................1927 Connector Receptacle Replacement....................................1929 Connector Plug Replacement..........................................1933 Connector Receptacle Pin Replacement................................1936 Connector Plug Socket Replacement...................................1941 Sealing Plugs...........................................................1945 Metri-Pack Connectors.......................................................1947 Remove and Install......................................................1947 Micro-Pack Connectors.......................................................1949 Weather-Pack Connectors.....................................................1949 Weather-Pack Terminal Repair............................................1950 Wire Repair.................................................................1951 Wire Splicing Requirements..............................................1951 Deutsch Jiffy Splice....................................................1951 Assemble............................................................1951 Disassemble.........................................................1953 Del-City Crimp-Solder-Shrink Splice.....................................1955 Twisted/Shielded Cable and Leads Repair.....................................1956 Twisted/Shielded Cable Repair...........................................1956 Twisted Leads Repair....................................................1957 Special Tools...............................................................1958 tables..........................................................................1887 Table 1. Wire Strip Length Specifications...................................1892 Table 2. Wire Splice Size...................................................1955 Yanmar -0600SRM1205-(05-2005)-US-EN.................................................1963 toc.............................................................................1963 Yanmar Diesel Engines.......................................................1963 Safety Precautions Maintenance and Repair...................................1964 General.....................................................................1969 Engine Identification...................................................1969 Major Engine Component Identification...............................1969 Location of Labels..................................................1969 Engine Removal and Installation.............................................1970 Cylinder Head Assembly Repair...............................................1970 Glow Plugs..............................................................1970 Remove..............................................................1970 Install.............................................................1970 Valve Cover.............................................................1972 Remove..............................................................1972 Clean and Inspect...................................................1972 Install.............................................................1973 Rocker Arm Assembly.....................................................1973 Remove..............................................................1973 Disassemble.........................................................1973 Clean and Inspect...................................................1973 Push Rods.......................................................1974 Rocker Arm Assembly.............................................1974 Assemble............................................................1975 Install.............................................................1975 Valve Clearance Adjustments.............................................1976 Cylinder Head Assembly..................................................1977 Remove..............................................................1977 Disassemble.........................................................1980 Valves and Valve Springs, Remove................................1980 Valve Guides, Remove............................................1981 Clean and Inspect...................................................1981 Cylinder Head...................................................1981 Valve Guides....................................................1982 Valves..........................................................1982 Valve Sink......................................................1982 Valve Seat......................................................1983 Valve Springs...................................................1983 Assemble............................................................1984 Valve Guides, Install...........................................1984 Valves and Valve Springs, Install...............................1984 Install.............................................................1985 Timing Gear Case and Timing Gears Repair....................................1986 Timing Gear Case Cover..................................................1986 Remove..............................................................1986 Clean and Inspect...................................................1986 Install.............................................................1987 Timing Gears............................................................1987 Crankshaft Gear.....................................................1988 Remove..........................................................1988 Install.........................................................1988 Idler Gear..........................................................1988 Remove..........................................................1988 Inspect.........................................................1988 Install.........................................................1988 Camshaft Gear.......................................................1989 Remove..........................................................1989 Install.........................................................1989 Timing Gear Case........................................................1990 Remove..............................................................1990 Clean and Inspect...................................................1990 Install.............................................................1990 Drive Train, Camshaft, and Cylinder Block Repair............................1991 Remove..................................................................1991 Disassemble.............................................................1991 Pistons and Connecting Rods.........................................1991 Crankshaft..........................................................1993 Camshaft............................................................1994 Clean and Inspect.......................................................1994 Cylinder Block......................................................1994 Honing and Boring...............................................1997 Pistons.............................................................1998 Piston Pin..........................................................1999 Connecting Rod......................................................1999 Tappets.............................................................1999 Crankshaft..........................................................2000 Camshaft............................................................2001 Camshaft Bushing....................................................2001 Assemble................................................................2001 Camshaft............................................................2001 Crankshaft..........................................................2002 Pistons and Connecting Rods.........................................2002 