Hyster Yale L177 Service Manual – PDF DOWNLOAD

Description

Hyster Yale L177 Service Manual – PDF DOWNLOAD

DESCRIPTION:

Hyster Yale L177 Service Manual – PDF DOWNLOAD

PART NO. 524233333

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 YALE APPROVED parts when making repairs. Replacement parts must meet
or exceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using
force to remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or
if the unit needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are
flammable. Be sure to follow the necessary safety precautions when handling these fuels
and when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away
from the area. Make sure the area is well ventilated.

TABLE OF CONTENTS:

Hyster Yale L177 Service Manual – PDF DOWNLOAD

0100YRM1185...............................................................................   1
	toc...................................................................................   1
		Frame.............................................................................   1
		Safety Precautions Maintenance and Repair.........................................   2
		General...........................................................................   5
		Description.......................................................................   5
		Repairs - General.................................................................   5
			Welding.......................................................................   6
		Covers, Panels, and Plates........................................................   6
			Front Frame Panel (Left and Right)............................................   6
			Operator Compartment Cover....................................................   7
			Drive Unit Compartment Door...................................................   7
			Door Pad......................................................................   7
			Operator Back Pad.............................................................   7
			Operator Front Pad............................................................   7
			Caster Wheel Cover............................................................   7
		Load Wheels.......................................................................   8
			Remove........................................................................   8
			Install.......................................................................   8
		Overhead Guard Replacement........................................................   9
			Remove........................................................................  13
			Install.......................................................................  13
			Front Lights..................................................................  13
				Bulb Replacement..........................................................  13
				Assembly Replacement......................................................  13
				Rear Work and Caution Light...............................................  14
				Caution Light.............................................................  14
		Painting Instructions.............................................................  16
		Safety Labels Replacement.........................................................  16
0620SRM1186...............................................................................  23
	toc...................................................................................  23
		AC Motor Repair...................................................................  23
		Safety Precautions Maintenance and Repair.........................................  24
		General...........................................................................  27
		Traction Motor Repair.............................................................  27
			Disassemble...................................................................  27
			Inspect.......................................................................  29
			Assemble......................................................................  29
			Drive End Bearing, Replace....................................................  30
		Hydraulic Motor Repair............................................................  30
			Disassemble...................................................................  30
			Inspect.......................................................................  32
			Assemble......................................................................  32
		Troubleshooting...................................................................  32
0620YRM1186...............................................................................  37
	toc...................................................................................  37
		AC Motor Repair...................................................................  37
		Safety Precautions Maintenance and Repair.........................................  38
		General...........................................................................  41
		Traction Motor Repair.............................................................  42
			Disassemble...................................................................  42
			Inspect.......................................................................  43
			Assemble......................................................................  43
			Drive End Bearing, Replace....................................................  44
		Hydraulic Motor Repair............................................................  44
			Disassemble...................................................................  44
			Inspect.......................................................................  46
			Assemble......................................................................  46
		Troubleshooting...................................................................  47
	tables................................................................................  37
		Table 1. Traction Motor Windings..................................................  43
		Table 2. Hydraulic Motor Windings.................................................  46
0630YRM1022...............................................................................  51
	toc...................................................................................  51
		Master Drive Unit.................................................................  51
		Safety Precautions Maintenance and Repair.........................................  52
		HFK400 Master Drive Unit..........................................................  55
			General.......................................................................  55
			Description...................................................................  55
			Drive Unit Maintenance and Repair.............................................  55
				Remove....................................................................  55
				Install...................................................................  57
				Disassemble...............................................................  57
				Assemble..................................................................  61
			Troubleshooting...............................................................  68
		GK Master Drive Unit..............................................................  70
			General.......................................................................  70
			Description...................................................................  70
			Maintenance and Repair........................................................  71
			Install.......................................................................  72
			Assemble......................................................................  73
				Mounting Electric Motor...................................................  73
				Pivoted Connection - Geared Steering......................................  73
			Disassemble...................................................................  74
			Troubleshooting...............................................................  74
	tables................................................................................  51
		Table 1. Tooth Contact Pattern....................................................  65
1400SRM1215...............................................................................  77
	toc...................................................................................  77
		Drive Axle Repair.................................................................  77
		Safety Precautions Maintenance and Repair.........................................  78
		General...........................................................................  81
			Identification Plate..........................................................  81
		Drive Axle Removal................................................................  81
		Reduction Gear Assembly...........................................................  86
			Reduction Gear Assembly Repair................................................  86
				Remove....................................................................  89
				Clean and Inspect.........................................................  96
				Install...................................................................  97
		Brake Repair...................................................................... 106
			Wet Disc Brake................................................................ 106
				Remove.................................................................... 110
				Clean and Inspect......................................................... 116
				Install................................................................... 117
			Parking Brake Control Lever................................................... 128
				Remove.................................................................... 129
				Clean and Inspect......................................................... 131
				Install................................................................... 131
		Differential Repair............................................................... 134
			Remove........................................................................ 134
				Flange.................................................................... 134
				Differential Assembly..................................................... 135
				Bevel Pinion.............................................................. 141
			Disassemble................................................................... 145
				Differential Assembly..................................................... 145
			Clean and Inspect............................................................. 148
			Assemble...................................................................... 148
				Differential Assembly..................................................... 149
			Install....................................................................... 153
				Determine Bevel Pinion Shim Thickness..................................... 153
				Bevel Pinion.............................................................. 155
				Differential Assembly..................................................... 159
				Gear Set, Tooth Contact Pattern Check..................................... 166
				Flange.................................................................... 169
		Drive Axle Installation........................................................... 170
		Special Tools..................................................................... 176
		Torque Specifications............................................................. 179
	tables................................................................................  77
		Table 1. Bevel Gear and Bevel Pinion Tooth Contact Adjustment..................... 166
		Table 2. Correct Tooth Contact.................................................... 167
		Table 3. Incorrect Tooth Contact.................................................. 168
1600YRM1187............................................................................... 185
	toc................................................................................... 185
		Steering System................................................................... 185
		Safety Precautions Maintenance and Repair......................................... 186
		General........................................................................... 189
			Discharging the Capacitors.................................................... 190
			Raising the Lift Truck........................................................ 191
				How to Raise the Drive Tire End........................................... 191
				How to Raise the Entire Lift Truck........................................ 192
		Description....................................................................... 192
		Steering Handle Assembly.......................................................... 195
			Fixed Handle.................................................................. 195
				Description............................................................... 195
				Remove.................................................................... 195
				Disassemble............................................................... 196
				Assemble.................................................................. 199
				Install................................................................... 199
			Adjustable Handle............................................................. 199
				Description............................................................... 199
				Remove.................................................................... 200
				Disassemble............................................................... 201
				Assemble.................................................................. 204
				Install................................................................... 204
		Steering Controller............................................................... 205
			Description................................................................... 205
			Remove........................................................................ 205
			Disassemble................................................................... 206
			Assemble...................................................................... 206
			Install....................................................................... 206
		Steering Proximity Switch......................................................... 206
			Replace....................................................................... 206
		Steering Motor.................................................................... 207
			Description................................................................... 207
			Remove........................................................................ 207
			Disassemble................................................................... 208
			Assemble...................................................................... 208
			Install....................................................................... 209
		Caster Wheel Assembly (Nonsteered)................................................ 209
			Description................................................................... 209
			Remove........................................................................ 210
			Disassemble................................................................... 210
				Upper and Lower Support Housings.......................................... 210
				Spring Assembly From Lower Support Assembly............................... 211
				Spring Assembly........................................................... 211
				Caster Spindle From Lower Support......................................... 212
				Caster Wheels............................................................. 212
				Lower Support Housing..................................................... 214
				Upper Support Housing..................................................... 215
			Assemble...................................................................... 215
				Upper Support Housing..................................................... 215
				Lower Support Housing..................................................... 216
				Caster Wheels............................................................. 217
				Caster Spindle to Lower Support........................................... 217
				Spring Assembly........................................................... 217
				Spring Assembly to Lower Support.......................................... 217
				Upper and Lower Support Housings.......................................... 217
			Install....................................................................... 218
			Adjust........................................................................ 219
		Caster Assembly (Steered)......................................................... 220
			Description................................................................... 220
			Remove........................................................................ 221
			Disassemble................................................................... 222
				Upper and Lower Support................................................... 222
				Spring Assembly From Lower Support Housing................................ 223
				Spring Assembly........................................................... 223
				Caster Spindle From Lower Support......................................... 224
				Caster Wheels............................................................. 224
				Lower Support Housing..................................................... 225
				Upper Support Housing..................................................... 226
				Caster Steering Motor..................................................... 227
			Assemble...................................................................... 227
				Caster Steering Motor..................................................... 227
				Upper Support Housing..................................................... 228
				Lower Support Housing..................................................... 228
				Caster Wheels............................................................. 229
				Caster Spindle to Lower Support........................................... 230
				Spring Assembly........................................................... 230
				Spring Assembly to Lower Support.......................................... 231
				Upper and Lower Support Housings.......................................... 231
			Install....................................................................... 231
			Adjust........................................................................ 232
		Troubleshooting................................................................... 233
	tables................................................................................ 185
		Table 1. Upper Adjustment Gap Measurement......................................... 220
		Table 2. Upper Adjustment Gap Measurement......................................... 233
1800SRM1188............................................................................... 237
	toc................................................................................... 237
		Brake System...................................................................... 237
		Safety Precautions Maintenance and Repair......................................... 238
		Introduction...................................................................... 241
			General....................................................................... 241
			Discharging the Capacitors.................................................... 241
		Parking Brake..................................................................... 242
			Remove........................................................................ 243
			Install....................................................................... 244
		Troubleshooting................................................................... 244
1900SRM1189............................................................................... 247
	toc................................................................................... 247
		Hydraulic System.................................................................. 247
		Safety Precautions Maintenance and Repair......................................... 248
		General........................................................................... 251
			Discharging the Capacitors.................................................... 252
		Description....................................................................... 253
		Control Handle.................................................................... 253
			Side-Stance................................................................... 253
			Fore/Aft...................................................................... 254
		Maintenance....................................................................... 256
			Oil Level and Leaks........................................................... 256
			Operation..................................................................... 256
			Oil Change.................................................................... 256
				Drain..................................................................... 256
				Fill...................................................................... 257
					Piston Type........................................................... 258
					Displacement Type..................................................... 258
			Breather Cap.................................................................. 259
				Inspect................................................................... 259
			Oil Filter.................................................................... 259
				Change.................................................................... 259
			Oil Strainer.................................................................. 260
				Check..................................................................... 260
		Hydraulic System.................................................................. 260
			General....................................................................... 260
				Cleaning.................................................................. 260
				Noise Levels.............................................................. 261
			Hoses......................................................................... 261
			Fittings...................................................................... 263
		Lift Pump and Motor............................................................... 264
			Complete Unit................................................................. 264
				Remove.................................................................... 264
				Install................................................................... 265
			Lift Pump..................................................................... 267
				Components................................................................ 267
					Pressure Flange Fitting............................................... 267
					Supply and Return Fittings............................................ 268
					Needle Valve (Manual Lowering)........................................ 268
					Pressure Test Ports................................................... 269
					Pressure Transducer................................................... 269
					Relief Valve.......................................................... 271
					Lowering Solenoid..................................................... 271
				Remove Pump............................................................... 271
				Install Pump.............................................................. 272
		Auxiliary Pump and Motor.......................................................... 273
			Remove........................................................................ 273
			Disassemble................................................................... 274
			Assemble...................................................................... 274
			Install....................................................................... 274
		Hydraulic Tank.................................................................... 275
			Remove........................................................................ 275
			Disassemble................................................................... 276
				Breather Assembly......................................................... 276
				Filter Assembly........................................................... 277
				Float Assembly............................................................ 278
				Tank Fittings............................................................. 279
			Clean and Inspect............................................................. 279
			Assemble...................................................................... 279
				Breather Assembly......................................................... 279
				Filter Assembly........................................................... 280
				Float Assembly............................................................ 280
				Tank Fittings............................................................. 280
			Install....................................................................... 280
		Troubleshooting................................................................... 281
	tables................................................................................ 247
		Table 1. Main Lift Pump and Motor Configurations.................................. 253
		Table 2. Main Lift Cylinder Types................................................. 257
2200YRM1190............................................................................... 285
	toc................................................................................... 285
		AC Motor Controllers/Display Panel................................................ 285
		Safety Precautions Maintenance and Repair......................................... 286
		Description....................................................................... 289
			General....................................................................... 289
				AC Motors................................................................. 289
				Motor Controllers......................................................... 289
				Master Controller......................................................... 289
				Dash Display.............................................................. 290
				Controller Area Network Bus (CANBus)...................................... 290
		AC Transistor Motor Controller Replacement........................................ 290
			General....................................................................... 290
			General Maintenance Instructions.............................................. 292
				Special Precautions....................................................... 293
			Fuses......................................................................... 293
			Fan........................................................................... 294
			Contactors.................................................................... 294
				Repair.................................................................... 294
		Master Controller Checks and Adjustments.......................................... 295
		Function Settings................................................................. 295
			General....................................................................... 295
		Troubleshooting................................................................... 296
			General....................................................................... 296
			Controller Status Light Emitting Diodes (LEDs)................................ 297
				AC Master Controller...................................................... 297
				AC Motor Controllers...................................................... 297
			Status Codes.................................................................. 299
		Display Panel..................................................................... 350
			General....................................................................... 350
				Premium Display Panel..................................................... 350
				Standard Display Panel.................................................... 351
		Standard Display Functions and Features........................................... 352
			Key-On Initialization......................................................... 352
			Passwords..................................................................... 352
			Performance Modes............................................................. 352
			Battery Discharge Indication (BDI)............................................ 353
			Hourmeters.................................................................... 353
		Standard Dash Display Service Menu Navigation..................................... 353
			General....................................................................... 353
			Moving Through Menu Selections................................................ 354
			Editing and Adding Information................................................ 354
			Access to Service Functions................................................... 354
			Service Functions............................................................. 354
		Premium Display Functions and Features............................................ 356
			Key-On Initialization......................................................... 356
			Passwords..................................................................... 356
			Operator Checklist Function................................................... 357
			Performance Modes............................................................. 357
			Battery Discharge Indicator................................................... 357
			Hour Meters................................................................... 357
		Premium Dash Display Service Menu Navigation...................................... 358
			General....................................................................... 358
			Moving Through Menu Selections................................................ 358
			Access to Service Functions................................................... 358
			Service Functions............................................................. 359
	tables................................................................................ 285
		Table 1. Factory Parameter Defaults............................................... 295
		Table 2. List of Status Codes..................................................... 300
		Table 3. Password Prompt Screen................................................... 352
		Table 4. Password Reminder Screen................................................. 352
		Table 5. Password Prompt Screen................................................... 353
		Table 6. Password Prompt Screen................................................... 354
		Table 7. Password Prompt Screen................................................... 356
		Table 8. Password Reminder Screen................................................. 356
		Table 9. Password Prompt Screen................................................... 358
		Table 10. Password Prompt Screen.................................................. 358
4000SRM1250............................................................................... 363
	toc................................................................................... 363
		Mast Repairs...................................................................... 363
		Safety Precautions Maintenance and Repair......................................... 364
		Safety Procedures When Working Near Mast.......................................... 367
		Forks Repair...................................................................... 369
			Remove........................................................................ 369
			Install....................................................................... 369
			Checks........................................................................ 370
		Carriage Replacement.............................................................. 370
			Remove........................................................................ 370
			Install....................................................................... 372
		Sideshift Carriage Repair......................................................... 372
			Remove........................................................................ 372
			Disassemble................................................................... 372
			Assemble...................................................................... 373
			Install....................................................................... 373
		Two-Stage Mast With Limited Free-Lift Repair...................................... 375
			Remove........................................................................ 375
			Disassemble................................................................... 377
			Clean and Inspect............................................................. 378
			Assemble...................................................................... 383
			Install, H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 10.............. 383
			Install, S4.0, 4.5, 5.50FT, S5.5FTS ([S80, 100, 120FT;] S80, 100.............. 384
			Header Hose Alignment......................................................... 388
		Two-Stage Mast With Full Free-Lift Repair......................................... 396
			Remove........................................................................ 396
			Disassemble................................................................... 396
			Clean and Inspect............................................................. 399
			Assemble...................................................................... 400
			Install....................................................................... 401
			Header Hose Installation and Adjustment....................................... 403
				Installation.............................................................. 403
				Adjustment................................................................ 403
		Three-Stage Mast With Full Free-Lift Repair....................................... 403
			Remove........................................................................ 403
			Disassemble................................................................... 404
			Clean and Inspect............................................................. 411
			Assemble...................................................................... 413
			Install....................................................................... 413
			Header Hose Alignment for S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, .............. 417
			Header Hose Alignment for H6.0FT, H7.0FT (H135FT, H155FT) (H006).............. 424
		Mast Operation Check.............................................................. 429
		Tilt Cylinder Adjustment.......................................................... 429
		Lift Chains Adjustment............................................................ 431
		Mast Adjustments.................................................................. 432
		Carriage Adjustments.............................................................. 434
	tables................................................................................ 363
		Table 1. Fork Tip Alignment....................................................... 370
		Table 2. Standard Mast Height; Header Hose Tension Mark Location.................. 394
		Table 3. Standard Mast Height; Header Hose Tension Mark Location.................. 394
		Table 4. Standard Mast Height; Header Hose Tension Mark Location.................. 395
		Table 5. Standard Mast Height; Header Hose Tension Mark Location.................. 395
		Table 6. Standard Mast Height; Header Hose Tension Mark Location.................. 395
		Table 7. Standard Mast Height; Header Hose Tension Mark Location.................. 422
		Table 8. Standard Mast Height; Header Hose Tension Mark Location.................. 423
		Table 9. Standard Mast Height; Header Hose Tension Mark Location.................. 423
		Table 10. Hook-Type Carriage Chain Adjustment..................................... 432
910442-8000SRM0231-(12-2004)-US-EN........................................................ 437
	toc................................................................................... 437
		Metric and Inch (SAE) Fasteners................................................... 437
		Safety Precautions Maintenance and Repair......................................... 438
		General........................................................................... 441
			Threaded Fasteners............................................................ 441
			Nomenclature, Threads......................................................... 441
			Strength Identification....................................................... 442
			Cotter (Split) Pins........................................................... 442
			Fastener Torque Tables........................................................ 447
			Conversion Table.............................................................. 449
	tables................................................................................ 437
		Table 1. Bolts and Screws......................................................... 443
		Table 2. Studs and Nuts........................................................... 444
		Table 3. Torque Nuts.............................................................. 445
		Table 4. Torque Nuts With Nylon Insert............................................ 446
		Table 5. Torque Values for Metric Fasteners*...................................... 447
		Table 6. Torque Values for Inch Fasteners*........................................ 448
		Table 7. Conversion Table for Metric and English Units............................ 449
		Table 8. Cotter Pin Dimensional Data.............................................. 450
		Table 9. Cotter Pin Dimensional Data.............................................. 451
		Table 10. Cotter Pin Dimensional Data............................................. 452
		Table 11. Cotter Pin Dimensional Data............................................. 454
1579259-9000SRM1112-(07-2007)-US-EN....................................................... 459
	toc................................................................................... 459
		Diagnostic Troubleshooting Manual................................................. 459
		Safety Precautions TROUBLESHOOTING PROCEDURES..................................... 460
		How To Use This Troubleshooting Manual............................................ 462
			General Instructions and Safety Information................................... 462
			How to Use Diagnostic Troubleshooting Manual.................................. 462
			General Instructions.......................................................... 463
		Operational Diagnostic Procedures................................................. 465
			Operational Checkout Procedures............................................... 467
				DTC Check................................................................. 468
				Horn Circuit Check........................................................ 468
				Light Circuit Check....................................................... 468
				Windshield Washer Wiper Check (If equipped)............................... 468
				Heater Check (If equipped)................................................ 469
				Dome Light Check (If equipped)............................................ 469
				Circulating (Accessory) Fan Check (If equipped)........................... 470
				Indicator Light Power Check............................................... 471
				Operator Presence System Check............................................ 472
				Engine Malfunction Indicator Check........................................ 472
				Cold Start Check (Cummins and Yanmar)..................................... 472
				Brake Pedal Check......................................................... 473
				Backup Alarm Check (If equipped).......................................... 473
				Armrest Hydraulic Interlock Check (If equipped and with original.......... 473
				Engine Cover Latch Sensor Check (If equipped)............................. 474
				Brake and Inching Pedal Check............................................. 474
				Park Brake Sensor Check................................................... 474
				Park Brake Check.......................................................... 475
				Engine Speed Check (All Cummins, Yanmar, and Mazda Engines Excep.......... 475
				Engine Power Check........................................................ 476
				Transmission Clutch Check................................................. 476
				Transmission Check........................................................ 477
				Transmission Speed Selection Check (If equipped).......................... 477
				Brake and Axle Drag Check................................................. 477
				Hydraulic Pump Flow Check................................................. 478
				Priority Flow Divider Valve Check......................................... 479
				Steering Relief Valve Low Pressure Check.................................. 479
				Steering Relief Valve High Pressure Check................................. 480
				Control Valve Load Check Valve (Manual Valve)............................. 480
				Tilt Function Counterbalance Check........................................ 480
				Lift Drift Check.......................................................... 481
				Tilt Function Drift Check................................................. 481
				Mast Cushion Check (All Except 2-Stage Mast).............................. 482
				Lift/Tilt Mast Adjustment Check........................................... 482
				Tilt Racking Check........................................................ 483
				Chain and Header Hose Adjustment Check.................................... 483
				Mast Mounting Check....................................................... 484
				Mast Channel Check........................................................ 484
				Carriage Adjustment Check................................................. 484
				Chain Sheave Check........................................................ 485
				Carriage Adjustment Check (Standard and Integral Side Shift).............. 485
		Engine............................................................................ 487
			Engine Basics................................................................. 493
				General Terminology....................................................... 493
				Combustion Theory......................................................... 493
				Engine Components – Cylinder Block........................................ 494
				Camshaft and Timing Set................................................... 495
				Cylinder Head Assembly.................................................... 495
				Valve Train Assembly...................................................... 495
				Air Cleaner/Filter........................................................ 495
				Carburetion............................................................... 495
				Electronic Fuel Injection (EFI)........................................... 495
				Positive Crankcase Ventilation (PCV)...................................... 496
			Engine Electrical............................................................. 496
				Introduction.............................................................. 496
				Battery Construction...................................................... 496
				Conventional Standard Battery............................................. 497
				Maintenance-Free Battery.................................................. 497
				Battery Charging.......................................................... 497
				Battery Fast Charging..................................................... 498
				Battery Slow Charging..................................................... 498
				Starting System Principles of Operation................................... 498
				Starting System Components - Ignition Switch.............................. 499
				Starting System Components - Starter Solenoid............................. 499
				Starting System Components - Flywheel and Ring Gear....................... 499
				Starting System Components - Starter Motor and Drive...................... 499
				Charging System - General................................................. 500
				Charging System - Regulator............................................... 500
				Charging System - Theory.................................................. 500
			Engine Fuel System/Exhaust and Emissions...................................... 501
				Introduction.............................................................. 501
				Gasoline System Components - Fuel Tank.................................... 501
				Electronic Fuel Injector (EFI) - General Description...................... 501
				Port Fuel System Components - ECU......................................... 501
				Port Fuel System Components - Fuel Pump/Filter............................ 501
				Port Fuel System Components - Fuel Rail................................... 501
				Port Fuel System Components - Pressure Regulator.......................... 502
				Port Fuel System Components - Fuel Injectors.............................. 502
				LPG Systems General Information........................................... 502
				LPG Fuel Properties....................................................... 502
				LPG Fuel Tank............................................................. 502
				AISAN Closed-Loop System.................................................. 503
					Filter/Lockoff and Regulator.......................................... 503
					Carburetor............................................................ 503
					Start Mode............................................................ 503
					Idle Mode............................................................. 504
					Run Mode.............................................................. 504
				Main Fuel Lockoff Solenoid................................................ 504
				Injector Fuel Lockoff Solenoid............................................ 504
					Oxygen (O 2 ) Sensor.................................................. 504
				Electronic Control Unit (ECU)............................................. 504
				Catalytic Converter/Muffler............................................... 504
			Engine Management............................................................. 505
				Introduction.............................................................. 505
				Ignition and Timing - Conventional Spark.................................. 505
				Components - Ignition Coil................................................ 505
				Components - Distributor.................................................. 505
				Spark Timing.............................................................. 505
				Components - Ignition Wires............................................... 505
				Components - Spark Plugs.................................................. 506
				Faulty or Fouled Spark Plugs.............................................. 506
				Electric Controlled Governing System - Mazda LPG.......................... 506
			Engine Identification......................................................... 506
			Cummins (Diesel) Engine....................................................... 509
				Description............................................................... 509
				Diesel Fuel System........................................................ 510
					Principle of Operation................................................ 510
				Fuel Injection Pump and Governor.......................................... 511
					Description........................................................... 511
					Principles of Operation............................................... 512
				Cummins Engine Control.................................................... 513
					Engine Speed (RPM) Sensor............................................. 514
					Throttle Position Sensor.............................................. 515
					Electronic Throttle Actuator.......................................... 516
					Engine Oil Pressure Sensor............................................ 516
					Coolant Temperature Sensor............................................ 516
					Air Restriction Switch................................................ 517
					Fuel Filter/Water Separator........................................... 517
					Fuel Level Sensor (In Tank)........................................... 517
				Engine Electrical System.................................................. 518
					Magnetic Valve (Engine Stop Solenoid)................................. 518
					Alternator............................................................ 518
					Grid Heater........................................................... 518
					Cold Start Timing Advance (Fuel Injection Pump)....................... 518
			Mazda Engine Overview......................................................... 519
				Description............................................................... 519
				Fuel System............................................................... 519
				Engine Controls Unit (ECU) and Emissions.................................. 519
				Cooling System............................................................ 519
				Ignition System........................................................... 519
			Mazda (LPG) Engine Controls................................................... 520
				LPG System (Aisan/E-Controls-Mechanical).................................. 520
					Description........................................................... 520
					Principles of Operation............................................... 521
					Control System........................................................ 524
					Oxygen (O 2 ) Sensor.................................................. 525
					Fuel Tank............................................................. 525
					Regulator............................................................. 526
						Start Mode........................................................ 526
						Idle Mode......................................................... 526
						Run Mode.......................................................... 527
					Resonator............................................................. 528
					Carburetor............................................................ 528
						Start Mode........................................................ 528
						Idle Mode......................................................... 529
						Run Mode.......................................................... 529
					Governor.............................................................. 529
				LPG System (E-Controls)................................................... 530
					Description........................................................... 530
					Principles of Operation............................................... 531
					Manifold Absolute Pressure Sensor..................................... 531
					Throttle Position Sensor.............................................. 531
					Oxygen (O 2 ) Sensor.................................................. 532
					Engine Coolant Temperature Sensor..................................... 532
					Intake Air Temperature Sensor......................................... 532
					Engine Control Unit................................................... 532
					Accelerator Pedal Position Sensor..................................... 532
					Three-Way Catalytic Converter......................................... 532
					Camshaft Position Sensor.............................................. 532
					Electric Controlled Governing System.................................. 534
					Electronic Governor Sensor............................................ 534
			Mazda (Gasoline) Engine Controls.............................................. 535
				Gasoline System........................................................... 535
					Description........................................................... 535
					Principles of Operation............................................... 536
				Control System............................................................ 538
					Camshaft Position Sensor.............................................. 539
					Intake Air Temperature Sensor......................................... 540
					Mass Air Flow Sensor.................................................. 541
					Throttle Position Sensor.............................................. 542
					Electronic Governor Sensor............................................ 543
					Electronic Governing System........................................... 544
					Manifold Absolute Pressure Sensor/Boost Sensor........................ 544
					Engine Coolant Temperature Sensor..................................... 545
				Intake Air System......................................................... 546
					Throttle Body......................................................... 546
					Idle Air Control Valve................................................ 547
				Fuel System............................................................... 548
					Fuel Injector......................................................... 548
					Pressure Regulator.................................................... 549
				Exhaust System............................................................ 550
					Heated Oxygen (O 2 ) Sensor........................................... 550
					Three-Way Catalytic Converter......................................... 551
			GM (LPG) Engine Controls...................................................... 552
				Engine Control System .................................................... 552
					Engine Control System Overview........................................ 553
					Principles of Operation............................................... 553
				Control System............................................................ 554
					GM/TGFI 2.4L (Four Cylinder) Control System Component Location........ 554
					GM/TGFI 4.3L (Six Cylinder) Control System Component Location......... 555
					GM/TGFI 2.4L (Four-Cylinder) LPG System............................... 556
					GM/TGFI 4.3L (Six-Cylinder) LPG System................................ 558
					Fuel Tank............................................................. 560
					Engine Control Unit................................................... 560
					Electronic Throttle Body/Throttle Position Sensor..................... 561
					Manifold Absolute Pressure/Manifold Air Temperature Sensor............ 561
					Propane Injectors..................................................... 562
					Engine Coolant Temperature Sensor..................................... 564
					Oxygen (O 2 ) Sensor.................................................. 564
					Crankshaft Position Sensor (Engine Speed Sensor)...................... 565
					Oil Pressure Sensor................................................... 565
					Power Latch Relay..................................................... 565
					GM 2.4L Camshaft Position Sensor...................................... 565
					GM 4.3L Camshaft Position Sensor...................................... 566
					Injector Driver Module................................................ 567
					Vaporizer/Regulator................................................... 567
					Accelerator Pedal Position Sensor..................................... 570
					Three-Way Catalytic Converter......................................... 570
				Ignition System........................................................... 571
					Ignition Coils........................................................ 571
					Distributorless Ignition System Module................................ 571
					Electronic Ignition Signals........................................... 572
					Distributor Ignition (DI) System...................................... 573
					Camshaft Position (CMP) Sensor........................................ 573
					Ignition Coil and Ignition Control Module (ICM)....................... 573
					Secondary Ignition Components......................................... 573
			GM (Gasoline) Engine Controls................................................. 574
				Engine Control System..................................................... 574
					GM 2.4L (Four Cylinder) Engine Control System......................... 574
					GM 4.3L (Six Cylinder) Engine Control System.......................... 575
					Engine Control System Overview........................................ 576
					Principles of Operation............................................... 576
				Control System............................................................ 576
					GM/TGFI 2.4L (Four Cylinder) Control System Component Location........ 576
					GM/TGFI 4.3L (Six Cylinder) Control System Component Location......... 578
					GM/TGFI 2.4L (Four-Cylinder) Gasoline System Components............... 579
					GM/TGFI 4.3L (Six Cylinder) Gasoline System Components................ 581
					Engine Control Unit................................................... 583
					Electronic Throttle Body/Throttle Position Sensor..................... 583
					Manifold Absolute Pressure/Manifold Air Temperature Sensor ........... 584
					Fuel Injector......................................................... 585
					Engine Coolant Temperature Sensor..................................... 586
					Oxygen (O 2 ) Sensor.................................................. 587
					Crankshaft Position Sensor (Engine Speed Sensor)...................... 587
					Oil Pressure Sensor................................................... 587
					Power Latch Relay..................................................... 587
					Camshaft Position Sensor.............................................. 587
					Accelerator Pedal Position Sensor..................................... 589
					Three-Way Catalytic Converter......................................... 589
				Ignition System........................................................... 589
					Ignition Coils........................................................ 589
					Distributorless Ignition System Module................................ 589
					Electronic Ignition Signals........................................... 590
			Yanmar (Diesel) Engine........................................................ 591
				Description............................................................... 591
				Diesel Fuel System........................................................ 592
					Principles of Operation............................................... 592
				Fuel Injection Pump and Governor.......................................... 593
					Description........................................................... 593
					Principles of Operation............................................... 595
					Timer................................................................. 596
					Feed Pump (Vane Type)................................................. 596
					Regulating Valve...................................................... 597
					Injection Pump Plunger................................................ 598
						Suction Process................................................... 599
						Injection Process................................................. 599
						End of Injection.................................................. 600
						Uniform Pressure Process.......................................... 600
					Reverse Rotation Prevention Mechanism................................. 601
					Fuel Injection Volume Adjustment Mechanism............................ 601
					Delivery Valve Assembly............................................... 602
					Delivery Valve Holder with Damping Valve.............................. 602
					All - Speed Governor.................................................. 603
					At Start of Engine.................................................... 605
					During Idle........................................................... 606
					At Full - Load Maximum Speed Control.................................. 607
					At No-Load Maximum Speed Control...................................... 608
					Full-Load Position Adjustment Mechanism............................... 609
				Structure and Operation of Timer.......................................... 610
					Standard Type Automatic Timer......................................... 610
				Yanmar Engine Controls.................................................... 611
					Engine Speed (RPM) Sensor............................................. 612
					Throttle Position Sensor.............................................. 612
					Electronic Throttle Actuator.......................................... 613
					Engine Oil Pressure Sensor............................................ 613
					Coolant Temperature Sensor............................................ 614
					Air Filter Restriction Switch......................................... 615
					Fuel Filter/Water Separator and Strainer.............................. 615
					Fuel Level Sensor..................................................... 615
				Engine Electrical System.................................................. 616
					Magnetic Valve (Engine Stop Solenoid)................................. 616
					Alternator............................................................ 616
					Glow Plugs............................................................ 616
					Cold Start Timing Advance (Fuel Injection Pump)....................... 616
			Cooling System - All Engines.................................................. 617
				Description............................................................... 617
				Radiator.................................................................. 617
					Combination Cooler/Standard Radiator.................................. 618
				Radiator Cap.............................................................. 618
				Thermostat................................................................ 618
				Engine Coolant Pump....................................................... 619
				Fan....................................................................... 619
				GM Engine Coolant Flow Diagram............................................ 619
				Yanmar Diesel Engine Coolant Flow Diagram................................. 620
			Engine Does Not Crank......................................................... 621
			Engine Does Not Start/Engine is Hard to Start................................. 624
			Engine Idle Speed Incorrect................................................... 630
			Engine Idle Speed is Unstable or Engine Stalls at Idle........................ 633
			Engine Cuts Out, Misses, Hesitates, Sags, or Stumbles......................... 638
			Engine Lack of Power.......................................................... 644
			Engine Speed Surge Or Engine Speed Unstable................................... 651
			Engine Backfires.............................................................. 655
			Engine Is Knocking or Pinging................................................. 658
			Excessive Engine Vibrations................................................... 662
			Abnormal Engine and Exhaust Noises............................................ 666
			Fan or Alternator Bearing Noise............................................... 670
			Abnormal Engine and Exhaust Smells............................................ 672
			High Engine Fuel Consumption.................................................. 674
			Fuel Leaks.................................................................... 677
			High Engine Oil Consumption................................................... 680
			Engine Oil Leaks.............................................................. 682
			Engine Oil is Discolored...................................................... 686
			Engine Coolant Leaks.......................................................... 688
			Engine Coolant is Discolored.................................................. 691
			Engine Exhaust is Discolored.................................................. 692
			Engine Fails Emission Compliance Check........................................ 696
			Alternator Light is Illuminated............................................... 700
			Engine is Overheating......................................................... 701
			Engine Coolant Temperature is Low............................................. 704
			Engine Oil Pressure is Low.................................................... 705
			Radiator Bubble Test.......................................................... 707
			Engine Compression Test (GM and Mazda)........................................ 708
			Engine Compression Test (Yanmar Diesel)....................................... 709
			Engine Oil Pressure Test...................................................... 710
			Fuel System Pressure Test (Gasoline Engines Only)............................. 712
			Fuel Injection Nozzle Test (Yanmar Diesel).................................... 714
			Vacuum Leak................................................................... 715
				Vacuum Leak Detection..................................................... 715
				Vacuum Leak Repairs....................................................... 715
			Coolant System Test........................................................... 716
		Electrical System................................................................. 717
			Troubleshooting Guidelines and Procedures..................................... 731
				Troubleshooting Guidelines................................................ 731
				Troubleshooting Procedures................................................ 734
					Troubleshooting Procedures, Identification............................ 734
					Troubleshooting Procedures, Location.................................. 734
					Troubleshooting Procedures, Structure................................. 735
					Troubleshooting Procedures, Performance............................... 736
			Diagnostic Trouble Codes...................................................... 736
				Diagnostic Trouble Codes.................................................. 736
			Wiring Reference Data......................................................... 746
			Harness Assembly Data......................................................... 749
			Electrical System............................................................. 795
				General Description....................................................... 795
				Description............................................................... 796
				Principles of Operation, Components....................................... 800
				Principles Of Operation, System........................................... 808
			100-2......................................................................... 815
			100-3......................................................................... 815
			523859-3...................................................................... 815
			524223-3...................................................................... 815
			524224-3...................................................................... 815
			524225-3...................................................................... 815
			524282-3...................................................................... 815
			523958-3...................................................................... 815
			523959-3...................................................................... 815
			100-4......................................................................... 823
			523859-4...................................................................... 823
			523958-4...................................................................... 823
			523959-4...................................................................... 823
			524223-4...................................................................... 823
			524224-4...................................................................... 823
			524225-4...................................................................... 823
			524282-4...................................................................... 823
			524223-0...................................................................... 831
			524224-0...................................................................... 831
			524225-0...................................................................... 831
			524229-0...................................................................... 831
			524270-0...................................................................... 831
			524276-0...................................................................... 831
			524223-1...................................................................... 835
			524224-1...................................................................... 835
			524225-1...................................................................... 835
			524229-1...................................................................... 835
			524270-1...................................................................... 835
			524276-1...................................................................... 835
			110-3......................................................................... 839
			110-5......................................................................... 839
			177-3......................................................................... 839
			522231-3...................................................................... 839
			522555-3...................................................................... 839
			522603-3...................................................................... 839
			524235-3...................................................................... 839
			110-4......................................................................... 847
			177-4......................................................................... 847
			522231-4...................................................................... 847
			522555-4...................................................................... 847
			522603-4...................................................................... 847
			524235-4...................................................................... 847
			110-2......................................................................... 855
			110-10........................................................................ 858
			522712-3...................................................................... 862
			522713-3...................................................................... 862
			522712-4...................................................................... 869
			522713-4...................................................................... 869
			51-2.......................................................................... 876
			51-7.......................................................................... 876
			91-2.......................................................................... 883
			522708-3...................................................................... 888
			522710-3...................................................................... 888
			522711-3...................................................................... 888
			522714-3...................................................................... 888
			522708-4...................................................................... 895
			522710-4...................................................................... 895
			522711-4...................................................................... 895
			522714-4...................................................................... 895
			515-0......................................................................... 901
			523780-3...................................................................... 903
			523860-3...................................................................... 903
			524245-3...................................................................... 903
			524275-3...................................................................... 903
			523780-4...................................................................... 909
			523860-4...................................................................... 909
			524245-4...................................................................... 909
			524275-4...................................................................... 909
			677-3......................................................................... 914
			2350-3........................................................................ 914
			522754-3...................................................................... 914
			522755-3...................................................................... 914
			522764-3...................................................................... 914
			522766-3...................................................................... 914
			524230-3...................................................................... 914
			SYMPTOMS WARNING.............................................................. 914
			677-4......................................................................... 920
			2350-4........................................................................ 920
			522754-4...................................................................... 920
			522755-4...................................................................... 920
			522764-4...................................................................... 920
			522766-4...................................................................... 920
			524230-4...................................................................... 920
			676-3......................................................................... 924
			524195-3...................................................................... 924
			524269-3...................................................................... 924
			676-4......................................................................... 930
			524195-4...................................................................... 930
			524269-4...................................................................... 930
			524269-7...................................................................... 936
			524215-3...................................................................... 938
			524215-6...................................................................... 938
			524237-3...................................................................... 942
			524238-3...................................................................... 942
			524240-3...................................................................... 942
			524237-4...................................................................... 947
			524238-4...................................................................... 947
			524240-4...................................................................... 947
			879-3......................................................................... 952
			880-3......................................................................... 952
			881-3......................................................................... 952
			882-3......................................................................... 952
			522772-3...................................................................... 952
			879-4......................................................................... 956
			880-4......................................................................... 956
			881-4......................................................................... 956
			882-4......................................................................... 956
			522772-4...................................................................... 956
			168-0......................................................................... 960
			168-3......................................................................... 960
			521982-3...................................................................... 963
			522760-3...................................................................... 963
			522761-3...................................................................... 963
			522762-3...................................................................... 963
			522128-3...................................................................... 972
			524251-0...................................................................... 972
			524260-0...................................................................... 972
			524260-3...................................................................... 972
			524261-0...................................................................... 972
			524261-3...................................................................... 972
			168-1......................................................................... 981
			168-4......................................................................... 981
			521982-4...................................................................... 984
			522760-4...................................................................... 984
			522761-4...................................................................... 984
			522761-6...................................................................... 984
			522762-4...................................................................... 984
			522128-4...................................................................... 991
			524251-1...................................................................... 991
			524260-1...................................................................... 991
			524260-4...................................................................... 991
			524261-1...................................................................... 991
			524261-4...................................................................... 991
			524260-2......................................................................1001
			524260-11.....................................................................1001
			524261-2......................................................................1001
			524261-11.....................................................................1001
			96-3..........................................................................1005
			96-4..........................................................................1005
			522810-4......................................................................1009
			524213-1......................................................................1013
			524213-3......................................................................1013
			524213-4......................................................................1013
			523920-3......................................................................1016
			523925-3......................................................................1016
			523930-3......................................................................1016
			523977-3......................................................................1016
			523978-3......................................................................1016
			523986-3......................................................................1016
			524284-3......................................................................1016
			524285-3......................................................................1016
			523920-4......................................................................1022
			523925-4......................................................................1022
			523930-4......................................................................1022
			523977-4......................................................................1022
			523978-4......................................................................1022
			523986-4......................................................................1022
			524284-4......................................................................1022
			524285-4......................................................................1022
			523920-6......................................................................1027
			523925-6......................................................................1027
			523930-6......................................................................1027
			523977-6......................................................................1027
			523978-6......................................................................1027
			523986-6......................................................................1027
			524284-6......................................................................1027
			524285-6......................................................................1027
			105-3.........................................................................1031
			522570-3......................................................................1031
			105-4.........................................................................1036
			522570-4......................................................................1036
			105-5.........................................................................1040
			106-3.........................................................................1043
			106-4.........................................................................1047
			106-0.........................................................................1051
			106-1.........................................................................1051
			106-2.........................................................................1051
			106-14........................................................................1051
			522739-3......................................................................1054
			522739-5......................................................................1058
			522739-6......................................................................1062
			522735-2......................................................................1066
			522735-4......................................................................1069
			522735-5......................................................................1072
			522735-6......................................................................1075
			522630-2......................................................................1079
			522631-2......................................................................1079
			522632-2......................................................................1079
			522633-2......................................................................1079
			522635-3......................................................................1079
			522636-4......................................................................1079
			522637-3......................................................................1079
			522638-4......................................................................1079
			522606-10.....................................................................1083
			522737-10.....................................................................1083
			651-3.........................................................................1086
			652-3.........................................................................1086
			653-3.........................................................................1086
			654-3.........................................................................1086
			655-3.........................................................................1086
			656-3.........................................................................1086
			522599-3......................................................................1086
			522600-3......................................................................1086
			522601-3......................................................................1086
			522602-3......................................................................1086
			522721-3......................................................................1086
			522722-3......................................................................1086
			522723-3......................................................................1086
			522724-3......................................................................1086
			522725-3......................................................................1086
			522726-3......................................................................1086
			522599-3......................................................................1086
			522600-3......................................................................1086
			522601-3......................................................................1086
			522602-3......................................................................1086
			651-5.........................................................................1093
			652-5.........................................................................1093
			653-5.........................................................................1093
			654-5.........................................................................1093
			655-5.........................................................................1093
			656-5.........................................................................1093
			522721-5......................................................................1093
			522722-5......................................................................1093
			522723-5......................................................................1093
			522724-5......................................................................1093
			522725-5......................................................................1093
			522726-5......................................................................1093
			651-6.........................................................................1098
			652-6.........................................................................1098
			653-6.........................................................................1098
			654-6.........................................................................1098
