Yale Forklift GDP/GLP20-30RF/TF (A875) Service Manual – PDF DOWNLOAD

Yale Forklift GDP/GLP20-30RF/TF (A875) Service Manual – PDF DOWNLOAD

FILE DETAILS:

Yale Forklift GDP/GLP20-30RF/TF (A875) Service Manual – PDF DOWNLOAD

Language : English
Pages : 1536
Downloadable : Yes
File Type : PDF

PN 524158636

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TABLE OF CONTENTS:

Yale Forklift GDP/GLP20-30RF/TF (A875) Service Manual – PDF DOWNLOAD

0100YRM505-524158636(06-2004)-EN 1
toc 1
Frame 1
Safety Precautions Maintenance and Repair 2
General 5
Description 5
Operator Module Repair 5
Remove 5
Install 5
Hood and Side Covers Repair 7
Remove 7
Install and Adjust 7
Overhead Guard Repair 9
Remove and Install 9
LED Backup and Brake Lights, Replace 10
Remove 10
Install 10
Counterweight Repair 11
Remove 11
Install 12
Exhaust System Repair 13
Muffler, Replace 14
Radiator and Cooling System Repair 20
Remove 20
Install 20
Operator Restraint System Repair 22
Engine Repair 23
Remove Engine Only 23
Remove Engine and Transmission 23
Install Engine Only 24
Install Engine and Transmission 25
Fuel and Hydraulic Tanks Repair 25
Inspect 25
Small Leaks, Repair 25
Large Leaks, Repair 25
Clean 26
Steam Method of Cleaning 26
Chemical Solution Method of Cleaning 26
Additional Preparations for Repair 26
Safety Labels 27
tables 1
Table 1 Weight of Counterweights 12
0600YRM496-524158742(01-2002)-EN 33
toc 33
Mazda Engine 33
Safety Precautions Maintenance and Repair 34
General 37
Description 37
Engine Removal and Installation 37
Cylinder Head, Camshaft, and Valve Mechanism Repair 38
Remove 38
Clean 39
Inspect and Repair 40
Cylinder Head 40
Rocker Shaft Assembly 40
Camshaft 40
Valve Guides 41
Valve Seats 42
Valves 42
Valve Springs 43
Install 43
Crankshaft and Main Bearings Repair 46
Remove 46
Inspect and Repair 46
Crankshaft 46
Main Bearings 46
Install 47
Pistons and Connecting Rods Repair 48
Remove and Disassemble 48
Clean 48
Inspect and Repair 48
Pistons 48
Piston Rings 48
Connecting Rods and Bearings 49
Assemble and Install 49
Cylinder Block Repair 51
Oil Pump Repair 51
Remove 51
Disassemble 52
Clean 52
Inspect 52
Assemble 53
Install 53
Cooling System Repair 54
Thermostat 54
Replace 54
Fan Assembly 54
Remove and Disassemble 54
Assemble and Install 55
Water Pump 55
Remove and Disassemble 55
Assemble and Install 56
Distributor Repair 57
Remove 57
Install 57
Flywheel and Ring Gear Repair 58
Remove 58
Ring Gear, Replace 58
Install 58
Flywheel Repair 59
Remove 59
Install 59
Valve Adjustment 60
Compression Pressure Check 61
Engine Timing Adjustment 61
Throttle Linkage Adjustment 62
Gasoline Engines 62
LPG Engines (IMPCO) 62
LPG Engines (AISAN) 62
Engine Specifications 62
Engine Data 62
Thermostat 62
Cylinder Head 63
Valve Mechanism 63
Camshaft 63
Crankshaft 64
Connecting Rods 64
Cylinder Block 64
Pistons 64
Oil Pump 64
Torque Specifications 65
Troubleshooting 66
0600YRM1019-524162461(05-2002)-EN XA-HA ENGINES 71
toc 71
Mazda XA and HA Diesel Engines 71
Safety Precautions Maintenance and Repair 72
General 77
Description 77
Engine Removal and Installation 78
Cylinder Head and Valve Mechanism Repair 79
Remove 79
Clean 79
Inspect and Repair 79
Cylinder Head 79
Rocker Shaft Assembly 80
Valve Guides 80
Valve Seats 81
Valves 81
Valve Springs 82
Push Rods 82
Cylinder Head, Assemble 82
Cylinder Head, Install 84
Timing Gears Repair 84
Remove 84
Clean and Inspect 85
Install 85
Camshaft Repair 86
Remove 86
Inspect and Repair 86
Install 87
Crankshaft and Main Bearings Repair 88
Remove 88
Inspect and Repair 88
Crankshaft 88
Main Bearings 89
Install 89
Piston and Connecting Rods Repair 89
Remove and Disassemble 89
Clean 90
Inspect and Repair 90
Pistons 90
Piston Rings 90
Connecting Rods and Bearings 90