Install.................................................................2003 Lubrication System Repair...................................................2004 Engine Oil and Oil Filter Change........................................2004 Oil Pan.................................................................2004 Remove..............................................................2004 Install.............................................................2005 Oil Suction Tube........................................................2005 Remove..............................................................2005 Clean...............................................................2005 Install.............................................................2005 Oil Pump................................................................2006 Remove..............................................................2006 Clean and Inspect...................................................2006 Outer Rotor Outside Clearance...................................2006 Outer Rotor to Inner Rotor Tip Clearance........................2006 Outer Rotor Side Clearance......................................2007 Rotor Shaft Clearance...........................................2007 Install.............................................................2007 Fuel System Repair..........................................................2008 Fuel Injectors..........................................................2008 Remove..............................................................2008 Inspect.............................................................2009 Clean...............................................................2009 Test................................................................2009 Install.............................................................2010 Electronic Throttle System..............................................2012 Remove..............................................................2012 Install.............................................................2014 Inspect.............................................................2015 Adjust..............................................................2015 Fuel Injection Pump.....................................................2015 Remove..............................................................2015 Clean and Inspect...................................................2018 Install.............................................................2018 Check/Adjust Fuel Injection Timing..................................2019 Cooling System Repair.......................................................2021 V-Belt..................................................................2021 Remove..............................................................2021 Inspect.............................................................2021 Install.............................................................2021 Adjust..............................................................2021 Water Pump..............................................................2022 4TNE92-NMHA Engines.................................................2022 Remove..........................................................2022 Install.........................................................2023 4TNE92-NMH and 4TNE98-NMH Engines...................................2024 Remove..........................................................2024 Install.........................................................2025 Thermostat..............................................................2026 Remove..............................................................2026 Inspect.............................................................2027 Install.............................................................2027 Electrical Equipment Repair.................................................2028 Alternator..............................................................2028 Remove..............................................................2028 Bench Test..........................................................2029 Regulate Voltage Check..............................................2030 No Load Test........................................................2030 Output Test.........................................................2030 Install.............................................................2030 Starter.................................................................2032 Remove..............................................................2033 No Load Test........................................................2034 Install.............................................................2034 Engine Specifications.......................................................2035 Engine Data.............................................................2035 Engine Tuning...........................................................2038 Cylinder Head...........................................................2038 Intake/Exhaust Valve and Guide..........................................2039 Valve Spring............................................................2039 Rocker Arm and Shaft....................................................2039 Push Rod................................................................2039 Gear Train and Camshaft.................................................2040 Camshaft............................................................2040 Idle Gear Shaft and Bushing.........................................2040 Backlash of Each Gear...............................................2041 Cylinder Block..........................................................2041 Crankshaft..............................................................2041 Thrust Bearing..........................................................2042 Piston..................................................................2042 Piston Ring.............................................................2042 Connecting Rod..........................................................2043 Rod Small End.......................................................2043 Tappet..............................................................2043 Oil Pump................................................................2043 Engine Oil Pressure.................................................2043 Outer Rotor Outside Clearance.......................................2044 Outer Rotor Side Clearance..........................................2044 Outer Rotor to Inner Rotor Tip Clearance............................2044 Rotor Shaft Clearance...............................................2044 Standard Torque Specifications..............................................2044 Standard Torque Chart...................................................2044 Special Torque Specifications...............................................2045 Special Tools...............................................................2046 tables..........................................................................1963 Table 1. Cylinder Measurement Worksheet.....................................1996 Table 2. Fuel Injector Spray Patterns.......................................2011 Table 3. V-Belt Deflection Table............................................2021 Table 4. Alternator Specifications..........................................2028 Table 5. Starter Specifications.............................................2032 Table 6. No Load Test Specifications........................................2034 Table 7. 4TNE92-NMH Engine..................................................2035 Table 8. 4TNE92-NMHA Engine.................................................2036 Table 9. 4TNE98-NMH Engine..................................................2037
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