			655-6.........................................................................1098
			656-6.........................................................................1098
			522599-4......................................................................1098
			522600-4......................................................................1098
			522601-4......................................................................1098
			522602-4......................................................................1098
			522721-6......................................................................1098
			522722-6......................................................................1098
			522723-6......................................................................1098
			522724-6......................................................................1098
			522725-6......................................................................1098
			522726-6......................................................................1098
			2000-9........................................................................1106
			2000-12.......................................................................1106
			2000-12.......................................................................1106
			2000-12.......................................................................1106
			2000-12.......................................................................1106
			2000-14.......................................................................1106
			2003-12.......................................................................1106
			2023-12.......................................................................1106
			2039-2........................................................................1106
			2039-12.......................................................................1106
			2235-12.......................................................................1106
			2236-12.......................................................................1106
			2238-12.......................................................................1106
			521670-12.....................................................................1106
			524258-2......................................................................1106
			522215-12.....................................................................1114
			522215-14.....................................................................1114
			524236-14.....................................................................1114
			524262-12.....................................................................1114
			524262-14.....................................................................1114
			524263-1......................................................................1114
			524268-12.....................................................................1114
			628-12........................................................................1116
			630-12........................................................................1116
			522690-2......................................................................1116
			522690-12.....................................................................1116
			522691-2......................................................................1116
			522691-12.....................................................................1116
			522692-2......................................................................1116
			522693-12.....................................................................1116
			522694-12.....................................................................1116
			522695-2......................................................................1116
			522696-2......................................................................1116
			522697-12.....................................................................1116
			522698-2......................................................................1116
			522699-2......................................................................1116
			522700-2......................................................................1116
			190-2.........................................................................1118
			190-7.........................................................................1118
			522120-1......................................................................1118
			522585-2......................................................................1118
			522752-9......................................................................1124
			524249-2......................................................................1127
			524250-2......................................................................1127
			524264-2......................................................................1127
			524264-14.....................................................................1127
			524265-2......................................................................1127
			524271-2......................................................................1127
			524225-14.....................................................................1127
			628-12........................................................................1132
			630-12........................................................................1132
			2660-3........................................................................1132
			2660-4........................................................................1132
			2661-3........................................................................1132
			2661-4........................................................................1132
			2802-12.......................................................................1132
			523510-12.....................................................................1132
			523511-12.....................................................................1132
			523515-3......................................................................1132
			523515-4......................................................................1132
			523519-3......................................................................1132
			523519-4......................................................................1132
			2802-12.......................................................................1134
			628-12........................................................................1134
			630-12........................................................................1134
			523261-3......................................................................1134
			523261-4......................................................................1134
			523257-3......................................................................1134
			523257-4......................................................................1134
			523253-3......................................................................1134
			523253-4......................................................................1134
			523249-3......................................................................1134
			523249-4......................................................................1134
			522780-3......................................................................1136
			522781-3......................................................................1136
			522780-4......................................................................1140
			522781-4......................................................................1140
			522780-2......................................................................1143
			522781-2......................................................................1143
			111-1.........................................................................1146
			524252-2......................................................................1150
			524253-14.....................................................................1152
			524255-2......................................................................1153
			108-0.........................................................................1154
			108-1.........................................................................1154
			522655-0......................................................................1157
			522655-1......................................................................1157
			522660-0......................................................................1157
			522660-1......................................................................1157
			524212-2......................................................................1161
			524211-2......................................................................1161
			524210-2......................................................................1161
			524209-2......................................................................1161
			524208-2......................................................................1161
			524207-2......................................................................1161
			524206-2......................................................................1161
			524205-2......................................................................1161
			524204-2......................................................................1161
			524203-2......................................................................1161
			524202-2......................................................................1161
			524201-2......................................................................1161
			524200-2......................................................................1161
			524199-2......................................................................1161
			524198-2......................................................................1161
			524197-2......................................................................1161
			522800-13.....................................................................1163
			522801-13.....................................................................1165
			522130-0......................................................................1166
			522131-0......................................................................1166
			522132-0......................................................................1166
			522133-0......................................................................1166
			522134-0......................................................................1166
			522130-1......................................................................1170
			522131-1......................................................................1170
			522132-1......................................................................1170
			522133-1......................................................................1170
			522134-1......................................................................1170
			522130-3......................................................................1175
			522131-3......................................................................1175
			522132-3......................................................................1175
			522133-3......................................................................1175
			522134-3......................................................................1175
			522130-4......................................................................1180
			522131-4......................................................................1180
			522132-4......................................................................1180
			522133-4......................................................................1180
			522134-4......................................................................1180
			522135-0......................................................................1184
			522137-0......................................................................1184
			522138-0......................................................................1184
			522135-1......................................................................1188
			522137-1......................................................................1188
			522138-1......................................................................1188
			522135-3......................................................................1192
			522137-3......................................................................1192
			522138-3......................................................................1192
			522135-4......................................................................1196
			522137-4......................................................................1196
			522138-4......................................................................1196
			522135-2......................................................................1200
			522137-2......................................................................1200
			522122-0......................................................................1207
			522124-0......................................................................1207
			522125-0......................................................................1207
			522126-0......................................................................1207
			522127-0......................................................................1207
			522122-1......................................................................1211
			522124-1......................................................................1211
			522125-1......................................................................1211
			522126-1......................................................................1211
			522127-1......................................................................1211
			522122-6......................................................................1215
			522124-6......................................................................1215
			522125-6......................................................................1215
			522126-6......................................................................1215
			522127-6......................................................................1215
			522122-8......................................................................1220
			522124-8......................................................................1220
			522125-8......................................................................1220
			522126-8......................................................................1220
			522127-8......................................................................1220
			522129-3......................................................................1224
			522129-4......................................................................1224
			522197-0......................................................................1226
			522198-0......................................................................1226
			522199-0......................................................................1226
			522200-0......................................................................1226
			522201-0......................................................................1226
			522197-1......................................................................1229
			522198-1......................................................................1229
			522199-1......................................................................1229
			522200-1......................................................................1229
			522201-1......................................................................1229
			522197-6......................................................................1230
			522198-6......................................................................1230
			522199-6......................................................................1230
			522200-6......................................................................1230
			522201-6......................................................................1230
			522197-7......................................................................1231
			522198-7......................................................................1231
			522199-7......................................................................1231
			522200-7......................................................................1231
			522201-7......................................................................1231
			522197-8......................................................................1232
			522198-8......................................................................1232
			522199-8......................................................................1232
			522200-8......................................................................1232
			522201-8......................................................................1232
			522197-14.....................................................................1234
			522198-14.....................................................................1234
			522199-14.....................................................................1234
			522200-14.....................................................................1234
			522201-14.....................................................................1234
			522197-27.....................................................................1235
			522198-27.....................................................................1235
			522199-27.....................................................................1235
			522200-27.....................................................................1235
			522201-27.....................................................................1235
			2039-2........................................................................1238
			522540-3......................................................................1241
			522540-4......................................................................1244
			522604-3......................................................................1248
			522604-4......................................................................1252
			522604-5......................................................................1256
			522697-12.....................................................................1261
			190-2.........................................................................1262
			190-4.........................................................................1262
			190-8.........................................................................1262
			522752-2......................................................................1262
			522752-4......................................................................1262
			522752-5......................................................................1268
			522598-3......................................................................1271
			522598-4......................................................................1274
			522592-0......................................................................1278
			522592-1......................................................................1280
			522593-12.....................................................................1282
			522594-12.....................................................................1286
			522595-12.....................................................................1286
			522596-12.....................................................................1286
			522597-12.....................................................................1286
			Engine Continues to Run When Engine Cover is Raised...........................1289
			Engine Stops or Fails to Start................................................1291
			Electrical Functions Do Not Operate...........................................1293
			Electrical Function Does Not Turn Off.........................................1298
			Electro-Hydraulics Do Not Function With Armrest Down .........................1304
			Electro-Hydraulics Can Still Function With Armrest Raised.....................1307
			Vehicle Does Not Power On.....................................................1310
			Heater Fan Does Not Operate Properly..........................................1316
			Heater Airflow Does Not Reach Desired Temperature.............................1319
			Heater Output Has Insufficient Airflow........................................1320
			Circulating (Accessory) Fan Inoperative.......................................1321
			Dome Light Inoperative........................................................1324
			Horn Failure..................................................................1327
		Drive Train.......................................................................1331
			Mechanical Overview...........................................................1335
			Engine........................................................................1335
				Description...............................................................1335
			Torque Converter..............................................................1335
				Description...............................................................1335
					Stator................................................................1336
					Turbine...............................................................1336
			Pump PTO......................................................................1337
				Chain Drive PTO...........................................................1337
				Spur Gear PTO.............................................................1338
			Transmission..................................................................1339
				Description...............................................................1339
				1.0-5.5 Ton Lift Truck Transmissions......................................1342
					Description...........................................................1342
						Single-Speed......................................................1342
						Two-Speed.........................................................1343
					Clutch Pack...........................................................1344
					Power Flow............................................................1346
						Single-Speed......................................................1346
						Two-Speed.........................................................1347
					Transmission Hydraulic Schematic......................................1349
					Transmission Oil Flow.................................................1350
					Control Valve Oil Flow................................................1350
				6.0-7.0 Ton Lift Truck Transmissions......................................1351
					Description...........................................................1351
						Two-Speed.........................................................1351
						Three-Speed.......................................................1351
					Clutch Pack...........................................................1353
						Input Shaft and Range Clutches....................................1353
						Directional Clutches..............................................1353
						Output Section....................................................1354
					Power Flow............................................................1354
						Two-Speed and Three-Speed.........................................1354
					Transmission Hydraulic Schematic......................................1358
						Two-Speed.........................................................1358
						Three-Speed.......................................................1360
			Transmission Control System Overview..........................................1362
				Transmission Control System...............................................1362
			Transmission Control Software.................................................1364
				Transmission Control Modes................................................1364
					Neutral...............................................................1364
					Gear Engagement Control...............................................1365
						Basic Powershift Gear Engagement Mode.............................1365
						DuraMatch™ and Electronic Extended Features Gear Engagement Mo....1365
					Normal Forward or Reverse.............................................1365
						Basic Powershift..................................................1365
						DuraMatch™ and Electronic Extended Features Transmission..........1365
					Auto-Shift............................................................1365
					1st Gear Lock.........................................................1365
					Inching...............................................................1365
						Basic Powershift Inching Mode.....................................1365
						DuraMatch™ Inching Mode...........................................1365
						Electronic Extended Features Inching Mode.........................1366
					Inch/Brake Overlap Adjustment.........................................1366
					Brake Wear Compensation...............................................1366
					Auto Decel............................................................1366
					Controlled Power Reversal.............................................1367
						Basic Multi-Speed.................................................1367
						Electronic Extended Features......................................1367
					Controlled Creep......................................................1367
						Basic Powershift..................................................1367
						DuraMatch™ and Electronic Extended Features.......................1367
					Controlled Roll Back..................................................1368
						DuraMatch™ .......................................................1368
						Electronic Extended Features......................................1368
					Travel Speed Limit (Optional).........................................1368
					Extended Drawbar Pull ( Electronic Extended Features Multi-Speed......1368
					Auto-Speed Hydraulics ( Electronic Extended Features Transmissio......1368
					Throttle Response Management ( Electronic Extended Features Tran......1368
						Steady Travel Speed...............................................1368
			Transmission Control Hardware.................................................1369
				Control Valve and Sensors.................................................1369
					Description...........................................................1369
					Principles of Operation...............................................1371
				Transmission Proportional Valve...........................................1372
					Description...........................................................1372
					Neutral...............................................................1372
					Proportional Control..................................................1372
				MONOTROL® Pedal...........................................................1373
					Description...........................................................1373
					Principles of Operation...............................................1373
				Directional Control Lever.................................................1373
					Principles of Operation...............................................1373
			Driveshaft, Differential, Drive Axle, and Brakes (Dry Brake Only..............1374
				Driveshaft................................................................1374
				Differential and Drive Axle...............................................1374
				Brake System..............................................................1376
					Description...........................................................1376
					Service Brakes........................................................1376
					Master Cylinder.......................................................1376
					Brake Position Sensor.................................................1376
					Parking Brake.........................................................1376
			Driveshaft, Differential, Drive Axle, and Brakes (Wet Brake Only..............1377
				Driveshaft................................................................1377
				Differential..............................................................1378
				Brake System..............................................................1380
					Description...........................................................1380
					Service Brakes, 2.0-3.5 Ton Only......................................1380
					Service Brakes, 4.0-7.0 Ton...........................................1382
					Brake Adjustment and Service..........................................1382
					Parking Brake.........................................................1382
			Overheating Brakes (Dry Brake Axle Only)......................................1385
			Overheating Brakes (Wet Brake Axle Only)......................................1387
			Poor Brake Performance (Dry Brake Axle Only)..................................1390
			Poor Brake Performance (Wet Brake Axle Only)..................................1393
			Brakes Make Too Much Noise (Dry Brake Axle Only)..............................1395
			Brakes Pull To One Side (Dry Brake Axle Only).................................1396
			Parking Brake Will Not Release................................................1399
			Parking Brake Will Not Hold Lift Truck (Dry Brake Axle Only)..................1400
			Parking Brake Will Not Hold Lift Truck (Wet Brake Axle Only)..................1401
			Abnormal Drive Axle Noise.....................................................1402
			Discolored Drive Axle Oil.....................................................1405
			Lift Truck Does Not Move (Drive Axle).........................................1407
			Abnormal Transmission Noise...................................................1409
			Bubbles or Foaming In Transmission Dipstick Tube..............................1411
			Inching Operation Is Not Smooth or Chatters...................................1413
			Lift Truck Does Not Move In One or Both Directions (Transmission..............1415
			Loss of Power/Drivetrain Performance..........................................1418
			Transmission Is Too Hot.......................................................1421
			Transmission Will Not Shift To Forward High Range.............................1424
			Transmission Warmup Procedure.................................................1425
			Transmission Pressure Test....................................................1425
				Transmission Charge Pump Pressure Test....................................1427
				Clutch Pack Pressure Test (Proportional Solenoid Valves)..................1427
				Torque Converter Pressure Test............................................1428
				Lubrication Pressure Test.................................................1428
			Transmission Clutch Drag Test (1.0-5.5 Ton Trucks Only).......................1429
			Torque Converter Stall Test...................................................1429
		Hydraulic Systems.................................................................1433
			Main Hydraulic System.........................................................1437
				Description...............................................................1437
				Principles of Operation...................................................1440
				Hydraulic Schematics......................................................1441
					Manual Control Valve Schematics.......................................1441
					Electro-Hydraulic Control Valve Schematics............................1446
			Manual Hydraulic Control Valve................................................1450
				Description...............................................................1450
				Principles of Operation...................................................1452
					Lift Section..........................................................1452
						Lift Operation....................................................1452
						Lower Operation...................................................1452
					Tilt Section..........................................................1454
						Tilt Backward.....................................................1454
						Tilt Forward......................................................1454
					Auxiliary Section.....................................................1456
					Anti-stall Feature....................................................1457
					Relief Valves.........................................................1457
						Main Relief Valve.................................................1457
						Secondary Relief Valve............................................1457
			Electro-Hydraulic Control Valve...............................................1458
				Description...............................................................1458
				Principles of Operation...................................................1460
					Inlet Pressure Compensator/Unloader...................................1460
					Lift/Lower EHPVs......................................................1461
						EHPV Operation....................................................1462
					Tilt and Auxiliary Spool Functions....................................1464
					Tilt Forward Function.................................................1466
					Main Relief Valve ....................................................1467
					Secondary Relief Valve................................................1467
					Secondary Function Anti-stall Valve...................................1468
					Emergency Lowering Valve..............................................1469
			Steering System...............................................................1469
				Component Locations.......................................................1469
					Description...........................................................1469
					Steering Axle Assembly................................................1469
					Steering Control Unit.................................................1469
				Steering Schematic........................................................1471
					Principles of Operation...............................................1472
					Steering Control Unit.................................................1472
			Actuation Functions With Armrest Up (E-Valve).................................1473
			Cycle Times Too Fast - Fast Actuation (E-Valve)...............................1474
			Jump/Delay In Lift or Lower Activation After Moving Joystick or ..............1476
			Jump/Delay In Secondary Function Actuation After Moving Joystick..............1478
			Jump/Delay In Tilt Forward Actuation (E-Valve)................................1480
			Forks Drop Slightly Before Lifting (E-Valve)..................................1482
			Forks Lower Without Command (E-Valve).........................................1483
			Forks Raise or Actuate Without Command (E-Valve)..............................1485
			Forks Tilt Forward Without Command (E-Valve)..................................1487
			Intermittent Activation (E-Valve) While Commanding Function...................1489
			Lift/Lower Function Maximum Speed Too Slow (E-Valve)..........................1491
			Lift Function Will Not Move With Joystick or MLM Movement (E-Val..............1494
			Lift/Lower Continues To Move For Awhile After Joystick or MLM Is..............1497
			Lift/Lower/Secondary Function Suddenly Jumps In Middle of Stroke..............1498
			Lower Function Will Not Move With Joystick or MLM Movement (E-Va..............1499
			Poor Metering on Lift or Lower Functions (E-Valve)............................1501
			Secondary Function Continues to Move for Awhile After Joystick o..............1504
			Secondary Function Exhibits Slight Movement in Opposite Directio..............1505
			Secondary Function Maximum Speed Too Slow (E-Valve)...........................1506
			Secondary Function or Tilt Back Moves Without Command (E-Valve)...............1509
			Secondary Function and Tilt Back Will Not Move With Joystick or ..............1510
			Tilt Forward Function Continues to Move for Awhile When Joystick..............1513
			Tilt Forward Will Not Move Upon Joystick or MLM Movement (E-Valv..............1514
			Too Much Joystick or MLM Movement (Deadband) to Start Function M..............1516
			Wrong Actuation Operates or Actuation is Backward (E-Valve)...................1517
			Actuation Exhibits Slight Movement in Opposite Direction Before ..............1518
			Auxiliary Function is Slow or Does Not Function (Manual Valve)................1519
			Cycle Times Too Fast - Fast Actuation (Manual Valve)..........................1521
			Function Continues to Activate After Returning to Neutral.....................1522
			Lift Function Is Slow or Does Not Function (Manual Valve).....................1523
			Tilt Back Function Will Not Operate (Manual Valve)............................1525
			Tilt Forward Functions When Spool is Activated Forward With Engi..............1526
			Tilt Forward Will Not Function When Activated (Manual Valve)..................1527
			Abnormal Steer Axle Noise.....................................................1528
			Abnormal Steering Wheel Vibration.............................................1530
			Back Lash/Kick Back in Steering Wheel.........................................1531
			No Steering (All Other Hydraulic Functions OK)................................1533
			Steering Is Slow or Difficult.................................................1535
			Steering Operation Is Not Smooth..............................................1537
			Steering Wheel End Lock Position Cannot Be Felt by Operator...................1539
			Steering Wheel Turns By Itself or Does Not Return To Neutral..................1540
			Steering Wheel Turns the Tires in the Wrong Direction.........................1541
			Abnormal Hydraulic Noise and/or Vibration.....................................1542
			Abnormal Smell/Discoloration/Foaming of Oil...................................1545
			Actuations Do Not Act Simultaneously..........................................1546
			Oil Leaking/Component Life Too Short..........................................1547
			Hydraulic Warmup Procedure....................................................1551
			Main Relief Valve Test and Adjustment.........................................1551
			Secondary Relief Valve Test and Adjustment....................................1553
			Hydraulic Pump Flow Test......................................................1555
			Main Control Valve LS Leakage Test (E-Valve)..................................1558
			Main Control Valve Unloader Margin Test.......................................1558
			Electro-Hydraulic Poppet Valve (EHPV) Leakage Test............................1560
			PPRV Pilot Pressure Test......................................................1563
			Steering Relief Pressure Test and Adjustment..................................1565
			Steering Control Unit LS Pressure Test........................................1566
			Lift Cylinder Leakage Test....................................................1568
			Tilt Cylinder Leakage Test....................................................1569
			Steering Cylinder Leakage Test................................................1570
		Operators Station.................................................................1573
			Operator Station General Description and Principles of Operation..............1575
				General Description and Location..........................................1575
			Display Switch Cluster (DSC)..................................................1578
				Detailed Description......................................................1578
				Control Inputs, Right Side................................................1579
				Right Indicator and Warning Group.........................................1580
				LCD Display...............................................................1580
				Left Indicator and Warning Group..........................................1582
				Control Inputs, Left Side (Cab Option Only)...............................1583
			Transmission Control and Braking..............................................1584
				Description...............................................................1584
					Vehicle System Manager (VSM)..........................................1584
					Display Switch Cluster................................................1585
						Interlock and Switching Features..................................1585
					MONOTROL® Directional Control.........................................1585
					Inch Brake/Service Brake Pedal........................................1585
					Parking Brake.........................................................1585
			Programming - Menus...........................................................1586
				Menus.....................................................................1586
					Main Menu.............................................................1589
					Save and Exit or Exit Without Saving..................................1589
					Back One Level........................................................1589
					Hourmeters............................................................1589
					View Versions.........................................................1590
					Passwords.............................................................1590
					Diagnostics...........................................................1590
					Setup Travel and Braking..............................................1590
					Setup Hydraulics......................................................1590
					Setup Display.........................................................1590
					Setup General Items...................................................1590
					Calibrations..........................................................1590
			Manual Hydraulic Control Levers...............................................1591
				General Description.......................................................1591
				System Components.........................................................1591
					Lift/Lower............................................................1591
					Tilt..................................................................1591
					Auxiliary 1...........................................................1591
					Auxiliary 2...........................................................1591
			E-Hydraulic System Interface..................................................1592
				General Description.......................................................1592
				System Components.........................................................1592
				E-Hydraulic Control Input Device..........................................1592
					Joystick..............................................................1592
						Lift/Lower........................................................1593
						Tilt..............................................................1593
						Auxiliary 1.......................................................1593
						Auxiliary 2.......................................................1593
						Push Button.......................................................1593
					Mini Lever Module (MLM)...............................................1594
						Lever 1...........................................................1594
						Lever 2...........................................................1594
						Lever 3...........................................................1595
						Lever 4...........................................................1595
				System Modes..............................................................1595
					Hydraulic Interlock Mode..............................................1595
					Fault Mode............................................................1595
					Engine Off Mode.......................................................1595
				Normal Operation..........................................................1595
					Normal Operation Mode.................................................1595
					Lifting Control.......................................................1595
					Lowering Control......................................................1596
					Tilt Control (Forward and Backward)...................................1596
					Auxiliary Control.....................................................1596
			Lighting Control..............................................................1596
				Description...............................................................1596
					Front Work Lights.....................................................1599
					Front Marker Lights (if equipped).....................................1599
					Front/Rear Turn Signal Lights.........................................1599
					Rear Tail/Marker Lights...............................................1599
					Rear Work Light.......................................................1599
					Rear Backup Lights....................................................1599
					Rear Stop Lights......................................................1599
					Strobe Light(s).......................................................1599
					Spot Light (if equipped)..............................................1599
			Cab...........................................................................1599
				Description...............................................................1599
				Component Descriptions....................................................1601
					Cab Heating System....................................................1601
					Lighting Control System...............................................1601
					Wiper/Washer System...................................................1601
				Cab Systems Operation.....................................................1602
		Front End (Mast) and Chassis......................................................1605
			Front End, Mast...............................................................1607
				Description...............................................................1607
			Carriages.....................................................................1607
				Description...............................................................1607
				Principles of Operation...................................................1608
					Integral Sideshift Carriage...........................................1608
			Mast Mounts...................................................................1609
				Description...............................................................1609
				Principles of Operation...................................................1610
			Two-Stage Limited Free-Lift (LFL) Mast........................................1610
				Description...............................................................1610
				Principles of Operation...................................................1611
			Two-Stage Full Free-Lift (FFL) Mast...........................................1612
				Description...............................................................1612
				Principles of Operation...................................................1613
			Three-Stage Full Free-Lift (FFL) Mast.........................................1614
				Description...............................................................1614
				Principles of Operation...................................................1615
			Four-Stage Full Free-Lift (FFL) Mast..........................................1616
				Description...............................................................1616
				Principles of Operation...................................................1618
			Cylinder Cushion During Lifting Sequence......................................1620
				Description...............................................................1620
				Principles of Operation...................................................1620
			Cylinder Cushion During Lowering Sequence.....................................1620
				Description...............................................................1620
				Principles of Operation...................................................1620
			Tilt and Sideshift Cylinders..................................................1621
				Description...............................................................1621
					Tilt Cylinder.........................................................1621
					Sideshift Cylinder....................................................1621
			Lowering Control Valves.......................................................1622
				Description...............................................................1622
				Principles of Operation...................................................1622
			Chassis.......................................................................1624
				Description...............................................................1624
			Abnormal Channel Wear.........................................................1625
			Abnormal Hose Wear............................................................1627
			Abnormal Mast Noise...........................................................1629
			Body Panels Making Noise......................................................1633
			External Leakage From Free-Lift or Main Lift Cylinders........................1634
			FFL Mast Banging During Phasing...............................................1635
			High Tire Wear - Drive Axle...................................................1637
			High Tire Wear - Steer Axle...................................................1639
			Hoses Not Tracking Correctly..................................................1641
			Integral Sideshift Moving Too Fast............................................1642
			Integral Sideshift Not Moving or Slow.........................................1643
			LP Tank Bracket Disengages....................................................1646
			LP Tank Rattles and Does Not Stay Latched.....................................1647
			Mast is Loose.................................................................1648
			Mast Lift Chains Are Loose....................................................1650
			Mast or Carriage Binding......................................................1651
			Mast/Carriage Bounces or is Spongy............................................1653
			Misphasing of Full Free-Lift Mast.............................................1654
			Overhead Guard Loose or Damaged...............................................1656
			Racking During Lift...........................................................1657
			Racking During Tilt...........................................................1659
			Truck Feels Unstable..........................................................1660
			Truck Wanders, Does Not Track Straight or Steer Well..........................1662
			Wheels Appear Tipped or Misaligned............................................1664
			Wheels Spinning On Uneven Floors..............................................1666
			Wheel Studs Breaking..........................................................1667
		Supplementary Data................................................................1669
			Abbreviations and Acronyms....................................................1671
			Special Tools List............................................................1679
			Fault Mode Indicator (FMI) Reference List.....................................1685
			TSP Reference Tables..........................................................1687
	tables................................................................................ 459
		Table 9020-10-1. IAT Ambient Temperature.......................................... 540
		Table 9020-40-1. Test Specifications.............................................. 707
		Table 9020-40-2. Test Specifications.............................................. 708
		Table 9020-40-3. Service Tools.................................................... 708
		Table 9020-40-4. Test Specifications.............................................. 709
		Table 9020-40-5. Service Tools.................................................... 709
		Table 9020-40-6. Test Specifications.............................................. 710
		Table 9020-40-7. Service Tools.................................................... 711
		Table 9020-40-8. Test Specifications - Mazda...................................... 712
		Table 9020-40-9. Test Specifications - GM......................................... 712
		Table 9020-40-10. Service Tools................................................... 712
		Table 9020-40-11. Test Specifications............................................. 714
		Table 9020-40-12. Service Tools................................................... 714
		Table 9020-40-13. Test Specifications............................................. 716
		Table 9020-40-14. Service Tools................................................... 716
		Table 9030-03-1. Circuit Group Identification..................................... 746
		Table 9030-03-2. Hyster Wiring Color Codes........................................ 747
		Table 9040-10-1. Two-Speed Transmission Clutch Pack Solenoid Val..................1359
		Table 9040-10-2. Three-Speed Transmission Electronic Proportiona..................1361
		Table 9040-10-3. Transmission Control Mode........................................1363
		Table 9040-40-1. Test Specifications..............................................1425
		Table 9040-40-2. Service Tools....................................................1425
		Table 9040-40-3. Service Tools....................................................1425
		Table 9040-40-4. Test Specifications..............................................1427
		Table 9040-40-5. Test Specifications..............................................1427
		Table 9040-40-6. Test Specifications..............................................1428
		Table 9040-40-7. Test Specifications..............................................1428
		Table 9040-40-8. Test Specifications..............................................1429
		Table 9040-40-9. Service Tools....................................................1429
		Table 9040-40-10. Stall Speeds....................................................1430
		Table 9050-10-1. Standby Pressure Table...........................................1460
		Table 9050-40-1. Test Specifications..............................................1551
		Table 9050-40-2. Service Tools....................................................1551
		Table 9050-40-3. Test Specifications..............................................1551
		Table 9050-40-4. Service Tools....................................................1552
		Table 9050-40-5. Test Specifications..............................................1553
		Table 9050-40-6. Service Tools....................................................1554
		Table 9050-40-7. Test Specifications..............................................1555
		Table 9050-40-8. Service Tools....................................................1556
		Table 9050-40-9. Test Specifications..............................................1558
		Table 9050-40-10. Test Specifications.............................................1558
		Table 9050-40-11. Service Tools...................................................1558
		Table 9050-40-12. Test Specifications.............................................1560
		Table 9050-40-13. Service Tools...................................................1560
		Table 9050-40-14. Test Specifications.............................................1563
		Table 9050-40-15. Service Tools...................................................1563
		Table 9050-40-16. Test Specifications.............................................1565
		Table 9050-40-17. Service Tools...................................................1565
		Table 9050-40-18. Test Specifications.............................................1566
		Table 9050-40-19. Service Tools...................................................1566
		Table 9050-40-20. Test Specifications.............................................1568
		Table 9050-40-21. Service Tools...................................................1568
		Table 9050-40-22. Test Specifications.............................................1569
		Table 9050-40-23. Service Tools...................................................1569
		Table 9050-40-24. Test Specifications.............................................1570
		Table 9050-40-25. Service Tools...................................................1570
		Table 9080-50-1. Abbreviations and Acronyms.......................................1671
		Table 9080-60-1. Special Tools....................................................1679
		Table 9080-70-1. FMI..............................................................1685
		Table 9080-80-1. Resistor-Temperature Characteristics ............................1687
1579259-9000SRM1112-(07-2008)-US-EN.......................................................1691
	toc...................................................................................1691
		Diagnostic Troubleshooting Manual.................................................1691
		Safety Precautions TROUBLESHOOTING PROCEDURES.....................................1692
		How To Use This Troubleshooting Manual............................................1694
			General Instructions and Safety Information...................................1694
			How to Use Diagnostic Troubleshooting Manual..................................1694
			General Instructions..........................................................1695
		Operational Diagnostic Procedures.................................................1697
			Operational Checkout Procedures...............................................1699
				DTC Check.................................................................1700
				Horn Circuit Check........................................................1700
				Light Circuit Check.......................................................1700
				Windshield Washer Wiper Check (If equipped)...............................1700
				Heater Check (If equipped)................................................1701
				Dome Light Check (If equipped)............................................1701
				Circulating (Accessory) Fan Check (If equipped)...........................1702
				Indicator Light Power Check...............................................1703
				Operator Presence System Check............................................1704
				Engine Malfunction Indicator Check........................................1704
				Cold Start Check (Cummins and Yanmar).....................................1704
				Brake Pedal Check.........................................................1705
				Backup Alarm Check (If equipped)..........................................1705
				Armrest Hydraulic Interlock Check (If equipped and with original..........1705
				Engine Cover Latch Sensor Check (If equipped).............................1706
				Brake and Inching Pedal Check.............................................1706
				Park Brake Sensor Check...................................................1706
				Park Brake Check..........................................................1707
				Engine Speed Check (All Cummins, Yanmar, and Mazda Engines Excep..........1707
				Engine Power Check........................................................1708
				Transmission Clutch Check.................................................1708
				Transmission Check........................................................1709
				Transmission Speed Selection Check (If equipped)..........................1709
				Brake and Axle Drag Check.................................................1709
				Hydraulic Pump Flow Check.................................................1710
				Priority Flow Divider Valve Check.........................................1711
				Steering Relief Valve Low Pressure Check..................................1711
				Steering Relief Valve High Pressure Check.................................1712
				Control Valve Load Check Valve (Manual Valve).............................1712
			Lift E-Valve Check............................................................1712
				Lift Check (E-Valve)......................................................1712
				Tilt Function Counterbalance Check........................................1713
				Lift Drift Check..........................................................1713
				Tilt Function Drift Check.................................................1714
				Mast Cushion Check (All Except 2-Stage Mast)..............................1714
				Lift/Tilt Mast Adjustment Check...........................................1714
				Tilt Racking Check........................................................1715
				Chain and Header Hose Adjustment Check....................................1715
				Mast Mounting Check.......................................................1716
				Mast Channel Check........................................................1716
				Carriage Adjustment Check.................................................1717
				Chain Sheave Check........................................................1717
				Carriage Adjustment Check (Standard and Integral Side Shift)..............1717
		Engine............................................................................1719
			Engine Basics.................................................................1725
				General Terminology.......................................................1725
				Combustion Theory.........................................................1725
				Engine Components – Cylinder Block........................................1726
				Camshaft and Timing Set...................................................1727
				Cylinder Head Assembly....................................................1727
				Valve Train Assembly......................................................1727
				Air Cleaner/Filter........................................................1727
				Carburetion...............................................................1727
				Electronic Fuel Injection (EFI)...........................................1727
				Positive Crankcase Ventilation (PCV)......................................1728
			Engine Electrical.............................................................1728
				Introduction..............................................................1728
				Battery Construction......................................................1728
				Conventional Standard Battery.............................................1729
				Maintenance-Free Battery..................................................1729
				Battery Charging..........................................................1729
				Battery Fast Charging.....................................................1730
				Battery Slow Charging.....................................................1730
				Starting System Principles of Operation...................................1730
				Starting System Components - Ignition Switch..............................1731
				Starting System Components - Starter Solenoid.............................1731
				Starting System Components - Flywheel and Ring Gear.......................1731
				Starting System Components - Starter Motor and Drive......................1731
				Charging System - General.................................................1732
				Charging System - Regulator...............................................1732
				Charging System - Theory..................................................1732
			Engine Fuel System/Exhaust and Emissions......................................1733
				Introduction..............................................................1733
				Gasoline System Components - Fuel Tank....................................1733
				Electronic Fuel Injector (EFI) - General Description......................1733
				Port Fuel System Components - ECU.........................................1733
				Port Fuel System Components - Fuel Pump/Filter............................1733
				Port Fuel System Components - Fuel Rail...................................1733
				Port Fuel System Components - Pressure Regulator..........................1733
				Port Fuel System Components - Fuel Injectors..............................1734
				LPG Systems General Information...........................................1734
				LPG Fuel Properties.......................................................1734
				LPG Fuel Tank.............................................................1734
				AISAN Closed-Loop System..................................................1735
					Filter/Lockoff and Regulator..........................................1735
					Carburetor............................................................1735
					Start Mode............................................................1735
					Idle Mode.............................................................1736
					Run Mode..............................................................1736
				Main Fuel Lockoff Solenoid................................................1736
				Injector Fuel Lockoff Solenoid............................................1736
					Oxygen (O 2 ) Sensor..................................................1736
				Electronic Control Unit (ECU).............................................1736
				Catalytic Converter/Muffler...............................................1736
			Engine Management.............................................................1736
				Introduction..............................................................1736
				Ignition and Timing - Conventional Spark..................................1736
				Components - Ignition Coil................................................1737
				Components - Distributor..................................................1737
				Spark Timing..............................................................1737
				Components - Ignition Wires...............................................1737
				Components - Spark Plugs..................................................1737
				Faulty or Fouled Spark Plugs..............................................1738
				Electric Controlled Governing System - Mazda LPG..........................1738
			Engine Identification.........................................................1739
			Cummins (Diesel) Engine.......................................................1741
				Description...............................................................1741
				Diesel Fuel System........................................................1742
					Principle of Operation................................................1742
				Fuel Injection Pump and Governor..........................................1743
					Description...........................................................1743
					Principles of Operation...............................................1744
				Cummins Engine Control....................................................1745
					Engine Speed (RPM) Sensor.............................................1746
					Throttle Position Sensor..............................................1747
					Electronic Throttle Actuator..........................................1748
					Engine Oil Pressure Sensor............................................1748
					Coolant Temperature Sensor............................................1748
					Air Restriction Switch................................................1749
					Fuel Filter/Water Separator...........................................1749
					Fuel Level Sensor (In Tank)...........................................1749
				Engine Electrical System..................................................1750
					Magnetic Valve (Engine Stop Solenoid).................................1750
					Alternator............................................................1750
					Grid Heater...........................................................1750
					Cold Start Timing Advance (Fuel Injection Pump).......................1750
			Cummins QSB 3.3L (Diesel) Engine..............................................1751
				Description...............................................................1751
				Diesel Fuel System........................................................1752
				Electronics System........................................................1755
					Engine Protection.....................................................1756
					Diagnostics...........................................................1756
					Grid Heater...........................................................1756
				Turbocharger and Charge Air Cooler........................................1756
				Cooling System............................................................1758
				Crankcase Oil Separator...................................................1759
				Lubrication System........................................................1760
			Mazda Engine Overview.........................................................1761
				Description...............................................................1761
				Fuel System...............................................................1761
				Engine Controls Unit (ECU) and Emissions..................................1761
				Cooling System............................................................1761
				Ignition System...........................................................1761
			Mazda (LPG) Engine Controls...................................................1762
				LPG System (Aisan/E-Controls-Mechanical)..................................1762
					Description...........................................................1762
					Principles of Operation...............................................1763
					Control System........................................................1766
					Oxygen (O 2 ) Sensor..................................................1767
					Fuel Tank.............................................................1767
					Regulator.............................................................1768
						Start Mode........................................................1769
						Idle Mode.........................................................1769
						Run Mode..........................................................1770
					Resonator.............................................................1770
					Carburetor............................................................1770
						Start Mode........................................................1770
						Idle Mode.........................................................1771
						Run Mode..........................................................1771
					Governor..............................................................1772
				LPG System (E-Controls)...................................................1772
					Description...........................................................1772
					Principles of Operation...............................................1773
					Manifold Absolute Pressure Sensor.....................................1773
					Throttle Position Sensor..............................................1773
					Oxygen (O 2 ) Sensor..................................................1774
					Engine Coolant Temperature Sensor.....................................1774
					Intake Air Temperature Sensor.........................................1774
					Engine Control Unit...................................................1774
					Accelerator Pedal Position Sensor.....................................1774
					Three-Way Catalytic Converter.........................................1774
					Camshaft Position Sensor..............................................1774
					Electric Controlled Governing System..................................1775
					Electronic Governor Sensor............................................1776
			Mazda (Gasoline) Engine Controls..............................................1777
				Gasoline System...........................................................1777
					Description...........................................................1777
					Principles of Operation...............................................1778
				Control System............................................................1780
					Camshaft Position Sensor..............................................1781
					Intake Air Temperature Sensor.........................................1782
					Mass Air Flow Sensor..................................................1783
					Throttle Position Sensor..............................................1784
					Electronic Governor Sensor............................................1785
					Electronic Governing System...........................................1786
					Manifold Absolute Pressure Sensor/Boost Sensor........................1786
					Engine Coolant Temperature Sensor.....................................1787
				Intake Air System.........................................................1788
					Throttle Body.........................................................1788
					Idle Air Control Valve................................................1789
				Fuel System...............................................................1790
					Fuel Injector.........................................................1790
					Pressure Regulator....................................................1791
				Exhaust System............................................................1792
					Heated Oxygen (O 2 ) Sensor...........................................1792
					Three-Way Catalytic Converter.........................................1793
			GM (LPG) Engine Controls......................................................1794
				Engine Control System ....................................................1794
					Engine Control System Overview........................................1795
					Principles of Operation...............................................1795
				Control System............................................................1796
					GM/TGFI 2.4L (Four Cylinder) Control System Component Location........1796
					GM/TGFI 4.3L (Six Cylinder) Control System Component Location.........1797
					GM/TGFI 2.4L (Four-Cylinder) LPG System...............................1798
					GM/TGFI 4.3L (Six-Cylinder) LPG System................................1800
					Fuel Tank.............................................................1802
					Engine Control Unit...................................................1802
					Electronic Throttle Body/Throttle Position Sensor.....................1803
					Manifold Absolute Pressure/Manifold Air Temperature Sensor............1803
					Propane Injectors.....................................................1804
					Engine Coolant Temperature Sensor.....................................1806
					Oxygen (O 2 ) Sensor..................................................1806
					Crankshaft Position Sensor (Engine Speed Sensor)......................1807
					Oil Pressure Sensor...................................................1807
					Power Latch Relay.....................................................1807
					GM 2.4L Camshaft Position Sensor......................................1807
					GM 4.3L Camshaft Position Sensor......................................1808
					Injector Driver Module................................................1809
					Vaporizer/Regulator...................................................1809
					Accelerator Pedal Position Sensor.....................................1812
					Three-Way Catalytic Converter.........................................1812
				Ignition System...........................................................1813
					Ignition Coils........................................................1813
					Distributorless Ignition System Module................................1813
					Electronic Ignition Signals...........................................1814
					Distributor Ignition (DI) System......................................1814
					Camshaft Position (CMP) Sensor........................................1815
					Ignition Coil and Ignition Control Module (ICM).......................1815
					Secondary Ignition Components.........................................1815
			GM (Gasoline) Engine Controls.................................................1816
				Engine Control System.....................................................1816
					GM 2.4L (Four Cylinder) Engine Control System.........................1816
					GM 4.3L (Six Cylinder) Engine Control System..........................1817
					Engine Control System Overview........................................1818
					Principles of Operation...............................................1818
				Control System............................................................1818
					GM/TGFI 2.4L (Four Cylinder) Control System Component Location........1818
					GM/TGFI 4.3L (Six Cylinder) Control System Component Location.........1820
					GM/TGFI 2.4L (Four-Cylinder) Gasoline System Components...............1821
					GM/TGFI 4.3L (Six Cylinder) Gasoline System Components................1823
					Engine Control Unit...................................................1825
					Electronic Throttle Body/Throttle Position Sensor.....................1825
					Manifold Absolute Pressure/Manifold Air Temperature Sensor ...........1826
					Fuel Injector.........................................................1827
					Engine Coolant Temperature Sensor.....................................1828
					Oxygen (O 2 ) Sensor..................................................1829
					Crankshaft Position Sensor (Engine Speed Sensor)......................1829
					Oil Pressure Sensor...................................................1829
					Power Latch Relay.....................................................1829
					Camshaft Position Sensor..............................................1830
					Accelerator Pedal Position Sensor.....................................1831
					Three-Way Catalytic Converter.........................................1832
				Ignition System...........................................................1832
					Ignition Coils........................................................1832
					Distributorless Ignition System Module................................1832
					Electronic Ignition Signals...........................................1833
			Yanmar (Diesel) Engine........................................................1834
				Description...............................................................1834
				Diesel Fuel System........................................................1835
					Principles of Operation...............................................1835
				Fuel Injection Pump and Governor..........................................1836
					Description...........................................................1836
					Principles of Operation...............................................1838
					Timer.................................................................1839
					Feed Pump (Vane Type).................................................1839
					Regulating Valve......................................................1840
					Injection Pump Plunger................................................1841
						Suction Process...................................................1842
						Injection Process.................................................1842
						End of Injection..................................................1843
						Uniform Pressure Process..........................................1843
					Reverse Rotation Prevention Mechanism.................................1844
					Fuel Injection Volume Adjustment Mechanism............................1844
					Delivery Valve Assembly...............................................1844
					Delivery Valve Holder with Damping Valve..............................1845
					All - Speed Governor..................................................1846
					At Start of Engine....................................................1848
					During Idle...........................................................1849
					At Full - Load Maximum Speed Control..................................1850
					At No-Load Maximum Speed Control......................................1851
					Full-Load Position Adjustment Mechanism...............................1852
				Structure and Operation of Timer..........................................1853
					Standard Type Automatic Timer.........................................1853
				Yanmar Engine Controls....................................................1854
					Engine Speed (RPM) Sensor.............................................1855
					Throttle Position Sensor..............................................1855
					Electronic Throttle Actuator..........................................1856
					Engine Oil Pressure Sensor............................................1856
					Coolant Temperature Sensor............................................1857
					Air Filter Restriction Switch.........................................1857
					Fuel Filter/Water Separator and Strainer..............................1858
					Fuel Level Sensor.....................................................1858
				Engine Electrical System..................................................1858
					Magnetic Valve (Engine Stop Solenoid).................................1858
					Alternator............................................................1859
					Glow Plugs............................................................1859
					Cold Start Timing Advance (Fuel Injection Pump).......................1859
			Cooling System - All Engines..................................................1860
				Description...............................................................1860
				Radiator..................................................................1860
					Combination Cooler/Standard Radiator..................................1861
				Radiator Cap..............................................................1861
				Thermostat................................................................1861
				Engine Coolant Pump.......................................................1862
				Fan.......................................................................1862
				GM Engine Coolant Flow Diagram............................................1862
				Yanmar Diesel Engine Coolant Flow Diagram.................................1863
			Engine Does Not Crank.........................................................1865
			Engine Does Not Start/Engine is Hard to Start.................................1868
			Engine Idle Speed Incorrect...................................................1874
			Engine Idle Speed is Unstable or Engine Stalls at Idle........................1877
			Engine Cuts Out, Misses, Hesitates, Sags, or Stumbles.........................1882
			Engine Lack of Power..........................................................1888
			Engine Speed Surge Or Engine Speed Unstable...................................1895
			Engine Backfires..............................................................1899
			Engine Is Knocking or Pinging.................................................1902
			Excessive Engine Vibrations...................................................1906
			Abnormal Engine and Exhaust Noises............................................1911
			Fan or Alternator Bearing Noise...............................................1915
			Abnormal Engine and Exhaust Smells............................................1917
			High Engine Fuel Consumption..................................................1919
			Fuel Leaks....................................................................1922
			High Engine Oil Consumption...................................................1925
			Engine Oil Leaks..............................................................1927
			Engine Oil is Discolored......................................................1932
			Engine Coolant Leaks..........................................................1934
			Engine Coolant is Discolored..................................................1937
			Engine Exhaust is Discolored..................................................1938
			Engine Fails Emission Compliance Check........................................1942
			Alternator Light is Illuminated...............................................1946
			Engine is Overheating.........................................................1947
			Air Intake Manifold Temperature too High (Cummins QSB 3.3L Only)..............1950
			Air Intake Manifold Pressure (Boost) is Below Normal (Cummins QS..............1951
			Engine Coolant Temperature is Low.............................................1952
			Engine Oil Pressure is Low....................................................1953
			Radiator Bubble Test..........................................................1955
			Engine Compression Test (GM and Mazda)........................................1956
			Engine Compression Test (Yanmar Diesel).......................................1957
			Engine Oil Pressure Test......................................................1958
			Fuel System Pressure Test (Gasoline Engines Only).............................1960
			Fuel Injection Nozzle Test (Yanmar Diesel)....................................1962
			Vacuum Leak...................................................................1963
				Vacuum Leak Detection.....................................................1963
				Vacuum Leak Repairs.......................................................1963
			Coolant System Test...........................................................1964
		Electrical System.................................................................1965
			Troubleshooting Guidelines and Procedures.....................................1979
				Troubleshooting Guidelines................................................1979
				Troubleshooting Procedures................................................1982
					Troubleshooting Procedures, Identification............................1982
					Troubleshooting Procedures, Location..................................1982
					Troubleshooting Procedures, Structure.................................1982
					Troubleshooting Procedures, Performance...............................1983
			Diagnostic Trouble Codes......................................................1984
				Diagnostic Trouble Codes..................................................1984
			Wiring Reference Data.........................................................1998
			Post 2007 Engine Connections..................................................2002
				Cummins 4.5L..............................................................2002
				GM 2.4L (GAS/LPG).........................................................2003
				GM 4.3L (GAS/LPG).........................................................2004
				Mazda 2.0/2.2L (GAS/LPG)..................................................2005
				Yanmar 2.6/3.3L...........................................................2006
			Harness Assembly Data.........................................................2007
			Electrical System.............................................................2053
				General Description.......................................................2053
				Description...............................................................2054
				Principles of Operation, Components.......................................2058
				Principles Of Operation, System...........................................2066
			100-2.........................................................................2073
			100-2.........................................................................2073
			100-3.........................................................................2073
			523859-3......................................................................2073
			524223-3......................................................................2073
			524224-3......................................................................2073
			524225-3......................................................................2073
			524282-3......................................................................2073
			523958-3......................................................................2073
			523959-3......................................................................2073
			100-4.........................................................................2081
			523859-4......................................................................2081
			523958-4......................................................................2081
			523959-4......................................................................2081
			524223-4......................................................................2081
			524224-4......................................................................2081
			524225-4......................................................................2081
			524282-4......................................................................2081
			524223-0......................................................................2089
			524224-0......................................................................2089
			524225-0......................................................................2089
			524229-0......................................................................2089
			524270-0......................................................................2089
			524276-0......................................................................2089
			524223-1......................................................................2093
			524224-1......................................................................2093
			524225-1......................................................................2093
			524229-1......................................................................2093
			524270-1......................................................................2093
			524276-1......................................................................2093
			110-3.........................................................................2097
			110-3.........................................................................2097
			110-5.........................................................................2097
			177-3.........................................................................2097
			522231-3......................................................................2097
			522555-3......................................................................2097
			522603-3......................................................................2097
			524235-3......................................................................2097
			110-4.........................................................................2105
			110-4.........................................................................2105
			177-4.........................................................................2105
			522231-4......................................................................2105
			522555-4......................................................................2105
			522603-4......................................................................2105
			524235-4......................................................................2105
			110-2.........................................................................2113
			110-2.........................................................................2113
			110-10........................................................................2116
			522712-3......................................................................2121
			522713-3......................................................................2121
			522712-4......................................................................2128
			522713-4......................................................................2128
			51-2..........................................................................2135
			51-7..........................................................................2135
			91-2..........................................................................2143
			91-2..........................................................................2143
			522708-3......................................................................2147
			522710-3......................................................................2147
			522711-3......................................................................2147
			522714-3......................................................................2147
			522708-4......................................................................2154
			522710-4......................................................................2154
			522711-4......................................................................2154
			522714-4......................................................................2154
			515-0.........................................................................2161
			523780-3......................................................................2163
			523860-3......................................................................2163
			524245-3......................................................................2163
			524275-3......................................................................2163
			523780-4......................................................................2169
			523860-4......................................................................2169
			524245-4......................................................................2169
			524275-4......................................................................2169
			677-3.........................................................................2174
			2350-3........................................................................2174
			522754-3......................................................................2174
			522755-3......................................................................2174
			522764-3......................................................................2174
			522766-3......................................................................2174
			524230-3......................................................................2174
			SYMPTOMS WARNING..............................................................2174
			677-4.........................................................................2180
			2350-4........................................................................2180
			522754-4......................................................................2180
			522755-4......................................................................2180
			522764-4......................................................................2180
			522766-4......................................................................2180
			524230-4......................................................................2180
			676-3.........................................................................2184
			524195-3......................................................................2184
			524269-3......................................................................2184
			676-4.........................................................................2190
			524195-4......................................................................2190
			524269-4......................................................................2190
			524269-7......................................................................2196
			524215-3......................................................................2198
			524215-6......................................................................2198
			524237-3......................................................................2202
			524238-3......................................................................2202
			524240-3......................................................................2202
			524237-4......................................................................2207
			524238-4......................................................................2207
			524240-4......................................................................2207
			879-3.........................................................................2212
			880-3.........................................................................2212
			881-3.........................................................................2212
			882-3.........................................................................2212
			522772-3......................................................................2212
			879-4.........................................................................2216
			880-4.........................................................................2216
			881-4.........................................................................2216
			882-4.........................................................................2216
			522772-4......................................................................2216
			168-0.........................................................................2220
			168-3.........................................................................2220
			521982-3......................................................................2223
			522760-3......................................................................2223
			522761-3......................................................................2223
			522762-3......................................................................2223
			522128-3......................................................................2232
			524251-0......................................................................2232
			524260-0......................................................................2232
			524260-3......................................................................2232
			524261-0......................................................................2232
			524261-3......................................................................2232
			168-1.........................................................................2241
			168-4.........................................................................2241
			521982-4......................................................................2244
			522760-4......................................................................2244
			522761-4......................................................................2244
			522761-6......................................................................2244
			522762-4......................................................................2244
			522128-4......................................................................2251
			524251-1......................................................................2251
			524260-1......................................................................2251
			524260-4......................................................................2251
			524261-1......................................................................2251
			524261-4......................................................................2251
			524260-2......................................................................2261
			524260-11.....................................................................2261
			524261-2......................................................................2261
			524261-11.....................................................................2261
			96-3..........................................................................2265
			96-4..........................................................................2265
			522810-4......................................................................2269
			524213-1......................................................................2273
			524213-3......................................................................2273
			524213-4......................................................................2273
			523920-3......................................................................2276
			523925-3......................................................................2276
			523930-3......................................................................2276
			523977-3......................................................................2276
			523978-3......................................................................2276
			523986-3......................................................................2276
			524284-3......................................................................2276
			524285-3......................................................................2276
			523920-4......................................................................2282
			523925-4......................................................................2282
			523930-4......................................................................2282
			523977-4......................................................................2282
			523978-4......................................................................2282
			523986-4......................................................................2282
			524284-4......................................................................2282
			524285-4......................................................................2282
			523920-6......................................................................2287
			523925-6......................................................................2287
			523930-6......................................................................2287
			523977-6......................................................................2287
			523978-6......................................................................2287
			523986-6......................................................................2287
			524284-6......................................................................2287
			524285-6......................................................................2287
			105-3.........................................................................2291
			105-3.........................................................................2291
			522570-3......................................................................2291
			105-4.........................................................................2296
			105-4.........................................................................2296
			522570-4......................................................................2296
			105-5.........................................................................2300
			106-3.........................................................................2303
			106-4.........................................................................2307
			106-0.........................................................................2311
			106-1.........................................................................2311
			106-2.........................................................................2311
			106-14........................................................................2311
			522739-3......................................................................2314
			522740-3......................................................................2314
			522739-5......................................................................2319
			522740-5......................................................................2319
			522739-6......................................................................2323
			522740-6......................................................................2323
			522735-2......................................................................2327
			522735-4......................................................................2330
			522735-5......................................................................2333
			522735-6......................................................................2336
			522630-2......................................................................2340
			522631-2......................................................................2340
			522632-2......................................................................2340
			522633-2......................................................................2340
			522635-3......................................................................2340
			522636-4......................................................................2340
			522637-3......................................................................2340
			522638-4......................................................................2340
			522606-10.....................................................................2344
			522737-10.....................................................................2344
			651-3.........................................................................2347
			652-3.........................................................................2347
			653-3.........................................................................2347
			654-3.........................................................................2347
			655-3.........................................................................2347
			656-3.........................................................................2347
			522599-3......................................................................2347
			522600-3......................................................................2347
			522601-3......................................................................2347
			522602-3......................................................................2347
			522721-3......................................................................2347
			522722-3......................................................................2347
			522723-3......................................................................2347
			522724-3......................................................................2347
			522725-3......................................................................2347
			522726-3......................................................................2347
			522599-3......................................................................2347
			522600-3......................................................................2347
			522601-3......................................................................2347
			522602-3......................................................................2347
			651-5.........................................................................2355
			651-5.........................................................................2355
			652-5.........................................................................2355
			652-5.........................................................................2355
			653-5.........................................................................2355
			653-5.........................................................................2355
			654-5.........................................................................2355
			654-5.........................................................................2355
			655-5.........................................................................2355
			656-5.........................................................................2355
			522721-5......................................................................2355
			522722-5......................................................................2355
			522723-5......................................................................2355
			522724-5......................................................................2355
			522725-5......................................................................2355
			522726-5......................................................................2355
			651-6.........................................................................2360
			652-6.........................................................................2360
			653-6.........................................................................2360
			654-6.........................................................................2360
			655-6.........................................................................2360
			656-6.........................................................................2360
			522599-4......................................................................2360
			522600-4......................................................................2360
			522601-4......................................................................2360
			522602-4......................................................................2360
			522721-6......................................................................2360
			522722-6......................................................................2360
			522723-6......................................................................2360
			522724-6......................................................................2360
			522725-6......................................................................2360
			522726-6......................................................................2360
			2000-9........................................................................2368
			2000-12.......................................................................2368
			2000-12.......................................................................2368
			2000-12.......................................................................2368
			2000-12.......................................................................2368
			2000-14.......................................................................2368
			2003-12.......................................................................2368
			2023-12.......................................................................2368
			2039-2........................................................................2368
			2039-12.......................................................................2368
			2235-12.......................................................................2368
			2236-12.......................................................................2368
			2238-12.......................................................................2368
			521670-12.....................................................................2368
			524258-2......................................................................2368
			522215-12.....................................................................2376
			522215-14.....................................................................2376
			524236-14.....................................................................2376
			524262-12.....................................................................2376
			524262-14.....................................................................2376
			524263-1......................................................................2376
			524268-12.....................................................................2376
			628-12........................................................................2378
			630-12........................................................................2378
			522690-2......................................................................2378
			522690-12.....................................................................2378
			522691-2......................................................................2378
			522691-12.....................................................................2378
			522692-2......................................................................2378
			522693-12.....................................................................2378
			522694-12.....................................................................2378
			522695-2......................................................................2378
			522696-2......................................................................2378
			522697-12.....................................................................2378
			522698-2......................................................................2378
			522699-2......................................................................2378
			522700-2......................................................................2378
			190-2.........................................................................2380
			190-2.........................................................................2380
			190-7.........................................................................2380
			522120-1......................................................................2380
			522585-2......................................................................2380
			522752-9......................................................................2386
			524249-2......................................................................2390
			524250-2......................................................................2390
			524264-2......................................................................2390
			524264-14.....................................................................2390
			524265-2......................................................................2390
			524271-2......................................................................2390
			524225-14.....................................................................2390
			628-12........................................................................2395
			630-12........................................................................2395
			2660-3........................................................................2395
			2660-4........................................................................2395
			2661-3........................................................................2395
			2661-4........................................................................2395
			2802-12.......................................................................2395
			523510-12.....................................................................2395
			523511-12.....................................................................2395
			523515-3......................................................................2395
			523515-4......................................................................2395
			523519-3......................................................................2395
			523519-4......................................................................2395
			2802-12.......................................................................2397
			628-12........................................................................2397
			630-12........................................................................2397
			523261-3......................................................................2397
			523261-4......................................................................2397
			523257-3......................................................................2397
			523257-4......................................................................2397
			523253-3......................................................................2397
			523253-4......................................................................2397
			523249-3......................................................................2397
			523249-4......................................................................2397
			522780-3......................................................................2399
			522781-3......................................................................2399
			522780-4......................................................................2403
			522781-4......................................................................2403
			522780-2......................................................................2406
			522781-2......................................................................2406
			111-1.........................................................................2409
			524252-2......................................................................2413
			524253-14.....................................................................2415
			524255-2......................................................................2416
			108-0.........................................................................2417
			108-1.........................................................................2417
			522655-0......................................................................2420
			522655-1......................................................................2420
			522660-0......................................................................2420
			522660-1......................................................................2420
			524212-2......................................................................2424
			524211-2......................................................................2424
			524210-2......................................................................2424
			524209-2......................................................................2424
			524208-2......................................................................2424
			524207-2......................................................................2424
			524206-2......................................................................2424
			524205-2......................................................................2424
			524204-2......................................................................2424
			524203-2......................................................................2424
			524202-2......................................................................2424
			524201-2......................................................................2424
			524200-2......................................................................2424
			524199-2......................................................................2424
			524198-2......................................................................2424
			524197-2......................................................................2424
			522800-13.....................................................................2426
			522801-13.....................................................................2428
			522130-0......................................................................2429
			522131-0......................................................................2429
			522132-0......................................................................2429
			522133-0......................................................................2429
			522134-0......................................................................2429
			522130-1......................................................................2433
			522131-1......................................................................2433
			522132-1......................................................................2433
			522133-1......................................................................2433
			522134-1......................................................................2433
			522130-3......................................................................2438
			522131-3......................................................................2438
			522132-3......................................................................2438
			522133-3......................................................................2438
			522134-3......................................................................2438
			522130-4......................................................................2443
			522131-4......................................................................2443
			522132-4......................................................................2443
			522133-4......................................................................2443
			522134-4......................................................................2443
			522135-0......................................................................2447
			522137-0......................................................................2447
			522138-0......................................................................2447
			522135-1......................................................................2451
			522137-1......................................................................2451
			522138-1......................................................................2451
			522135-3......................................................................2455
			522137-3......................................................................2455
			522138-3......................................................................2455
			522135-4......................................................................2459
			522137-4......................................................................2459
			522138-4......................................................................2459
			522155-2......................................................................2463
			522157-2......................................................................2463
			522122-0......................................................................2470
			522124-0......................................................................2470
			522125-0......................................................................2470
			522126-0......................................................................2470
			522127-0......................................................................2470
			522122-1......................................................................2474
			522124-1......................................................................2474
			522125-1......................................................................2474
			522126-1......................................................................2474
			522127-1......................................................................2474
			522122-6......................................................................2478
			522124-6......................................................................2478
			522125-6......................................................................2478
			522126-6......................................................................2478
			522127-6......................................................................2478
			522122-8......................................................................2483
			522124-8......................................................................2483
			522125-8......................................................................2483
			522126-8......................................................................2483
			522127-8......................................................................2483
			522129-3......................................................................2487
			522129-4......................................................................2487
			522197-0......................................................................2489
			522198-0......................................................................2489
			522199-0......................................................................2489
			522200-0......................................................................2489
			522201-0......................................................................2489
			522197-1......................................................................2492
			522198-1......................................................................2492
			522199-1......................................................................2492
			522200-1......................................................................2492
			522201-1......................................................................2492
			522197-6......................................................................2493
			522198-6......................................................................2493
			522199-6......................................................................2493
			522200-6......................................................................2493
			522201-6......................................................................2493
			522197-7......................................................................2494
			522198-7......................................................................2494
			522199-7......................................................................2494
			522200-7......................................................................2494
			522201-7......................................................................2494
			522197-8......................................................................2495
			522198-8......................................................................2495
			522199-8......................................................................2495
			522200-8......................................................................2495
			522201-8......................................................................2495
			522197-14.....................................................................2497
			522198-14.....................................................................2497
			522199-14.....................................................................2497
			522200-14.....................................................................2497
			522201-14.....................................................................2497
			522197-27.....................................................................2498
			522198-27.....................................................................2498
			522199-27.....................................................................2498
			522200-27.....................................................................2498
			522201-27.....................................................................2498
			2039-2........................................................................2501
			522540-3......................................................................2504
			522540-4......................................................................2508
			522604-3......................................................................2513
			522604-4......................................................................2517
			522604-5......................................................................2521
			522697-12.....................................................................2526
			190-2.........................................................................2527
			190-4.........................................................................2527
			190-8.........................................................................2527
			522752-2......................................................................2527
			522752-4......................................................................2527
			522752-5......................................................................2533
			522598-3......................................................................2536
			522598-4......................................................................2540
			522592-0......................................................................2544
			522592-1......................................................................2546
			522593-12.....................................................................2548
			522594-12.....................................................................2552
			522595-12.....................................................................2552
			522596-12.....................................................................2552
			522597-12.....................................................................2552
			522614-7......................................................................2555
			522616-8......................................................................2555
			522617-5......................................................................2555
			524226-3......................................................................2556
			524226-4......................................................................2558
			524239........................................................................2560
			524241........................................................................2560
			524246........................................................................2560
			524267........................................................................2560
			524248........................................................................2560
			524746-2......................................................................2563
			Engine Continues to Run When Engine Cover is Raised...........................2565
			Engine Stops or Fails to Start................................................2567
			Electrical Functions Do Not Operate...........................................2569
			Electrical Function Does Not Turn Off.........................................2574
			Electro-Hydraulics Do Not Function With Armrest Down .........................2580
			Electro-Hydraulics Can Still Function With Armrest Raised.....................2583
			Vehicle Does Not Power On.....................................................2586
			Heater Fan Does Not Operate Properly..........................................2591
			Heater Airflow Does Not Reach Desired Temperature.............................2594
			Heater Output Has Insufficient Airflow........................................2595
			Circulating (Accessory) Fan Inoperative.......................................2596
			Dome Light Inoperative........................................................2599
			Horn Failure..................................................................2602
		Drive Train.......................................................................2605
			Mechanical Overview...........................................................2609
			Engine........................................................................2609
				Description...............................................................2609
			Torque Converter..............................................................2609
				Description...............................................................2609
					Stator................................................................2610
					Turbine...............................................................2610
			Pump PTO......................................................................2611
				Chain Drive PTO...........................................................2611
				Spur Gear PTO.............................................................2612
			Transmission..................................................................2613
				Description...............................................................2613
				1.0-5.5 Ton Lift Truck Transmissions......................................2616
					Description...........................................................2616
						Single-Speed......................................................2616
						Two-Speed.........................................................2617
					Clutch Pack...........................................................2618
					Power Flow............................................................2620
						Single-Speed......................................................2620
						Two-Speed.........................................................2621
					Transmission Hydraulic Schematic......................................2623
					Transmission Oil Flow.................................................2624
					Control Valve Oil Flow................................................2624
				6.0-7.0 Ton Lift Truck Transmissions......................................2626
					Description...........................................................2626
						Two-Speed.........................................................2626
						Three-Speed.......................................................2626
					Clutch Pack...........................................................2628
						Input Shaft and Range Clutches....................................2628
						Directional Clutches..............................................2628
						Output Section....................................................2629
					Power Flow............................................................2630
						Two-Speed and Three-Speed.........................................2630
					Transmission Hydraulic Schematic......................................2634
						Two-Speed.........................................................2634
						Three-Speed.......................................................2635
			Transmission Control System Overview..........................................2637
				Transmission Control System...............................................2637
			Transmission Control Software.................................................2640
				Transmission Control Modes................................................2640
					Neutral...............................................................2640
					Gear Engagement Control...............................................2640
						Basic Powershift Gear Engagement Mode.............................2640
						DuraMatch™ and Electronic Extended Features Gear Engagement Mo....2640
					Normal Forward or Reverse.............................................2640
						Basic Powershift..................................................2640
						DuraMatch™ and Electronic Extended Features Transmission..........2640
					Auto-Shift............................................................2640
					1st Gear Lock.........................................................2641
					Inching...............................................................2641
						Basic Powershift Inching Mode.....................................2641
						DuraMatch™ Inching Mode...........................................2641
						Electronic Extended Features Inching Mode.........................2641
					Inch/Brake Overlap Adjustment.........................................2641
					Brake Wear Compensation...............................................2641
					Auto Decel............................................................2642
					Controlled Power Reversal.............................................2642
						Basic Multi-Speed.................................................2642
						Electronic Extended Features......................................2642
					Controlled Creep......................................................2642
						Basic Powershift..................................................2642
						DuraMatch™ and Electronic Extended Features.......................2643
					Controlled Roll Back..................................................2643
						DuraMatch™ .......................................................2643
						Electronic Extended Features......................................2643
					Travel Speed Limit (Optional).........................................2643
					Extended Drawbar Pull ( Electronic Extended Features Multi-Speed......2643
					Auto-Speed Hydraulics ( Electronic Extended Features Transmissio......2643
					Throttle Response Management ( Electronic Extended Features Tran......2644
						Steady Travel Speed...............................................2644
			Transmission Control Hardware.................................................2644
				Control Valve and Sensors.................................................2644
					Description...........................................................2644
					Principles of Operation...............................................2646
				Transmission Proportional Valve...........................................2647
					Description...........................................................2647
					Neutral...............................................................2647
					Proportional Control..................................................2647
				MONOTROL® Pedal...........................................................2648
					Description...........................................................2648
					Principles of Operation...............................................2648
				Directional Control Lever.................................................2648
					Principles of Operation...............................................2648
			Driveshaft, Differential, Drive Axle, and Brakes (Dry Brake Only..............2649
				Driveshaft................................................................2649
				Differential and Drive Axle...............................................2649
				Brake System..............................................................2651
					Description...........................................................2651
					Service Brakes........................................................2651
					Master Cylinder.......................................................2651
					Brake Position Sensor.................................................2652
					Parking Brake.........................................................2652
			Driveshaft, Differential, Drive Axle, and Brakes (Wet Brake Only..............2652
				Driveshaft................................................................2652
				Differential..............................................................2653
				Brake System..............................................................2655
					Description...........................................................2655
					Service Brakes, 2.0-3.5 Ton Only......................................2655
					Service Brakes, 4.0-7.0 Ton...........................................2657
					Brake Adjustment and Service..........................................2657
					Parking Brake.........................................................2657
			Overheating Brakes (Dry Brake Axle Only)......................................2661
			Overheating Brakes (Wet Brake Axle Only)......................................2663
			Poor Brake Performance (Dry Brake Axle Only)..................................2666
			Poor Brake Performance (Wet Brake Axle Only)..................................2669
			Brakes Make Too Much Noise (Dry Brake Axle Only)..............................2671
			Brakes Pull To One Side (Dry Brake Axle Only).................................2672
			Parking Brake Will Not Release................................................2675
			Parking Brake Will Not Hold Lift Truck (Dry Brake Axle Only)..................2676
			Parking Brake Will Not Hold Lift Truck (Wet Brake Axle Only)..................2677
			Abnormal Drive Axle Noise.....................................................2678
			Discolored Drive Axle Oil.....................................................2681
			Lift Truck Does Not Move (Drive Axle).........................................2683
			Abnormal Transmission Noise...................................................2686
			Bubbles or Foaming In Transmission Dipstick Tube..............................2688
			Inching Operation Is Not Smooth or Chatters...................................2690
			Lift Truck Does Not Move In One or Both Directions (Transmission..............2692
			Loss of Power/Drivetrain Performance..........................................2695
			Transmission Is Too Hot.......................................................2698
			Transmission Will Not Shift To Forward High Range.............................2701
			Transmission Warmup Procedure.................................................2703
			Transmission Pressure Test....................................................2703
				Transmission Charge Pump Pressure Test....................................2705
				Clutch Pack Pressure Test (Proportional Solenoid Valves)..................2705
				Torque Converter Pressure Test............................................2706
				Lubrication Pressure Test.................................................2706
			Transmission Clutch Drag Test (1.0-5.5 Ton Trucks Only).......................2707
			Torque Converter Stall Test...................................................2707
		Hydraulic Systems.................................................................2711
			Main Hydraulic System.........................................................2715
				Description...............................................................2715
				Principles of Operation...................................................2718
				Hydraulic Schematics......................................................2719
					Manual Control Valve Schematics.......................................2719
					Electro-Hydraulic Control Valve Schematics............................2724
			Manual Hydraulic Control Valve................................................2728
				Description...............................................................2728
				Principles of Operation...................................................2730
					Lift Section..........................................................2730
						Lift Operation....................................................2730
						Lower Operation...................................................2730
					Tilt Section..........................................................2731
						Tilt Backward.....................................................2731
						Tilt Forward......................................................2731
					Auxiliary Section.....................................................2733
					Anti-stall Feature....................................................2734
					Relief Valves.........................................................2734
						Main Relief Valve.................................................2734
						Secondary Relief Valve............................................2734
			Electro-Hydraulic Control Valve...............................................2735
				Description...............................................................2735
				Principles of Operation...................................................2736
					Inlet Pressure Compensator/Unloader...................................2736
					Lift/Lower EHPVs......................................................2738
						EHPV Operation....................................................2739
					Tilt and Auxiliary Spool Functions....................................2740
					Tilt Forward Function.................................................2742
					Main Relief Valve ....................................................2743
					Secondary Relief Valve................................................2743
					Secondary Function Anti-stall Valve...................................2744
					Emergency Lowering Valve..............................................2745
			Steering System...............................................................2745
				Component Locations.......................................................2745
					Description...........................................................2745
					Steering Axle Assembly................................................2745
					Steering Control Unit.................................................2745
				Steering Schematic........................................................2747
					Principles of Operation...............................................2748
					Steering Control Unit.................................................2748
			Actuation Functions With Armrest Up (E-Valve).................................2749
			Cycle Times Too Fast - Fast Actuation (E-Valve)...............................2750
			Jump/Delay In Lift or Lower Activation After Moving Joystick or ..............2752
			Jump/Delay In Secondary Function Actuation After Moving Joystick..............2755
			Jump/Delay In Tilt Forward Actuation (E-Valve)................................2757
			Forks Drop Slightly Before Lifting (E-Valve)..................................2759
			Forks Lower Without Command (E-Valve).........................................2760
			Forks Raise or Actuate Without Command (E-Valve)..............................2762
			Forks Tilt Forward Without Command (E-Valve)..................................2764
			Intermittent Activation (E-Valve) While Commanding Function...................2766
			Lift/Lower Function Maximum Speed Too Slow (E-Valve)..........................2768
			Lift Function Will Not Move With Joystick or MLM Movement (E-Val..............2771
			Lift/Lower Continues To Move For Awhile After Joystick or MLM Is..............2775
			Lift/Lower/Secondary Function Suddenly Jumps In Middle of Stroke..............2776
			Lower Function Will Not Move With Joystick or MLM Movement (E-Va..............2777
			Poor Metering on Lift or Lower Functions (E-Valve)............................2779
			Secondary Function Continues to Move for Awhile After Joystick o..............2782
			Secondary Function Exhibits Slight Movement in Opposite Directio..............2783
			Secondary Function Maximum Speed Too Slow (E-Valve)...........................2784
			Secondary Function or Tilt Back Moves Without Command (E-Valve)...............2787
			Secondary Function and Tilt Back Will Not Move With Joystick or ..............2789
			Tilt Forward Function Continues to Move for Awhile When Joystick..............2793
			Tilt Forward Will Not Move Upon Joystick or MLM Movement (E-Valv..............2794
			Too Much Joystick or MLM Movement (Deadband) to Start Function M..............2796
			Wrong Actuation Operates or Actuation is Backward (E-Valve)...................2797
			Actuation Exhibits Slight Movement in Opposite Direction Before ..............2798
			Auxiliary Function is Slow or Does Not Function (Manual Valve)................2799
			Cycle Times Too Fast - Fast Actuation (Manual Valve)..........................2801
			Function Continues to Activate After Returning to Neutral.....................2802
			Lift Function Is Slow or Does Not Function (Manual Valve).....................2803
			Tilt Back Function Will Not Operate (Manual Valve)............................2805
			Tilt Forward Functions When Spool is Activated Forward With Engi..............2806
			Tilt Forward Will Not Function When Activated (Manual Valve)..................2807
			Abnormal Steer Axle Noise.....................................................2808
			Abnormal Steering Wheel Vibration.............................................2810
			Back Lash/Kick Back in Steering Wheel.........................................2811
			No Steering (All Other Hydraulic Functions OK)................................2813
			Steering Is Slow or Difficult.................................................2815
			Steering Operation Is Not Smooth..............................................2817
			Steering Wheel End Lock Position Cannot Be Felt by Operator...................2819
			Steering Wheel Turns By Itself or Does Not Return To Neutral..................2820
			Steering Wheel Turns the Tires in the Wrong Direction.........................2821
			Abnormal Hydraulic Noise and/or Vibration.....................................2822
			Abnormal Smell/Discoloration/Foaming of Oil...................................2825
			Actuations Do Not Act Simultaneously..........................................2826
			Oil Leaking/Component Life Too Short..........................................2827
			Hydraulic Warmup Procedure....................................................2831
			Main Relief Valve Test and Adjustment.........................................2832
			Secondary Relief Valve Test and Adjustment....................................2834
			Hydraulic Pump Flow Test......................................................2836
			Main Control Valve LS Leakage Test (E-Valve)..................................2838
			Main Control Valve Unloader Margin Test.......................................2839
			Electro-Hydraulic Poppet Valve (EHPV) Leakage Test............................2840
			PPRV Pilot Pressure Test......................................................2843
			Steering Relief Pressure Test and Adjustment..................................2844
			Steering Control Unit LS Pressure Test........................................2845
			Lift Cylinder Leakage Test....................................................2847
			Tilt Cylinder Leakage Test....................................................2848
			Steering Cylinder Leakage Test................................................2849
		Operators Station.................................................................2851
			Operator Station General Description and Principles of Operation..............2853
				General Description and Location..........................................2853
			Display Switch Cluster (DSC)..................................................2855
				Detailed Description......................................................2855
				Control Inputs, Right Side................................................2856
				Right Indicator and Warning Group.........................................2858
				LCD Display...............................................................2859
				Left Indicator and Warning Group..........................................2860
				Control Inputs, Left Side (Cab Option Only)...............................2861
			Transmission Control and Braking..............................................2862
				Description...............................................................2862
					Vehicle System Manager (VSM)..........................................2863
					Display Switch Cluster................................................2863
						Interlock and Switching Features..................................2863
					MONOTROL® Directional Control.........................................2863
					Inch Brake/Service Brake Pedal........................................2863
					Parking Brake.........................................................2864
			Programming - Menus...........................................................2864
				Menus.....................................................................2864
					Main Menu.............................................................2867
					Save and Exit or Exit Without Saving..................................2867
					Back One Level........................................................2867
					Hourmeters............................................................2867
					View Versions.........................................................2868
					Passwords.............................................................2868
					Diagnostics...........................................................2868
					Setup Travel and Braking..............................................2868
					Setup Hydraulics......................................................2868
					Setup Display.........................................................2868
					Setup General Items...................................................2868
					Calibrations..........................................................2868
			Manual Hydraulic Control Levers...............................................2869
				General Description.......................................................2869
				System Components.........................................................2869
					Lift/Lower............................................................2869
					Tilt..................................................................2869
					Auxiliary 1...........................................................2869
					Auxiliary 2...........................................................2869
			E-Hydraulic System Interface..................................................2870
				General Description.......................................................2870
				System Components.........................................................2870
				E-Hydraulic Control Input Device..........................................2870
					Joystick..............................................................2870
						Lift/Lower........................................................2871
						Tilt..............................................................2871
						Auxiliary 1.......................................................2871
						Auxiliary 2.......................................................2871
						Push Button.......................................................2871
					Mini Lever Module (MLM)...............................................2872
						Lever 1...........................................................2872
						Lever 2...........................................................2872
						Lever 3...........................................................2873
						Lever 4...........................................................2873
				System Modes..............................................................2873
					Hydraulic Interlock Mode..............................................2873
					Fault Mode............................................................2873
					Engine Off Mode.......................................................2873
				Normal Operation..........................................................2873
					Normal Operation Mode.................................................2873
					Lifting Control.......................................................2873
					Lowering Control......................................................2874
					Tilt Control (Forward and Backward)...................................2874
					Auxiliary Control.....................................................2874
			Lighting Control..............................................................2874
				Description...............................................................2874
					Front Work Lights.....................................................2877
					Front Marker Lights (if equipped).....................................2877
					Front/Rear Turn Signal Lights.........................................2877
					Rear Tail/Marker Lights...............................................2877
					Rear Work Light.......................................................2877
					Rear Backup Lights....................................................2877
					Rear Stop Lights......................................................2877
					Strobe Light(s).......................................................2877
					Spot Light (if equipped)..............................................2877
			Cab...........................................................................2877
				Description...............................................................2877
				Component Descriptions....................................................2879
					Cab Heating System....................................................2879
					Lighting Control System...............................................2879
					Wiper/Washer System...................................................2879
				Cab Systems Operation.....................................................2880
		Front End (Mast) and Chassis......................................................2883
			Front End, Mast...............................................................2885
				Description...............................................................2885
			Carriages.....................................................................2885
				Description...............................................................2885
				Principles of Operation...................................................2886
					Integral Sideshift Carriage...........................................2886
			Mast Mounts...................................................................2888
				Description...............................................................2888
				Principles of Operation...................................................2888
			Two-Stage Limited Free-Lift (LFL) Mast........................................2890
				Description...............................................................2890
				Principles of Operation...................................................2891
			Two-Stage Full Free-Lift (FFL) Mast...........................................2892
				Description...............................................................2892
				Principles of Operation...................................................2893
			Three-Stage Full Free-Lift (FFL) Mast.........................................2894
				Description...............................................................2894
				Principles of Operation...................................................2894
			Four-Stage Full Free-Lift (FFL) Mast..........................................2896
				Description...............................................................2896
				Principles of Operation...................................................2897
			Cylinder Cushion During Lifting Sequence......................................2899
				Description...............................................................2899
				Principles of Operation...................................................2899
			Cylinder Cushion During Lowering Sequence.....................................2900
				Description...............................................................2900
				Principles of Operation...................................................2900
			Tilt and Sideshift Cylinders..................................................2900
				Description...............................................................2900
					Tilt Cylinder.........................................................2900
					Sideshift Cylinder....................................................2900
			Lowering Control Valves.......................................................2901
				Description...............................................................2901
				Principles of Operation...................................................2901
			Chassis.......................................................................2903
				Description...............................................................2903
			Abnormal Channel Wear.........................................................2905
			Abnormal Hose Wear............................................................2907
			Abnormal Mast Noise...........................................................2909
			Body Panels Making Noise......................................................2913
			External Leakage From Free-Lift or Main Lift Cylinders........................2914
			FFL Mast Banging During Phasing...............................................2915
			High Tire Wear - Drive Axle...................................................2917
			High Tire Wear - Steer Axle...................................................2919
			Hoses Not Tracking Correctly..................................................2921
			Integral Sideshift Moving Too Fast............................................2922
			Integral Sideshift Not Moving or Slow.........................................2923
			LP Tank Bracket Disengages....................................................2926
			LP Tank Rattles and Does Not Stay Latched.....................................2927
			Mast is Loose.................................................................2928
			Mast Lift Chains Are Loose....................................................2930
			Mast or Carriage Binding......................................................2931
			Mast/Carriage Bounces or is Spongy............................................2933
			Misphasing of Full Free-Lift Mast.............................................2934
			Overhead Guard Loose or Damaged...............................................2936
			Racking During Lift...........................................................2937
			Racking During Tilt...........................................................2939
			Truck Feels Unstable..........................................................2940
			Truck Wanders, Does Not Track Straight or Steer Well..........................2942
			Wheels Appear Tipped or Misaligned............................................2944
			Wheels Spinning On Uneven Floors..............................................2946
			Wheel Studs Breaking..........................................................2947
		Supplementary Data................................................................2949
			Abbreviations and Acronyms....................................................2951
			Special Tools List............................................................2959
			Fault Mode Indicator (FMI) Reference List.....................................2965
			TSP Reference Tables..........................................................2967
	tables................................................................................1691
		Table 9020-10-1. IAT Ambient Temperature..........................................1782
		Table 9020-40-1. Test Specifications..............................................1955
		Table 9020-40-2. Test Specifications..............................................1956
		Table 9020-40-3. Service Tools....................................................1956
		Table 9020-40-4. Test Specifications..............................................1957
		Table 9020-40-5. Service Tools....................................................1957
		Table 9020-40-6. Test Specifications..............................................1958
		Table 9020-40-7. Service Tools....................................................1959
		Table 9020-40-8. Test Specifications - Mazda......................................1960
		Table 9020-40-9. Test Specifications - GM.........................................1960
		Table 9020-40-10. Service Tools...................................................1960
		Table 9020-40-11. Test Specifications.............................................1962
		Table 9020-40-12. Service Tools...................................................1962
		Table 9020-40-13. Test Specifications.............................................1964
		Table 9020-40-14. Service Tools...................................................1964
		Table 9030-03-1. Cummins QSB 3.3L Fault Codes.....................................1995
		Table 9030-03-2. Circuit Group Identification.....................................1998
		Table 9030-03-3. Hyster Wiring Color Codes........................................1999
		Table 9040-10-1. Two-Speed Transmission Clutch Pack Solenoid Val..................2635
		Table 9040-10-2. Three-Speed Transmission Electronic Proportiona..................2636
		Table 9040-10-3. Transmission Control Mode........................................2638
		Table 9040-40-1. Test Specifications..............................................2703
		Table 9040-40-2. Service Tools....................................................2703
		Table 9040-40-3. Service Tools....................................................2703
		Table 9040-40-4. Test Specifications..............................................2705
		Table 9040-40-5. Test Specifications..............................................2705
		Table 9040-40-6. Test Specifications..............................................2706
		Table 9040-40-7. Test Specifications..............................................2706
		Table 9040-40-8. Test Specifications..............................................2707
		Table 9040-40-9. Service Tools....................................................2707
		Table 9040-40-10. Stall Speeds....................................................2708
		Table 9050-10-1. Standby Pressure Table...........................................2737
		Table 9050-40-1. Test Specifications..............................................2831
		Table 9050-40-2. Service Tools....................................................2831
		Table 9050-40-3. Test Specifications..............................................2832
		Table 9050-40-4. Service Tools....................................................2832
		Table 9050-40-5. Test Specifications..............................................2834
		Table 9050-40-6. Service Tools....................................................2834
		Table 9050-40-7. Test Specifications..............................................2836
		Table 9050-40-8. Service Tools....................................................2837
		Table 9050-40-9. Test Specifications..............................................2838
		Table 9050-40-10. Test Specifications.............................................2839
		Table 9050-40-11. Service Tools...................................................2839
		Table 9050-40-12. Test Specifications.............................................2840
		Table 9050-40-13. Service Tools...................................................2840
		Table 9050-40-14. Test Specifications.............................................2843
		Table 9050-40-15. Service Tools...................................................2843
		Table 9050-40-16. Test Specifications.............................................2844
		Table 9050-40-17. Service Tools...................................................2844
		Table 9050-40-18. Test Specifications.............................................2845
		Table 9050-40-19. Service Tools...................................................2846
		Table 9050-40-20. Test Specifications.............................................2847
		Table 9050-40-21. Service Tools...................................................2847
		Table 9050-40-22. Test Specifications.............................................2848
		Table 9050-40-23. Service Tools...................................................2848
		Table 9050-40-24. Test Specifications.............................................2849
		Table 9050-40-25. Service Tools...................................................2849
		Table 9080-50-1. Abbreviations and Acronyms.......................................2951
		Table 9080-60-1. Special Tools....................................................2959
		Table 9080-70-1. FMI..............................................................2965
		Table 9080-80-1. Resistor-Temperature Characteristics ............................2967
1580502-0100SRM1120-(01-2007)-US-EN.......................................................2971
	toc...................................................................................2971
		Frame.............................................................................2971
		Safety Precautions Maintenance and Repair.........................................2972
		General...........................................................................2975
		Description.......................................................................2976
		Hood, Seat, and Side Covers Replacement...........................................2976
			Remove........................................................................2976
			Install.......................................................................2981
		LPG Tank and Bracket Replacement..................................................2983
			Remove........................................................................2983
				LPG Tank..................................................................2983
				LPG Bracket...............................................................2986
			Install.......................................................................2986
				LPG Bracket...............................................................2986
				LPG Tank..................................................................2987
		Counterweight Replacement.........................................................2988
			Remove........................................................................2988
			Install.......................................................................2989
			Tow Pin, Remove and Install...................................................2990
		Overhead Guard Replacement........................................................2990
			Remove and Install............................................................2990
			LED Tail, Backup, and Brake Lights, Replace...................................2991
		Operator Restraint System Replacement.............................................2992
			Description...................................................................2992
				Automatic Locking Retractor (ALR).........................................2992
				Emergency Locking Retractor (ELR).........................................2992
		Engine Replacement................................................................2993
			Remove Engine Only............................................................2993
			Remove Engine and Transmission................................................2997
			Install Engine Only...........................................................2997
			Install Engine and Transmission...............................................2998
		Throttle Pedal and Cable Adjustment...............................................2999
			Mazda Gas/LPG Engines With Basic Power Shift Transmission and Ma..............2999
			Mazda Gasoline Engine With Electronic Transmission............................3002
			Throttle Pedal Stop Adjustment, Mazda 2007 Emission Compliant En..............3003
			Yanmar Diesel Engine With Basic Power Shift Transmission......................3003
			Yanmar Diesel Engine With Electronic Throttle.................................3003
		Exhaust System Repair.............................................................3005
			Lift Trucks With Counterweight Exhaust System.................................3005
				Mazda and GM Gas and LPG Engines..........................................3005
					Remove and Disassemble................................................3005
					Inspect...............................................................3005
					Assemble and Install..................................................3007
				Yanmar Diesel Engine......................................................3009
					Remove and Disassemble................................................3009
					Inspect...............................................................3009
					Assemble and Install..................................................3009
			Lift Trucks With Overhead Exhaust System......................................3011
				Yanmar Diesel Engine......................................................3011
					Remove and Disassemble................................................3011
					Inspect...............................................................3011
					Assemble and Install..................................................3012
				Mazda Gas and LPG Engines.................................................3014
					Remove and Disassemble................................................3014
					Inspect...............................................................3014
					Assemble and Install..................................................3014
		Cooling System....................................................................3018
			Description...................................................................3018
		Fuel and Hydraulic Tanks Repair...................................................3018
			Inspect.......................................................................3018
			Clean.........................................................................3018
				Steam Method of Cleaning..................................................3018
				Chemical Solution Method of Cleaning......................................3019
			Additional Preparations for Repair............................................3019
			Small Leaks, Repair...........................................................3020
			Large Leaks, Repair...........................................................3020
			Preparations for Use After Repair.............................................3020
		Safety Labels.....................................................................3020
	tables................................................................................2971
		Table 1. Weight of Counterweights, Lift Truck Models S2.0-3.5FT ..................2989
		Table 2. Weight of Counterweights, Lift Truck Models S30FT, S35F..................2989
		Table 3. Weight of Counterweights, Lift Truck Models H1.6FT, H1...................2989
		Table 4. Weight of Counterweights, Lift Truck Models H2.0-3.5FT ..................2989
1580503-0600SRM1121-(06-2007)-US-EN.......................................................3025
	toc...................................................................................3025
		GM Engine Repair..................................................................3025
		Safety Precautions Maintenance and Repair.........................................3026
		General...........................................................................3031
		Engine Serial Number..............................................................3031
		Engine Removal and Installation...................................................3032
		Intake Manifold...................................................................3032
			Remove........................................................................3032
			Clean and Inspect.............................................................3033
			Install.......................................................................3033
		Exhaust Manifold..................................................................3034
			Remove........................................................................3034
			Clean and Inspect.............................................................3034
			Install.......................................................................3035
		Camshaft and Cylinder Head Repair.................................................3035
			Rocker Arm Cover..............................................................3035
				Remove....................................................................3035
				Install...................................................................3035
			Camshaft Timing Pulley and/or Front Seal......................................3036
				Remove....................................................................3036
				Install...................................................................3036
			Camshaft Position (CMP) Sensor Assembly.......................................3037
				Remove....................................................................3037
				Install...................................................................3037
			Camshaft Carrier and Cylinder Head............................................3037
				Remove....................................................................3037
				Disassemble...............................................................3039
					Camshaft Carrier......................................................3039
					Cylinder Head.........................................................3040
				Clean and Inspect.........................................................3040
					Camshaft Carrier......................................................3040
					Cylinder Head.........................................................3041
				Valve and Valve Seat......................................................3043
				Assemble..................................................................3044
					Cylinder Head.........................................................3044
					Camshaft Carrier......................................................3044
				Install...................................................................3044
		Timing Belt.......................................................................3046
			Timing Belt Front Cover.......................................................3046
				Remove....................................................................3046
				Install...................................................................3047
			Timing Belt and Timing Belt Tensioner.........................................3047
				Remove....................................................................3047
				Install...................................................................3048
			Timing Belt Rear Cover........................................................3049
				Remove....................................................................3049
				Install...................................................................3049
		Lubrication System Repair.........................................................3050
			Oil Pan.......................................................................3050
				Remove....................................................................3050
				Install...................................................................3050
			Oil Pump......................................................................3052
				Remove....................................................................3052
				Clean and Inspect.........................................................3053
				Install...................................................................3054
		Piston and Piston Rod Assemblies Repair...........................................3055
			Piston Rod Bearings, Replace..................................................3055
			Piston and Piston Rod Assemblies..............................................3057
				Remove....................................................................3057
				Disassemble...............................................................3058
				Pistons, Clean and Inspect................................................3058
				Cylinder Bores, Inspect and Repair........................................3059
				Piston Rings, Inspect.....................................................3059
				Assemble..................................................................3060
				Install...................................................................3061
		Crankshaft and Main Bearings......................................................3062
			Crankshaft Timing Pulley and/or Front Seal....................................3062
				Remove....................................................................3062
				Install...................................................................3063
			Crankshaft Rear Main Oil Seal.................................................3063
				Remove....................................................................3063
				Install...................................................................3063
			Crankshaft/RPM Sensor.........................................................3064
				Remove....................................................................3064
				Install...................................................................3064
			Crankshaft Reluctor Wheel.....................................................3064
				Remove and Install........................................................3064
			Crankshaft and Main Bearings..................................................3065
				Remove....................................................................3065
				Inspect and Repair........................................................3066
				Bearing Selection.........................................................3066
				Main Bearings and Journal Clearance, Check................................3068
				Install...................................................................3069
		Flywheel and Flywheel Housing.....................................................3070
			Remove........................................................................3070
			Install.......................................................................3070
		Cooling System Repair.............................................................3071
			Serpentine Belt...............................................................3071
				Remove....................................................................3071
				Inspect...................................................................3071
				Install...................................................................3071
			Water Pump....................................................................3072
				Remove....................................................................3072
				Inspect...................................................................3074
				Install...................................................................3074
			Thermostat....................................................................3075
				Remove....................................................................3075
				Check.....................................................................3076
				Install...................................................................3076
			Thermostat Housing............................................................3077
				Remove....................................................................3077
				Clean and Inspect.........................................................3078
				Install...................................................................3078
		Ignition System...................................................................3079
			Spark Plug Wire Inspection....................................................3079
			Spark Plug Wire Replacement...................................................3079
				Remove....................................................................3079
				Install...................................................................3080
			Spark Plug Replacement........................................................3080
				Remove....................................................................3080
				Install...................................................................3080
			Spark Plug Inspection.........................................................3081
				Usage.....................................................................3081
				Inspect...................................................................3081
				Visual Inspection.........................................................3082
			Coil Pack.....................................................................3083
				Remove....................................................................3083
				Install...................................................................3083
		Alternator Repair.................................................................3083
			Alternator....................................................................3083
				Remove....................................................................3083
				Install...................................................................3084
			Alternator Fuse, Replace......................................................3084
		Starter Repair....................................................................3085
			Remove........................................................................3085
			Install.......................................................................3085
		Engine Specifications.............................................................3085
			Engine Data...................................................................3085
			Cylinder Bore.................................................................3086
			Piston........................................................................3086
			Piston Rings..................................................................3086
			Wrist Pin.....................................................................3086
			Crankshaft....................................................................3087
			Piston Rod....................................................................3087
			Camshaft and Camshaft Carrier.................................................3087
			Valve System..................................................................3088
			Cylinder Head Warpage.........................................................3088
			Lubrication System............................................................3088
			Cooling System................................................................3089
		Torque Specifications.............................................................3089
		Special Tools.....................................................................3090
1580504-0600SRM1122-(12-2006)-US-EN.......................................................3097
	toc...................................................................................3097
		Mazda Engine......................................................................3097
		Safety Precautions Maintenance and Repair.........................................3098
		General...........................................................................3101
			Serial Number.................................................................3101
		Engine Removal and Installation...................................................3101
		Cylinder Head, Camshaft, and Valve Mechanism Repair...............................3102
			Remove........................................................................3102
			Clean.........................................................................3104
			Inspect and Repair............................................................3104
				Cylinder Head.............................................................3104
				Rocker Shaft Assembly.....................................................3104
				Camshaft..................................................................3104
				Valve Guides..............................................................3106
				Valve Seats...............................................................3106
				Valves....................................................................3106
				Valve Springs.............................................................3107
			Install.......................................................................3107
		Crankshaft and Main Bearings Repair...............................................3111
			Remove........................................................................3111
			Inspect and Repair............................................................3112
				Crankshaft................................................................3112
				Main Bearings.............................................................3112
			Install.......................................................................3113
		Pistons and Connecting Rods Repair................................................3114
			Remove and Disassemble........................................................3114
			Clean.........................................................................3114
			Inspect and Repair............................................................3114
				Pistons...................................................................3114
				Piston Rings..............................................................3114
				Connecting Rods and Bearings..............................................3115
			Assemble and Install..........................................................3115
		Cylinder Block Repair.............................................................3117
		Oil Pump Repair...................................................................3117
			Remove........................................................................3117
			Disassemble...................................................................3119
			Clean.........................................................................3119
			Inspect.......................................................................3119
			Assemble......................................................................3120
			Install.......................................................................3120
		Cooling System Repair.............................................................3122
			Thermostat....................................................................3122
				Replace...................................................................3122
			Fan Assembly..................................................................3122
				Remove and Disassemble....................................................3122
				Assemble and Install......................................................3122
			Water Pump....................................................................3123
				Remove....................................................................3123
				Install...................................................................3124
		Flywheel and Ring Gear Repair.....................................................3124
			Remove........................................................................3124
			Install.......................................................................3124
		Valve Adjustment..................................................................3125
		Compression Pressure Check........................................................3126
		Engine Timing Adjustment..........................................................3127
		Engine Specifications.............................................................3127
			Engine Data...................................................................3127
			Engine Speeds.................................................................3127
				2007 Emission Compliant Engines...........................................3127
				All Engines Except 2007 Emission Compliant Engines........................3128
			Thermostat....................................................................3128
			Cylinder Head.................................................................3128
			Valve Mechanism...............................................................3128
			Camshaft......................................................................3129
			Crankshaft....................................................................3129
			Connecting Rods...............................................................3130
			Cylinder Block................................................................3130
			Pistons.......................................................................3130
			Oil Pump......................................................................3131
		Torque Specifications.............................................................3131
	tables................................................................................3097
		Table 1. Pressure Specifications..................................................3126
1580505-0700SRM1123-(03-2007)-US-EN.......................................................3135
	toc...................................................................................3135
		Cooling System....................................................................3135
		Safety Precautions Maintenance and Repair.........................................3136
		General...........................................................................3139
		Cooling System Checks.............................................................3139
			Exhaust Leaks Into Cooling System.............................................3139
			Water Flow Restrictions in Radiator...........................................3139
			Radiator Hoses................................................................3139
			Water Pump....................................................................3139
		Flushing The Cooling System.......................................................3140
			Cooling System, Clean.........................................................3140
		Radiator Replacement..............................................................3141
			Radiator, Remove for Lift Trucks Models S30FT, S35FT, S40FTS (E0..............3141
			Radiator, Remove for Lift Truck Models S6.0FT, S7.0FT (S135FT, S..............3147
			Radiator, Remove for Lift Truck Models H6.0FT, H7.0FT (H135FT, H..............3148
			Radiator, Install for Lift Truck Models S30FT, S35FT, S40FTS (E0..............3149
			Radiator, Install for Lift Truck Models S6.0FT, S7.0FT (S135FT, ..............3152
			Radiator, Install for Lift Truck Models H6.0FT, H7.0FT (H135FT, ..............3154
		Fan Assembly Replacement..........................................................3157
			Fan Removal...................................................................3157
			Inspect.......................................................................3164
			Fan Installation..............................................................3164
1580506-0900SRM1124-(08-2006)-US-EN.......................................................3167
	toc...................................................................................3167
		LPG Fuel System...................................................................3167
		Safety Precautions Maintenance and Repair.........................................3168
		General...........................................................................3171
		Hoses Replacement.................................................................3171
		LPG Tank Replacement..............................................................3171
			Remove........................................................................3171
			Install.......................................................................3173
		Fuel Filter Unit Repair...........................................................3174
			Fuel Filter Element...........................................................3174
				Remove....................................................................3174
				Clean/Inspect.............................................................3174
				Install...................................................................3174
			Fuel Filter Housing...........................................................3175
				Remove....................................................................3175
				Disassemble...............................................................3175
				Assemble..................................................................3176
				Install...................................................................3176
		Electronic Throttle Body Repair...................................................3176
			Electronic Throttle Body......................................................3176
				Remove....................................................................3176
				Install...................................................................3176
			Electronic Throttle Body Adapter Plate........................................3177
				Remove....................................................................3177
				Install...................................................................3177
		Fuel Injector Repair..............................................................3178
			Fuel Rail.....................................................................3178
				Remove....................................................................3178
				Install...................................................................3178
			Fuel Injector.................................................................3179
				Remove....................................................................3179
				Clean.....................................................................3180
				Install...................................................................3180
			Fuel Injector Adapters........................................................3181
				Remove....................................................................3181
				Install...................................................................3181
		LPG Regulator Repair..............................................................3182
			LPG Regulator.................................................................3182
				Remove....................................................................3182
				Install...................................................................3183
			LPG Regulator Fuel Filter.....................................................3184
				Remove....................................................................3184
				Install...................................................................3184
			Lock-Off Solenoid and Cartridge...............................................3185
				Remove....................................................................3185
				Install...................................................................3185
		Control System....................................................................3186
			Electronic Control Unit (ECU).................................................3186
				Remove....................................................................3186
				Install...................................................................3186
			Power Latch Relay.............................................................3187
				Remove....................................................................3187
				Install...................................................................3188
			Injector Driver Module........................................................3188
				Remove....................................................................3188
				Install...................................................................3189
			Camshaft Position (CMP) Sensor................................................3189
				Remove....................................................................3189
				Install...................................................................3189
			Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) ..............3190
				Remove....................................................................3190
				Install...................................................................3190
			Engine Coolant Temperature (ECT) Sensor.......................................3190
				Remove....................................................................3190
				Install...................................................................3190
			Oxygen Sensor.................................................................3191
				Remove....................................................................3191
				Install...................................................................3191
1580507-0900SRM1125-(05-2005)-US-EN.......................................................3195
	toc...................................................................................3195
		LPG Fuel System...................................................................3195
		Safety Precautions Maintenance and Repair.........................................3196
		General...........................................................................3199
		Hoses Replacement.................................................................3199
		LPG Tank Replacement..............................................................3199
			Remove........................................................................3199
			Install.......................................................................3199
		Fuel Filter.......................................................................3201
			Remove........................................................................3201
			Clean and Inspect.............................................................3202
			Install.......................................................................3203
		Relief Valve Replacement..........................................................3204
			Remove and Install............................................................3204
		Carburetor Repair.................................................................3204
			Remove........................................................................3204
			Disassemble...................................................................3204
			Clean.........................................................................3206
			Assemble......................................................................3206
			Install.......................................................................3206
		Fuel Injector Repair..............................................................3207
			Remove........................................................................3207
			Clean and Inspect.............................................................3207
			Install.......................................................................3207
		Governor Repair...................................................................3207
			Remove........................................................................3207
			Install.......................................................................3207
		Regulator Repair..................................................................3208
			Remove........................................................................3208
			Install.......................................................................3209
		Control System....................................................................3209
			Engine Control Unit (ECU).....................................................3209
				Remove....................................................................3209
				Install...................................................................3209
			Engine Coolant Temperature (ECT) Sensor.......................................3210
				Remove....................................................................3210
				Install...................................................................3210
			Camshaft Position (CMP) Sensor................................................3210
				Voltage Check.............................................................3210
			Intake Air Temperature (IAT) Sensor...........................................3211
				Remove....................................................................3211
				Install...................................................................3211
			Manifold Absolute Pressure (MAP) Sensor.......................................3212
				Remove....................................................................3212
				Install...................................................................3212
			Oxygen Sensor.................................................................3212
				Remove....................................................................3212
				Install...................................................................3212
			Throttle Position (TP) Sensor.................................................3213
				Remove....................................................................3213
				Install...................................................................3213
1580508-0900SRM1126-(05-2005)-US-EN.......................................................3217
	toc...................................................................................3217
		Gasoline Fuel System..............................................................3217
		Safety Precautions Maintenance and Repair.........................................3218
		General...........................................................................3221
		Electronic Throttle Body Repair...................................................3221
			Electronic Throttle Body......................................................3221
				Remove....................................................................3221
				Install...................................................................3221
		Fuel System Repair................................................................3222
			Before Repair Procedure.......................................................3222
			After Repair Procedure........................................................3222
				Fuel Leakage Check........................................................3222
			Fuel Line Pressure Check......................................................3223
			Fuel Injectors................................................................3224
				Remove....................................................................3224
				Install...................................................................3225
			Pressure Regulator............................................................3225
				Remove....................................................................3225
				Install...................................................................3226
		Control System....................................................................3226
			Electronic Control Unit (ECU).................................................3226
				Remove....................................................................3226
				Install...................................................................3227
			Power Latch Relay.............................................................3227
				Remove....................................................................3227
				Install...................................................................3228
			Camshaft Position (CMP) Sensor................................................3228
				Remove....................................................................3228
				Install...................................................................3228
			Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) ..............3229
				Remove....................................................................3229
				Install...................................................................3229
			Engine Coolant Temperature (ECT) Sensor.......................................3229
				Remove....................................................................3229
				Install...................................................................3230
			Oxygen Sensor.................................................................3230
				Remove....................................................................3230
				Install...................................................................3231
1580509-0900SRM1127-(05-2005)-US-EN.......................................................3235
	toc...................................................................................3235
		Gasoline Fuel System..............................................................3235
		Safety Precautions Maintenance and Repair.........................................3236
		General...........................................................................3239
		Abbreviations.....................................................................3239
		Engine Tune-up....................................................................3239
			Engine Tune-Up Preparation....................................................3239
			Idle Speed Adjustment.........................................................3239
			Idle-Up Speed Check...........................................................3239
		Intake-Air System.................................................................3241
			Intake-Air System Manifold Vacuum Check.......................................3241
			Throttle Body.................................................................3242
				Remove....................................................................3242
				Install...................................................................3242
			Electronic Governor...........................................................3242
				Remove....................................................................3242
				Install...................................................................3242
			Intake-Air Control (IAC) Valve................................................3242
				Remove....................................................................3242
				Install...................................................................3244
			Intake Manifold...............................................................3244
				Remove....................................................................3244
				Install...................................................................3244
		Fuel System.......................................................................3245
			Before Repair Procedure.......................................................3245
				Fuel Line Safety Procedure................................................3245
			After Repair Procedure........................................................3245
				Fuel Hose, Install........................................................3245
				Fuel Leakage Check........................................................3246
			Fuel Line Pressure Check......................................................3246
			Fuel Injector.................................................................3247
				Remove....................................................................3247
				Install...................................................................3247
			Pressure Regulator............................................................3248
				Remove....................................................................3248
				Install...................................................................3249
		Exhaust System....................................................................3250
			Exhaust System, Inspect.......................................................3250
			Three-Way Catalytic (TWC) Converter...........................................3250
				Remove and Install........................................................3250
			Exhaust Manifold..............................................................3250
				Remove....................................................................3250
				Install...................................................................3250
			Positive Crankcase Ventilation (PCV) Valve....................................3252
				Remove....................................................................3252
				Inspect...................................................................3252
				Install...................................................................3252
		Control System....................................................................3252
			Engine Control Unit (ECU).....................................................3252
				Remove....................................................................3252
				Install...................................................................3254
			Intake Air Temperature (IAT) Sensor...........................................3255
				Remove....................................................................3255
				Install...................................................................3255
			Mass Air Flow (MAF) Sensor....................................................3255
				Remove....................................................................3255
				Install...................................................................3255
			Throttle Position (TP) Sensor.................................................3256
				TP Sensor, Adjust.........................................................3256
				Remove....................................................................3257
				Install...................................................................3257
			Engine Coolant Temperature (ECT) Sensor.......................................3257
				Remove....................................................................3257
				Install...................................................................3258
			Camshaft Position (CMP) Sensor................................................3258
				Voltage Check.............................................................3258
			Oxygen Sensor.................................................................3258
				Remove....................................................................3258
				Install...................................................................3258
			Manifold Absolute Pressure (MAP)/Boost Sensor.................................3259
				Remove....................................................................3259
				Install...................................................................3259
		Technical Data....................................................................3260
	tables................................................................................3235
		Table 1. PCV Valve Specifications.................................................3252
		Table 2. Closed Throttle Position Specifications..................................3257
		Table 3. Gasoline Fuel Systems Technical Data.....................................3260
1580510-1300SRM1129-(03-2007)-US-EN.......................................................3263
	toc...................................................................................3263
		Powershift Transmission...........................................................3263
		Safety Precautions Maintenance and Repair.........................................3264
		General...........................................................................3267
			Serial Number.................................................................3267
		Charge Pump Repair................................................................3268
			Remove........................................................................3268
			Inspect.......................................................................3268
			Install.......................................................................3268
		Torque Converter Replace..........................................................3269
			Remove........................................................................3269
			Install.......................................................................3273
		Front Cover Housing and Chain Drive Repair........................................3278
			Remove........................................................................3278
			Clean.........................................................................3285
			Inspect.......................................................................3285
			Install.......................................................................3285
		Clutch Packs Repair...............................................................3291
			Remove and Disassemble........................................................3291
				Transmission, Remove and Disassemble......................................3291
				Clutch Assemblies, Remove and Disassemble.................................3302
			Clean.........................................................................3308
			Inspect.......................................................................3308
			Assemble and Install..........................................................3309
				Clutch Assemblies, Assemble and Install...................................3309
				Transmission, Assemble and Install........................................3317
		Control Valve Repair..............................................................3322
			Remove and Disassemble........................................................3322
			Clean.........................................................................3323
			Inspect.......................................................................3323
			Assemble and Install..........................................................3325
		MONOTROL® Pedal Repair............................................................3326
			Remove and Disassemble........................................................3326
			Assemble and Install..........................................................3329
		Direction Control Lever...........................................................3330
			Remove........................................................................3330
			Install.......................................................................3330
1580512-1600SRM1133-(03-2007)-US-EN.......................................................3335
	toc...................................................................................3335
		Steering Axle.....................................................................3335
		Safety Precautions Maintenance and Repair.........................................3336
		General...........................................................................3339
		Steering Axle Assembly Repair.....................................................3340
			Remove........................................................................3340
			Disassemble...................................................................3341
			Clean.........................................................................3341
			Inspect.......................................................................3341
			Assemble......................................................................3348
			Install.......................................................................3353
		Spindles, Bearings, and Tie Rods Repair...........................................3354
			Spindles and Bearings.........................................................3354
				S2.0-3.5FT (S40-70FT, S55FTS) (F187), S4.0, 4.5, 5.5FT, S5.5FTS,..........3354
					Remove................................................................3354
					Disassemble...........................................................3355
					Clean.................................................................3356
					Inspect...............................................................3356
					Assemble..............................................................3356
					Install...............................................................3357
			Spindles and Bearings.........................................................3360
				S30FT, S35FT, S40FTS (E010), H1.6FT, H1.8FT, H2.0FTS (H30FT, H35..........3360
					Remove and Disassemble................................................3360
					Assemble and Install..................................................3360
			Tie Rods......................................................................3361
				S2.0-3.5FT (S40-70FT, S55FTS) (F187), and S4.0, 4.5, 5.5FT, S5.5..........3361
					Remove................................................................3361
					Install...............................................................3362
			Tie Rods......................................................................3363
				S30FT, S35FT, S40FTS (E010), H1.6FT, H1.8FT, H2.0FTS (H30FT, H35..........3363
					Remove................................................................3363
					Install...............................................................3363
		Steering Cylinder Repair..........................................................3366
			Remove and Disassemble........................................................3366
			Clean and Inspect.............................................................3367
			Assemble and Install..........................................................3367
		Torque Specifications.............................................................3368
1580514-1900SRM1136-(03-2007)-US-EN.......................................................3373
	toc...................................................................................3373
		Hydraulic Gear Pump...............................................................3373
		Safety Precautions Maintenance and Repair.........................................3374
		General...........................................................................3377
		Single Gear Pump Assembly Repair..................................................3377
			Remove........................................................................3377
			Disassemble...................................................................3378
			Clean.........................................................................3378
			Inspect.......................................................................3378
			Assemble......................................................................3378
			Install.......................................................................3382
		Tandem Gear Pump Assembly.........................................................3383
			Remove........................................................................3383
			Disassemble...................................................................3385
			Clean.........................................................................3387
			Inspect.......................................................................3387
			Assemble......................................................................3387
			Install.......................................................................3388
		Gear Pump Specifications..........................................................3388
		Torque Specifications.............................................................3392
	tables................................................................................3373
		Table 1. Standard Gear Pump for Lift Truck Models S30FT, S35FT, ..................3388
		Table 2. High Pressure Gear Pump for Lift Truck Models S30FT, S3..................3389
		Table 3. Standard Gear Pump for Lift Truck Models S4.0, 4.5, 5.5..................3390
		Table 4. High Pressure Gear Pump for Lift Truck Models S4.0, 4.5..................3390
		Table 5. Standard Gear Pump for Lift Truck Models S6.0FT, S7.0FT..................3391
		Table 6. High Pressure Gear Pump for Lift Truck Models S6.0FT, S..................3391
1580515-2000SRM1137-(06-2007)-US-EN.......................................................3395
	toc...................................................................................3395
		Main Control Valve................................................................3395
		Safety Precautions Maintenance and Repair.........................................3396
		General...........................................................................3401
		Electro-Hydraulic Main Control Valve..............................................3401
			Description...................................................................3401
			Remove........................................................................3404
			Electro-Hydraulic Control Valve Sections......................................3408
				General...................................................................3408
				Outlet Control Valve Section..............................................3408
					Remove................................................................3408
					Disassemble...........................................................3408
					Clean.................................................................3408
					Inspect...............................................................3409
					Assemble..............................................................3410
					Install...............................................................3410
				Auxiliary Control Valve Sections..........................................3410
					Remove................................................................3410
					Disassemble...........................................................3412
					Clean.................................................................3412
					Inspect...............................................................3413
					Assemble..............................................................3413
					Install...............................................................3413
				Tilt Control Valve Section................................................3413
					Remove................................................................3413
					Disassemble...........................................................3414
					Clean.................................................................3415
					Inspect...............................................................3416
					Assemble..............................................................3416
					Install...............................................................3416
				Lift/Lower Control Valve Section..........................................3416
					Remove................................................................3416
					Disassemble...........................................................3416
					Clean.................................................................3419
					Inspect...............................................................3419
					Assemble..............................................................3419
					Install...............................................................3420
				Mid-Inlet Section.........................................................3420
					Remove................................................................3420
					Clean.................................................................3421
					Inspect...............................................................3421
					Install...............................................................3421
			Install.......................................................................3421
			Electro Hydraulic Poppet Valve (EHPV) Pilot Pin Adjustment....................3425
				Lift Pilot Pin............................................................3425
				Lower Pilot Pin...........................................................3427
				Abnormal/Erroneous EHPV Adjustment........................................3429
		Manual Main Control Valve.........................................................3429
			Description...................................................................3429
			Remove........................................................................3430
			Manual Control Valve Sections.................................................3435
				General...................................................................3435
				Outlet Control Valve Section..............................................3435
					Remove................................................................3435
					Disassemble...........................................................3435
					Clean.................................................................3437
					Inspect...............................................................3437
					Assemble..............................................................3437
					Install...............................................................3437
				Auxiliary Control Valve Sections..........................................3437
					Remove................................................................3437
					Disassemble...........................................................3438
					Clean.................................................................3438
					Inspect...............................................................3438
					Assemble..............................................................3438
					Install...............................................................3440
				Lift/Tilt Control Valve Section...........................................3440
					Remove................................................................3440
					Disassemble...........................................................3440
					Clean.................................................................3443
					Inspect...............................................................3443
					Assemble..............................................................3443
					Install...............................................................3444
				Mid-Inlet Section.........................................................3444
					Remove................................................................3444
					Clean.................................................................3444
					Inspect...............................................................3445
					Install...............................................................3445
			Install.......................................................................3445
		Pressure Relief Valve Check and Adjustment........................................3449
			Primary Relief Valve..........................................................3449
			Secondary Relief Valve........................................................3450
		Steering Control Unit Repair......................................................3452
			Steering Control Unit, Remove.................................................3452
			Steering Control Unit, Disassemble............................................3455
			Steering Control Unit, Clean..................................................3456
			Steering Control Unit, Inspect................................................3456
			Steering Control Unit, Assemble...............................................3456
			Relief Valve, Disassemble.....................................................3457
			Relief Valve, Clean...........................................................3457
			Relief Valve, Inspect.........................................................3458
			Relief Valve, Assemble........................................................3458
			Steering Control Unit, Install................................................3458
	tables................................................................................3395
		Table 1. Relief Valve Settings....................................................3449
1580516-2100SRM1139-(03-2007)-US-EN.......................................................3461
	toc...................................................................................3461
		Cylinder Repair...................................................................3461
		Safety Precautions Maintenance and Repair.........................................3462
		General...........................................................................3465
		Description.......................................................................3465
		Safety Procedures When Working Near Mast..........................................3466
		Tilt Cylinder Repair..............................................................3468
			Remove........................................................................3468
			Disassemble...................................................................3469
			Inspect.......................................................................3469
			Clean.........................................................................3469
			Assemble......................................................................3469
			Install.......................................................................3472
			Tilt Cylinders, Adjust........................................................3472
			Tilt Cylinder Leak Check......................................................3474
			Torque Specifications.........................................................3475
				Piston Rod Nut............................................................3475
				Gland.....................................................................3475
				Tilt Cylinder Mounting Capscrew...........................................3476
				Tilt Cylinder Rod End Capscrew............................................3476
		Lift Cylinder Repair..............................................................3476
			Main Lift Cylinders...........................................................3476
				Remove....................................................................3476
				Disassemble...............................................................3477
				Clean.....................................................................3478
				Inspect...................................................................3478
				Assemble..................................................................3478
				Install...................................................................3479
			Two-Stage FFL Left Side Main Lift Cylinder....................................3480
				Disassemble...............................................................3480
				Clean.....................................................................3482
				Inspect...................................................................3482
				Assemble..................................................................3482
				Install...................................................................3482
			Free-Lift Cylinder............................................................3482
				Remove....................................................................3482
				Disassemble...............................................................3485
				Clean.....................................................................3486
				Inspect...................................................................3486
				Assemble..................................................................3486
				Install...................................................................3487
			Torque Specifications.........................................................3487
			Lift Cylinders Leak Check.....................................................3488
	tables................................................................................3461
		Table 1. Movement Rates (Maximum) for Tilt Cylinders..............................3475
1580517-2200SRM1128-(03-2007)-US-EN.......................................................3491
	toc...................................................................................3491
		Wire Harness Repair...............................................................3491
		Safety Precautions Maintenance and Repair.........................................3492
		General...........................................................................3495
		Deutsch Crimping Tool.............................................................3495
			How to Strip a Wire for Use With Deutsch Crimping Tool........................3495
			How to Crimp With the Deutsch Crimping Tool...................................3496
			Calibration Test for the Deutsch Crimping Tool................................3497
		Deutsch Connectors................................................................3499
			DT, DTM, and DTP Series Connectors............................................3499
				Connector Receptacle Replacement..........................................3507
				Connector Plug Replacement................................................3515
				Connector Receptacle Pin Replacement......................................3523
				Connector Plug Socket Replacement.........................................3532
			HD Series Connectors..........................................................3541
				Connector Receptacle Replacement..........................................3543
				Connector Plug Replacement................................................3547
				Connector Receptacle Pin Replacement......................................3550
				Connector Plug Socket Replacement.........................................3556
			Sealing Plugs.................................................................3560
		Metri-Pack Connectors.............................................................3562
			Remove and Install............................................................3562
		Micro-Pack Connectors.............................................................3564
		Weather-Pack Connectors...........................................................3565
			Weather-Pack Terminal Repair..................................................3565
		Wire Repair.......................................................................3566
			Wire Splicing Requirements....................................................3566
			Deutsch Jiffy Splice..........................................................3566
				Assemble..................................................................3567
				Disassemble...............................................................3569
			Del-City Crimp-Solder-Shrink Splice...........................................3570
		Twisted/Shielded Cable and Leads Repair...........................................3572
			Twisted/Shielded Cable Repair.................................................3572
			Twisted Leads Repair..........................................................3573
		Special Tools.....................................................................3574
	tables................................................................................3491
		Table 1. Wire Strip Length Specifications.........................................3496
		Table 2. Wire Splice Size.........................................................3570
1580518-2200SRM1130-(03-2007)-US-EN.......................................................3579
	toc...................................................................................3579
		User Interface....................................................................3579
		Safety Precautions Maintenance and Repair.........................................3580
		General...........................................................................3583
			Description...................................................................3583
			Dash Display Menu Access......................................................3583
		Menu Navigation...................................................................3584
			Standard Display..............................................................3584
		Main Menu.........................................................................3584
		Passwords Menu....................................................................3585
		Password Administration...........................................................3585
			Add Password..................................................................3585
			Delete Password...............................................................3586
			Edit Password.................................................................3586
		Other Password Functions..........................................................3587
			Operator Passwords - Enable/Disable...........................................3587
			Password Time-Out Delay.......................................................3588
			Passwords - Number Wrong to Disable...........................................3588
			Lockout Reset Password........................................................3589
			View Password Log.............................................................3589
		View Versions.....................................................................3590
			VSM Versions..................................................................3590
			Dash Display Versions.........................................................3591
			Engine Controller Version.....................................................3592
			Transmission (Xmsn) Controller Version........................................3593
			Truck Serial Number...........................................................3594
		Diagnostics.......................................................................3595
			View Fault Log................................................................3595
		Set Travel and Braking............................................................3596
			Speed Limit...................................................................3596
			Acceleration Rate.............................................................3597
			Auto-Deceleration Rate........................................................3597
			Set Power Reversal Rate.......................................................3598
			Set Inching/Brake Overlap.....................................................3599
		Setup Display Menu................................................................3600
			Set Operator Language.........................................................3600
			Set Units.....................................................................3601
			Set Time Format (12/24 Hour)..................................................3601
			Set Daylight Saving Time......................................................3602
			Set Time......................................................................3604
			Set Date Format...............................................................3604
			Set Date......................................................................3604
		Setup Hydraulics..................................................................3605
			Return to Set Tilt Delay/On/Off...............................................3605
		Setup General Items...............................................................3606
			Light Shutdown Time-Out.......................................................3606
			Impact Sensor - Enable/Disable................................................3607
			Impact Sensor - Soft Impact Settings..........................................3608
			Impact Sensor - Hard Impact Settings..........................................3608
			Adjust Impact Sensor Settings.................................................3609
				Initial Adjustment of Soft and Hard Impact Settings.......................3611
				Readjustment of Soft and Hard Impact Settings.............................3612
			Impact Sensor - Impact Alarm/Shutdown Reset...................................3612
			Impact Sensor - Alarm Time Duration and Deactivation..........................3613
			Impact Sensor - View Impact Event Log.........................................3614
		Operator Checklist................................................................3615
			Operator Checklist Off-On Mode................................................3615
			Edit Operator Checklist.......................................................3615
			Set Operator Checklist Expiration.............................................3616
			View Checklist Log............................................................3616
			Clear Operator Checklist Log..................................................3617
			Clear Operator Checklist Fault................................................3617
		Calibrations......................................................................3618
			Set Tilt Stop Point...........................................................3618
			Calibrate Loaded Weight.......................................................3618
	tables................................................................................3579
		Table 1. Password Screen..........................................................3583
		Table 2. Exit Options Menu........................................................3584
		Table 3. Add Password Menu........................................................3585
		Table 4. Delete Password Menu.....................................................3586
		Table 5. Edit Password Menu.......................................................3587
		Table 6. Operator Passwords Menu..................................................3587
		Table 7. Password Time-Out Delay Menu.............................................3588
		Table 8. Passwords - Number Wrong to Disable Menu.................................3588
		Table 9. View Password Log Menu...................................................3589
		Table 10. View VSM Versions Menu..................................................3590
		Table 11. View Dash Display Versions Menu.........................................3591
		Table 12. View Engine Controller Versions Menu....................................3592
		Table 13. View Transmission Controller Versions Menu..............................3593
		Table 14. View Truck Serial Number Menu...........................................3594
		Table 15. View Fault Log..........................................................3595
		Table 16. Speed Limit Menu........................................................3596
		Table 17. Acceleration Rate Menu..................................................3597
		Table 18. Auto-Decel Menu.........................................................3597
		Table 19. Power Reversal Menu.....................................................3598
		Table 20. Inch/Brake Overlap Menu.................................................3599
		Table 21. Set Language Menu.......................................................3600
		Table 22. Set Units Menu..........................................................3601
		Table 23. Set Time Format Menu....................................................3601
		Table 24. Set Daylight Saving Time Menu...........................................3602
		Table 25. Set Time Menu...........................................................3604
		Table 26. Set Date Format Menu....................................................3604
		Table 27. Set Date Menu...........................................................3604
		Table 28. Tilt Delay Menu.........................................................3605
		Table 29. Light Time-Out Menu.....................................................3606
		Table 30. Impact Sensor Enable/Disable............................................3607
		Table 31. Soft Impact Settings Menu...............................................3608
		Table 32. Hard Impact Settings Menu...............................................3609
		Table 33. Impact Sensor Default Settings..........................................3609
		Table 34. Recommended Starting Values for Impact Sensor Settings..................3611
		Table 35. Shutdown Reset Menu.....................................................3612
		Table 36. Alarm Duration Menu.....................................................3613
		Table 37. View Event Log Menu.....................................................3614
		Table 38. Checklist Off-On Mode Menu..............................................3615
		Table 39. Edit Checklist Menu.....................................................3615
		Table 40. Checklist Expiration Menu...............................................3616
		Table 41. View Checklist Log Menu.................................................3616
		Table 42. Clear Checklist Log Menu................................................3617
		Table 43. Clear Checklist Fault Menu..............................................3617
		Table 44. Tilt Stop Point Menu....................................................3618
		Table 45. Calibrate Loaded Weight.................................................3618
1580519-2200SRM1131-(03-2007)-US-EN.......................................................3621
	toc...................................................................................3621
		User Interface....................................................................3621
		Safety Precautions Maintenance and Repair.........................................3622
		General...........................................................................3625
			Description...................................................................3625
			Dash Display Menu Access......................................................3625
		Menu Navigation...................................................................3626
		Main Menu.........................................................................3627
		Passwords.........................................................................3627
			Adding Passwords..............................................................3628
		Hourmeters........................................................................3629
		View Versions.....................................................................3630
			VSM Versions..................................................................3630
			Dash Display Versions.........................................................3631
			Engine Controller Version.....................................................3632
			Transmission (Xmsn) Controller Version........................................3633
			Truck Serial Number...........................................................3634
			Truck Configuration...........................................................3635
		Diagnostics.......................................................................3636
			Clear Fault Log...............................................................3636
			View Fault Log................................................................3637
			No-Run Data Display...........................................................3638
			Engine Accelerator and Throttle Data Display..................................3639
			Engine Speeds and Governor Data Display.......................................3640
			Engine Fuel and Emissions Data Display........................................3641
			Engine General Data Display...................................................3644
			XMSN/Brake Data Display.......................................................3645
			Hydraulic Data Display........................................................3647
			General Truck Data Display....................................................3649
		Set Travel and Braking............................................................3651
			Speed Limit...................................................................3651
			Acceleration Rate.............................................................3652
			Auto-Deceleration Rate........................................................3652
			Set Power Reversal Rate.......................................................3653
			Set Inching/Brake Overlap.....................................................3654
		Setup Hydraulics..................................................................3655
			Lift Maximum Speed............................................................3655
			Lower Maximum Speed...........................................................3656
			Tilt Maximum Speed............................................................3656
			Auxiliary Function One, Direction A, Maximum Speed............................3658
			Auxiliary Function One, Direction B, Maximum Speed............................3658
			Auxiliary Function Two, Direction A, Maximum Speed............................3659
			Auxiliary Function Two, Direction B, Maximum Speed............................3659
			Auxiliary Function Three, Direction A, Maximum Speed..........................3660
			Auxiliary Function Three, Direction B, Maximum Speed..........................3660
			Lift/Lower Ramp Rate..........................................................3661
			Hydraulic Auxiliary Ramp Rate.................................................3662
			Return to Set Tilt Delay/On/Off...............................................3663
		Setup Display.....................................................................3664
			Set Service Language..........................................................3664
		Setup General Items...............................................................3665
			Motion Alarm Activation Type..................................................3665
			Light Shutdown Time-Out.......................................................3666
			Restore Default Settings......................................................3667
			Restore Engine Controller Default Calibration.................................3667
			Impact Sensor - Enable/Disable................................................3668
			Impact Sensor - Soft Impact Settings..........................................3669
			Impact Sensor - Hard Impact Settings..........................................3669
			Adjust Impact Sensor Settings.................................................3670
				Initial Adjustment of Soft and Hard Impact Settings.......................3672
				Readjustment of Soft and Hard Impact Settings.............................3673
			Impact Sensor - Impact Alarm/Shutdown Reset...................................3673
			Impact Sensor - Alarm Time Duration and Deactivation..........................3674
			Impact Sensor - View Impact Event Log.........................................3675
		Calibrations......................................................................3675
			Calibrate Transmission Valve..................................................3677
			Set Tilt Stop Point...........................................................3677
			Calibrate Loaded Weight.......................................................3679
			Calibrate Travel Speed Sensor.................................................3679
			Calibrate Mazda LP and Gas Accelerator Pedal..................................3680
	tables................................................................................3621
		Table 1. Password Screen..........................................................3625
		Table 2. Exit Menu................................................................3626
		Table 3. Add Password Menu........................................................3628
		Table 4. Hourmeters Menu..........................................................3629
		Table 5. View VSM Versions Menu...................................................3630
		Table 6. View Dash Display Versions Menu..........................................3631
		Table 7. View Engine Controller Versions Menu.....................................3632
		Table 8. View Transmission Controller Versions Menu...............................3633
		Table 9. View Truck Serial Number Menu............................................3634
		Table 10. View Truck Configuration Menu...........................................3635
		Table 11. Clear Fault Log.........................................................3636
		Table 12. View Fault Log..........................................................3637
		Table 13. No-Run Data Display.....................................................3638
		Table 14. Engine Accelerator and Throttle Data Display............................3639
		Table 15. Engine Speeds and Governor Data Display.................................3640
		Table 16. Engine Fuel and Emissions Data Display..................................3641
		Table 17. Engine General Data Display.............................................3644
		Table 18. XMSN Brake Data Display.................................................3645
		Table 19. Hydraulic Data Display..................................................3647
		Table 20. General Truck Data Display..............................................3649
		Table 21. Speed Limit Menu........................................................3651
		Table 22. Acceleration Rate Menu..................................................3652
		Table 23. Auto-Decel Menu.........................................................3652
		Table 24. Power Reversal Menu.....................................................3653
		Table 25. Inch/Brake Overlap Menu.................................................3654
		Table 26. Lift Speed Menu.........................................................3655
		Table 27. Lower Speed Menu........................................................3656
		Table 28. Tilt Speed Menu.........................................................3656
		Table 29. Auxiliary Function Speed Menu...........................................3658
		Table 30. Auxiliary Function Speed Menu...........................................3658
		Table 31. Auxiliary Function Speed Menu...........................................3659
		Table 32. Auxiliary Function Speed Menu...........................................3659
		Table 33. Auxiliary Function Speed Menu...........................................3660
		Table 34. Auxiliary Function Speed Menu...........................................3660
		Table 35. Lift/Lower Ramp Rate Menu...............................................3661
		Table 36. Hydraulic Auxiliary Ramp Rate Menu......................................3662
		Table 37. Tilt Delay Menu.........................................................3663
		Table 38. Service Language Menu...................................................3664
		Table 39. Alarm Type Menu.........................................................3665
		Table 40. Light Time-Out Menu.....................................................3666
		Table 41. Restore Defaults Menu...................................................3667
		Table 42. Restore Settings Menu...................................................3667
		Table 43. Impact Sensor Enable/Disable............................................3668
		Table 44. Soft Impact Settings Menu...............................................3669
		Table 45. Hard Impact Settings Menu...............................................3670
		Table 46. Impact Sensor Default Settings..........................................3670
		Table 47. Recommended Starting Values for Impact Sensor Settings..................3672
		Table 48. Shutdown Reset Menu.....................................................3673
		Table 49. Alarm Duration Menu.....................................................3674
		Table 50. View Event Log Menu.....................................................3675
		Table 51. Calibrate Electro-Hydraulic Valve Menu..................................3676
		Table 52. Calibrate Transmission Valve Menu.......................................3677
		Table 53. Tilt Stop Point Menu....................................................3677
		Table 54. Calibrate Loaded Weight.................................................3679
		Table 55. Travel Speed Menu.......................................................3679
		Table 56. Travel Speed Menu.......................................................3680
1580520-2200SRM1142-(03-2007)-US-EN.......................................................3683
	toc...................................................................................3683
		Electrical System.................................................................3683
		Safety Precautions Maintenance and Repair.........................................3684
		General...........................................................................3693
		Display Switch Cluster............................................................3694
			Remove........................................................................3694
			Install.......................................................................3696
			Direction Control and Turn Signal Levers......................................3696
				Remove....................................................................3696
				Install...................................................................3696
			Key Switch....................................................................3698
				Remove....................................................................3698
				Install...................................................................3698
			Display Switch Cluster Panel Bezel and Overlay................................3699
				Remove....................................................................3699
				Install...................................................................3699
		Steering Column Repair............................................................3699
			Remove........................................................................3699
			Disassemble...................................................................3700
			Assemble......................................................................3700
			Install.......................................................................3700
		Sensors and Switches..............................................................3702
			General.......................................................................3702
				Dash and Kick Panel Remove and Install....................................3702
					Remove................................................................3702
					Install...............................................................3702
			Accelerator Pedal Position Sensor.............................................3704
				Remove....................................................................3704
				Install...................................................................3704
			Brake Fluid Level Switch......................................................3707
				Remove....................................................................3707
				Install...................................................................3707
			Service Brake Pedal Position Sensor...........................................3708
				Remove....................................................................3708
				Install...................................................................3708
			Parking Brake Sensor..........................................................3709
				Remove....................................................................3709
				Install...................................................................3709
			Service Brake Pressure Sensor.................................................3710
				Remove....................................................................3710
				Install...................................................................3710
			MONOTROL® Sensor Microswitch..................................................3710
				Remove....................................................................3710
				Install...................................................................3712
			Low Coolant Level Sensor......................................................3712
				Remove....................................................................3712
				Install...................................................................3714
			Fuel Level Sensor, Gas and Diesel Engines Only................................3714
				Remove....................................................................3714
				Install...................................................................3714
			Armrest Switch................................................................3715
				Remove....................................................................3715
				Install...................................................................3715
			Seat Sensor (Operator Presence System)........................................3717
				Non-Suspension and Semi-Suspension Seats; All Lift truck Models ..........3717
					Remove................................................................3717
					Install...............................................................3717
				Non-Suspension Seats; Lift Truck Models H6.0FT, H7.0FT (H135FT, ..........3718
					Remove................................................................3718
					Install...............................................................3718
				Full Suspension Seats; All Lift Truck Models..............................3718
					Remove................................................................3718
					Install...............................................................3719
			Hood Shut Off Switch..........................................................3719
				Remove....................................................................3719
				Install...................................................................3719
			Hydraulic Filter Pressure Switch..............................................3723
				Remove....................................................................3723
				Install...................................................................3723
			Transmission Speed Sensor.....................................................3723
				Remove....................................................................3723
				Install...................................................................3724
			Transmission Pressure Sensors.................................................3724
				Remove....................................................................3724
				Install...................................................................3724
			Transmission Temperature Sensor...............................................3724
				Remove....................................................................3724
				Install...................................................................3725
			Engine Speed Sensor...........................................................3726
				Remove....................................................................3726
				Install...................................................................3726
			Intermediate Speed Sensor.....................................................3726
				Remove....................................................................3726
				Install...................................................................3726
			Return to Set Tilt (Tilt Angle) Sensor........................................3726
				Lift Truck Models S30FT, S35FT, S40FTS (E010); H1.6FT, H1.8FT, H..........3726
					Remove................................................................3727
					Install...............................................................3727
				Lift Truck Models S6.0FT, S7.0FT (S135FT, S155FT) (D024); S4.0, ..........3727
					Remove................................................................3727
					Install...............................................................3728
			Rear Horn Button Switch.......................................................3728
				Remove....................................................................3728
				Install...................................................................3728
			Impact Sensor.................................................................3729
				All Lift Truck Models Except H6.0FT, H7.0FT (H135FT, H155FT) (H0..........3729
					Remove................................................................3729
					Install...............................................................3729
				Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (H006)..................3731
					Remove................................................................3731
					Install...............................................................3732
			Load Weight Sensor............................................................3732
				Remove....................................................................3732
				Install...................................................................3732
			Engine and Fuel Sensors - Mazda 2.0L and 2.2L Gas and LPG Engine..............3734
				Oxygen Sensor.............................................................3734
					Remove................................................................3734
					Install...............................................................3734
				Intake Air Temperature (IAT) Sensor.......................................3734
					Remove................................................................3734
					Install...............................................................3734
				Manifold Absolute Pressure (MAP)/Boost Sensor.............................3735
					Remove................................................................3735
					Install...............................................................3735
				Throttle Position (TPS) Sensor............................................3735
					Remove................................................................3735
					Install...............................................................3735
			Engine and Fuel Sensors and Switches - Mazda 2.0L and 2.2L LPG E..............3736
				Oil Pressure Sensor.......................................................3736
					Remove................................................................3736
					Install...............................................................3736
				Low LPG Pressure Switch...................................................3736
					Remove................................................................3736
					Install...............................................................3737
				Air Filter Restriction Switch.............................................3737
					Remove................................................................3737
					Install...............................................................3737
				Engine Coolant Temperature (ECT) Sensor...................................3737
					Remove................................................................3737
					Install...............................................................3737
			Engine and Fuel Sensors and Switches- Mazda 2.0L and 2.2L Gas En..............3738
				Oil Pressure Sensor.......................................................3738
					Remove................................................................3738
					Install...............................................................3738
				Mass Air Flow (MAF) Sensor................................................3738
					Remove................................................................3738
					Install...............................................................3738
				Air Filter Restriction Switch.............................................3739
					Remove................................................................3739
					Install...............................................................3739
				Engine Coolant Temperature (ECT) Sensor...................................3739
					Remove................................................................3739
					Install...............................................................3739
			Engine and Fuel Sensors and Switches - Mazda 2.0L and 2.2L Gas a..............3740
				Oil Pressure Sensor.......................................................3740
					Remove................................................................3740
					Install...............................................................3740
				Air Filter Restriction Switch.............................................3740
					Remove................................................................3740
					Install...............................................................3740
				CAM Angle Sensor..........................................................3741
					Voltage Check.........................................................3741
				Oxygen Sensor.............................................................3742
					Remove................................................................3742
					Install...............................................................3742
			Engine and Fuel Sensors and Switches - Mazda 2.0L and 2.2L LPG E..............3743
				Engine Coolant Temperature (ECT) Sensor...................................3743
					Remove................................................................3743
					Install...............................................................3743
				Manifold Absolute Pressure (MAP) Sensor...................................3744
					Remove................................................................3744
					Install...............................................................3744
				Intake Air Temperature (IAT) Sensor.......................................3744
					Remove................................................................3744
					Install...............................................................3745
				Fuel Temperature Sensor...................................................3745
					Remove................................................................3745
					Install...............................................................3746
				Low LPG Pressure Switch...................................................3746
					Remove................................................................3746
					Install...............................................................3746
			Engine and Fuel Sensors and Switches- Mazda 2.0L and 2.2L Gas En..............3747
				Intake Air Temperature (IAT) Sensor.......................................3747
					Remove................................................................3747
					Install...............................................................3747
				Engine Coolant Temperature (ECT) Sensor...................................3748
					Remove................................................................3748
					Install...............................................................3748
				Manifold Absolute Pressure (MAP) Sensor...................................3749
					Remove................................................................3749
					Install...............................................................3749
			Engine and Fuel Sensors and Switches, GM 2.4L and 4.3L Gas and L..............3749
				Crankshaft Sensor.........................................................3749
					Remove................................................................3749
					Install...............................................................3750
				Camshaft Position (CMP) Sensor............................................3750
					Remove................................................................3750
					Install...............................................................3751
				Camshaft Position (CMP) Sensor Assembly...................................3751
					Remove................................................................3751
					Install...............................................................3751
				Oil Pressure Sensor.......................................................3752
					Remove................................................................3752
					Install...............................................................3752
				Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) ..........3753
					Remove................................................................3753
					Install...............................................................3753
				Engine Coolant Temperature (ECT) Sensor...................................3754
					Remove................................................................3754
					Install...............................................................3754
				Air Flow Restriction Switch...............................................3754
					Remove................................................................3754
					Install...............................................................3755
				Oxygen Sensor.............................................................3755
					Remove................................................................3755
					Install...............................................................3758
			Engine and Fuel Switches, GM 2.4L and GM 4.3L LPG Trucks Only.................3759
				Low LPG Pressure Switch...................................................3759
					Remove................................................................3759
					Install...............................................................3759
				LPG Pressure Sensor, GM 4.3L Engine Only..................................3760
					Remove................................................................3760
					Install...............................................................3760
			Engine and Fuel Sensors and Switches, Yanmar Diesel Trucks....................3760
				Air Filter Restriction Switch.............................................3760
					Remove................................................................3760
					Install...............................................................3760
				Oil Pressure Sensor.......................................................3760
					Remove................................................................3760
					Install...............................................................3760
				Engine Speed Sensor.......................................................3760
					Remove................................................................3760
					Install...............................................................3760
				Engine Coolant Temperature (ECT) Sensor...................................3760
					Remove................................................................3760
					Install...............................................................3762
				Throttle Position Sensor (TPS)............................................3762
					Remove................................................................3762
					Install...............................................................3763
				Fuel/Water Separator Sensor...............................................3763
					Remove................................................................3763
					Install...............................................................3763
				Glow Plug Relay...........................................................3764
					Remove................................................................3764
					Install...............................................................3764
			Engine and Fuel Sensors and Switches, Cummins 4.5L Diesel Engine..............3766
				Air Filter Restriction Switch.............................................3766
					Remove................................................................3766
					Install...............................................................3766
				Oil Pressure Sensor.......................................................3768
					Remove................................................................3768
					Install...............................................................3768
				Engine Speed Sensor.......................................................3768
					Remove................................................................3768
					Install...............................................................3768
				Engine Coolant Temperature (ECT) Sensor...................................3768
					Remove................................................................3768
					Install...............................................................3768
				Throttle Position Sensor (TPS)............................................3769
					Remove................................................................3769
					Install...............................................................3769
				Fuel/Water Separator Sensor...............................................3770
					Remove................................................................3770
					Install...............................................................3770
		Vehicle System Manager (VSM)......................................................3770
			General.......................................................................3770
			VSM Replacement...............................................................3770
				Remove....................................................................3770
				Install...................................................................3771
			Programming a New VSM and/or Display Switch Cluster...........................3772
				General...................................................................3772
				PC Service Tool Software..................................................3772
				Data Transferring.........................................................3773
					New or Used VSM.......................................................3773
					New (Blank) Display Switch Cluster....................................3773
					Used (Non-Blank) Display Switch Cluster...............................3773
		Power Distribution Module (PDM) and Component Parts...............................3774
			Remove........................................................................3774
				PDM as a Unit.............................................................3774
			Install.......................................................................3777
				PDM as a Unit.............................................................3777
			Remove and Install............................................................3777
				PDM Component Parts.......................................................3777
		Transmission Control Unit.........................................................3778
			Remove S6.0FT, S7.0FT, (S135FT,S155FT) (D024) and H6.0FT, H7.0FT..............3778
			Install S6.0FT, S7.0FT, (S135FT,S155FT) (D024) and H6.0FT, H7.0F..............3778
		Battery...........................................................................3779
			Remove........................................................................3779
			Install.......................................................................3779
		Lights............................................................................3779
			Work Lights (Front and Rear)..................................................3779
				Remove....................................................................3779
				Install...................................................................3780
			Strobe Light..................................................................3780
				Remove....................................................................3780
				Install...................................................................3780
			LED Tail, Backup, and Brake Lights............................................3780
				Remove....................................................................3780
				Install...................................................................3781
		Electronic-Hydraulic Controls.....................................................3782
			General.......................................................................3782
			Mini-Levers...................................................................3782
				Remove....................................................................3782
				Install...................................................................3782
			Joystick......................................................................3782
				Remove and Disassemble....................................................3782
				Inspect...................................................................3782
				Assemble and Install......................................................3782
	tables................................................................................3683
		Table 1. VSM and Display Switch Cluster Replacement...............................3774
1580521-2200SRM1143-(05-2005)-US-EN.......................................................3787
	toc...................................................................................3787
		Electrical System.................................................................3787
		Safety Precautions Maintenance and Repair.........................................3788
		Ignition System...................................................................3791
			General.......................................................................3791
			Ignition Timing Adjustment, Gasoline and LPG..................................3791
			Spark Plugs Check.............................................................3791
			Spark Plug Wires Check........................................................3791
		Distributor Repair................................................................3794
			Remove........................................................................3794
			Disassemble...................................................................3795
			Inspect.......................................................................3795
			Assemble......................................................................3796
			Install.......................................................................3796
			Igniter.......................................................................3797
				Remove....................................................................3797
				Test......................................................................3797
				Install...................................................................3797
			Camshaft Position (CMP) Sensor................................................3798
				Voltage Check.............................................................3798
		Ignition Coil Check...............................................................3799
			Primary Coil Winding..........................................................3799
			Secondary Coil Winding........................................................3799
		Starter Repair....................................................................3800
			General.......................................................................3800
			Remove........................................................................3800
			No-Load Test..................................................................3801
			Magnetic Switch Test..........................................................3801
				Pull-Out Test.............................................................3801
				Holding Coil Test.........................................................3802
				Return Test...............................................................3802
				Pinion Movement Inspection................................................3802
			Install.......................................................................3802
		Alternator Repair.................................................................3803
			General.......................................................................3803
			Charging System Inspection....................................................3803
			Output Current Check..........................................................3804
			No-Load Adjusted Voltage Check................................................3804
			Remove........................................................................3805
			Inspect.......................................................................3805
				Rectifier Check...........................................................3805
			Install.......................................................................3806
	tables................................................................................3787
		Table 1. Spark Plug Wire..........................................................3791
		Table 2. Starter Specifications...................................................3800
		Table 3. Problem Diagnosis Chart..................................................3801
		Table 4. Specifications...........................................................3804
		Table 5. Rectifier Check Table....................................................3805
1580524-4000SRM1148-(03-2007)-US-EN.......................................................3809
	toc...................................................................................3809
		Mast Repairs......................................................................3809
		Safety Precautions Maintenance and Repair.........................................3810
		General...........................................................................3813
		Safety Procedures When Working Near Mast..........................................3813
		Fork Repair.......................................................................3815
			Remove........................................................................3815
			Install.......................................................................3816
			Checks........................................................................3816
		Carriages Repair..................................................................3817
			Standard Carriage.............................................................3817
				Remove....................................................................3817
				Repair....................................................................3817
				Install...................................................................3818
			Integral Sideshift Carriage...................................................3818
				Remove....................................................................3818
				Clean and Inspect.........................................................3821
				Repair....................................................................3821
				Install...................................................................3822
		Mast Repair.......................................................................3823
			Mast, Remove..................................................................3823
			Two-Stage LFL and Two-Stage FFL Masts, Disassemble............................3826
			Clean and Inspect.............................................................3832
			Three-Stage FFL Mast..........................................................3833
				Disassemble...............................................................3833
				Clean and Inspect.........................................................3837
			Two-Stage LFL and Two-Stage FFL Mast, Assemble................................3838
			Three-Stage FFL Mast, Assemble................................................3839
			Four-Stage FFL, Disassemble...................................................3840
			Clean and Inspect.............................................................3844
			Four-Stage FFL, Assemble......................................................3846
			Mast, Install.................................................................3849
		Header Hose Arrangement...........................................................3851
			Two-Stage LFL.................................................................3851
			Two-Stage FFL.................................................................3857
			Three-Stage FFL...............................................................3870
			Four-Stage FFL................................................................3885
			Adjustment....................................................................3893
		Lift Chains Adjustment............................................................3894
		Carriage Adjustments..............................................................3896
		Tilt Cylinders Adjustment.........................................................3896
		Mast Adjustments..................................................................3900
	tables................................................................................3809
		Table 1. Fork Tip Alignment.......................................................3816
		Table 2. Pneumatic Tire Trucks....................................................3854
		Table 3. Cushion Tire Trucks......................................................3854
		Table 4. Standard Two-Stage Hose Dimensions.......................................3857
		Table 5. Pneumatic Tire Trucks....................................................3861
		Table 6. Cushion Tire Trucks......................................................3861
		Table 7. Pneumatic Tire Trucks....................................................3879
		Table 8. Cushion Tire Trucks......................................................3879
		Table 9. Standard Three-Stage Hose Dimensions.....................................3882
		Table 10. Standard Four-Stage Hose Dimensions.....................................3886
		Table 11. Hook-Type Carriage Chain Adjustment.....................................3894
		Table 12. Pin-Type Carriage Chain Adjustment......................................3895
1580525-8000SRM1150-(07-2007)-US-EN.......................................................3905
	toc...................................................................................3905
		Periodic Maintenance..............................................................3905
		Safety Precautions Maintenance and Repair.........................................3906
		General...........................................................................3911
			Serial Number Data............................................................3911
			How to Move Disabled Lift Truck...............................................3911
				How to Tow Lift Truck.....................................................3911
			How to Put Lift Truck on Blocks...............................................3912
				How to Raise Drive Tires..................................................3912
				How to Raise Steering Tires...............................................3913
		Maintenance Schedule..............................................................3913
		Maintenance Procedures Every 8 Hours or Daily.....................................3930
			How To Make Checks With Engine Stopped........................................3930
				Tires and Wheels..........................................................3930
				Safety Labels.............................................................3930
				Mast, Carriage, Lift Chains, Header Hoses, Attachment.....................3931
				Operator Restraint System.................................................3931
					Automatic Locking Retractor (ALR).....................................3931
					Emergency Locking Retractor (ELR).....................................3931
				Hood and Seat Latches.....................................................3933
				Engine Compartment........................................................3933
				Paper Application.........................................................3933
				Fuel, Oil, and Coolant Leaks, Check.......................................3934
				Hydraulic Hoses...........................................................3934
				Coolant Hoses.............................................................3935
				Steering Column Gas Cylinder..............................................3935
				Transmission..............................................................3935
				Hydraulic System Oil......................................................3935
				Engine Oil................................................................3935
				Forks.....................................................................3941
					Remove................................................................3941
					Inspect...............................................................3941
					Install...............................................................3941
					Adjust................................................................3941
			How To Make Checks With Engine Running........................................3942
				Indicator Lights, Horn, Fuses, and Relays.................................3942
				Service Brakes............................................................3944
					Brake Fluid Level.....................................................3944
					Operation, Check......................................................3945
				Parking Brake.............................................................3945
				Engine Oil Pressure.......................................................3945
				Cooling System............................................................3946
				Steering System...........................................................3947
				Control Levers and Pedals.................................................3947
				Lift System, Operate......................................................3947
		First Service After First 100 Hours of Operation..................................3948
			Mazda and GM Engine Oil Filter................................................3948
			Yanmar Engine Oil Filter......................................................3948
			Hydraulic System..............................................................3949
				Hydraulic Filter, Replace.................................................3949
			Transmission Oil Filter, Replace..............................................3950
		Maintenance Procedures Every 250 Hours or 6 months................................3950
			Mazda and GM Engine Oil and Filter............................................3950
			Drive Belt....................................................................3951
				Mazda 2.0L and 2.2L Engines...............................................3951
					Fan and Alternator Drive Belt.........................................3951
				GM 2.4L Engine............................................................3952
					Fan and Alternator Drive Belt.........................................3952
			Drain Tar From LPG Regulator (Except 2007 Mazda Emission Complia..............3952
			Drain Tar From LPG Regulator (2007 Mazda Emission Compliant Engi..............3953
		Maintenance Procedures Every 500 Hours or 6 Months................................3954
			Hydraulic System Oil..........................................................3954
			Hydraulic Tank Breather.......................................................3954
				Inspect...................................................................3954
			Battery.......................................................................3955
			Yanmar Engine Oil and Filter..................................................3955
			Air Filter....................................................................3955
			Drive Belt....................................................................3956
				Yanmar Diesel Engine......................................................3956
					Fan and Alternator Drive Belt.........................................3956
			PCV Valve.....................................................................3957
			Clean Debris From Radiator Core...............................................3957
			Transmission Oil Level........................................................3957
			Wet Brake Planetary Housing Oil Level Check...................................3958
			Forks.........................................................................3959
			Mast Lubrication..............................................................3959
			Header Hose Checks............................................................3963
			Lift Chain Lubrication........................................................3963
			Tilt Cylinder Lubrication.....................................................3963
			Master Brake Cylinder Rod End Pin Lubrication.................................3964
			Manual Hydraulic Levers Lubrication...........................................3964
			Brake Fluid...................................................................3965
			Tie Rod Lubrication (H40-70FT)................................................3966
			Differential and Drive Axle Oil (Dry Brake)...................................3966
		Maintenance Procedures Every 1000 Hours or 6 Months...............................3966
			Valve Clearance, Check and Adjust.............................................3966
			Ignition System...............................................................3967
				GM 2.4L Engine............................................................3967
				Mazda 2.0L and 2.2L Engines...............................................3967
			LPG Fuel Filter Element Replace, GM 2.4L Engine...............................3967
				Remove....................................................................3967
				Install...................................................................3967
			LPG Vapor Fuel Filter Replace, Mazda Engines (Except 2007 Mazda ..............3968
			LPG Fuel Filter Replace, Mazda 2007 Emission Compliant Engines O..............3968
				Remove....................................................................3968
				Clean/Inspect.............................................................3969
				Install...................................................................3969
			Gasoline Fuel Filter Replacement, Mazda 2007 Emission Compliant ..............3969
				Remove and Replace........................................................3969
			Fuel Filter Replacement, Yanmar Engine........................................3970
			Priming the Fuel System (Yanmar)..............................................3971
			Lift Chains Wear Check........................................................3972
			Lift Chain Lubrication........................................................3973
			Integral Sideshift Carriage, Check Bearings...................................3973
			Steering Axle.................................................................3974
			Control Levers and Pedals.....................................................3974
		Maintenance Procedures Every 2000 Hours or Annually...............................3975
			Hydraulic System..............................................................3975
				Hydraulic Filter, Replace.................................................3975
				Hydraulic Tank Breather, Replace..........................................3976
			Air Filter Element............................................................3976
			PCV Valve.....................................................................3977
			Oxygen Sensor.................................................................3977
			LPG Regulator Fuel Filter, Mazda Engines (Except 2007 Mazda Emis..............3978
				Remove and Replace........................................................3978
			LPG Regulator Fuel Filter, GM Engine..........................................3979
				Remove....................................................................3979
				Install...................................................................3979
			Gasoline Fuel Filter..........................................................3979
				Remove and Replace........................................................3979
			Timing Belt...................................................................3980
				Mazda Engines.............................................................3980
				GM 2.4L Engine............................................................3980
			LPG Fuel Injector, Mazda Engines (Except 2007 Mazda Emission Com..............3980
			Gasoline Fuel Injector, Mazda Engines.........................................3980
			LPG Fuel Injector, GM Engines.................................................3980
			Gasoline Fuel Injector, GM Engines............................................3980
			Fuel Injector, Yanmar Engines.................................................3980
			Forks.........................................................................3981
			Integral Sideshift Carriage...................................................3981
				Bearings, Replace.........................................................3981
			Transmission Oil and Filter (Dry Brake), Replace..............................3981
			Transmission and Left Planetary Housing Oil Change, Wet Brake Dr..............3982
			Wet Brake Axle Center Section And Right Side Planetary Housing, ..............3984
			Brake Fluid (Master Cylinder), Change.........................................3985
			Brake Fluid (Dry Brake), Remove...............................................3986
			Service Brakes (Dry Brake)....................................................3986
			Differential (Dry Brake)......................................................3987
		Maintenance Procedures Every 4000 Hours or 2 Years................................3988
			Hydraulic Oil, Replace........................................................3988
			Cooling System................................................................3988
		Safety Procedures When Working Near Mast..........................................3989
		Hood Latch Check..................................................................3992
		Lift Chain Adjustments............................................................3993
		Jump-Starting the Lift Truck......................................................3994
			Jump-Starting Using a Battery Charger.........................................3994
			Jump-Starting a Lift Truck Using Another Lift Truck...........................3994
		Welding Repairs...................................................................3995
		Overhead Guard Changes............................................................3995
		Wheel and Tire Replacement........................................................3996
			General.......................................................................3996
			Solid Rubber Tire, Change ( S Series).........................................3996
				Remove and Install Tire on Wheel..........................................3996
			Pneumatic Tire With Tube, Repair..............................................3997
				Remove Wheels From Lift Truck.............................................3997
				Remove Tire From Wheel....................................................3997
					Remove Tire From Two-Piece Wheel......................................3998
					Remove Tire From Three- and Four-Piece Wheels.........................3999
				Install Wheel in Tire.....................................................4000
					Install Three-Piece or Four-Piece Wheel in Tire.......................4000
					Install Tire on Two-Piece Wheel.......................................4001
					Install Two-Piece Wheel in Tire.......................................4002
			Add Air to Pneumatic Tires With Tube..........................................4002
				Install the Wheels........................................................4003
				Dual Drive Wheels, Install................................................4003
			Pneumatic Tubeless Tire, Repair...............................................4004
				Remove Wheels From Lift Truck.............................................4004
				Remove Tire From Wheel....................................................4004
				Install Tire on Wheel.....................................................4006
				Add Air to Pneumatic Tubeless Tire........................................4008
				Wheels, Install...........................................................4009
			Solid Rubber Tires on Pneumatic Wheels, Change................................4009
				Remove Wheel From Tire....................................................4009
				Install Tire on Wheel.....................................................4011
		Adhesives and Sealants............................................................4013
	tables................................................................................3905
		Table 1. Maintenance Schedule.....................................................3921
		Table 2. V-Belt Deflection Table..................................................3956
		Table 3. Carriage Chain Adjustment, Forks Not Installed...........................3994
1580526-8000SRM1151-(06-2007)-US-EN.......................................................4017
	toc...................................................................................4017
		Capacities and Specifications.....................................................4017
		Safety Precautions Maintenance and Repair.........................................4018
		Lift Truck Lifting Capacity.......................................................4021
		Counterweight Weights.............................................................4021
		Tire Sizes........................................................................4021
		Capacities........................................................................4022
		Electrical System.................................................................4025
		Transmission Oil Pressures........................................................4027
		Hydraulic System Relief Pressures.................................................4029
		Steering System...................................................................4029
		Stall Speeds (in RPM ±100 rpm)....................................................4030
			Mazda 2.0L (Except 2007 Emission Compliant Engines)...........................4030
			Mazda 2.0L (2007 Emission Compliant Engines Only).............................4030
			Mazda 2.2L (Except 2007 Emission Compliant Engines)...........................4030
			Mazda 2.2L (2007 Emission Compliant Engines Only).............................4030
			GM 2.4L.......................................................................4030
			Yanmar 2.6L...................................................................4030
			Yanmar 3.3L...................................................................4031
		Mast Speeds.......................................................................4031
		Tilt Angles.......................................................................4034
		Front End Equipment - Mast Creep..................................................4035
			Mast Creep....................................................................4035
		Engine Specifications.............................................................4036
		Torque Specifications.............................................................4038
			Frame.........................................................................4038
			Mast..........................................................................4038
			Steering System, Cushioned Tire Trucks........................................4038
			Steering System, Pneumatic Tire Trucks........................................4038
			Drive Axle (Dry Brake)........................................................4038
			Drive Axle (Wet Brake)........................................................4039
			Transmission..................................................................4039
			Engine - Mazda 2.0L and 2.2L..................................................4040
			Engine - GM 2.4L..............................................................4040
			Engine - Yanmar 2.6L and 3.3L Diesel..........................................4042
	tables................................................................................4017
		Table 1. Lift Truck Models S2.0-3.5FT (S40-70FT, S55FTS) (F187)...................4031
		Table 2. Lift Truck Models H2.0-3.5FT (H40-70FT) (L177)...........................4032
		Table 3. S2.0-3.5FT (S40-70FT, S55FTS) (F187) Lift Truck Models...................4034
		Table 4. H2.0-3.5FT (H40-70FT) (L177) Lift Truck Models...........................4034
		Table 5. S2.0-3.5FT (S40-70FT, S55FTS) (F187) Lift Truck Models...................4035
		Table 6. H2.0-3.5FT (H40-70FT) (L177) Lift Truck Models...........................4035
1580527-8000SRM1152-(07-2007)-US-EN.......................................................4045
	toc...................................................................................4045
		Diagrams and Schematics...........................................................4045
		Safety Precautions Maintenance and Repair.........................................4046
		General Information About Diagrams and Schematics.................................4049
			Symbol Definitions............................................................4049
	tables................................................................................4045
		Table 1. Wire Colors..............................................................4049
		Table 2. Symbol Definitions.......................................................4049
1580527-8000SRM1152-(10-2006)-US-EN.......................................................4111
	toc...................................................................................4111
		Diagrams and Schematics...........................................................4111
		Safety Precautions Maintenance and Repair.........................................4112
		General Information About Diagrams and Schematics.................................4115
			Symbol Definitions............................................................4115
	tables................................................................................4111
		Table 1. Wire Colors..............................................................4115
		Table 2. Symbol Definitions.......................................................4115
1580528-8000SRM1134-(06-2007)-US-EN.......................................................4165
	toc...................................................................................4165
		Calibration Procedures............................................................4165
		Safety Precautions Maintenance and Repair.........................................4166
		Description.......................................................................4171
		Proc_Cal_001: Service Password Entry..............................................4174
			When to Perform...............................................................4174
			Why Perform...................................................................4174
			How to Perform................................................................4174
		Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed...................4176
			When to Perform...............................................................4176
			Calibration Order.............................................................4176
			Why Perform...................................................................4176
			How to Perform................................................................4176
		Proc_Cal_003: Save and Exit.......................................................4178
			When to Perform...............................................................4178
			Why Perform...................................................................4178
			How to Perform................................................................4178
		Proc_Cal_004: Lift Valve Output Threshold.........................................4180
			When to Perform...............................................................4180
			Calibration Order.............................................................4180
			Why Perform...................................................................4180
			How to Perform................................................................4180
		Proc_Cal_005: Lower Valve Output Threshold........................................4182
			When to Perform...............................................................4182
			Calibration Order.............................................................4182
			Why Perform...................................................................4182
			How to Perform................................................................4182
		Proc_Cal_006: Tilt Back Valve Output Threshold....................................4186
			When to Perform...............................................................4186
			Calibration Order.............................................................4186
			Why Perform...................................................................4186
			How to Perform................................................................4186
		Proc_Cal_007: Tilt Forward Valve Output Threshold.................................4188
			When to Perform...............................................................4188
			Calibration Order.............................................................4188
			Why Perform...................................................................4188
			How to Perform................................................................4189
		Proc_Cal_008: Aux 1 Dir A Valve Output Threshold..................................4192
			When to Perform...............................................................4192
			Calibration Order.............................................................4192
			Why Perform...................................................................4192
			How to Perform................................................................4192
		Proc_Cal_009: Aux 1 Dir B Valve Output Threshold..................................4194
			When to Perform...............................................................4194
			Calibration Order.............................................................4194
			Why Perform...................................................................4194
			How to Perform................................................................4194
		Proc_Cal_010: Aux 2 Dir A Valve Output Threshold..................................4198
			When to Perform...............................................................4198
			Calibration Order.............................................................4198
			Why Perform...................................................................4198
			How to Perform................................................................4198
		Proc_Cal_011: Aux 2 Dir B Valve Output Threshold..................................4200
			When to Perform...............................................................4200
			Calibration Order.............................................................4200
			Why Perform...................................................................4200
			How to Perform................................................................4201
		Proc_Cal_012: Aux 3 Dir A Valve Output Threshold..................................4204
			When to Perform...............................................................4204
			Calibration Order.............................................................4204
			Why Perform...................................................................4204
			How to Perform................................................................4204
		Proc_Cal_013: Aux 3 Dir B Valve Output Threshold..................................4206
			When to Perform...............................................................4206
			Calibration Order.............................................................4206
			Why Perform...................................................................4206
			How to Perform................................................................4207
		Proc_Cal_014: Load Weight Zero Point..............................................4210
			When to Perform...............................................................4210
			Calibration Order.............................................................4210
			Why Perform...................................................................4210
			How to Perform................................................................4210
		Proc_Cal_015: Loaded Weight Calibration...........................................4212
			When to Perform...............................................................4212
			Calibration Order.............................................................4212
			Why Perform...................................................................4212
			How to Perform................................................................4212
		Proc_Cal_016: Transmission Valve Calibration......................................4214
			Applicable System/Option......................................................4214
			When to Perform...............................................................4214
			Calibration Order.............................................................4214
			Why Perform...................................................................4215
			How to Perform................................................................4215
			Applicable System/Option......................................................4216
			When to Perform...............................................................4216
			Calibration Order.............................................................4216
			Why Perform...................................................................4216
			How to Perform................................................................4216
		Proc_Cal_016A: Transmission Valve Calibration-Electronic Extende..................4218
			Applicable System/Option......................................................4218
			When to Perform...............................................................4218
			Calibration Order.............................................................4218
			Why Perform...................................................................4218
			How to Perform................................................................4218
		Proc_Cal_016B: Trans. Valve Calibration-Electronic and Electroni..................4220
			Applicable System/Option......................................................4220
			When to Perform...............................................................4220
			Calibration Order.............................................................4220
			Why Perform...................................................................4220
			How to Perform................................................................4220
		Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment.......................4222
			Required Tools................................................................4222
			When to Perform...............................................................4222
			Calibration Order.............................................................4222
			Why Perform...................................................................4222
			How to Perform................................................................4222
		Proc_Cal_025: Hydraulic Valve Pressure Gage Installation..........................4224
			When to Perform...............................................................4224
			Why Perform...................................................................4224
			How to Perform................................................................4224
		Proc_Cal_026: Travel Speed Calibration............................................4226
			When to Perform...............................................................4226
			Calibration Order.............................................................4226
			Why Perform...................................................................4226
			How to Perform................................................................4226
	tables................................................................................4165
		Table 1. Calibration Procedures...................................................4171
		Table 2. How to Read Calibration Procedure........................................4172
		Table 3. Proc_Cal_001: Service Password Entry.....................................4175
		Table 4. Proc_Cal_002: Hydraulic Valve Calibration Warm Up and A..................4176
		Table 5. Proc_Cal_003: Save and Exit..............................................4179
		Table 6. Proc_Cal_004: Lift Valve Output Threshold................................4180
		Table 7. Proc_Cal_005: Lower Valve Output Threshold...............................4183
		Table 8. Proc_Cal_006: Tilt Back Valve Output Threshold...........................4186
		Table 9. Proc_Cal_007: Tilt Forward Valve Output Threshold........................4189
		Table 10. Proc_Cal_008: Aux 1 Dir A Valve Output Threshold........................4192
		Table 11. Proc_Cal_009: Aux 1 Dir B Valve Output Threshold........................4195
		Table 12. Proc_Cal_010: Aux 2 Dir A Valve Output Threshold........................4198
		Table 13. Proc_Cal_011: Aux 2 Dir B Valve Output Threshold........................4201
		Table 14. Proc_Cal_012: Aux 3 Dir A Valve Output Threshold........................4204
		Table 15. Proc_Cal_013: Aux 3 Dir B Valve Output Threshold........................4207
		Table 16. Proc_Cal_014: Load Weight Zero Point....................................4210
		Table 17. Proc_Cal_015: Loaded Weight Calibration.................................4212
		Table 18. Proc_Cal_016: Transmission Valve Calibration............................4215
		Table 19. Proc_Cal_016: Transmission Valve Calibration ( S6.0FT,..................4217
		Table 20. Proc_Cal_016A: Transmission Valve Calibration...........................4219
		Table 21. Proc_Cal_016B: Transmission Valve Calibration...........................4221
		Table 22. Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjus..................4223
		Table 23. Proc_Cal_025: Hydraulic Valve Pressure Gage Installati..................4225
		Table 24. Proc_Cal_026: Travel Speed Calibration..................................4226
1598588-0600SRM1205-(03-2007)-US-EN.......................................................4231
	toc...................................................................................4231
		Yanmar Diesel Engines.............................................................4231
		Safety Precautions Maintenance and Repair.........................................4232
		General...........................................................................4237
			Engine Identification.........................................................4237
				Major Engine Component Identification.....................................4237
				Location of Labels........................................................4237
		Engine Removal and Installation...................................................4238
		Cylinder Head Assembly Repair.....................................................4238
			Glow Plugs....................................................................4240
				Remove....................................................................4240
				Install...................................................................4240
			Valve Cover...................................................................4240
				Remove....................................................................4240
				Clean and Inspect.........................................................4240
				Install...................................................................4241
			Rocker Arm Assembly...........................................................4241
				Remove....................................................................4241
				Disassemble...............................................................4242
				Clean and Inspect.........................................................4242
					Push Rods.............................................................4242
					Rocker Arm Assembly...................................................4242
				Assemble..................................................................4243
				Install...................................................................4243
			Valve Clearance Adjustments...................................................4243
			Cylinder Head Assembly........................................................4245
				Remove....................................................................4245
				Disassemble...............................................................4248
					Valves and Valve Springs, Remove......................................4248
					Valve Guides, Remove..................................................4249
				Clean and Inspect.........................................................4249
					Cylinder Head.........................................................4250
					Valve Guides..........................................................4250
					Valves................................................................4250
					Valve Sink............................................................4250
					Valve Seat............................................................4251
					Valve Springs.........................................................4251
				Assemble..................................................................4252
					Valve Guides, Install.................................................4252
					Valves and Valve Springs, Install.....................................4252
				Install...................................................................4253
		Timing Gear Case and Timing Gears Repair..........................................4254
			Timing Gear Case Cover........................................................4254
				Remove....................................................................4254
				Clean and Inspect.........................................................4255
				Install...................................................................4255
			Timing Gears..................................................................4256
				Crankshaft Gear...........................................................4256
					Remove................................................................4256
					Install...............................................................4256
				Idler Gear................................................................4256
					Remove................................................................4256
					Inspect...............................................................4257
					Install...............................................................4257
				Camshaft Gear.............................................................4257
					Remove................................................................4257
					Install...............................................................4258
			Timing Gear Case..............................................................4258
				Remove....................................................................4258
				Clean and Inspect.........................................................4258
				Install...................................................................4258
		Drive Train, Camshaft, and Cylinder Block Repair..................................4259
			Remove........................................................................4259
			Disassemble...................................................................4259
				Pistons and Connecting Rods...............................................4259
				Crankshaft................................................................4260
				Camshaft..................................................................4262
			Clean and Inspect.............................................................4263
				Cylinder Block............................................................4263
					Honing and Boring.....................................................4266
				Pistons...................................................................4267
				Piston Pin................................................................4267
				Connecting Rod............................................................4268
				Tappets...................................................................4268
				Crankshaft................................................................4268
				Camshaft..................................................................4270
				Camshaft Bushing..........................................................4270
			Assemble......................................................................4270
				Camshaft..................................................................4270
				Crankshaft................................................................4271
				Pistons and Connecting Rods...............................................4271
			Install.......................................................................4272
		Lubrication System Repair.........................................................4273
			Engine Oil and Oil Filter Change..............................................4273
			Oil Pan.......................................................................4273
				Remove....................................................................4273
				Install...................................................................4274
			Oil Suction Tube..............................................................4274
				Remove....................................................................4274
				Clean.....................................................................4274
				Install...................................................................4275
			Oil Pump......................................................................4275
				Remove....................................................................4275
				Clean and Inspect.........................................................4275
					Outer Rotor Outside Clearance.........................................4276
					Outer Rotor to Inner Rotor Tip Clearance..............................4276
					Outer Rotor Side Clearance............................................4276
					Rotor Shaft Clearance.................................................4276
				Install...................................................................4277
		Fuel System Repair................................................................4277
			Fuel Injectors................................................................4277
				Remove....................................................................4277
				Inspect...................................................................4278
				Clean.....................................................................4278
				Test......................................................................4279
				Install...................................................................4281
			Electronic Throttle System....................................................4281
				Remove....................................................................4281
				Install...................................................................4284
				Inspect...................................................................4285
				Adjust....................................................................4285
			Fuel Injection Pump...........................................................4285
				Remove....................................................................4285
				Clean and Inspect.........................................................4288
				Install...................................................................4288
				Check/Adjust Fuel Injection Timing........................................4289
		Cooling System Repair.............................................................4291
			V-Belt........................................................................4291
				Remove....................................................................4291
				Inspect...................................................................4291
				Install...................................................................4291
				Adjust....................................................................4291
			Water Pump....................................................................4292
				4TNE92-NMHA Engines.......................................................4292
					Remove................................................................4292
					Install...............................................................4293
				4TNE92-NMH and 4TNE98-NMH Engines.........................................4294
					Remove................................................................4294
					Install...............................................................4295
			Thermostat....................................................................4296
				Remove....................................................................4296
				Inspect...................................................................4296
				Install...................................................................4297
		Flywheel and Flywheel Housing.....................................................4298
			Flywheel......................................................................4298
				Remove....................................................................4298
				Install...................................................................4298
			Flywheel Housing..............................................................4299
				Remove....................................................................4299
				Install...................................................................4299
		Electrical Equipment Repair.......................................................4300
			Alternator....................................................................4300
				Remove....................................................................4300
				Bench Test................................................................4302
				Regulate Voltage Check....................................................4302
				No Load Test..............................................................4304
				Output Test...............................................................4304
				Install...................................................................4304
			Starter.......................................................................4304
				Remove....................................................................4306
				No Load Test..............................................................4306
				Install...................................................................4306
		Engine Specifications.............................................................4307
			Engine Data...................................................................4307
			Engine Tuning.................................................................4310
			Cylinder Head.................................................................4311
			Intake/Exhaust Valve and Guide................................................4311
			Valve Spring..................................................................4312
			Rocker Arm and Shaft..........................................................4312
			Push Rod......................................................................4312
			Gear Train and Camshaft.......................................................4312
				Camshaft..................................................................4312
				Idle Gear Shaft and Bushing...............................................4313
				Backlash of Each Gear.....................................................4313
			Cylinder Block................................................................4314
			Crankshaft....................................................................4314
			Thrust Bearing................................................................4314
			Piston........................................................................4314
			Piston Ring...................................................................4315
			Connecting Rod................................................................4315
				Rod Small End.............................................................4316
				Tappet....................................................................4316
			Oil Pump......................................................................4316
				Engine Oil Pressure.......................................................4316
				Outer Rotor Outside Clearance.............................................4316
				Outer Rotor Side Clearance................................................4316
				Outer Rotor to Inner Rotor Tip Clearance..................................4316
				Rotor Shaft Clearance.....................................................4317
		Standard Torque Specifications....................................................4317
			Standard Torque Chart.........................................................4317
		Special Torque Specifications.....................................................4318
		Special Tools.....................................................................4319
	tables................................................................................4231
		Table 1. Cylinder Measurement Worksheet...........................................4265
		Table 2. Fuel Injector Spray Patterns.............................................4280
		Table 3. V-Belt Deflection Table..................................................4291
		Table 4. Alternator Specifications................................................4300
		Table 5. Starter Specifications...................................................4305
		Table 6. No Load Test Specifications..............................................4306
		Table 7. 4TNE92-NMH Engine........................................................4307
		Table 8. 4TNE92-NMHA Engine.......................................................4308
		Table 9. 4TNE98-NMH Engine........................................................4309
1599962-1400SRM1215-(05-2006)-US-EN.......................................................4327
	toc...................................................................................4327
		Drive Axle Repair.................................................................4327
		Safety Precautions Maintenance and Repair.........................................4328
		General...........................................................................4331
			Identification Plate..........................................................4331
		Drive Axle Removal................................................................4331
		Reduction Gear Assembly...........................................................4337
			Reduction Gear Assembly Repair................................................4337
				Remove....................................................................4339
				Clean and Inspect.........................................................4346
				Install...................................................................4347
		Brake Repair......................................................................4358
			Wet Disc Brake................................................................4358
				Remove....................................................................4361
				Clean and Inspect.........................................................4367
				Install...................................................................4368
			Parking Brake Control Lever...................................................4380
				General...................................................................4380
				Remove....................................................................4381
				Clean and Inspect.........................................................4382
				Install...................................................................4383
		Differential Repair...............................................................4386
			Remove........................................................................4386
				Flange....................................................................4386
				Differential Assembly.....................................................4388
				Bevel Pinion..............................................................4394
			Disassemble...................................................................4399
				Differential Assembly.....................................................4399
			Clean and Inspect.............................................................4401
			Assemble......................................................................4402
				Differential Assembly.....................................................4402
			Install.......................................................................4406
				Determine Bevel Pinion Shim Thickness.....................................4406
				Bevel Pinion..............................................................4408
				Differential Assembly.....................................................4412
				Gear Set, Tooth Contact Pattern Check.....................................4420
				Flange....................................................................4422
		Drive Axle Installation...........................................................4423
		Special Tools.....................................................................4428
		Torque Specifications.............................................................4431
	tables................................................................................4327
		Table 1. Bevel Gear and Bevel Pinion Tooth Contact Adjustment.....................4420
		Table 2. Correct Tooth Contact....................................................4420
		Table 3. Incorrect Tooth Contact..................................................4421
1599963-1400SRM1214-(12-2005)-US-EN.......................................................4437
	toc...................................................................................4437
		Drive Axle and Differential Assembly Repair.......................................4437
		Safety Precautions Maintenance and Repair.........................................4438
		General...........................................................................4441
		Drive Axle Repair.................................................................4441
			Remove and Disassemble........................................................4441
			Clean and Inspect.............................................................4443
			Assemble and Install..........................................................4443
		Differential Repair...............................................................4446
			Remove........................................................................4446
				Differential Assembly From Center Section.................................4446
				Drive Pinion, Pinion Gear, and Bearings From Center Section...............4449
			Disassemble...................................................................4455
				Differential Assembly.....................................................4455
				Drop Box Housing..........................................................4457
				Center Section............................................................4458
			Clean and Inspect.............................................................4461
			Assemble......................................................................4461
				Center Section............................................................4461
				Drop Box Housing..........................................................4464
				Differential Assembly.....................................................4465
			Install.......................................................................4469
				Pinion Inner Shim Set, Adjust Thickness (Depth of Pinion).................4469
				Drive Pinion, Pinion Gear, and Bearings Into Center Section...............4470
				Differential Assembly Into Center Section.................................4475
				Ring Gear Backlash, Adjust................................................4480
				Ring Gear, Runout Check...................................................4481
				Gear Set, Tooth Contact Pattern Check.....................................4481
		Torque Specifications.............................................................4484
	tables................................................................................4437
		Table 1. Pinion Variation Numbers Examples........................................4470
		Table 2. Ring and Pinion Tooth Contact Adjustment.................................4482
		Table 3. Correct Tooth Contact....................................................4482
		Table 4. Incorrect Tooth Contact..................................................4483
1653957-0900SRM1325-(12-2006)-US-EN.......................................................4487
	toc...................................................................................4487
		Gasoline Fuel System..............................................................4487
		Safety Precautions Maintenance and Repair.........................................4488
		General...........................................................................4491
		Abbreviations.....................................................................4491
		Intake-Air System.................................................................4491
			Intake-Air System Manifold Vacuum Check.......................................4491
			Throttle Body.................................................................4492
				Remove....................................................................4493
				Install...................................................................4493
			Intake Manifold...............................................................4493
				Remove....................................................................4493
				Install...................................................................4494
		Fuel System.......................................................................4494
			Before Repair Procedure.......................................................4494
				Fuel Line Safety Procedure................................................4494
			After Repair Procedure........................................................4496
				Fuel Hose, Install........................................................4496
				Fuel Leakage Check........................................................4496
			Fuel Line Pressure Check......................................................4497
			Fuel Injectors................................................................4498
				Remove....................................................................4498
				Install...................................................................4498
			Pressure Regulator............................................................4500
				Remove....................................................................4500
				Install...................................................................4500
		Exhaust System....................................................................4501
			Exhaust System, Inspect.......................................................4501
			Three-Way Catalytic (TWC) Converter...........................................4501
				Remove and Install........................................................4501
			Exhaust Manifold..............................................................4501
				Remove....................................................................4501
				Install...................................................................4501
			Positive Crankcase Ventilation (PCV) Valve....................................4503
				Remove....................................................................4503
				Inspect...................................................................4503
				Install...................................................................4503
		Control System....................................................................4503
			Engine Control Unit (ECU).....................................................4503
				Remove....................................................................4503
				Install...................................................................4503
			Intake Air Temperature (IAT) Sensor...........................................4506
				Remove....................................................................4506
				Install...................................................................4506
			Engine Coolant Temperature (ECT) Sensor.......................................4507
				Remove....................................................................4507
				Install...................................................................4508
			CAM Angle Sensor..............................................................4508
				Voltage Check.............................................................4508
			Manifold Absolute Pressure (MAP) Sensor.......................................4509
				Remove....................................................................4509
				Install...................................................................4509
			Oxygen Sensor.................................................................4510
				Remove....................................................................4510
				Install...................................................................4510
		Technical Data....................................................................4511
	tables................................................................................4487
		Table 1. PCV Valve Specifications.................................................4503
		Table 2. Gasoline Fuel Systems Technical Data.....................................4511
1653958-0900SRM1326-(03-2007)-US-EN.......................................................4515
	toc...................................................................................4515
		LPG Fuel System...................................................................4515
		Safety Precautions Maintenance and Repair.........................................4516
		General...........................................................................4519
		LPG Tank Replacement..............................................................4519
			Remove........................................................................4519
			Install.......................................................................4521
		Fuel Filter Unit Repair...........................................................4522
			Fuel Filter Element...........................................................4522
				Remove....................................................................4522
				Clean/Inspect.............................................................4522
				Install...................................................................4522
			Fuel Filter Housing...........................................................4523
				Remove....................................................................4523
				Disassemble...............................................................4524
				Assemble..................................................................4524
				Install...................................................................4525
		Electronic Throttle Body Repair...................................................4525
			Remove........................................................................4525
			Install.......................................................................4526
		Electronic Pressure Regulator (EPR) Repair........................................4527
			Remove........................................................................4527
			Disassemble...................................................................4528
			Assemble......................................................................4530
			Install.......................................................................4532
		LPG Shutoff Valve Assembly........................................................4533
			Remove........................................................................4533
			Install.......................................................................4533
		Fuel Mixer Repair.................................................................4535
			Remove........................................................................4535
			Install.......................................................................4536
		Control System....................................................................4538
			Engine Control Unit (ECU).....................................................4538
				Remove....................................................................4538
				Install...................................................................4539
			Engine Coolant Temperature (ECT) Sensor.......................................4540
				Remove....................................................................4540
				Install...................................................................4540
			CAM Angle Sensor..............................................................4541
				Voltage Check.............................................................4541
			Manifold Absolute Pressure (MAP) Sensor.......................................4542
				Remove....................................................................4542
				Install...................................................................4542
			Intake Air Temperature (IAT) Sensor...........................................4542
				Remove....................................................................4542
				Install...................................................................4542
			Fuel Temperature Sensor.......................................................4543
				Remove....................................................................4543
				Install...................................................................4543
			Oxygen Sensor.................................................................4544
				Remove....................................................................4544
				Install...................................................................4544
		Exhaust System....................................................................4545
			Exhaust System, Inspect.......................................................4545
			Three-Way Catalytic (TWC) Converter...........................................4545
				Remove and Install........................................................4545
			Exhaust Manifold..............................................................4545
				Remove....................................................................4545
				Install...................................................................4545
			Positive Crankcase Ventilation (PCV) Valve....................................4547
				Remove....................................................................4547
				Inspect...................................................................4547
				Install...................................................................4547
	tables................................................................................4515
		Table 1. PCV Valve Specifications.................................................4547
1653959-2200SRM1327-(03-2007)-US-EN.......................................................4551
	toc...................................................................................4551
		Electrical System.................................................................4551
		Safety Precautions Maintenance and Repair.........................................4552
		Ignition System...................................................................4555
			General.......................................................................4555
			Ignition Timing Adjustment, Gasoline and LPG..................................4555
			Spark Plugs Check.............................................................4558
			Spark Plug Wires Check........................................................4558
		CAM Angle Sensor Repair...........................................................4558
			Remove........................................................................4558
			Install.......................................................................4559
		Coil Replacement..................................................................4560
			Remove........................................................................4560
			Inspect.......................................................................4561
			Install.......................................................................4561
		Starter Repair....................................................................4562
			General.......................................................................4562
			Remove........................................................................4563
			No-Load Test..................................................................4563
			Magnetic Switch Test..........................................................4564
				Pull-Out Test.............................................................4564
				Holding Coil Test.........................................................4564
				Return Test...............................................................4564
				Pinion Movement Inspection................................................4564
			Install.......................................................................4565
		Alternator Repair.................................................................4565
			General.......................................................................4565
			Charging System Inspection....................................................4566
			Output Current Check..........................................................4566
			No-Load Adjusted Voltage Check................................................4567
			Remove........................................................................4567
			Inspect.......................................................................4567
				Rectifier Check...........................................................4567
			Install.......................................................................4568
	tables................................................................................4551
		Table 1. Spark Plug Wires.........................................................4558
		Table 2. Coil Inspection..........................................................4561
		Table 3. Starter Specifications...................................................4562
		Table 4. Problem Diagnosis Chart..................................................4563
		Table 5. Specifications...........................................................4566
		Table 6. Rectifier Check Table....................................................4567
1673866-0100SRM1290-(07-2007)-US-EN.......................................................4571
	toc...................................................................................4571
		Operator's Cab....................................................................4571
		Safety Precautions Maintenance and Repair.........................................4572
		General...........................................................................4577
		Cab Replacement...................................................................4578
			Remove, for Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F001); H2...............4578
			Install, for Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F001); H2..............4589
			Remove, for Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (H..............4590
			Install, for Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (..............4594
		Door Assemblies...................................................................4595
			Right Side Door Assembly, Lift Truck Models H1.6FT, H1.8FT, 2.0F..............4595
				Remove....................................................................4595
				Disassemble...............................................................4600
					Door Cover............................................................4600
					Heater Assembly.......................................................4602
					Door Lock Assembly....................................................4603
					Windows...............................................................4604
				Clean.....................................................................4604
				Inspect...................................................................4604
				Assemble..................................................................4604
					Windows...............................................................4604
					Door Lock Assembly....................................................4604
					Heater Assembly.......................................................4605
					Door Cover............................................................4605
				Install...................................................................4605
			Left Side Door Assembly, Lift Truck Models H1.6FT, H1.8FT, 2.0FT..............4605
				Remove....................................................................4605
				Disassemble...............................................................4605
					Door Cover............................................................4605
					Door Lock Assembly....................................................4607
					Windows...............................................................4607
				Clean.....................................................................4607
				Inspect...................................................................4607
				Assemble..................................................................4607
					Windows...............................................................4607
					Door Lock Assembly....................................................4607
					Door Cover............................................................4607
				Install...................................................................4607
			Right and Left Side Door Assemblies, Lift Truck Models H6.0FT, H..............4608
				Remove....................................................................4608
				Disassemble...............................................................4608
					Door Cover............................................................4608
					Door Lock Assembly....................................................4610
					Windows...............................................................4610
				Clean.....................................................................4610
				Inspect...................................................................4610
				Assemble..................................................................4611
					Windows...............................................................4611
					Door Lock Assembly....................................................4611
					Door Cover............................................................4611
				Install...................................................................4612
		Window Wipers Replacement.........................................................4612
			General.......................................................................4612
			Front Wiper Assembly and Motor................................................4612
				Remove, Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F001) and H2.0..........4612
				Install, Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F001) and H2...........4612
				Remove, Lift Truck Models H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-5..........4614
				Install, Lift Truck Models H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-..........4614
			Rear Wiper Assembly and Motor.................................................4616
				Remove, Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F001)...................4616
				Install, Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F001)..................4616
				Remove, Lift Truck Models H2.0-3.5FT (H40-70FT) (L177)....................4618
				Install, Lift Truck Models H2.0-3.5FT (H40-70FT) (L177)...................4618
				Remove, Lift Truck Models H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-5..........4621
				Install, Lift Truck Models H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-..........4621
				Remove, Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (H006)..........4623
				Install, Lift Truck Models H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-..........4623
		Window Replacement................................................................4625
			General.......................................................................4625
			Remove Door Window, Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F0..............4625
			Install Door Windows, Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (..............4626
			Remove Door Window, Lift Truck Models H6.0FT, H7.0FT (H135FT, H1..............4627
			Install Door Window, Lift Truck Models H6.0FT, H7.0FT (H135FT, H..............4628
		Heater Replacement................................................................4628
			Remove, for Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (H..............4628
			Install, for Lift truck Models H6.0FT, H7.0FT (H135FT, H155FT) (..............4631
		Light Replacement.................................................................4632
			Work Lights (Front and Rear)..................................................4632
				Remove....................................................................4632
				Install...................................................................4632
			Strobe Light..................................................................4634
				Remove....................................................................4634
				Install...................................................................4634
			Turn, Stop, Tail, and Backup Light............................................4635
				Remove....................................................................4635
				Install...................................................................4635
			Front Marker/Turn Signal Lights...............................................4635
				Remove....................................................................4635
				Install...................................................................4635
		Display Switches..................................................................4636
		Electrical Schematics.............................................................4640
		Optional Equipment................................................................4643
			Heavy Duty Pre-Cleaner........................................................4643
				Remove....................................................................4643
				Clean.....................................................................4644
				Inspect...................................................................4644
				Install...................................................................4644
			Fan...........................................................................4644
				Remove....................................................................4644
				Install...................................................................4644
			Mirror........................................................................4644
				Remove....................................................................4644
				Install...................................................................4644
		Label Replacement.................................................................4644
Brake System1800SRM1188...................................................................4649
	toc...................................................................................4649
		Brake System......................................................................4649
		Safety Precautions Maintenance and Repair.........................................4650
		Introduction......................................................................4653
			General.......................................................................4653
			Discharging the Capacitors....................................................4653
		Parking Brake.....................................................................4654
			Remove........................................................................4655
			Install.......................................................................4656
		Troubleshooting...................................................................4656
Cooling System 1580505-0700SRM1123-(03-2007)-US-EN........................................4659
	toc...................................................................................4659
		Cooling System....................................................................4659
		Safety Precautions Maintenance and Repair.........................................4660
		General...........................................................................4663
		Cooling System Checks.............................................................4663
			Exhaust Leaks Into Cooling System.............................................4663
			Water Flow Restrictions in Radiator...........................................4663
			Radiator Hoses................................................................4663
			Water Pump....................................................................4663
		Flushing The Cooling System.......................................................4664
			Cooling System, Clean.........................................................4664
		Radiator Replacement..............................................................4665
			Radiator, Remove for Lift Trucks Models S30FT, S35FT, S40FTS (E0..............4665
			Radiator, Remove for Lift Truck Models S6.0FT, S7.0FT (S135FT, S..............4671
			Radiator, Remove for Lift Truck Models H6.0FT, H7.0FT (H135FT, H..............4672
			Radiator, Install for Lift Truck Models S30FT, S35FT, S40FTS (E0..............4673
			Radiator, Install for Lift Truck Models S6.0FT, S7.0FT (S135FT, ..............4676
			Radiator, Install for Lift Truck Models H6.0FT, H7.0FT (H135FT, ..............4678
		Fan Assembly Replacement..........................................................4681
			Fan Removal...................................................................4681
			Inspect.......................................................................4688
			Fan Installation..............................................................4688
Diagnostic Manual 1579259-9000SRM1112-(07-2007)-US-EN.....................................4691
	toc...................................................................................4691
		Diagnostic Troubleshooting Manual.................................................4691
		Safety Precautions TROUBLESHOOTING PROCEDURES.....................................4692
		How To Use This Troubleshooting Manual............................................4694
			General Instructions and Safety Information...................................4694
			How to Use Diagnostic Troubleshooting Manual..................................4694
			General Instructions..........................................................4695
		Operational Diagnostic Procedures.................................................4697
			Operational Checkout Procedures...............................................4699
				DTC Check.................................................................4700
				Horn Circuit Check........................................................4700
				Light Circuit Check.......................................................4700
				Windshield Washer Wiper Check (If equipped)...............................4700
				Heater Check (If equipped)................................................4701
				Dome Light Check (If equipped)............................................4701
				Circulating (Accessory) Fan Check (If equipped)...........................4702
				Indicator Light Power Check...............................................4703
				Operator Presence System Check............................................4704
				Engine Malfunction Indicator Check........................................4704
				Cold Start Check (Cummins and Yanmar).....................................4704
				Brake Pedal Check.........................................................4705
				Backup Alarm Check (If equipped)..........................................4705
				Armrest Hydraulic Interlock Check (If equipped and with original..........4705
				Engine Cover Latch Sensor Check (If equipped).............................4706
				Brake and Inching Pedal Check.............................................4706
				Park Brake Sensor Check...................................................4706
				Park Brake Check..........................................................4707
				Engine Speed Check (All Cummins, Yanmar, and Mazda Engines Excep..........4707
				Engine Power Check........................................................4708
				Transmission Clutch Check.................................................4708
				Transmission Check........................................................4709
				Transmission Speed Selection Check (If equipped)..........................4709
				Brake and Axle Drag Check.................................................4709
				Hydraulic Pump Flow Check.................................................4710
				Priority Flow Divider Valve Check.........................................4711
				Steering Relief Valve Low Pressure Check..................................4711
				Steering Relief Valve High Pressure Check.................................4712
				Control Valve Load Check Valve (Manual Valve).............................4712
				Tilt Function Counterbalance Check........................................4712
				Lift Drift Check..........................................................4713
				Tilt Function Drift Check.................................................4713
				Mast Cushion Check (All Except 2-Stage Mast)..............................4714
				Lift/Tilt Mast Adjustment Check...........................................4714
				Tilt Racking Check........................................................4715
				Chain and Header Hose Adjustment Check....................................4715
				Mast Mounting Check.......................................................4716
				Mast Channel Check........................................................4716
				Carriage Adjustment Check.................................................4716
				Chain Sheave Check........................................................4717
				Carriage Adjustment Check (Standard and Integral Side Shift)..............4717
		Engine............................................................................4719
			Engine Basics.................................................................4725
				General Terminology.......................................................4725
				Combustion Theory.........................................................4725
				Engine Components – Cylinder Block........................................4726
				Camshaft and Timing Set...................................................4727
				Cylinder Head Assembly....................................................4727
				Valve Train Assembly......................................................4727
				Air Cleaner/Filter........................................................4727
				Carburetion...............................................................4727
				Electronic Fuel Injection (EFI)...........................................4727
				Positive Crankcase Ventilation (PCV)......................................4728
			Engine Electrical.............................................................4728
				Introduction..............................................................4728
				Battery Construction......................................................4728
				Conventional Standard Battery.............................................4729
				Maintenance-Free Battery..................................................4729
				Battery Charging..........................................................4729
				Battery Fast Charging.....................................................4730
				Battery Slow Charging.....................................................4730
				Starting System Principles of Operation...................................4730
				Starting System Components - Ignition Switch..............................4731
				Starting System Components - Starter Solenoid.............................4731
				Starting System Components - Flywheel and Ring Gear.......................4731
				Starting System Components - Starter Motor and Drive......................4731
				Charging System - General.................................................4732
				Charging System - Regulator...............................................4732
				Charging System - Theory..................................................4732
			Engine Fuel System/Exhaust and Emissions......................................4733
				Introduction..............................................................4733
				Gasoline System Components - Fuel Tank....................................4733
				Electronic Fuel Injector (EFI) - General Description......................4733
				Port Fuel System Components - ECU.........................................4733
				Port Fuel System Components - Fuel Pump/Filter............................4733
				Port Fuel System Components - Fuel Rail...................................4733
				Port Fuel System Components - Pressure Regulator..........................4734
				Port Fuel System Components - Fuel Injectors..............................4734
				LPG Systems General Information...........................................4734
				LPG Fuel Properties.......................................................4734
				LPG Fuel Tank.............................................................4734
				AISAN Closed-Loop System..................................................4735
					Filter/Lockoff and Regulator..........................................4735
					Carburetor............................................................4735
					Start Mode............................................................4735
					Idle Mode.............................................................4736
					Run Mode..............................................................4736
				Main Fuel Lockoff Solenoid................................................4736
				Injector Fuel Lockoff Solenoid............................................4736
					Oxygen (O 2 ) Sensor..................................................4736
				Electronic Control Unit (ECU).............................................4736
				Catalytic Converter/Muffler...............................................4736
			Engine Management.............................................................4737
				Introduction..............................................................4737
				Ignition and Timing - Conventional Spark..................................4737
				Components - Ignition Coil................................................4737
				Components - Distributor..................................................4737
				Spark Timing..............................................................4737
				Components - Ignition Wires...............................................4737
				Components - Spark Plugs..................................................4738
				Faulty or Fouled Spark Plugs..............................................4738
				Electric Controlled Governing System - Mazda LPG..........................4738
			Engine Identification.........................................................4738
			Cummins (Diesel) Engine.......................................................4741
				Description...............................................................4741
				Diesel Fuel System........................................................4742
					Principle of Operation................................................4742
				Fuel Injection Pump and Governor..........................................4743
					Description...........................................................4743
					Principles of Operation...............................................4744
				Cummins Engine Control....................................................4745
					Engine Speed (RPM) Sensor.............................................4746
					Throttle Position Sensor..............................................4747
					Electronic Throttle Actuator..........................................4748
					Engine Oil Pressure Sensor............................................4748
					Coolant Temperature Sensor............................................4748
					Air Restriction Switch................................................4749
					Fuel Filter/Water Separator...........................................4749
					Fuel Level Sensor (In Tank)...........................................4749
				Engine Electrical System..................................................4750
					Magnetic Valve (Engine Stop Solenoid).................................4750
					Alternator............................................................4750
					Grid Heater...........................................................4750
					Cold Start Timing Advance (Fuel Injection Pump).......................4750
			Mazda Engine Overview.........................................................4751
				Description...............................................................4751
				Fuel System...............................................................4751
				Engine Controls Unit (ECU) and Emissions..................................4751
				Cooling System............................................................4751
				Ignition System...........................................................4751
			Mazda (LPG) Engine Controls...................................................4752
				LPG System (Aisan/E-Controls-Mechanical)..................................4752
					Description...........................................................4752
					Principles of Operation...............................................4753
					Control System........................................................4756
					Oxygen (O 2 ) Sensor..................................................4757
					Fuel Tank.............................................................4757
					Regulator.............................................................4758
						Start Mode........................................................4758
						Idle Mode.........................................................4758
						Run Mode..........................................................4759
					Resonator.............................................................4760
					Carburetor............................................................4760
						Start Mode........................................................4760
						Idle Mode.........................................................4761
						Run Mode..........................................................4761
					Governor..............................................................4761
				LPG System (E-Controls)...................................................4762
					Description...........................................................4762
					Principles of Operation...............................................4763
					Manifold Absolute Pressure Sensor.....................................4763
					Throttle Position Sensor..............................................4763
					Oxygen (O 2 ) Sensor..................................................4764
					Engine Coolant Temperature Sensor.....................................4764
					Intake Air Temperature Sensor.........................................4764
					Engine Control Unit...................................................4764
					Accelerator Pedal Position Sensor.....................................4764
					Three-Way Catalytic Converter.........................................4764
					Camshaft Position Sensor..............................................4764
					Electric Controlled Governing System..................................4766
					Electronic Governor Sensor............................................4766
			Mazda (Gasoline) Engine Controls..............................................4767
				Gasoline System...........................................................4767
					Description...........................................................4767
					Principles of Operation...............................................4768
				Control System............................................................4770
					Camshaft Position Sensor..............................................4771
					Intake Air Temperature Sensor.........................................4772
					Mass Air Flow Sensor..................................................4773
					Throttle Position Sensor..............................................4774
					Electronic Governor Sensor............................................4775
					Electronic Governing System...........................................4776
					Manifold Absolute Pressure Sensor/Boost Sensor........................4776
					Engine Coolant Temperature Sensor.....................................4777
				Intake Air System.........................................................4778
					Throttle Body.........................................................4778
					Idle Air Control Valve................................................4779
				Fuel System...............................................................4780
					Fuel Injector.........................................................4780
					Pressure Regulator....................................................4781
				Exhaust System............................................................4782
					Heated Oxygen (O 2 ) Sensor...........................................4782
					Three-Way Catalytic Converter.........................................4783
			GM (LPG) Engine Controls......................................................4784
				Engine Control System ....................................................4784
					Engine Control System Overview........................................4785
					Principles of Operation...............................................4785
				Control System............................................................4786
					GM/TGFI 2.4L (Four Cylinder) Control System Component Location........4786
					GM/TGFI 4.3L (Six Cylinder) Control System Component Location.........4787
					GM/TGFI 2.4L (Four-Cylinder) LPG System...............................4788
					GM/TGFI 4.3L (Six-Cylinder) LPG System................................4790
					Fuel Tank.............................................................4792
					Engine Control Unit...................................................4792
					Electronic Throttle Body/Throttle Position Sensor.....................4793
					Manifold Absolute Pressure/Manifold Air Temperature Sensor............4793
					Propane Injectors.....................................................4794
					Engine Coolant Temperature Sensor.....................................4796
					Oxygen (O 2 ) Sensor..................................................4796
					Crankshaft Position Sensor (Engine Speed Sensor)......................4797
					Oil Pressure Sensor...................................................4797
					Power Latch Relay.....................................................4797
					GM 2.4L Camshaft Position Sensor......................................4797
					GM 4.3L Camshaft Position Sensor......................................4798
					Injector Driver Module................................................4799
					Vaporizer/Regulator...................................................4799
					Accelerator Pedal Position Sensor.....................................4802
					Three-Way Catalytic Converter.........................................4802
				Ignition System...........................................................4803
					Ignition Coils........................................................4803
					Distributorless Ignition System Module................................4803
					Electronic Ignition Signals...........................................4804
					Distributor Ignition (DI) System......................................4805
					Camshaft Position (CMP) Sensor........................................4805
					Ignition Coil and Ignition Control Module (ICM).......................4805
					Secondary Ignition Components.........................................4805
			GM (Gasoline) Engine Controls.................................................4806
				Engine Control System.....................................................4806
					GM 2.4L (Four Cylinder) Engine Control System.........................4806
					GM 4.3L (Six Cylinder) Engine Control System..........................4807
					Engine Control System Overview........................................4808
					Principles of Operation...............................................4808
				Control System............................................................4808
					GM/TGFI 2.4L (Four Cylinder) Control System Component Location........4808
					GM/TGFI 4.3L (Six Cylinder) Control System Component Location.........4810
					GM/TGFI 2.4L (Four-Cylinder) Gasoline System Components...............4811
					GM/TGFI 4.3L (Six Cylinder) Gasoline System Components................4813
					Engine Control Unit...................................................4815
					Electronic Throttle Body/Throttle Position Sensor.....................4815
					Manifold Absolute Pressure/Manifold Air Temperature Sensor ...........4816
					Fuel Injector.........................................................4817
					Engine Coolant Temperature Sensor.....................................4818
					Oxygen (O 2 ) Sensor..................................................4819
					Crankshaft Position Sensor (Engine Speed Sensor)......................4819
					Oil Pressure Sensor...................................................4819
					Power Latch Relay.....................................................4819
					Camshaft Position Sensor..............................................4819
					Accelerator Pedal Position Sensor.....................................4821
					Three-Way Catalytic Converter.........................................4821
				Ignition System...........................................................4821
					Ignition Coils........................................................4821
					Distributorless Ignition System Module................................4821
					Electronic Ignition Signals...........................................4822
			Yanmar (Diesel) Engine........................................................4823
				Description...............................................................4823
				Diesel Fuel System........................................................4824
					Principles of Operation...............................................4824
				Fuel Injection Pump and Governor..........................................4825
					Description...........................................................4825
					Principles of Operation...............................................4827
					Timer.................................................................4828
					Feed Pump (Vane Type).................................................4828
					Regulating Valve......................................................4829
					Injection Pump Plunger................................................4830
						Suction Process...................................................4831
						Injection Process.................................................4831
						End of Injection..................................................4832
						Uniform Pressure Process..........................................4832
					Reverse Rotation Prevention Mechanism.................................4833
					Fuel Injection Volume Adjustment Mechanism............................4833
					Delivery Valve Assembly...............................................4834
					Delivery Valve Holder with Damping Valve..............................4834
					All - Speed Governor..................................................4835
					At Start of Engine....................................................4837
					During Idle...........................................................4838
					At Full - Load Maximum Speed Control..................................4839
					At No-Load Maximum Speed Control......................................4840
					Full-Load Position Adjustment Mechanism...............................4841
				Structure and Operation of Timer..........................................4842
					Standard Type Automatic Timer.........................................4842
				Yanmar Engine Controls....................................................4843
					Engine Speed (RPM) Sensor.............................................4844
					Throttle Position Sensor..............................................4844
					Electronic Throttle Actuator..........................................4845
					Engine Oil Pressure Sensor............................................4845
					Coolant Temperature Sensor............................................4846
					Air Filter Restriction Switch.........................................4847
					Fuel Filter/Water Separator and Strainer..............................4847
					Fuel Level Sensor.....................................................4847
				Engine Electrical System..................................................4848
					Magnetic Valve (Engine Stop Solenoid).................................4848
					Alternator............................................................4848
					Glow Plugs............................................................4848
					Cold Start Timing Advance (Fuel Injection Pump).......................4848
			Cooling System - All Engines..................................................4849
				Description...............................................................4849
				Radiator..................................................................4849
					Combination Cooler/Standard Radiator..................................4850
				Radiator Cap..............................................................4850
				Thermostat................................................................4850
				Engine Coolant Pump.......................................................4851
				Fan.......................................................................4851
				GM Engine Coolant Flow Diagram............................................4851
				Yanmar Diesel Engine Coolant Flow Diagram.................................4852
			Engine Does Not Crank.........................................................4853
			Engine Does Not Start/Engine is Hard to Start.................................4856
			Engine Idle Speed Incorrect...................................................4862
			Engine Idle Speed is Unstable or Engine Stalls at Idle........................4865
			Engine Cuts Out, Misses, Hesitates, Sags, or Stumbles.........................4870
			Engine Lack of Power..........................................................4876
			Engine Speed Surge Or Engine Speed Unstable...................................4883
			Engine Backfires..............................................................4887
			Engine Is Knocking or Pinging.................................................4890
			Excessive Engine Vibrations...................................................4894
			Abnormal Engine and Exhaust Noises............................................4898
			Fan or Alternator Bearing Noise...............................................4902
			Abnormal Engine and Exhaust Smells............................................4904
			High Engine Fuel Consumption..................................................4906
			Fuel Leaks....................................................................4909
			High Engine Oil Consumption...................................................4912
			Engine Oil Leaks..............................................................4914
			Engine Oil is Discolored......................................................4918
			Engine Coolant Leaks..........................................................4920
			Engine Coolant is Discolored..................................................4923
			Engine Exhaust is Discolored..................................................4924
			Engine Fails Emission Compliance Check........................................4928
			Alternator Light is Illuminated...............................................4932
			Engine is Overheating.........................................................4933
			Engine Coolant Temperature is Low.............................................4936
			Engine Oil Pressure is Low....................................................4937
			Radiator Bubble Test..........................................................4939
			Engine Compression Test (GM and Mazda)........................................4940
			Engine Compression Test (Yanmar Diesel).......................................4941
			Engine Oil Pressure Test......................................................4942
			Fuel System Pressure Test (Gasoline Engines Only).............................4944
			Fuel Injection Nozzle Test (Yanmar Diesel)....................................4946
			Vacuum Leak...................................................................4947
				Vacuum Leak Detection.....................................................4947
				Vacuum Leak Repairs.......................................................4947
			Coolant System Test...........................................................4948
		Electrical System.................................................................4949
			Troubleshooting Guidelines and Procedures.....................................4963
				Troubleshooting Guidelines................................................4963
				Troubleshooting Procedures................................................4966
					Troubleshooting Procedures, Identification............................4966
					Troubleshooting Procedures, Location..................................4966
					Troubleshooting Procedures, Structure.................................4967
					Troubleshooting Procedures, Performance...............................4968
			Diagnostic Trouble Codes......................................................4968
				Diagnostic Trouble Codes..................................................4968
			Wiring Reference Data.........................................................4978
			Harness Assembly Data.........................................................4981
			Electrical System.............................................................5027
				General Description.......................................................5027
				Description...............................................................5028
				Principles of Operation, Components.......................................5032
				Principles Of Operation, System...........................................5040
			100-2.........................................................................5047
			100-3.........................................................................5047
			523859-3......................................................................5047
			524223-3......................................................................5047
			524224-3......................................................................5047
			524225-3......................................................................5047
			524282-3......................................................................5047
			523958-3......................................................................5047
			523959-3......................................................................5047
			100-4.........................................................................5055
			523859-4......................................................................5055
			523958-4......................................................................5055
			523959-4......................................................................5055
			524223-4......................................................................5055
			524224-4......................................................................5055
			524225-4......................................................................5055
			524282-4......................................................................5055
			524223-0......................................................................5063
			524224-0......................................................................5063
			524225-0......................................................................5063
			524229-0......................................................................5063
			524270-0......................................................................5063
			524276-0......................................................................5063
			524223-1......................................................................5067
			524224-1......................................................................5067
			524225-1......................................................................5067
			524229-1......................................................................5067
			524270-1......................................................................5067
			524276-1......................................................................5067
			110-3.........................................................................5071
			110-5.........................................................................5071
			177-3.........................................................................5071
			522231-3......................................................................5071
			522555-3......................................................................5071
			522603-3......................................................................5071
			524235-3......................................................................5071
			110-4.........................................................................5079
			177-4.........................................................................5079
			522231-4......................................................................5079
			522555-4......................................................................5079
			522603-4......................................................................5079
			524235-4......................................................................5079
			110-2.........................................................................5087
			110-10........................................................................5090
			522712-3......................................................................5094
			522713-3......................................................................5094
			522712-4......................................................................5101
			522713-4......................................................................5101
			51-2..........................................................................5108
			51-7..........................................................................5108
			91-2..........................................................................5115
			522708-3......................................................................5120
			522710-3......................................................................5120
			522711-3......................................................................5120
			522714-3......................................................................5120
			522708-4......................................................................5127
			522710-4......................................................................5127
			522711-4......................................................................5127
			522714-4......................................................................5127
			515-0.........................................................................5133
			523780-3......................................................................5135
			523860-3......................................................................5135
			524245-3......................................................................5135
			524275-3......................................................................5135
			523780-4......................................................................5141
			523860-4......................................................................5141
			524245-4......................................................................5141
			524275-4......................................................................5141
			677-3.........................................................................5146
			2350-3........................................................................5146
			522754-3......................................................................5146
			522755-3......................................................................5146
			522764-3......................................................................5146
			522766-3......................................................................5146
			524230-3......................................................................5146
			SYMPTOMS WARNING..............................................................5146
			677-4.........................................................................5152
			2350-4........................................................................5152
			522754-4......................................................................5152
			522755-4......................................................................5152
			522764-4......................................................................5152
			522766-4......................................................................5152
			524230-4......................................................................5152
			676-3.........................................................................5156
			524195-3......................................................................5156
			524269-3......................................................................5156
			676-4.........................................................................5162
			524195-4......................................................................5162
			524269-4......................................................................5162
			524269-7......................................................................5168
			524215-3......................................................................5170
			524215-6......................................................................5170
			524237-3......................................................................5174
			524238-3......................................................................5174
			524240-3......................................................................5174
			524237-4......................................................................5179
			524238-4......................................................................5179
			524240-4......................................................................5179
			879-3.........................................................................5184
			880-3.........................................................................5184
			881-3.........................................................................5184
			882-3.........................................................................5184
			522772-3......................................................................5184
			879-4.........................................................................5188
			880-4.........................................................................5188
			881-4.........................................................................5188
			882-4.........................................................................5188
			522772-4......................................................................5188
			168-0.........................................................................5192
			168-3.........................................................................5192
			521982-3......................................................................5195
			522760-3......................................................................5195
			522761-3......................................................................5195
			522762-3......................................................................5195
			522128-3......................................................................5204
			524251-0......................................................................5204
			524260-0......................................................................5204
			524260-3......................................................................5204
			524261-0......................................................................5204
			524261-3......................................................................5204
			168-1.........................................................................5213
			168-4.........................................................................5213
			521982-4......................................................................5216
			522760-4......................................................................5216
			522761-4......................................................................5216
			522761-6......................................................................5216
			522762-4......................................................................5216
			522128-4......................................................................5223
			524251-1......................................................................5223
			524260-1......................................................................5223
			524260-4......................................................................5223
			524261-1......................................................................5223
			524261-4......................................................................5223
			524260-2......................................................................5233
			524260-11.....................................................................5233
			524261-2......................................................................5233
			524261-11.....................................................................5233
			96-3..........................................................................5237
			96-4..........................................................................5237
			522810-4......................................................................5241
			524213-1......................................................................5245
			524213-3......................................................................5245
			524213-4......................................................................5245
			523920-3......................................................................5248
			523925-3......................................................................5248
			523930-3......................................................................5248
			523977-3......................................................................5248
			523978-3......................................................................5248
			523986-3......................................................................5248
			524284-3......................................................................5248
			524285-3......................................................................5248
			523920-4......................................................................5254
			523925-4......................................................................5254
			523930-4......................................................................5254
			523977-4......................................................................5254
			523978-4......................................................................5254
			523986-4......................................................................5254
			524284-4......................................................................5254
			524285-4......................................................................5254
			523920-6......................................................................5259
			523925-6......................................................................5259
			523930-6......................................................................5259
			523977-6......................................................................5259
			523978-6......................................................................5259
			523986-6......................................................................5259
			524284-6......................................................................5259
			524285-6......................................................................5259
			105-3.........................................................................5263
			522570-3......................................................................5263
			105-4.........................................................................5268
			522570-4......................................................................5268
			105-5.........................................................................5272
			106-3.........................................................................5275
			106-4.........................................................................5279
			106-0.........................................................................5283
			106-1.........................................................................5283
			106-2.........................................................................5283
			106-14........................................................................5283
			522739-3......................................................................5286
			522739-5......................................................................5290
			522739-6......................................................................5294
			522735-2......................................................................5298
			522735-4......................................................................5301
			522735-5......................................................................5304
			522735-6......................................................................5307
			522630-2......................................................................5311
			522631-2......................................................................5311
			522632-2......................................................................5311
			522633-2......................................................................5311
			522635-3......................................................................5311
			522636-4......................................................................5311
			522637-3......................................................................5311
			522638-4......................................................................5311
			522606-10.....................................................................5315
			522737-10.....................................................................5315
			651-3.........................................................................5318
			652-3.........................................................................5318
			653-3.........................................................................5318
			654-3.........................................................................5318
			655-3.........................................................................5318
			656-3.........................................................................5318
			522599-3......................................................................5318
			522600-3......................................................................5318
			522601-3......................................................................5318
			522602-3......................................................................5318
			522721-3......................................................................5318
			522722-3......................................................................5318
			522723-3......................................................................5318
			522724-3......................................................................5318
			522725-3......................................................................5318
			522726-3......................................................................5318
			522599-3......................................................................5318
			522600-3......................................................................5318
			522601-3......................................................................5318
			522602-3......................................................................5318
			651-5.........................................................................5325
			652-5.........................................................................5325
			653-5.........................................................................5325
			654-5.........................................................................5325
			655-5.........................................................................5325
			656-5.........................................................................5325
			522721-5......................................................................5325
			522722-5......................................................................5325
			522723-5......................................................................5325
			522724-5......................................................................5325
			522725-5......................................................................5325
			522726-5......................................................................5325
			651-6.........................................................................5330
			652-6.........................................................................5330
			653-6.........................................................................5330
			654-6.........................................................................5330
			655-6.........................................................................5330
			656-6.........................................................................5330
			522599-4......................................................................5330
			522600-4......................................................................5330
			522601-4......................................................................5330
			522602-4......................................................................5330
			522721-6......................................................................5330
			522722-6......................................................................5330
			522723-6......................................................................5330
			522724-6......................................................................5330
			522725-6......................................................................5330
			522726-6......................................................................5330
			2000-9........................................................................5338
			2000-12.......................................................................5338
			2000-12.......................................................................5338
			2000-12.......................................................................5338
			2000-12.......................................................................5338
			2000-14.......................................................................5338
			2003-12.......................................................................5338
			2023-12.......................................................................5338
			2039-2........................................................................5338
			2039-12.......................................................................5338
			2235-12.......................................................................5338
			2236-12.......................................................................5338
			2238-12.......................................................................5338
			521670-12.....................................................................5338
			524258-2......................................................................5338
			522215-12.....................................................................5346
			522215-14.....................................................................5346
			524236-14.....................................................................5346
			524262-12.....................................................................5346
			524262-14.....................................................................5346
			524263-1......................................................................5346
			524268-12.....................................................................5346
			628-12........................................................................5348
			630-12........................................................................5348
			522690-2......................................................................5348
			522690-12.....................................................................5348
			522691-2......................................................................5348
			522691-12.....................................................................5348
			522692-2......................................................................5348
			522693-12.....................................................................5348
			522694-12.....................................................................5348
			522695-2......................................................................5348
			522696-2......................................................................5348
			522697-12.....................................................................5348
			522698-2......................................................................5348
			522699-2......................................................................5348
			522700-2......................................................................5348
			190-2.........................................................................5350
			190-7.........................................................................5350
			522120-1......................................................................5350
			522585-2......................................................................5350
			522752-9......................................................................5356
			524249-2......................................................................5359
			524250-2......................................................................5359
			524264-2......................................................................5359
			524264-14.....................................................................5359
			524265-2......................................................................5359
			524271-2......................................................................5359
			524225-14.....................................................................5359
			628-12........................................................................5364
			630-12........................................................................5364
			2660-3........................................................................5364
			2660-4........................................................................5364
			2661-3........................................................................5364
			2661-4........................................................................5364
			2802-12.......................................................................5364
			523510-12.....................................................................5364
			523511-12.....................................................................5364
			523515-3......................................................................5364
			523515-4......................................................................5364
			523519-3......................................................................5364
			523519-4......................................................................5364
			2802-12.......................................................................5366
			628-12........................................................................5366
			630-12........................................................................5366
			523261-3......................................................................5366
			523261-4......................................................................5366
			523257-3......................................................................5366
			523257-4......................................................................5366
			523253-3......................................................................5366
			523253-4......................................................................5366
			523249-3......................................................................5366
			523249-4......................................................................5366
			522780-3......................................................................5368
			522781-3......................................................................5368
			522780-4......................................................................5372
			522781-4......................................................................5372
			522780-2......................................................................5375
			522781-2......................................................................5375
			111-1.........................................................................5378
			524252-2......................................................................5382
			524253-14.....................................................................5384
			524255-2......................................................................5385
			108-0.........................................................................5386
			108-1.........................................................................5386
			522655-0......................................................................5389
			522655-1......................................................................5389
			522660-0......................................................................5389
			522660-1......................................................................5389
			524212-2......................................................................5393
			524211-2......................................................................5393
			524210-2......................................................................5393
			524209-2......................................................................5393
			524208-2......................................................................5393
			524207-2......................................................................5393
			524206-2......................................................................5393
			524205-2......................................................................5393
			524204-2......................................................................5393
			524203-2......................................................................5393
			524202-2......................................................................5393
			524201-2......................................................................5393
			524200-2......................................................................5393
			524199-2......................................................................5393
			524198-2......................................................................5393
			524197-2......................................................................5393
			522800-13.....................................................................5395
			522801-13.....................................................................5397
			522130-0......................................................................5398
			522131-0......................................................................5398
			522132-0......................................................................5398
			522133-0......................................................................5398
			522134-0......................................................................5398
			522130-1......................................................................5402
			522131-1......................................................................5402
			522132-1......................................................................5402
			522133-1......................................................................5402
			522134-1......................................................................5402
			522130-3......................................................................5407
			522131-3......................................................................5407
			522132-3......................................................................5407
			522133-3......................................................................5407
			522134-3......................................................................5407
			522130-4......................................................................5412
			522131-4......................................................................5412
			522132-4......................................................................5412
			522133-4......................................................................5412
			522134-4......................................................................5412
			522135-0......................................................................5416
			522137-0......................................................................5416
			522138-0......................................................................5416
			522135-1......................................................................5420
			522137-1......................................................................5420
			522138-1......................................................................5420
			522135-3......................................................................5424
			522137-3......................................................................5424
			522138-3......................................................................5424
			522135-4......................................................................5428
			522137-4......................................................................5428
			522138-4......................................................................5428
			522135-2......................................................................5432
			522137-2......................................................................5432
			522122-0......................................................................5439
			522124-0......................................................................5439
			522125-0......................................................................5439
			522126-0......................................................................5439
			522127-0......................................................................5439
			522122-1......................................................................5443
			522124-1......................................................................5443
			522125-1......................................................................5443
			522126-1......................................................................5443
			522127-1......................................................................5443
			522122-6......................................................................5447
			522124-6......................................................................5447
			522125-6......................................................................5447
			522126-6......................................................................5447
			522127-6......................................................................5447
			522122-8......................................................................5452
			522124-8......................................................................5452
			522125-8......................................................................5452
			522126-8......................................................................5452
			522127-8......................................................................5452
			522129-3......................................................................5456
			522129-4......................................................................5456
			522197-0......................................................................5458
			522198-0......................................................................5458
			522199-0......................................................................5458
			522200-0......................................................................5458
			522201-0......................................................................5458
			522197-1......................................................................5461
			522198-1......................................................................5461
			522199-1......................................................................5461
			522200-1......................................................................5461
			522201-1......................................................................5461
			522197-6......................................................................5462
			522198-6......................................................................5462
			522199-6......................................................................5462
			522200-6......................................................................5462
			522201-6......................................................................5462
			522197-7......................................................................5463
			522198-7......................................................................5463
			522199-7......................................................................5463
			522200-7......................................................................5463
			522201-7......................................................................5463
			522197-8......................................................................5464
			522198-8......................................................................5464
			522199-8......................................................................5464
			522200-8......................................................................5464
			522201-8......................................................................5464
			522197-14.....................................................................5466
			522198-14.....................................................................5466
			522199-14.....................................................................5466
			522200-14.....................................................................5466
			522201-14.....................................................................5466
			522197-27.....................................................................5467
			522198-27.....................................................................5467
			522199-27.....................................................................5467
			522200-27.....................................................................5467
			522201-27.....................................................................5467
			2039-2........................................................................5470
			522540-3......................................................................5473
			522540-4......................................................................5476
			522604-3......................................................................5480
			522604-4......................................................................5484
			522604-5......................................................................5488
			522697-12.....................................................................5493
			190-2.........................................................................5494
			190-4.........................................................................5494
			190-8.........................................................................5494
			522752-2......................................................................5494
			522752-4......................................................................5494
			522752-5......................................................................5500
			522598-3......................................................................5503
			522598-4......................................................................5506
			522592-0......................................................................5510
			522592-1......................................................................5512
			522593-12.....................................................................5514
			522594-12.....................................................................5518
			522595-12.....................................................................5518
			522596-12.....................................................................5518
			522597-12.....................................................................5518
			Engine Continues to Run When Engine Cover is Raised...........................5521
			Engine Stops or Fails to Start................................................5523
			Electrical Functions Do Not Operate...........................................5525
			Electrical Function Does Not Turn Off.........................................5530
			Electro-Hydraulics Do Not Function With Armrest Down .........................5536
			Electro-Hydraulics Can Still Function With Armrest Raised.....................5539
			Vehicle Does Not Power On.....................................................5542
			Heater Fan Does Not Operate Properly..........................................5548
			Heater Airflow Does Not Reach Desired Temperature.............................5551
			Heater Output Has Insufficient Airflow........................................5552
			Circulating (Accessory) Fan Inoperative.......................................5553
			Dome Light Inoperative........................................................5556
			Horn Failure..................................................................5559
		Drive Train.......................................................................5563
			Mechanical Overview...........................................................5567
			Engine........................................................................5567
				Description...............................................................5567
			Torque Converter..............................................................5567
				Description...............................................................5567
					Stator................................................................5568
					Turbine...............................................................5568
			Pump PTO......................................................................5569
				Chain Drive PTO...........................................................5569
				Spur Gear PTO.............................................................5570
			Transmission..................................................................5571
				Description...............................................................5571
				1.0-5.5 Ton Lift Truck Transmissions......................................5574
					Description...........................................................5574
						Single-Speed......................................................5574
						Two-Speed.........................................................5575
					Clutch Pack...........................................................5576
					Power Flow............................................................5578
						Single-Speed......................................................5578
						Two-Speed.........................................................5579
					Transmission Hydraulic Schematic......................................5581
					Transmission Oil Flow.................................................5582
					Control Valve Oil Flow................................................5582
				6.0-7.0 Ton Lift Truck Transmissions......................................5583
					Description...........................................................5583
						Two-Speed.........................................................5583
						Three-Speed.......................................................5583
					Clutch Pack...........................................................5585
						Input Shaft and Range Clutches....................................5585
						Directional Clutches..............................................5585
						Output Section....................................................5586
					Power Flow............................................................5586
						Two-Speed and Three-Speed.........................................5586
					Transmission Hydraulic Schematic......................................5590
						Two-Speed.........................................................5590
						Three-Speed.......................................................5592
			Transmission Control System Overview..........................................5594
				Transmission Control System...............................................5594
			Transmission Control Software.................................................5596
				Transmission Control Modes................................................5596
					Neutral...............................................................5596
					Gear Engagement Control...............................................5597
						Basic Powershift Gear Engagement Mode.............................5597
						DuraMatch™ and Electronic Extended Features Gear Engagement Mo....5597
					Normal Forward or Reverse.............................................5597
						Basic Powershift..................................................5597
						DuraMatch™ and Electronic Extended Features Transmission..........5597
					Auto-Shift............................................................5597
					1st Gear Lock.........................................................5597
					Inching...............................................................5597
						Basic Powershift Inching Mode.....................................5597
						DuraMatch™ Inching Mode...........................................5597
						Electronic Extended Features Inching Mode.........................5598
					Inch/Brake Overlap Adjustment.........................................5598
					Brake Wear Compensation...............................................5598
					Auto Decel............................................................5598
					Controlled Power Reversal.............................................5599
						Basic Multi-Speed.................................................5599
						Electronic Extended Features......................................5599
					Controlled Creep......................................................5599
						Basic Powershift..................................................5599
						DuraMatch™ and Electronic Extended Features.......................5599
					Controlled Roll Back..................................................5600
						DuraMatch™ .......................................................5600
						Electronic Extended Features......................................5600
					Travel Speed Limit (Optional).........................................5600
					Extended Drawbar Pull ( Electronic Extended Features Multi-Speed......5600
					Auto-Speed Hydraulics ( Electronic Extended Features Transmissio......5600
					Throttle Response Management ( Electronic Extended Features Tran......5600
						Steady Travel Speed...............................................5600
			Transmission Control Hardware.................................................5601
				Control Valve and Sensors.................................................5601
					Description...........................................................5601
					Principles of Operation...............................................5603
				Transmission Proportional Valve...........................................5604
					Description...........................................................5604
					Neutral...............................................................5604
					Proportional Control..................................................5604
				MONOTROL® Pedal...........................................................5605
					Description...........................................................5605
					Principles of Operation...............................................5605
				Directional Control Lever.................................................5605
					Principles of Operation...............................................5605
			Driveshaft, Differential, Drive Axle, and Brakes (Dry Brake Only..............5606
				Driveshaft................................................................5606
				Differential and Drive Axle...............................................5606
				Brake System..............................................................5608
					Description...........................................................5608
					Service Brakes........................................................5608
					Master Cylinder.......................................................5608
					Brake Position Sensor.................................................5608
					Parking Brake.........................................................5608
			Driveshaft, Differential, Drive Axle, and Brakes (Wet Brake Only..............5609
				Driveshaft................................................................5609
				Differential..............................................................5610
				Brake System..............................................................5612
					Description...........................................................5612
					Service Brakes, 2.0-3.5 Ton Only......................................5612
					Service Brakes, 4.0-7.0 Ton...........................................5614
					Brake Adjustment and Service..........................................5614
					Parking Brake.........................................................5614
			Overheating Brakes (Dry Brake Axle Only)......................................5617
			Overheating Brakes (Wet Brake Axle Only)......................................5619
			Poor Brake Performance (Dry Brake Axle Only)..................................5622
			Poor Brake Performance (Wet Brake Axle Only)..................................5625
			Brakes Make Too Much Noise (Dry Brake Axle Only)..............................5627
			Brakes Pull To One Side (Dry Brake Axle Only).................................5628
			Parking Brake Will Not Release................................................5631
			Parking Brake Will Not Hold Lift Truck (Dry Brake Axle Only)..................5632
			Parking Brake Will Not Hold Lift Truck (Wet Brake Axle Only)..................5633
			Abnormal Drive Axle Noise.....................................................5634
			Discolored Drive Axle Oil.....................................................5637
			Lift Truck Does Not Move (Drive Axle).........................................5639
			Abnormal Transmission Noise...................................................5641
			Bubbles or Foaming In Transmission Dipstick Tube..............................5643
			Inching Operation Is Not Smooth or Chatters...................................5645
			Lift Truck Does Not Move In One or Both Directions (Transmission..............5647
			Loss of Power/Drivetrain Performance..........................................5650
			Transmission Is Too Hot.......................................................5653
			Transmission Will Not Shift To Forward High Range.............................5656
			Transmission Warmup Procedure.................................................5657
			Transmission Pressure Test....................................................5657
				Transmission Charge Pump Pressure Test....................................5659
				Clutch Pack Pressure Test (Proportional Solenoid Valves)..................5659
				Torque Converter Pressure Test............................................5660
				Lubrication Pressure Test.................................................5660
			Transmission Clutch Drag Test (1.0-5.5 Ton Trucks Only).......................5661
			Torque Converter Stall Test...................................................5661
		Hydraulic Systems.................................................................5665
			Main Hydraulic System.........................................................5669
				Description...............................................................5669
				Principles of Operation...................................................5672
				Hydraulic Schematics......................................................5673
					Manual Control Valve Schematics.......................................5673
					Electro-Hydraulic Control Valve Schematics............................5678
			Manual Hydraulic Control Valve................................................5682
				Description...............................................................5682
				Principles of Operation...................................................5684
					Lift Section..........................................................5684
						Lift Operation....................................................5684
						Lower Operation...................................................5684
					Tilt Section..........................................................5686
						Tilt Backward.....................................................5686
						Tilt Forward......................................................5686
					Auxiliary Section.....................................................5688
					Anti-stall Feature....................................................5689
					Relief Valves.........................................................5689
						Main Relief Valve.................................................5689
						Secondary Relief Valve............................................5689
			Electro-Hydraulic Control Valve...............................................5690
				Description...............................................................5690
				Principles of Operation...................................................5692
					Inlet Pressure Compensator/Unloader...................................5692
					Lift/Lower EHPVs......................................................5693
						EHPV Operation....................................................5694
					Tilt and Auxiliary Spool Functions....................................5696
					Tilt Forward Function.................................................5698
					Main Relief Valve ....................................................5699
					Secondary Relief Valve................................................5699
					Secondary Function Anti-stall Valve...................................5700
					Emergency Lowering Valve..............................................5701
			Steering System...............................................................5701
				Component Locations.......................................................5701
					Description...........................................................5701
					Steering Axle Assembly................................................5701
					Steering Control Unit.................................................5701
				Steering Schematic........................................................5703
					Principles of Operation...............................................5704
					Steering Control Unit.................................................5704
			Actuation Functions With Armrest Up (E-Valve).................................5705
			Cycle Times Too Fast - Fast Actuation (E-Valve)...............................5706
			Jump/Delay In Lift or Lower Activation After Moving Joystick or ..............5708
			Jump/Delay In Secondary Function Actuation After Moving Joystick..............5710
			Jump/Delay In Tilt Forward Actuation (E-Valve)................................5712
			Forks Drop Slightly Before Lifting (E-Valve)..................................5714
			Forks Lower Without Command (E-Valve).........................................5715
			Forks Raise or Actuate Without Command (E-Valve)..............................5717
			Forks Tilt Forward Without Command (E-Valve)..................................5719
			Intermittent Activation (E-Valve) While Commanding Function...................5721
			Lift/Lower Function Maximum Speed Too Slow (E-Valve)..........................5723
			Lift Function Will Not Move With Joystick or MLM Movement (E-Val..............5726
			Lift/Lower Continues To Move For Awhile After Joystick or MLM Is..............5729
			Lift/Lower/Secondary Function Suddenly Jumps In Middle of Stroke..............5730
			Lower Function Will Not Move With Joystick or MLM Movement (E-Va..............5731
			Poor Metering on Lift or Lower Functions (E-Valve)............................5733
			Secondary Function Continues to Move for Awhile After Joystick o..............5736
			Secondary Function Exhibits Slight Movement in Opposite Directio..............5737
			Secondary Function Maximum Speed Too Slow (E-Valve)...........................5738
			Secondary Function or Tilt Back Moves Without Command (E-Valve)...............5741
			Secondary Function and Tilt Back Will Not Move With Joystick or ..............5742
			Tilt Forward Function Continues to Move for Awhile When Joystick..............5745
			Tilt Forward Will Not Move Upon Joystick or MLM Movement (E-Valv..............5746
			Too Much Joystick or MLM Movement (Deadband) to Start Function M..............5748
			Wrong Actuation Operates or Actuation is Backward (E-Valve)...................5749
			Actuation Exhibits Slight Movement in Opposite Direction Before ..............5750
			Auxiliary Function is Slow or Does Not Function (Manual Valve)................5751
			Cycle Times Too Fast - Fast Actuation (Manual Valve)..........................5753
			Function Continues to Activate After Returning to Neutral.....................5754
			Lift Function Is Slow or Does Not Function (Manual Valve).....................5755
			Tilt Back Function Will Not Operate (Manual Valve)............................5757
			Tilt Forward Functions When Spool is Activated Forward With Engi..............5758
			Tilt Forward Will Not Function When Activated (Manual Valve)..................5759
			Abnormal Steer Axle Noise.....................................................5760
			Abnormal Steering Wheel Vibration.............................................5762
			Back Lash/Kick Back in Steering Wheel.........................................5763
			No Steering (All Other Hydraulic Functions OK)................................5765
			Steering Is Slow or Difficult.................................................5767
			Steering Operation Is Not Smooth..............................................5769
			Steering Wheel End Lock Position Cannot Be Felt by Operator...................5771
			Steering Wheel Turns By Itself or Does Not Return To Neutral..................5772
			Steering Wheel Turns the Tires in the Wrong Direction.........................5773
			Abnormal Hydraulic Noise and/or Vibration.....................................5774
			Abnormal Smell/Discoloration/Foaming of Oil...................................5777
			Actuations Do Not Act Simultaneously..........................................5778
			Oil Leaking/Component Life Too Short..........................................5779
			Hydraulic Warmup Procedure....................................................5783
			Main Relief Valve Test and Adjustment.........................................5783
			Secondary Relief Valve Test and Adjustment....................................5785
			Hydraulic Pump Flow Test......................................................5787
			Main Control Valve LS Leakage Test (E-Valve)..................................5790
			Main Control Valve Unloader Margin Test.......................................5790
			Electro-Hydraulic Poppet Valve (EHPV) Leakage Test............................5792
			PPRV Pilot Pressure Test......................................................5795
			Steering Relief Pressure Test and Adjustment..................................5797
			Steering Control Unit LS Pressure Test........................................5798
			Lift Cylinder Leakage Test....................................................5800
			Tilt Cylinder Leakage Test....................................................5801
			Steering Cylinder Leakage Test................................................5802
		Operators Station.................................................................5805
			Operator Station General Description and Principles of Operation..............5807
				General Description and Location..........................................5807
			Display Switch Cluster (DSC)..................................................5810
				Detailed Description......................................................5810
				Control Inputs, Right Side................................................5811
				Right Indicator and Warning Group.........................................5812
				LCD Display...............................................................5812
				Left Indicator and Warning Group..........................................5814
				Control Inputs, Left Side (Cab Option Only)...............................5815
			Transmission Control and Braking..............................................5816
				Description...............................................................5816
					Vehicle System Manager (VSM)..........................................5816
					Display Switch Cluster................................................5817
						Interlock and Switching Features..................................5817
					MONOTROL® Directional Control.........................................5817
					Inch Brake/Service Brake Pedal........................................5817
					Parking Brake.........................................................5817
			Programming - Menus...........................................................5818
				Menus.....................................................................5818
					Main Menu.............................................................5821
					Save and Exit or Exit Without Saving..................................5821
					Back One Level........................................................5821
					Hourmeters............................................................5821
					View Versions.........................................................5822
					Passwords.............................................................5822
					Diagnostics...........................................................5822
					Setup Travel and Braking..............................................5822
					Setup Hydraulics......................................................5822
					Setup Display.........................................................5822
					Setup General Items...................................................5822
					Calibrations..........................................................5822
			Manual Hydraulic Control Levers...............................................5823
				General Description.......................................................5823
				System Components.........................................................5823
					Lift/Lower............................................................5823
					Tilt..................................................................5823
					Auxiliary 1...........................................................5823
					Auxiliary 2...........................................................5823
			E-Hydraulic System Interface..................................................5824
				General Description.......................................................5824
				System Components.........................................................5824
				E-Hydraulic Control Input Device..........................................5824
					Joystick..............................................................5824
						Lift/Lower........................................................5825
						Tilt..............................................................5825
						Auxiliary 1.......................................................5825
						Auxiliary 2.......................................................5825
						Push Button.......................................................5825
					Mini Lever Module (MLM)...............................................5826
						Lever 1...........................................................5826
						Lever 2...........................................................5826
						Lever 3...........................................................5827
						Lever 4...........................................................5827
				System Modes..............................................................5827
					Hydraulic Interlock Mode..............................................5827
					Fault Mode............................................................5827
					Engine Off Mode.......................................................5827
				Normal Operation..........................................................5827
					Normal Operation Mode.................................................5827
					Lifting Control.......................................................5827
					Lowering Control......................................................5828
					Tilt Control (Forward and Backward)...................................5828
					Auxiliary Control.....................................................5828
			Lighting Control..............................................................5828
				Description...............................................................5828
					Front Work Lights.....................................................5831
					Front Marker Lights (if equipped).....................................5831
					Front/Rear Turn Signal Lights.........................................5831
					Rear Tail/Marker Lights...............................................5831
					Rear Work Light.......................................................5831
					Rear Backup Lights....................................................5831
					Rear Stop Lights......................................................5831
					Strobe Light(s).......................................................5831
					Spot Light (if equipped)..............................................5831
			Cab...........................................................................5831
				Description...............................................................5831
				Component Descriptions....................................................5833
					Cab Heating System....................................................5833
					Lighting Control System...............................................5833
					Wiper/Washer System...................................................5833
				Cab Systems Operation.....................................................5834
		Front End (Mast) and Chassis......................................................5837
			Front End, Mast...............................................................5839
				Description...............................................................5839
			Carriages.....................................................................5839
				Description...............................................................5839
				Principles of Operation...................................................5840
					Integral Sideshift Carriage...........................................5840
			Mast Mounts...................................................................5841
				Description...............................................................5841
				Principles of Operation...................................................5842
			Two-Stage Limited Free-Lift (LFL) Mast........................................5842
				Description...............................................................5842
				Principles of Operation...................................................5843
			Two-Stage Full Free-Lift (FFL) Mast...........................................5844
				Description...............................................................5844
				Principles of Operation...................................................5845
			Three-Stage Full Free-Lift (FFL) Mast.........................................5846
				Description...............................................................5846
				Principles of Operation...................................................5847
			Four-Stage Full Free-Lift (FFL) Mast..........................................5848
				Description...............................................................5848
				Principles of Operation...................................................5850
			Cylinder Cushion During Lifting Sequence......................................5852
				Description...............................................................5852
				Principles of Operation...................................................5852
			Cylinder Cushion During Lowering Sequence.....................................5852
				Description...............................................................5852
				Principles of Operation...................................................5852
			Tilt and Sideshift Cylinders..................................................5853
				Description...............................................................5853
					Tilt Cylinder.........................................................5853
					Sideshift Cylinder....................................................5853
			Lowering Control Valves.......................................................5854
				Description...............................................................5854
				Principles of Operation...................................................5854
			Chassis.......................................................................5856
				Description...............................................................5856
			Abnormal Channel Wear.........................................................5857
			Abnormal Hose Wear............................................................5859
			Abnormal Mast Noise...........................................................5861
			Body Panels Making Noise......................................................5865
			External Leakage From Free-Lift or Main Lift Cylinders........................5866
			FFL Mast Banging During Phasing...............................................5867
			High Tire Wear - Drive Axle...................................................5869
			High Tire Wear - Steer Axle...................................................5871
			Hoses Not Tracking Correctly..................................................5873
			Integral Sideshift Moving Too Fast............................................5874
			Integral Sideshift Not Moving or Slow.........................................5875
			LP Tank Bracket Disengages....................................................5878
			LP Tank Rattles and Does Not Stay Latched.....................................5879
			Mast is Loose.................................................................5880
			Mast Lift Chains Are Loose....................................................5882
			Mast or Carriage Binding......................................................5883
			Mast/Carriage Bounces or is Spongy............................................5885
			Misphasing of Full Free-Lift Mast.............................................5886
			Overhead Guard Loose or Damaged...............................................5888
			Racking During Lift...........................................................5889
			Racking During Tilt...........................................................5891
			Truck Feels Unstable..........................................................5892
			Truck Wanders, Does Not Track Straight or Steer Well..........................5894
			Wheels Appear Tipped or Misaligned............................................5896
			Wheels Spinning On Uneven Floors..............................................5898
			Wheel Studs Breaking..........................................................5899
		Supplementary Data................................................................5901
			Abbreviations and Acronyms....................................................5903
			Special Tools List............................................................5911
			Fault Mode Indicator (FMI) Reference List.....................................5917
			TSP Reference Tables..........................................................5919
	tables................................................................................4691
		Table 9020-10-1. IAT Ambient Temperature..........................................4772
		Table 9020-40-1. Test Specifications..............................................4939
		Table 9020-40-2. Test Specifications..............................................4940
		Table 9020-40-3. Service Tools....................................................4940
		Table 9020-40-4. Test Specifications..............................................4941
		Table 9020-40-5. Service Tools....................................................4941
		Table 9020-40-6. Test Specifications..............................................4942
		Table 9020-40-7. Service Tools....................................................4943
		Table 9020-40-8. Test Specifications - Mazda......................................4944
		Table 9020-40-9. Test Specifications - GM.........................................4944
		Table 9020-40-10. Service Tools...................................................4944
		Table 9020-40-11. Test Specifications.............................................4946
		Table 9020-40-12. Service Tools...................................................4946
		Table 9020-40-13. Test Specifications.............................................4948
		Table 9020-40-14. Service Tools...................................................4948
		Table 9030-03-1. Circuit Group Identification.....................................4978
		Table 9030-03-2. Hyster Wiring Color Codes........................................4979
		Table 9040-10-1. Two-Speed Transmission Clutch Pack Solenoid Val..................5591
		Table 9040-10-2. Three-Speed Transmission Electronic Proportiona..................5593
		Table 9040-10-3. Transmission Control Mode........................................5595
		Table 9040-40-1. Test Specifications..............................................5657
		Table 9040-40-2. Service Tools....................................................5657
		Table 9040-40-3. Service Tools....................................................5657
		Table 9040-40-4. Test Specifications..............................................5659
		Table 9040-40-5. Test Specifications..............................................5659
		Table 9040-40-6. Test Specifications..............................................5660
		Table 9040-40-7. Test Specifications..............................................5660
		Table 9040-40-8. Test Specifications..............................................5661
		Table 9040-40-9. Service Tools....................................................5661
		Table 9040-40-10. Stall Speeds....................................................5662
		Table 9050-10-1. Standby Pressure Table...........................................5692
		Table 9050-40-1. Test Specifications..............................................5783
		Table 9050-40-2. Service Tools....................................................5783
		Table 9050-40-3. Test Specifications..............................................5783
		Table 9050-40-4. Service Tools....................................................5784
		Table 9050-40-5. Test Specifications..............................................5785
		Table 9050-40-6. Service Tools....................................................5786
		Table 9050-40-7. Test Specifications..............................................5787
		Table 9050-40-8. Service Tools....................................................5788
		Table 9050-40-9. Test Specifications..............................................5790
		Table 9050-40-10. Test Specifications.............................................5790
		Table 9050-40-11. Service Tools...................................................5790
		Table 9050-40-12. Test Specifications.............................................5792
		Table 9050-40-13. Service Tools...................................................5792
		Table 9050-40-14. Test Specifications.............................................5795
		Table 9050-40-15. Service Tools...................................................5795
		Table 9050-40-16. Test Specifications.............................................5797
		Table 9050-40-17. Service Tools...................................................5797
		Table 9050-40-18. Test Specifications.............................................5798
		Table 9050-40-19. Service Tools...................................................5798
		Table 9050-40-20. Test Specifications.............................................5800
		Table 9050-40-21. Service Tools...................................................5800
		Table 9050-40-22. Test Specifications.............................................5801
		Table 9050-40-23. Service Tools...................................................5801
		Table 9050-40-24. Test Specifications.............................................5802
		Table 9050-40-25. Service Tools...................................................5802
		Table 9080-50-1. Abbreviations and Acronyms.......................................5903
		Table 9080-60-1. Special Tools....................................................5911
		Table 9080-70-1. FMI..............................................................5917
		Table 9080-80-1. Resistor-Temperature Characteristics ............................5919
Diagrams and Schematics 1580527-8000SRM1152-(07-2007)-US-EN...............................5923
	toc...................................................................................5923
		Diagrams and Schematics...........................................................5923
		Safety Precautions Maintenance and Repair.........................................5924
		General Information About Diagrams and Schematics.................................5927
			Symbol Definitions............................................................5927
	tables................................................................................5923
		Table 1. Wire Colors..............................................................5927
		Table 2. Symbol Definitions.......................................................5927
Fasteners 910442-8000SRM0231-(12-2004)-US-EN..............................................5989
	toc...................................................................................5989
		Metric and Inch (SAE) Fasteners...................................................5989
		Safety Precautions Maintenance and Repair.........................................5990
		General...........................................................................5993
			Threaded Fasteners............................................................5993
			Nomenclature, Threads.........................................................5993
			Strength Identification.......................................................5994
			Cotter (Split) Pins...........................................................5994
			Fastener Torque Tables........................................................5999
			Conversion Table..............................................................6001
	tables................................................................................5989
		Table 1. Bolts and Screws.........................................................5995
		Table 2. Studs and Nuts...........................................................5996
		Table 3. Torque Nuts..............................................................5997
		Table 4. Torque Nuts With Nylon Insert............................................5998
		Table 5. Torque Values for Metric Fasteners*......................................5999
		Table 6. Torque Values for Inch Fasteners*........................................6000
		Table 7. Conversion Table for Metric and English Units............................6001
		Table 8. Cotter Pin Dimensional Data..............................................6002
		Table 9. Cotter Pin Dimensional Data..............................................6003
		Table 10. Cotter Pin Dimensional Data.............................................6004
		Table 11. Cotter Pin Dimensional Data.............................................6006
Frame 1580502-0100SRM1120-(01-2007)-US-EN.................................................6011
	toc...................................................................................6011
		Frame.............................................................................6011
		Safety Precautions Maintenance and Repair.........................................6012
		General...........................................................................6015
		Description.......................................................................6016
		Hood, Seat, and Side Covers Replacement...........................................6016
			Remove........................................................................6016
			Install.......................................................................6021
		LPG Tank and Bracket Replacement..................................................6023
			Remove........................................................................6023
				LPG Tank..................................................................6023
				LPG Bracket...............................................................6026
			Install.......................................................................6026
				LPG Bracket...............................................................6026
				LPG Tank..................................................................6027
		Counterweight Replacement.........................................................6028
			Remove........................................................................6028
			Install.......................................................................6029
			Tow Pin, Remove and Install...................................................6030
		Overhead Guard Replacement........................................................6030
			Remove and Install............................................................6030
			LED Tail, Backup, and Brake Lights, Replace...................................6031
		Operator Restraint System Replacement.............................................6032
			Description...................................................................6032
				Automatic Locking Retractor (ALR).........................................6032
				Emergency Locking Retractor (ELR).........................................6032
		Engine Replacement................................................................6033
			Remove Engine Only............................................................6033
			Remove Engine and Transmission................................................6037
			Install Engine Only...........................................................6037
			Install Engine and Transmission...............................................6038
		Throttle Pedal and Cable Adjustment...............................................6039
			Mazda Gas/LPG Engines With Basic Power Shift Transmission and Ma..............6039
			Mazda Gasoline Engine With Electronic Transmission............................6042
			Throttle Pedal Stop Adjustment, Mazda 2007 Emission Compliant En..............6043
			Yanmar Diesel Engine With Basic Power Shift Transmission......................6043
			Yanmar Diesel Engine With Electronic Throttle.................................6043
		Exhaust System Repair.............................................................6045
			Lift Trucks With Counterweight Exhaust System.................................6045
				Mazda and GM Gas and LPG Engines..........................................6045
					Remove and Disassemble................................................6045
					Inspect...............................................................6045
					Assemble and Install..................................................6047
				Yanmar Diesel Engine......................................................6049
					Remove and Disassemble................................................6049
					Inspect...............................................................6049
					Assemble and Install..................................................6049
			Lift Trucks With Overhead Exhaust System......................................6051
				Yanmar Diesel Engine......................................................6051
					Remove and Disassemble................................................6051
					Inspect...............................................................6051
					Assemble and Install..................................................6052
				Mazda Gas and LPG Engines.................................................6054
					Remove and Disassemble................................................6054
					Inspect...............................................................6054
					Assemble and Install..................................................6054
		Cooling System....................................................................6058
			Description...................................................................6058
		Fuel and Hydraulic Tanks Repair...................................................6058
			Inspect.......................................................................6058
			Clean.........................................................................6058
				Steam Method of Cleaning..................................................6058
				Chemical Solution Method of Cleaning......................................6059
			Additional Preparations for Repair............................................6059
			Small Leaks, Repair...........................................................6060
			Large Leaks, Repair...........................................................6060
			Preparations for Use After Repair.............................................6060
		Safety Labels.....................................................................6060
	tables................................................................................6011
		Table 1. Weight of Counterweights, Lift Truck Models S2.0-3.5FT ..................6029
		Table 2. Weight of Counterweights, Lift Truck Models S30FT, S35F..................6029
		Table 3. Weight of Counterweights, Lift Truck Models H1.6FT, H1...................6029
		Table 4. Weight of Counterweights, Lift Truck Models H2.0-3.5FT ..................6029
GM Engine Repair 1580503-0600SRM1121-(06-2007)-US-EN......................................6065
	toc...................................................................................6065
		GM Engine Repair..................................................................6065
		Safety Precautions Maintenance and Repair.........................................6066
		General...........................................................................6071
		Engine Serial Number..............................................................6071
		Engine Removal and Installation...................................................6072
		Intake Manifold...................................................................6072
			Remove........................................................................6072
			Clean and Inspect.............................................................6073
			Install.......................................................................6073
		Exhaust Manifold..................................................................6074
			Remove........................................................................6074
			Clean and Inspect.............................................................6074
			Install.......................................................................6075
		Camshaft and Cylinder Head Repair.................................................6075
			Rocker Arm Cover..............................................................6075
				Remove....................................................................6075
				Install...................................................................6075
			Camshaft Timing Pulley and/or Front Seal......................................6076
				Remove....................................................................6076
				Install...................................................................6076
			Camshaft Position (CMP) Sensor Assembly.......................................6077
				Remove....................................................................6077
				Install...................................................................6077
			Camshaft Carrier and Cylinder Head............................................6077
				Remove....................................................................6077
				Disassemble...............................................................6079
					Camshaft Carrier......................................................6079
					Cylinder Head.........................................................6080
				Clean and Inspect.........................................................6080
					Camshaft Carrier......................................................6080
					Cylinder Head.........................................................6081
				Valve and Valve Seat......................................................6083
				Assemble..................................................................6084
					Cylinder Head.........................................................6084
					Camshaft Carrier......................................................6084
				Install...................................................................6084
		Timing Belt.......................................................................6086
			Timing Belt Front Cover.......................................................6086
				Remove....................................................................6086
				Install...................................................................6087
			Timing Belt and Timing Belt Tensioner.........................................6087
				Remove....................................................................6087
				Install...................................................................6088
			Timing Belt Rear Cover........................................................6089
				Remove....................................................................6089
				Install...................................................................6089
		Lubrication System Repair.........................................................6090
			Oil Pan.......................................................................6090
				Remove....................................................................6090
				Install...................................................................6090
			Oil Pump......................................................................6092
				Remove....................................................................6092
				Clean and Inspect.........................................................6093
				Install...................................................................6094
		Piston and Piston Rod Assemblies Repair...........................................6095
			Piston Rod Bearings, Replace..................................................6095
			Piston and Piston Rod Assemblies..............................................6097
				Remove....................................................................6097
				Disassemble...............................................................6098
				Pistons, Clean and Inspect................................................6098
				Cylinder Bores, Inspect and Repair........................................6099
				Piston Rings, Inspect.....................................................6099
				Assemble..................................................................6100
				Install...................................................................6101
		Crankshaft and Main Bearings......................................................6102
			Crankshaft Timing Pulley and/or Front Seal....................................6102
				Remove....................................................................6102
				Install...................................................................6103
			Crankshaft Rear Main Oil Seal.................................................6103
				Remove....................................................................6103
				Install...................................................................6103
			Crankshaft/RPM Sensor.........................................................6104
				Remove....................................................................6104
				Install...................................................................6104
			Crankshaft Reluctor Wheel.....................................................6104
				Remove and Install........................................................6104
			Crankshaft and Main Bearings..................................................6105
				Remove....................................................................6105
				Inspect and Repair........................................................6106
				Bearing Selection.........................................................6106
				Main Bearings and Journal Clearance, Check................................6108
				Install...................................................................6109
		Flywheel and Flywheel Housing.....................................................6110
			Remove........................................................................6110
			Install.......................................................................6110
		Cooling System Repair.............................................................6111
			Serpentine Belt...............................................................6111
				Remove....................................................................6111
				Inspect...................................................................6111
				Install...................................................................6111
			Water Pump....................................................................6112
				Remove....................................................................6112
				Inspect...................................................................6114
				Install...................................................................6114
			Thermostat....................................................................6115
				Remove....................................................................6115
				Check.....................................................................6116
				Install...................................................................6116
			Thermostat Housing............................................................6117
				Remove....................................................................6117
				Clean and Inspect.........................................................6118
				Install...................................................................6118
		Ignition System...................................................................6119
			Spark Plug Wire Inspection....................................................6119
			Spark Plug Wire Replacement...................................................6119
				Remove....................................................................6119
				Install...................................................................6120
			Spark Plug Replacement........................................................6120
				Remove....................................................................6120
				Install...................................................................6120
			Spark Plug Inspection.........................................................6121
				Usage.....................................................................6121
				Inspect...................................................................6121
				Visual Inspection.........................................................6122
			Coil Pack.....................................................................6123
				Remove....................................................................6123
				Install...................................................................6123
		Alternator Repair.................................................................6123
			Alternator....................................................................6123
				Remove....................................................................6123
				Install...................................................................6124
			Alternator Fuse, Replace......................................................6124
		Starter Repair....................................................................6125
			Remove........................................................................6125
			Install.......................................................................6125
		Engine Specifications.............................................................6125
			Engine Data...................................................................6125
			Cylinder Bore.................................................................6126
			Piston........................................................................6126
			Piston Rings..................................................................6126
			Wrist Pin.....................................................................6126
			Crankshaft....................................................................6127
			Piston Rod....................................................................6127
			Camshaft and Camshaft Carrier.................................................6127
			Valve System..................................................................6128
			Cylinder Head Warpage.........................................................6128
			Lubrication System............................................................6128
			Cooling System................................................................6129
		Torque Specifications.............................................................6129
		Special Tools.....................................................................6130
Hydraulic System 1900SRM1189..............................................................6137
	toc...................................................................................6137
		Hydraulic System..................................................................6137
		Safety Precautions Maintenance and Repair.........................................6138
		General...........................................................................6141
			Discharging the Capacitors....................................................6142
		Description.......................................................................6143
		Control Handle....................................................................6143
			Side-Stance...................................................................6143
			Fore/Aft......................................................................6144
		Maintenance.......................................................................6146
			Oil Level and Leaks...........................................................6146
			Operation.....................................................................6146
			Oil Change....................................................................6146
				Drain.....................................................................6146
				Fill......................................................................6147
					Piston Type...........................................................6148
					Displacement Type.....................................................6148
			Breather Cap..................................................................6149
				Inspect...................................................................6149
			Oil Filter....................................................................6149
				Change....................................................................6149
			Oil Strainer..................................................................6150
				Check.....................................................................6150
		Hydraulic System..................................................................6150
			General.......................................................................6150
				Cleaning..................................................................6150
				Noise Levels..............................................................6151
			Hoses.........................................................................6151
			Fittings......................................................................6153
		Lift Pump and Motor...............................................................6154
			Complete Unit.................................................................6154
				Remove....................................................................6154
				Install...................................................................6155
			Lift Pump.....................................................................6157
				Components................................................................6157
					Pressure Flange Fitting...............................................6157
					Supply and Return Fittings............................................6158
					Needle Valve (Manual Lowering)........................................6158
					Pressure Test Ports...................................................6159
					Pressure Transducer...................................................6159
					Relief Valve..........................................................6161
					Lowering Solenoid.....................................................6161
				Remove Pump...............................................................6161
				Install Pump..............................................................6162
		Auxiliary Pump and Motor..........................................................6163
			Remove........................................................................6163
			Disassemble...................................................................6164
			Assemble......................................................................6164
			Install.......................................................................6164
		Hydraulic Tank....................................................................6165
			Remove........................................................................6165
			Disassemble...................................................................6166
				Breather Assembly.........................................................6166
				Filter Assembly...........................................................6167
				Float Assembly............................................................6168
				Tank Fittings.............................................................6169
			Clean and Inspect.............................................................6169
			Assemble......................................................................6169
				Breather Assembly.........................................................6169
				Filter Assembly...........................................................6170
				Float Assembly............................................................6170
				Tank Fittings.............................................................6170
			Install.......................................................................6170
		Troubleshooting...................................................................6171
	tables................................................................................6137
		Table 1. Main Lift Pump and Motor Configurations..................................6143
		Table 2. Main Lift Cylinder Types.................................................6147
Mast Repairs 4000SRM1250..................................................................6175
	toc...................................................................................6175
		Mast Repairs......................................................................6175
		Safety Precautions Maintenance and Repair.........................................6176
		Safety Procedures When Working Near Mast..........................................6179
		Forks Repair......................................................................6181
			Remove........................................................................6181
			Install.......................................................................6181
			Checks........................................................................6182
		Carriage Replacement..............................................................6182
			Remove........................................................................6182
			Install.......................................................................6184
		Sideshift Carriage Repair.........................................................6184
			Remove........................................................................6184
			Disassemble...................................................................6184
			Assemble......................................................................6185
			Install.......................................................................6185
		Two-Stage Mast With Limited Free-Lift Repair......................................6187
			Remove........................................................................6187
			Disassemble...................................................................6189
			Clean and Inspect.............................................................6190
			Assemble......................................................................6195
			Install, H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 10..............6195
			Install, S4.0, 4.5, 5.50FT, S5.5FTS ([S80, 100, 120FT;] S80, 100..............6196
			Header Hose Alignment.........................................................6200
		Two-Stage Mast With Full Free-Lift Repair.........................................6208
			Remove........................................................................6208
			Disassemble...................................................................6208
			Clean and Inspect.............................................................6211
			Assemble......................................................................6212
			Install.......................................................................6213
			Header Hose Installation and Adjustment.......................................6215
				Installation..............................................................6215
				Adjustment................................................................6215
		Three-Stage Mast With Full Free-Lift Repair.......................................6215
			Remove........................................................................6215
			Disassemble...................................................................6216
			Clean and Inspect.............................................................6223
			Assemble......................................................................6225
			Install.......................................................................6225
			Header Hose Alignment for S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, ..............6229
			Header Hose Alignment for H6.0FT, H7.0FT (H135FT, H155FT) (H006)..............6236
		Mast Operation Check..............................................................6241
		Tilt Cylinder Adjustment..........................................................6241
		Lift Chains Adjustment............................................................6243
		Mast Adjustments..................................................................6244
		Carriage Adjustments..............................................................6246
	tables................................................................................6175
		Table 1. Fork Tip Alignment.......................................................6182
		Table 2. Standard Mast Height; Header Hose Tension Mark Location..................6206
		Table 3. Standard Mast Height; Header Hose Tension Mark Location..................6206
		Table 4. Standard Mast Height; Header Hose Tension Mark Location..................6207
		Table 5. Standard Mast Height; Header Hose Tension Mark Location..................6207
		Table 6. Standard Mast Height; Header Hose Tension Mark Location..................6207
		Table 7. Standard Mast Height; Header Hose Tension Mark Location..................6234
		Table 8. Standard Mast Height; Header Hose Tension Mark Location..................6235
		Table 9. Standard Mast Height; Header Hose Tension Mark Location..................6235
		Table 10. Hook-Type Carriage Chain Adjustment.....................................6244
Mazda Engine 1580504-0600SRM1122-(12-2006)-US-EN..........................................6249
	toc...................................................................................6249
		Mazda Engine......................................................................6249
		Safety Precautions Maintenance and Repair.........................................6250
		General...........................................................................6253
			Serial Number.................................................................6253
		Engine Removal and Installation...................................................6253
		Cylinder Head, Camshaft, and Valve Mechanism Repair...............................6254
			Remove........................................................................6254
			Clean.........................................................................6256
			Inspect and Repair............................................................6256
				Cylinder Head.............................................................6256
				Rocker Shaft Assembly.....................................................6256
				Camshaft..................................................................6256
				Valve Guides..............................................................6258
				Valve Seats...............................................................6258
				Valves....................................................................6258
				Valve Springs.............................................................6259
			Install.......................................................................6259
		Crankshaft and Main Bearings Repair...............................................6263
			Remove........................................................................6263
			Inspect and Repair............................................................6264
				Crankshaft................................................................6264
				Main Bearings.............................................................6264
			Install.......................................................................6265
		Pistons and Connecting Rods Repair................................................6266
			Remove and Disassemble........................................................6266
			Clean.........................................................................6266
			Inspect and Repair............................................................6266
				Pistons...................................................................6266
				Piston Rings..............................................................6266
				Connecting Rods and Bearings..............................................6267
			Assemble and Install..........................................................6267
		Cylinder Block Repair.............................................................6269
		Oil Pump Repair...................................................................6269
			Remove........................................................................6269
			Disassemble...................................................................6271
			Clean.........................................................................6271
			Inspect.......................................................................6271
			Assemble......................................................................6272
			Install.......................................................................6272
		Cooling System Repair.............................................................6274
			Thermostat....................................................................6274
				Replace...................................................................6274
			Fan Assembly..................................................................6274
				Remove and Disassemble....................................................6274
				Assemble and Install......................................................6274
			Water Pump....................................................................6275
				Remove....................................................................6275
				Install...................................................................6276
		Flywheel and Ring Gear Repair.....................................................6276
			Remove........................................................................6276
			Install.......................................................................6276
		Valve Adjustment..................................................................6277
		Compression Pressure Check........................................................6278
		Engine Timing Adjustment..........................................................6279
		Engine Specifications.............................................................6279
			Engine Data...................................................................6279
			Engine Speeds.................................................................6279
				2007 Emission Compliant Engines...........................................6279
				All Engines Except 2007 Emission Compliant Engines........................6280
			Thermostat....................................................................6280
			Cylinder Head.................................................................6280
			Valve Mechanism...............................................................6280
			Camshaft......................................................................6281
			Crankshaft....................................................................6281
			Connecting Rods...............................................................6282
			Cylinder Block................................................................6282
			Pistons.......................................................................6282
			Oil Pump......................................................................6283
		Torque Specifications.............................................................6283
	tables................................................................................6249
		Table 1. Pressure Specifications..................................................6278
TroubleshootingManual-EN..................................................................6287
	toc...................................................................................6287
		Diagnostic Troubleshooting Manual.................................................6287
		Safety Precautions TROUBLESHOOTING PROCEDURES.....................................6288
		How To Use This Troubleshooting Manual............................................6290
			General Instructions and Safety Information...................................6290
			How to Use Diagnostic Troubleshooting Manual..................................6290
			General Instructions..........................................................6291
		Operational Diagnostic Procedures.................................................6293
			Operational Checkout Procedures...............................................6295
				DTC Check.................................................................6296
				Horn Circuit Check........................................................6296
				Light Circuit Check.......................................................6296
				Windshield Washer Wiper Check (If equipped)...............................6296
				Heater Check (If equipped)................................................6297
				Dome Light Check (If equipped)............................................6297
				Circulating (Accessory) Fan Check (If equipped)...........................6298
				Indicator Light Power Check...............................................6298
				Seat Occupancy Check......................................................6299
				Engine Malfunction Indicator Check........................................6299
				Cold Start Check (Cummins and Yanmar).....................................6299
				Brake Pedal Check.........................................................6300
				Backup Alarm Check (If equipped)..........................................6300
				Armrest Hydraulic Interlock Check (If equipped)...........................6300
				Engine Cover Latch Sensor Check (If equipped).............................6301
				Brake and Inching Pedal Check.............................................6301
				Park Brake Sensor Check...................................................6301
				Park Brake Check..........................................................6302
				Transmission Anti-Rollback Check (DuraMatch™ Transmissions Onl............6302
				Engine Speed Check........................................................6302
				Engine Power Check........................................................6303
				Transmission Clutch Check.................................................6303
				Transmission Check........................................................6304
				Transmission Speed Selection Check (If equipped)..........................6304
				Brake and Axle Drag Check.................................................6304
				Hydraulic Pump Flow Check.................................................6305
				Priority Flow Divider Valve Check.........................................6306
				Steering Relief Valve Low Pressure Check..................................6306
				Steering Relief Valve High Pressure Check.................................6307
				Control Valve Load Check Valve (Manual Valve).............................6307
				Tilt Function Counterbalance Check........................................6307
				Lift Drift Check..........................................................6308
				Tilt Function Drift Check.................................................6308
				Mast Cushion Check (All Except 2-Stage Mast)..............................6309
				Lift/Tilt Mast Adjustment Check...........................................6309
				Tilt Racking Check........................................................6310
				Chain and Header Hose Adjustment Check....................................6310
				Mast Mounting Check.......................................................6311
				Mast Channel Check........................................................6311
				Carriage Adjustment Check.................................................6311
				Chain Sheave Check........................................................6312
				Carriage Adjustment Check (Standard and Integral Side Shift)..............6312
		Engine............................................................................6313
			Engine Basics.................................................................6319
				General Terminology.......................................................6319
				Combustion Theory.........................................................6319
				Engine Components – Cylinder Block........................................6320
				Camshaft and Timing Set...................................................6321
				Cylinder Head Assembly....................................................6321
				Valve Train Assembly......................................................6321
				Air Cleaner/Filter........................................................6321
				Carburetion...............................................................6321
				Electronic Fuel Injection (EFI)...........................................6321
				Positive Crankcase Ventilation (PCV)......................................6322
			Engine Electrical.............................................................6322
				Introduction..............................................................6322
				Battery Construction......................................................6322
				Conventional Standard Battery.............................................6323
				Maintenance-Free Battery..................................................6323
				Battery Charging..........................................................6323
				Battery Fast Charging.....................................................6324
				Battery Slow Charging.....................................................6324
				Starting System Principles of Operation...................................6324
				Starting System Components - Ignition Switch..............................6325
				Starting System Components - Starter Solenoid.............................6325
				Starting System Components - Flywheel and Ring Gear.......................6325
				Starting System Components - Starter Motor and Drive......................6325
				Charging System - General.................................................6326
				Charging System - Regulator...............................................6326
				Charging System - Theory..................................................6326
			Engine Fuel System/Exhaust and Emissions......................................6327
				Introduction..............................................................6327
				Gasoline System Components - Fuel Tank....................................6327
				Electronic Fuel Injector (EFI) - General Description......................6327
				Port Fuel System Components - ECU.........................................6327
				Port Fuel System Components - Fuel Pump/Filter............................6327
				Port Fuel System Components - Fuel Rail...................................6327
				Port Fuel System Components - Pressure Regulator..........................6327
				Port Fuel System Components - Fuel Injectors..............................6328
				LPG Systems General Information...........................................6328
				LPG Fuel Properties.......................................................6328
				LPG Fuel Tank.............................................................6328
				AISAN Closed-Loop System..................................................6329
					Filter/Lockoff and Regulator..........................................6329
					Carburetor............................................................6329
					Start Mode............................................................6329
					Idle Mode.............................................................6330
					Run Mode..............................................................6330
				Main Fuel Lockoff Solenoid................................................6330
				Injector Fuel Lockoff Solenoid............................................6330
					Oxygen (O 2 ) Sensor..................................................6330
				Electronic Control Unit (ECU).............................................6330
				Catalytic Converter/Muffler...............................................6330
			Engine Management.............................................................6330
				Introduction..............................................................6330
				Ignition and Timing - Conventional Spark..................................6330
				Components - Ignition Coil................................................6331
				Components - Distributor..................................................6331
				Spark Timing..............................................................6331
				Components - Ignition Wires...............................................6331
				Components - Spark Plugs..................................................6331
				Faulty or Fouled Spark Plugs..............................................6332
				Electric Controlled Governing System - Mazda LPG..........................6332
			Engine Identification.........................................................6333
			Cummins (Diesel) Engine.......................................................6335
				Description...............................................................6335
				Diesel Fuel System........................................................6336
					Principle of Operation................................................6336
				Fuel Injection Pump and Governor..........................................6337
					Description...........................................................6337
					Principles of Operation...............................................6338
				Cummins Engine Control....................................................6339
					Engine Speed (RPM) Sensor.............................................6340
					Throttle Position Sensor..............................................6341
					Electronic Throttle Actuator..........................................6342
					Engine Oil Pressure Sensor............................................6342
					Coolant Temperature Sensor............................................6342
					Air Restriction Switch................................................6343
					Fuel Filter/Water Separator...........................................6343
					Fuel Level Sensor (In Tank)...........................................6343
				Engine Electrical System..................................................6344
					Magnetic Valve (Engine Stop Solenoid).................................6344
					Alternator............................................................6344
					Grid Heater...........................................................6344
					Cold Start Timing Advance (Fuel Injection Pump).......................6344
			Mazda Engine Overview.........................................................6345
				Description...............................................................6345
				Fuel System...............................................................6345
				Engine Controls Unit (ECU) and Emissions..................................6345
				Cooling System............................................................6345
				Ignition System...........................................................6345
			Mazda (LPG) Engine Controls...................................................6346
				LPG System (Aisan/E-Controls-Mechanical)..................................6346
					Description...........................................................6346
					Principles of Operation...............................................6347
					Control System........................................................6350
					Oxygen (O 2 ) Sensor..................................................6351
					Fuel Tank.............................................................6351
					Regulator.............................................................6352
						Start Mode........................................................6353
						Idle Mode.........................................................6353
						Run Mode..........................................................6354
					Resonator.............................................................6354
					Carburetor............................................................6354
						Start Mode........................................................6354
						Idle Mode.........................................................6355
						Run Mode..........................................................6355
					Governor..............................................................6355
				LPG System (E-Controls)...................................................6355
					Description...........................................................6355
					Principles of Operation...............................................6357
					Manifold Absolute Pressure Sensor.....................................6357
					Throttle Position Sensor..............................................6358
					Oxygen (O 2 ) Sensor..................................................6358
					Engine Coolant Temperature Sensor.....................................6358
					Intake Air Temperature Sensor.........................................6358
					Engine Control Unit...................................................6358
					Accelerator Pedal Position Sensor.....................................6358
					Three-Way Catalytic Converter.........................................6358
					Camshaft Position Sensor..............................................6359
					Electric Controlled Governing System..................................6360
					Electronic Governor Sensor............................................6360
			Mazda (Gasoline) Engine Controls..............................................6361
				Gasoline System...........................................................6361
					Description...........................................................6361
					Principles of Operation...............................................6362
				Control System............................................................6364
					Camshaft Position Sensor..............................................6365
					Intake Air Temperature Sensor.........................................6366
					Mass Air Flow Sensor..................................................6367
					Throttle Position Sensor..............................................6368
					Electronic Governor Sensor............................................6368
					Electronic Governing System...........................................6369
					Manifold Absolute Pressure Sensor/Boost Sensor........................6370
					Engine Coolant Temperature Sensor.....................................6371
				Intake Air System.........................................................6372
					Throttle Body.........................................................6372
					Idle Air Control Valve................................................6373
				Fuel System...............................................................6374
					Fuel Injector.........................................................6374
					Pressure Regulator....................................................6375
				Exhaust System............................................................6376
					Heated Oxygen (O 2 ) Sensor...........................................6376
					Three-Way Catalytic Converter.........................................6377
			GM (LPG) Engine Controls......................................................6378
				Engine Control System ....................................................6378
					Engine Control System Overview........................................6379
					Principles of Operation...............................................6379
				Control System............................................................6380
					GM/TGFI 2.4L (Four Cylinder) Control System Component Location........6380
					GM/TGFI 4.3L (Six Cylinder) Control System Component Location.........6381
					GM/TGFI 2.4L (Four-Cylinder) LPG System...............................6382
					GM/TGFI 4.3L (Six-Cylinder) LPG System................................6384
					Fuel Tank.............................................................6386
					Engine Control Unit...................................................6386
					Electronic Throttle Body/Throttle Position Sensor.....................6387
					Manifold Absolute Pressure/Manifold Air Temperature Sensor............6387
					Propane Injectors.....................................................6388
					Engine Coolant Temperature Sensor.....................................6389
					Oxygen (O 2 ) Sensor..................................................6390
					Crankshaft Position Sensor (Engine Speed Sensor)......................6391
					Oil Pressure Sensor...................................................6391
					Power Latch Relay.....................................................6391
					GM 2.4L Camshaft Position Sensor......................................6391
					GM 4.3L Camshaft Position Sensor......................................6392
					Injector Driver Module................................................6393
					Vaporizer/Regulator...................................................6393
					Accelerator Pedal Position Sensor.....................................6396
					Three-Way Catalytic Converter.........................................6397
				Ignition System...........................................................6397
					Ignition Coils........................................................6397
					Distributorless Ignition System Module................................6397
					Electronic Ignition Signals...........................................6398
					Distributor Ignition (DI) System......................................6399
					Camshaft Position (CMP) Sensor........................................6399
					Ignition Coil and Ignition Control Module (ICM).......................6399
					Secondary Ignition Components.........................................6399
			GM (Gasoline) Engine Controls.................................................6400
				Engine Control System.....................................................6400
					GM 2.4L (Four Cylinder) Engine Control System.........................6400
					GM 4.3L (Six Cylinder) Engine Control System..........................6401
					Engine Control System Overview........................................6402
					Principles of Operation...............................................6402
				Control System............................................................6403
					GM/TGFI 2.4L (Four Cylinder) Control System Component Location........6403
					GM/TGFI 4.3L (Six Cylinder) Control System Component Location.........6404
					GM/TGFI 2.4L (Four-Cylinder) Gasoline System Components...............6405
					GM/TGFI 4.3L (Six Cylinder) Gasoline System Components................6407
					Engine Control Unit...................................................6409
					Electronic Throttle Body/Throttle Position Sensor.....................6409
					Manifold Absolute Pressure/Manifold Air Temperature Sensor ...........6410
					Fuel Injector.........................................................6411
					Engine Coolant Temperature Sensor.....................................6411
					Oxygen (O 2 ) Sensor..................................................6412
					Crankshaft Position Sensor (Engine Speed Sensor)......................6413
					Oil Pressure Sensor...................................................6413
					Power Latch Relay.....................................................6413
					Camshaft Position Sensor..............................................6413
					Accelerator Pedal Position Sensor.....................................6414
					Three-Way Catalytic Converter.........................................6414
				Ignition System...........................................................6415
					Ignition Coils........................................................6415
					Distributorless Ignition System Module................................6415
					Electronic Ignition Signals...........................................6416
			Yanmar (Diesel) Engine........................................................6417
				Description...............................................................6417
				Diesel Fuel System........................................................6418
					Principles of Operation...............................................6418
				Fuel Injection Pump and Governor..........................................6419
					Description...........................................................6419
					Principles of Operation...............................................6421
					Timer.................................................................6422
					Feed Pump (Vane Type).................................................6422
					Regulating Valve......................................................6423
					Injection Pump Plunger................................................6424
						Suction Process...................................................6425
						Injection Process.................................................6425
						End of Injection..................................................6426
						Uniform Pressure Process..........................................6426
					Reverse Rotation Prevention Mechanism.................................6427
					Fuel Injection Volume Adjustment Mechanism............................6427
					Delivery Valve Assembly...............................................6427
					Delivery Valve Holder with Damping Valve..............................6428
					All - Speed Governor..................................................6429
					At Start of Engine....................................................6431
					During Idle...........................................................6432
					At Full - Load Maximum Speed Control..................................6433
					At No-Load Maximum Speed Control......................................6434
					Full-Load Position Adjustment Mechanism...............................6435
				Structure and Operation of Timer..........................................6436
					Standard Type Automatic Timer.........................................6436
				Yanmar Engine Controls....................................................6437
					Engine Speed (RPM) Sensor.............................................6438
					Throttle Position Sensor..............................................6438
					Electronic Throttle Actuator..........................................6439
					Engine Oil Pressure Sensor............................................6439
					Coolant Temperature Sensor............................................6440
					Air Filter Restriction Switch.........................................6441
					Fuel Filter/Water Separator and Strainer..............................6441
					Fuel Level Sensor.....................................................6441
				Engine Electrical System..................................................6442
					Magnetic Valve (Engine Stop Solenoid).................................6442
					Alternator............................................................6442
					Glow Plugs............................................................6442
					Cold Start Timing Advance (Fuel Injection Pump).......................6442
			Cooling System - All Engines..................................................6443
				Description...............................................................6443
				Radiator..................................................................6443
					Combination Cooler/Standard Radiator..................................6443
				Radiator Cap..............................................................6444
				Thermostat................................................................6444
				Engine Coolant Pump.......................................................6445
				Fan.......................................................................6445
				GM Engine Coolant Flow Diagram............................................6445
				Yanmar Diesel Engine Coolant Flow Diagram.................................6446
			Engine Does Not Crank.........................................................6447
			Engine Does Not Start/Engine is Hard to Start.................................6450
			Engine Idle Speed Incorrect...................................................6455
			Engine Idle Speed is Unstable or Engine Stalls at Idle........................6458
			Engine Cuts Out, Misses, Hesitates, Sags, or Stumbles.........................6463
			Engine Lack of Power..........................................................6468
			Engine Speed Surge Or Engine Speed Unstable...................................6475
			Engine Backfires..............................................................6479
			Engine Is Knocking or Pinging.................................................6482
			Excessive Engine Vibrations...................................................6486
			Abnormal Engine and Exhaust Noises............................................6490
			Fan or Alternator Bearing Noise...............................................6494
			Abnormal Engine and Exhaust Smells............................................6496
			High Engine Fuel Consumption..................................................6498
			Fuel Leaks....................................................................6501
			High Engine Oil Consumption...................................................6504
			Engine Oil Leaks..............................................................6506
			Engine Oil is Discolored......................................................6510
			Engine Coolant Leaks..........................................................6512
			Engine Coolant is Discolored..................................................6515
			Engine Exhaust is Discolored..................................................6516
			Engine Fails Emission Compliance Check........................................6520
			Alternator Light is Illuminated...............................................6524
			Engine is Overheating.........................................................6525
			Engine Coolant Temperature is Low.............................................6528
			Engine Oil Pressure is Low....................................................6529
			Radiator Bubble Test..........................................................6531
			Engine Compression Test (GM and Mazda)........................................6532
			Engine Compression Test (Yanmar Diesel).......................................6533
			Engine Oil Pressure Test......................................................6534
			Fuel System Pressure Test (Gasoline Engines Only).............................6536
			Fuel Injection Nozzle Test (Yanmar Diesel)....................................6538
			Vacuum Leak...................................................................6539
				Vacuum Leak Detection.....................................................6539
				Vacuum Leak Repairs.......................................................6539
			Coolant System Test...........................................................6540
		Electrical System.................................................................6541
			Troubleshooting Guidelines and Procedures.....................................6551
				Troubleshooting Guidelines................................................6551
				Troubleshooting Procedures................................................6553
					Troubleshooting Procedures, Identification............................6553
					Troubleshooting Procedures, Location..................................6554
					Troubleshooting Procedures, Structure.................................6554
					Troubleshooting Procedures, Performance...............................6555
			Diagnostic Trouble Codes......................................................6556
				Diagnostic Trouble Codes..................................................6556
			Wiring Reference Data.........................................................6563
			Harness Assembly Data.........................................................6567
			Electrical System.............................................................6613
				General Description.......................................................6613
				Description...............................................................6614
				Principles of Operation, Components.......................................6618
				Principles Of Operation, System...........................................6626
			100-2.........................................................................6633
			100-3.........................................................................6633
			523859-3......................................................................6633
			523958-3......................................................................6633
			523959-3......................................................................6633
			524223-3......................................................................6633
			524224-3......................................................................6633
			524225-3......................................................................6633
			524282-3......................................................................6633
			100-4.........................................................................6640
			523859-4......................................................................6640
			523958-4......................................................................6640
			523959-4......................................................................6640
			524223-4......................................................................6640
			524224-4......................................................................6640
			524225-4......................................................................6640
			524282-4......................................................................6640
			524223-0......................................................................6647
			524224-0......................................................................6647
			524225-0......................................................................6647
			524229-0......................................................................6647
			524270-0......................................................................6647
			524276-0......................................................................6647
			524223-1......................................................................6651
			524224-1......................................................................6651
			524225-1......................................................................6651
			524229-1......................................................................6651
			524270-1......................................................................6651
			524276-1......................................................................6651
			110-3.........................................................................6655
			110-5.........................................................................6655
			177-3.........................................................................6655
			522555-3......................................................................6655
			524235-3......................................................................6655
			110-4.........................................................................6661
			177-4.........................................................................6661
			522555-4......................................................................6661
			524235-4......................................................................6661
			110-2.........................................................................6667
			110-10........................................................................6670
			522712-3......................................................................6674
			522713-3......................................................................6674
			522712-4......................................................................6679
			522713-4......................................................................6679
			51-2..........................................................................6684
			51-7..........................................................................6684
			91-2..........................................................................6688
			522708-3......................................................................6692
			522710-3......................................................................6692
			522711-3......................................................................6692
			522714-3......................................................................6692
			522708-4......................................................................6698
			522710-4......................................................................6698
			522711-4......................................................................6698
			522714-4......................................................................6698
			515-0.........................................................................6704
			523780-3......................................................................6705
			523860-3......................................................................6705
			524245-3......................................................................6705
			524275-3......................................................................6705
			523780-4......................................................................6710
			523860-4......................................................................6710
			524245-4......................................................................6710
			524275-4......................................................................6710
			677-3.........................................................................6714
			2350-3........................................................................6714
			522754-3......................................................................6714
			522755-3......................................................................6714
			522764-3......................................................................6714
			522766-3......................................................................6714
			524230-3......................................................................6714
			SYMPTOMS WARNING..............................................................6714
			677-4.........................................................................6720
			2350-4........................................................................6720
			522754-4......................................................................6720
			522755-4......................................................................6720
			522764-4......................................................................6720
			522766-4......................................................................6720
			524230-4......................................................................6720
			676-3.........................................................................6724
			524195-3......................................................................6724
			524269-3......................................................................6724
			676-4.........................................................................6730
			524195-4......................................................................6730
			524269-4......................................................................6730
			524269-7......................................................................6735
			524215-3......................................................................6737
			524215-6......................................................................6737
			524237-3......................................................................6741
			524238-3......................................................................6741
			524240-3......................................................................6741
			524237-4......................................................................6746
			524238-4......................................................................6746
			524240-4......................................................................6746
			879-3.........................................................................6751
			880-3.........................................................................6751
			881-3.........................................................................6751
			882-3.........................................................................6751
			522772-3......................................................................6751
			879-4.........................................................................6755
			880-4.........................................................................6755
			881-4.........................................................................6755
			882-4.........................................................................6755
			522772-4......................................................................6755
			168-3.........................................................................6758
			522760-3......................................................................6760
			522761-3......................................................................6760
			522762-3......................................................................6760
			524251-0......................................................................6767
			524260-0......................................................................6767
			524261-0......................................................................6767
			524261-3......................................................................6767
			168-4.........................................................................6775
			522760-4......................................................................6777
			522761-4......................................................................6777
			522761-6......................................................................6777
			522762-4......................................................................6777
			524251-1......................................................................6783
			524260-1......................................................................6783
			524261-1......................................................................6783
			524261-4......................................................................6783
			524260-2......................................................................6790
			524260-11.....................................................................6790
			524261-2......................................................................6790
			524261-11.....................................................................6790
			96-3..........................................................................6794
			96-4..........................................................................6794
			522810-4......................................................................6798
			524213-1......................................................................6802
			524213-3......................................................................6802
			524213-4......................................................................6802
			523920-3......................................................................6805
			523925-3......................................................................6805
			523930-3......................................................................6805
			523977-3......................................................................6805
			523978-3......................................................................6805
			523986-3......................................................................6805
			524284-3......................................................................6805
			524285-3......................................................................6805
			523978-4......................................................................6810
			523977-4......................................................................6810
			523986-4......................................................................6810
			524284-4......................................................................6810
			524285-4......................................................................6810
			523930-4......................................................................6810
			523920-4......................................................................6810
			523925-4......................................................................6810
			523920-6......................................................................6814
			523925-6......................................................................6814
			523930-6......................................................................6814
			523977-6......................................................................6814
			523978-6......................................................................6814
			523986-6......................................................................6814
			524284-6......................................................................6814
			524285-6......................................................................6814
			105-3.........................................................................6818
			522570-3......................................................................6818
			105-4.........................................................................6822
			522570-4......................................................................6822
			105-5.........................................................................6825
			106-3.........................................................................6827
			106-4.........................................................................6831
			106-0.........................................................................6835
			106-1.........................................................................6835
			106-2.........................................................................6835
			106-14........................................................................6835
			522739-3......................................................................6838
			522739-5......................................................................6842
			522739-6......................................................................6846
			522735-2......................................................................6849
			522735-4......................................................................6852
			522735-5......................................................................6855
			522735-6......................................................................6858
			522630-2......................................................................6861
			522631-2......................................................................6861
			522635-3......................................................................6861
			522636-4......................................................................6861
			522737-10.....................................................................6865
			651-3.........................................................................6867
			652-3.........................................................................6867
			653-3.........................................................................6867
			654-3.........................................................................6867
			655-3.........................................................................6867
			656-3.........................................................................6867
			522721-3......................................................................6867
			522722-3......................................................................6867
			522723-3......................................................................6867
			522724-3......................................................................6867
			522725-3......................................................................6867
			522726-3......................................................................6867
			651-5.........................................................................6873
			652-5.........................................................................6873
			653-5.........................................................................6873
			654-5.........................................................................6873
			655-5.........................................................................6873
			656-5.........................................................................6873
			522721-5......................................................................6873
			522722-5......................................................................6873
			522723-5......................................................................6873
			522724-5......................................................................6873
			522725-5......................................................................6873
			522726-5......................................................................6873
			651-6.........................................................................6877
			652-6.........................................................................6877
			653-6.........................................................................6877
			654-6.........................................................................6877
			655-6.........................................................................6877
			656-6.........................................................................6877
			522721-6......................................................................6877
			522722-6......................................................................6877
			522723-6......................................................................6877
			522724-6......................................................................6877
			522725-6......................................................................6877
			522726-6......................................................................6877
			2000-9........................................................................6883
			2000-12.......................................................................6883
			2000-12.......................................................................6883
			2003-12.......................................................................6883
			2023-12.......................................................................6883
			2039-12.......................................................................6883
			2235-12.......................................................................6883
			2236-12.......................................................................6883
			2238-12.......................................................................6883
			521670-12.....................................................................6883
			524258-2......................................................................6883
			524236-14.....................................................................6890
			524262-12.....................................................................6890
			524263-1......................................................................6890
			524268-12.....................................................................6890
			522690-2......................................................................6892
			522690-12.....................................................................6892
			522691-2......................................................................6892
			522691-12.....................................................................6892
			522692-2......................................................................6892
			522693-12.....................................................................6892
			522694-12.....................................................................6892
			522695-2......................................................................6892
			522696-2......................................................................6892
			522698-2......................................................................6892
			522699-2......................................................................6892
			522700-2......................................................................6892
			628-12........................................................................6892
			630-12........................................................................6892
			522697-12.....................................................................6892
			190-2.........................................................................6894
			190-7.........................................................................6894
			522585-2......................................................................6894
			522752-9......................................................................6899
			524264-2......................................................................6902
			524264-14.....................................................................6902
			524265-2......................................................................6902
			524271-2......................................................................6902
			628-12........................................................................6907
			630-12........................................................................6907
			2660-3........................................................................6907
			2660-4........................................................................6907
			2661-3........................................................................6907
			2661-4........................................................................6907
			2802-12.......................................................................6907
			523510-12.....................................................................6907
			523511-12.....................................................................6907
			523515-3......................................................................6907
			523515-4......................................................................6907
			523519-3......................................................................6907
			523519-4......................................................................6907
			2802-12.......................................................................6909
			628-12........................................................................6909
			630-12........................................................................6909
			523261-3......................................................................6909
			523261-4......................................................................6909
			523257-3......................................................................6909
			523257-4......................................................................6909
			523253-3......................................................................6909
			523253-4......................................................................6909
			523249-3......................................................................6909
			523249-4......................................................................6909
			522780-3......................................................................6911
			522781-3......................................................................6911
			522780-4......................................................................6914
			522781-4......................................................................6914
			522780-2......................................................................6916
			522781-2......................................................................6916
			111-1.........................................................................6918
			524252-2......................................................................6922
			524253-14.....................................................................6923
			524255-2......................................................................6924
			108-0.........................................................................6925
			108-1.........................................................................6925
			522655-0......................................................................6927
			522655-1......................................................................6927
			522660-0......................................................................6927
			522660-1......................................................................6927
			524212-2......................................................................6931
			524211-2......................................................................6931
			524210-2......................................................................6931
			524209-2......................................................................6931
			524208-2......................................................................6931
			524207-2......................................................................6931
			524206-2......................................................................6931
			524205-2......................................................................6931
			524204-2......................................................................6931
			524203-2......................................................................6931
			524202-2......................................................................6931
			524201-2......................................................................6931
			524200-2......................................................................6931
			524199-2......................................................................6931
			524198-2......................................................................6931
			524197-2......................................................................6931
			522800-13.....................................................................6933
			522801-13.....................................................................6934
			Engine Continues to Run When Engine Cover is Raised...........................6935
			Engine Stops or Fails to Start................................................6937
			Electrical Functions Do Not Operate...........................................6939
			Electrical Function Does Not Turn Off.........................................6944
			Electro-Hydraulics Do Not Function With Armrest Down .........................6950
			Electro-Hydraulics Can Still Function With Armrest Raised.....................6953
			Vehicle Does Not Power On.....................................................6956
			Heater Fan Does Not Operate Properly..........................................6962
			Heater Airflow Does Not Reach Desired Temperature.............................6965
			Heater Output Has Insufficient Airflow........................................6966
			Circulating (Accessory) Fan Inoperative (if equipped).........................6967
			Dome Light Inoperative........................................................6970
			Horn Failure..................................................................6973
		Drive Train.......................................................................6977
			Transmission..................................................................6981
				Description...............................................................6981
			Single-Speed Transmission.....................................................6984
				Description...............................................................6984
			Two-Speed Transmission........................................................6985
				Description...............................................................6985
			Mechanical Overview...........................................................6986
			Engine........................................................................6986
				Description...............................................................6986
			Torque Converter..............................................................6986
				Description...............................................................6986
				Principles of Operation...................................................6986
					Stator................................................................6987
					Turbine...............................................................6987
			Chain Drive...................................................................6989
				Description...............................................................6989
			Clutch Assemblies.............................................................6990
				Description...............................................................6990
				Single-Speed Power Flow...................................................6992
				Two-Speed Power Flow......................................................6993
			Transmission Hydraulic System.................................................6995
				Principles of Operation...................................................6995
			Transmission Control System Overview..........................................6999
				Transmission Control System...............................................6999
			Transmission Control Hardware.................................................7001
				Control Valve and Sensors.................................................7001
					Description...........................................................7001
					Principles of Operation...............................................7003
				MONOTROL® Pedal...........................................................7003
					Description...........................................................7003
					Principles of Operation...............................................7003
				Directional Control Lever.................................................7003
					Principles of Operation...............................................7003
			Transmission Control Software.................................................7004
				Transmission Control Modes................................................7004
					Neutral Mode ( Basic Powershift and DuraMatch™ )......................7004
					Gear Engagement Mode..................................................7004
						Basic Powershift Gear Engagement Mode.............................7004
						DuraMatch™ Gear Engagement Mode...................................7004
					Controlled Creep Mode ( Basic Powershift Transmission Only)...........7005
					Normal Mode (Forward or Reverse)......................................7005
					Inching Mode..........................................................7005
						Basic Powershift Inching Mode.....................................7005
						DuraMatch™ Inching Mode...........................................7005
					Controlled Creep Mode - DuraMatch™ Transmission.......................7005
					Roll Back Mode - DuraMatch™ Transmission..............................7006
					Auto Decel Mode - DuraMatch™ Transmission.............................7006
					Auto-Shift Mode (Multispeed Only).....................................7006
					1st Gear Lock Mode (Multispeed Only)..................................7006
					Extended Drawbar Pull (2-Speed Only)..................................7006
			Transmission Proportional Valve...............................................7006
				Description...............................................................7006
				Principles of Operation...................................................7007
				Neutral...................................................................7007
				Proportional Control......................................................7007
				Forward...................................................................7008
				Forward-Inching...........................................................7008
			Driveshaft, Differential, and Drive Axle (Dry Brake Only).....................7009
				Driveshaft................................................................7009
				Differential and Drive Axle...............................................7009
				Brake System..............................................................7011
					Description...........................................................7011
					Service Brakes........................................................7011
					Master Cylinder.......................................................7012
					Brake Position Sensor.................................................7012
					Parking Brake.........................................................7012
			Driveshaft, Differential, and Drive Axle (Wet Brake Only).....................7013
				Driveshaft................................................................7013
				Differential and Drive Shaft..............................................7013
				Brake System..............................................................7014
					Description...........................................................7014
					Master Cylinder.......................................................7014
					Service Brakes, 2.0-3.5 Ton Only......................................7014
					Service Brakes, 4.0-5.5 Ton...........................................7016
					Brake Adjustment and Service..........................................7016
					Parking Brake.........................................................7016
			Overheating Brakes (Dry Brake Axle Only)......................................7019
			Overheating Brakes (Wet Brake Axle Only)......................................7021
			Poor Brake Performance (Dry Brake Axle Only)..................................7024
			Poor Brake Performance (Wet Brake Axle Only)..................................7027
			Brakes Make Too Much Noise (Dry Brake Axle Only)..............................7029
			Brakes Pull To One Side (Dry Brake Axle Only).................................7030
			Parking Brake Will Not Release................................................7033
			Parking Brake Will Not Hold Lift Truck (Dry Brake Axle Only)..................7034
			Parking Brake Will Not Hold Lift Truck (Wet Brake Axle Only)..................7035
			Abnormal Drive Axle Noise.....................................................7036
			Discolored Drive Axle Oil.....................................................7039
			Lift Truck Does Not Move (Drive Axle).........................................7040
			Abnormal Transmission Noise...................................................7042
			Bubbles or Foaming In Transmission Dipstick Tube..............................7044
			Inching Operation Is Not Smooth or Chatters...................................7046
			Lift Truck Does Not Move In One or Both Directions (Transmission..............7048
			Loss of Power/Drivetrain Performance..........................................7051
			Transmission Is Too Hot.......................................................7054
			Transmission Will Not Shift To Forward High Range.............................7057
			Transmission Warmup Procedure.................................................7059
			Transmission Pressure Test....................................................7059
				Transmission Charge Pump Pressure Test....................................7060
				Clutch Pack Pressure Test (Proportional Solenoid Valves)..................7060
				Torque Converter Pressure Test............................................7061
				Lubrication Pressure Test.................................................7061
			Transmission Clutch Drag Test.................................................7061
			Torque Converter Stall Test...................................................7062
		Hydraulic Systems.................................................................7065
			Main Hydraulic System.........................................................7069
				Description...............................................................7069
				Principles of Operation...................................................7069
				Hydraulic Schematics......................................................7071
					Manual Control Valve Schematic........................................7071
					Electro-Hydraulic Control Valve Schematic.............................7074
			Manual Hydraulic Control Valve................................................7077
				Description...............................................................7077
				Principles of Operation...................................................7078
					Lift Section..........................................................7078
						Lift Operation....................................................7078
						Lower Operation...................................................7078
					Tilt Section..........................................................7079
						Tilt Backward.....................................................7079
						Tilt Forward......................................................7079
					Auxiliary Section.....................................................7081
					Anti-stall Feature....................................................7082
					Relief Valves.........................................................7082
						Main Relief Valve.................................................7082
						Secondary Relief Valve............................................7082
			Electro-Hydraulic Control Valve...............................................7083
				Description...............................................................7083
				Principles of Operation...................................................7084
					Inlet Pressure Compensator/Unloader...................................7084
					Lift/Lower EHPVs......................................................7085
						EHPV Operation....................................................7086
					Tilt and Auxiliary Spool Functions....................................7088
					Tilt Forward Function.................................................7090
					Main Relief Valve ....................................................7091
					Secondary Relief Valve................................................7091
					Secondary Function Anti-stall Valve...................................7092
					Manual Lowering Valve.................................................7093
			Steering System...............................................................7093
				Component Locations.......................................................7093
					Description...........................................................7093
					Steering Axle Assembly................................................7093
					Steering Control Unit.................................................7093
				Steering Schematic........................................................7095
					Principles of Operation...............................................7096
					Steering Control Unit.................................................7096
			Actuation Functions With Armrest Up (E-Valve).................................7097
			Cycle Times Too Fast - Fast Actuation (E-Valve)...............................7098
			Jump/Delay In Lift or Lower Activation After Moving Joystick or ..............7100
			Jump/Delay In Secondary Function Actuation After Moving Joystick..............7102
			Jump/Delay In Tilt Forward Actuation (E-Valve)................................7104
			Forks Drop Slightly Before Lifting (E-Valve)..................................7106
			Forks Lower Without Command (E-Valve).........................................7107
			Forks Raise or Actuate Without Command (E-Valve)..............................7109
			Forks Tilt Forward Without Command (E-Valve)..................................7111
			Intermittent Activation (E-Valve) While Commanding Function...................7113
			Lift/Lower Function Maximum Speed Too Slow (E-Valve)..........................7115
			Lift Function Will Not Move With Joystick or MLM Movement (E-Val..............7118
			Lift/Lower Continues To Move For Awhile After Joystick or MLM Is..............7121
			Lift/Lower/Secondary Function Suddenly Jumps In Middle of Stroke..............7122
			Lower Function Will Not Move With Joystick or MLM Movement (E-Va..............7123
			Poor Metering on Lift or Lower Functions (E-Valve)............................7124
			Secondary Function Continues to Move for Awhile After Joystick o..............7127
			Secondary Function Exhibits Slight Movement in Opposite Directio..............7128
			Secondary Function Maximum Speed Too Slow (E-Valve)...........................7129
			Secondary Function or Tilt Back Moves Without Command (E-Valve)...............7132
			Secondary Function and Tilt Back Will Not Move With Joystick or ..............7133
			Tilt Forward Function Continues to Move for Awhile When Joystick..............7136
			Tilt Forward Will Not Move Upon Joystick or MLM Movement (E-Valv..............7137
			Too Much Joystick or MLM Movement (Deadband) to Start Function M..............7139
			Wrong Actuation Operates or Actuation is Backward (E-Valve)...................7140
			Actuation Exhibits Slight Movement in Opposite Direction Before ..............7141
			Auxiliary Function is Slow or Does Not Function (Manual Valve)................7142
			Cycle Times Too Fast - Fast Actuation (Manual Valve)..........................7144
			Function Continues to Activate After Returning to Neutral.....................7145
			Lift Function Is Slow or Does Not Function (Manual Valve).....................7146
			Tilt Back Function Will Not Operate (Manual Valve)............................7148
			Tilt Forward Functions When Spool is Activated Forward With Engi..............7149
			Tilt Forward Will Not Function When Activated (Manual Valve)..................7150
			Abnormal Steer Axle Noise.....................................................7151
			Abnormal Steering Wheel Vibration.............................................7153
			Back Lash/Kick Back in Steering Wheel.........................................7154
			No Steering (All Other Hydraulic Functions OK)................................7156
			Steering Is Slow or Difficult.................................................7158
			Steering Operation Is Not Smooth..............................................7160
			Steering Wheel End Lock Position Cannot Be Felt by Operator...................7162
			Steering Wheel Turns By Itself or Does Not Return To Neutral..................7163
			Steering Wheel Turns the Tires in the Wrong Direction.........................7164
			Abnormal Hydraulic Noise and/or Vibration.....................................7165
			Abnormal Smell/Discoloration/Foaming of Oil...................................7168
			Actuations Do Not Act Simultaneously..........................................7169
			Oil Leaking/Component Life Too Short..........................................7170
			Hydraulic Warmup Procedure....................................................7173
			Main Relief Valve Test and Adjustment.........................................7174
			Secondary Relief Valve Test and Adjustment....................................7176
			Hydraulic Pump Flow Test......................................................7178
			Main Control Valve LS Leakage Test (E-Valve)..................................7180
			Main Control Valve Unloader Margin Test.......................................7180
			Electro-Hydraulic Poppet Valve (EHPV) Leakage Test............................7181
			PPRV Pilot Pressure Test......................................................7184
			Steering Relief Pressure Test and Adjustment..................................7186
			Steering Control Unit LS Pressure Test........................................7187
			Lift Cylinder Leakage Test....................................................7188
			Tilt Cylinder Leakage Test....................................................7190
			Steering Cylinder Leakage Test................................................7191
		Operators Station.................................................................7193
			Operator's Station General Description and Principles of Operati..............7195
				General Description and Location..........................................7195
			Display Switch Cluster (DSC)..................................................7198
				Detailed Description......................................................7198
				Control Inputs, Right Side................................................7199
				Right Indicator and Warning Group.........................................7200
				LCD Display...............................................................7200
				Left Indicator and Warning Group..........................................7202
				Control Inputs, Left Side (Cab Option Only)...............................7203
			Transmission Control and Braking..............................................7204
				Description...............................................................7204
					Vehicle System Manager (VSM)..........................................7204
					Display Switch Cluster................................................7205
						Interlock and Switching Features..................................7205
					MONOTROL® Directional Control.........................................7205
					Inch Brake/Service Brake Pedal........................................7205
					Parking Brake.........................................................7205
			Programming - Menus...........................................................7206
				Menus.....................................................................7206
					Main Menu.............................................................7206
					Save and Exit or Exit Without Saving..................................7206
					Back One Level........................................................7206
					Hourmeters............................................................7206
					View Versions.........................................................7206
					Passwords.............................................................7206
					Diagnostics...........................................................7206
					Setup Travel and Braking..............................................7209
					Setup Hydraulics......................................................7209
					Setup Display.........................................................7209
					Setup General Items...................................................7209
					Calibrations..........................................................7209
			Manual Hydraulic Control Levers...............................................7209
				General Description.......................................................7209
				System Components.........................................................7209
					Lift/Lower............................................................7209
					Tilt..................................................................7209
					Auxiliary 1...........................................................7209
					Auxiliary 2...........................................................7209
			E-Hydraulic System Interface..................................................7210
				General Description.......................................................7210
				System Components.........................................................7210
				E-Hydraulic Control Input Device..........................................7211
					Joystick..............................................................7211
						Lift/Lower........................................................7211
						Tilt..............................................................7211
						Auxiliary 1.......................................................7211
						Auxiliary 2.......................................................7211
						Push Button.......................................................7212
					Mini Lever Module (MLM)...............................................7212
						Lever 1...........................................................7212
						Lever 2...........................................................7212
						Lever 3...........................................................7213
						Lever 4...........................................................7213
				System Modes..............................................................7213
					Hydraulic Interlock Mode..............................................7213
					Fault Mode............................................................7213
					Engine Off Mode.......................................................7213
				Normal Operation..........................................................7213
					Normal Operation Mode.................................................7213
					Lifting Control.......................................................7213
					Lowering Control......................................................7214
					Tilt Control (Forward and Backward)...................................7214
					Auxiliary Control.....................................................7214
			Lighting Control..............................................................7214
				Description...............................................................7214
					Front Work Lights.....................................................7217
					Front Marker Lights (if equipped).....................................7217
					Front/Rear Turn Signal Lights.........................................7217
					Rear Tail/Marker Lights...............................................7217
					Rear Work Light.......................................................7217
					Rear Backup Lights....................................................7217
					Rear Stop Lights......................................................7217
					Strobe Light(s).......................................................7217
					Spot Light (if equipped)..............................................7217
			Cab...........................................................................7217
				Description...............................................................7217
				Component Descriptions....................................................7219
					Cab Heating System....................................................7219
					Lighting Control System...............................................7219
					Wiper/Washer System...................................................7219
				Cab Systems Operation.....................................................7220
		Front End (Mast) and Chassis......................................................7223
			Front End, Mast...............................................................7225
				Description...............................................................7225
			Carriages.....................................................................7225
				Description...............................................................7225
				Principles of Operation...................................................7226
					Integral Sideshift Carriage...........................................7226
			Mast Mounts...................................................................7227
				Description...............................................................7227
				Principles of Operation...................................................7228
			Two-Stage Limited Free-Lift (LFL) Mast........................................7229
				Description...............................................................7229
				Principles of Operation...................................................7230
			Two-Stage Full Free-Lift (FFL) Mast...........................................7231
				Description...............................................................7231
				Principles of Operation...................................................7232
			Three-Stage Full Free-Lift (FFL) Mast.........................................7233
				Description...............................................................7233
				Principles of Operation...................................................7234
			Four-Stage Full Free-Lift (FFL) Mast..........................................7235
				Description...............................................................7235
				Principles of Operation...................................................7236
			Cylinder Cushion During Lifting Sequence......................................7239
				Description...............................................................7239
				Principles of Operation...................................................7239
			Cylinder Cushion During Lowering Sequence.....................................7240
				Description...............................................................7240
				Principles of Operation...................................................7240
			Tilt and Sideshift Cylinders..................................................7240
				Description...............................................................7240
					Tilt Cylinder.........................................................7240
					Sideshift Cylinder....................................................7240
			Lowering Control Valves.......................................................7241
				Description...............................................................7241
				Principles of Operation...................................................7241
			Chassis.......................................................................7243
				Description...............................................................7243
			Abnormal Channel Wear.........................................................7245
			Abnormal Hose Wear............................................................7247
			Abnormal Mast Noise...........................................................7249
			Body Panels Making Noise......................................................7253
			External Leakage From Free-Lift or Main Lift Cylinders........................7254
			FFL Mast Banging During Phasing...............................................7255
			High Tire Wear - Drive Axle...................................................7257
			High Tire Wear - Steer Axle...................................................7259
			Hoses Not Tracking Correctly..................................................7261
			Integral Sideshift Moving Too Fast............................................7262
			Integral Sideshift Not Moving or Slow.........................................7263
			LP Tank Bracket Disengages....................................................7266
			LP Tank Rattles and Does Not Stay Latched.....................................7267
			Mast is Loose.................................................................7268
			Mast Lift Chains Are Loose....................................................7270
			Mast or Carriage Binding......................................................7271
			Mast/Carriage Bounces or is Spongy............................................7273
			Misphasing of Full Free-Lift Mast.............................................7274
			Overhead Guard Loose or Damaged...............................................7276
			Racking During Lift...........................................................7277
			Racking During Tilt...........................................................7279
			Truck Feels Unstable..........................................................7280
			Truck Wanders, Does Not Track Straight or Steer Well..........................7282
			Wheels Appear Tipped or Misaligned............................................7284
			Wheels Spinning On Uneven Floors..............................................7286
			Wheel Studs Breaking..........................................................7287
		Supplementary Data................................................................7289
			Abbreviations and Acronyms....................................................7291
			Special Tools List............................................................7299
			Fault Mode Indicator (FMI) Reference List.....................................7301
			TSP Reference Tables..........................................................7303
	tables................................................................................6287
		Table 9020-40-1. Test Specifications..............................................6531
		Table 9020-40-2. Test Specifications..............................................6532
		Table 9020-40-3. Service Tools....................................................6532
		Table 9020-40-4. Test Specifications..............................................6533
		Table 9020-40-5. Service Tools....................................................6533
		Table 9020-40-6. Test Specifications..............................................6534
		Table 9020-40-7. Service Tools....................................................6535
		Table 9020-40-8. Test Specifications - Mazda......................................6536
		Table 9020-40-9. Test Specifications - GM.........................................6536
		Table 9020-40-10. Service Tools...................................................6536
		Table 9020-40-11. Test Specifications.............................................6538
		Table 9020-40-12. Service Tools...................................................6538
		Table 9020-40-13. Test Specifications.............................................6540
		Table 9020-40-14. Service Tools...................................................6540
		Table 9030-03-1. Circuit Group Identification.....................................6564
		Table 9030-03-2. Hyster Wiring Color Codes........................................6565
		Table 9040-10-1. Transmission Control Mode........................................7000
		Table 9040-40-1. Test Specifications..............................................7059
		Table 9040-40-2. Service Tools....................................................7059
		Table 9040-40-3. Service Tools....................................................7059
		Table 9040-40-4. Test Specifications..............................................7060
		Table 9040-40-5. Test Specifications..............................................7060
		Table 9040-40-6. Test Specifications..............................................7061
		Table 9040-40-7. Test Specifications..............................................7061
		Table 9040-40-8. Test Specifications..............................................7061
		Table 9040-40-9. Service Tools....................................................7061
		Table 9040-40-10. Stall Speeds....................................................7063
		Table 9050-40-1. Test Specifications..............................................7173
		Table 9050-40-2. Service Tools....................................................7173
		Table 9050-40-3. Test Specifications..............................................7174
		Table 9050-40-4. Service Tools....................................................7174
		Table 9050-40-5. Test Specifications..............................................7176
		Table 9050-40-6. Service Tools....................................................7176
		Table 9050-40-7. Test Specifications..............................................7178
		Table 9050-40-8. Service Tools....................................................7179
		Table 9050-40-9. Test Specifications..............................................7180
		Table 9050-40-10. Test Specifications.............................................7180
		Table 9050-40-11. Service Tools...................................................7180
		Table 9050-40-12. Test Specifications.............................................7181
		Table 9050-40-13. Service Tools...................................................7182
		Table 9050-40-14. Test Specifications.............................................7184
		Table 9050-40-15. Service Tools...................................................7184
		Table 9050-40-16. Test Specifications.............................................7186
		Table 9050-40-17. Service Tools...................................................7186
		Table 9050-40-18. Test Specifications.............................................7187
		Table 9050-40-19. Service Tools...................................................7187
		Table 9050-40-20. Test Specifications.............................................7188
		Table 9050-40-21. Service Tools...................................................7189
		Table 9050-40-22. Test Specifications.............................................7190
		Table 9050-40-23. Service Tools...................................................7190
		Table 9050-40-24. Test Specifications.............................................7191
		Table 9050-40-25. Service Tools...................................................7191
		Table 9080-50-1. Abbreviations and Acronyms.......................................7291
		Table 9080-60-1. Special Tools....................................................7299
		Table 9080-70-1. FMI..............................................................7301
		Table 9080-80-1. Resistor-Temperature Characteristics ............................7303
wet brake axle 1400SRM1215................................................................7307
	toc...................................................................................7307
		Drive Axle Repair.................................................................7307
		Safety Precautions Maintenance and Repair.........................................7308
		General...........................................................................7311
			Identification Plate..........................................................7311
		Drive Axle Removal................................................................7311
		Reduction Gear Assembly...........................................................7316
			Reduction Gear Assembly Repair................................................7316
				Remove....................................................................7319
				Clean and Inspect.........................................................7326
				Install...................................................................7327
		Brake Repair......................................................................7336
			Wet Disc Brake................................................................7336
				Remove....................................................................7340
				Clean and Inspect.........................................................7346
				Install...................................................................7347
			Parking Brake Control Lever...................................................7358
				Remove....................................................................7359
				Clean and Inspect.........................................................7361
				Install...................................................................7361
		Differential Repair...............................................................7364
			Remove........................................................................7364
				Flange....................................................................7364
				Differential Assembly.....................................................7365
				Bevel Pinion..............................................................7371
			Disassemble...................................................................7375
				Differential Assembly.....................................................7375
			Clean and Inspect.............................................................7378
			Assemble......................................................................7378
				Differential Assembly.....................................................7379
			Install.......................................................................7383
				Determine Bevel Pinion Shim Thickness.....................................7383
				Bevel Pinion..............................................................7385
				Differential Assembly.....................................................7389
				Gear Set, Tooth Contact Pattern Check.....................................7396
				Flange....................................................................7399
		Drive Axle Installation...........................................................7400
		Special Tools.....................................................................7406
		Torque Specifications.............................................................7409
	tables................................................................................7307
		Table 1. Bevel Gear and Bevel Pinion Tooth Contact Adjustment.....................7396
		Table 2. Correct Tooth Contact....................................................7397
		Table 3. Incorrect Tooth Contact..................................................7398

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