Assemble and Install 91
Cylinder Block and Liners Repair 92
Inspect and Repair 92
Lubrication System Repair 94
Oil Pump 94
Remove 94
Disassemble 94
Clean 94
Inspect 94
Assemble 95
Install 96
Oil Filter Mount 96
Remove 96
Install 96
Oil Cooler 97
Remove 97
Clean and Inspect 97
Install 97
Cooling System Repair 97
Thermostat 97
Remove and Install 97
Water Pump 98
Remove 98
Disassemble 98
Inspect 99
Assemble 99
Install 100
Fuel System Repair 100
Description and Operation 100
Fuel Injection Pump 102
Remove 102
Install 103
Fuel Filter 103
Filter, Replace 103
Water Sensor Check 103
Fuel System Air Removal 104
Fuel Injectors 104
Remove and Disassemble 104
Clean and Inspect 104
Assemble 104
Inspect and Adjust 104
Install 105
Flywheel and Ring Gear Repair 106
Flywheel, Remove 106
Ring Gear, Replace 106
Flywheel, Install 106
Flywheel, Remove 106
Flywheel, Install 107
Alternator Repair 107
Starting System Repair 108
Cold Start Aid 108
Description and Operation 108
Glow Plugs, Replace 108
Glow Plugs, Check 109
Fuse 109
Relay and Controller 109
Checks and Adjustments 110
Valves, Adjust 110
Compression Pressure Check 110
Throttle Linkage, Adjust 111
Fuel Injection Pump Timing Check 111
Engine Specifications 112
Engine Data 112
Cylinder Head 113
Camshaft 114
Crankshaft 115
Connecting Rods 116
Cylinder Block 116
Pistons 116
Oil Pump 117
Torque Specifications 117
Special Tools 118
Troubleshooting 120
tables 71
Table 1 Camshaft Journal Diameters 87
Table 2 Crankshaft Journal Diameters 88
Table 3 Piston Diameters 90
Table 4 Cylinder Liner Diameters 93
0600YRM1020-524158637(08-2003)-EN 127
toc 127
GM Engine Repair 127
Safety Precautions Maintenance and Repair 128
General 131
Description 131
Engine Removal and Installation 131
Cylinder Head and Valve Mechanism Repair 139
Cylinder Head, Remove 139
Cylinder Head, Disassemble 139
Clean and Inspect 142
Valves and Valve Seats 143
Studs for Rocker Arms 144
Hydraulic Valve Lifters 144
Replace 144
Clean and Inspect 145
Cylinder Head, Assemble 145
Cylinder Head, Install 145
Valve Clearance, Adjust 146
Rocker Arm Cover, Install 147
Timing Gear Cover Repair 147
Remove 147
Install 148
Camshaft Repair 149
Camshaft, Remove 149
Camshaft, Clean and Inspect 149
Camshaft Bearings, Remove 151
Camshaft Bearings, Clean and Inspect 151
Camshaft Bearings, Install 151
Camshaft, Install 152
Distributor Repair 152
Remove 152
Install 153
Lubrication System Repair 154
Oil Pan 154
Remove 154
Install 154
Oil Pump 154
Remove 154
Disassemble 155
Clean and Inspect 156
Assemble 156
Install 156
Piston and Piston Rod Assemblies Repair 156
Piston Rod Bearings, Replace 156
Piston and Piston Rod Assemblies, Remove 158
Piston and Piston Rod Assemblies, Disassemble 158
Pistons, Clean and Inspect 159
Cylinder Bores, Inspect and Repair 159
Piston Rings, Inspect 160
Piston and Piston Rod Assemblies, Assemble 161
Piston and Piston Rod Assemblies, Install 161
Crankshaft Repair 162
Main Bearings, Replace 162
Oil Seal for Rear Main Bearing, Replace 163
Crankshaft, Remove 163
Inspect and Repair 164
Main Bearing and Journal Clearance, Check 165
Crankshaft, Install 166
Flywheel and Flywheel Housing Repair 166
Flywheel, Remove 167
Ring Gear, Replace 168
Flywheel, Install 168
Cooling System Repair 168
Water Pump 168
Remove 168
Inspect 168
Install 169
Thermostat 169
Remove and Install 169
Alternator Repair 169
Starter Repair 169
Checks and Adjustments 171
Engine Compression Test 171
Test Procedure 171
Test Results 171
Engine Noise Diagnostic Test 171
Description 171
Test Procedure 171
Engine Specifications 173
Engine Data 173
Cylinder Bore 173
Piston 173
Piston Rings 173
Wrist Pin 174
Crankshaft 174
Piston Rod 175
Camshaft 175
Hydraulic Valve System 175
Cylinder Head Warpage 176
Lubrication System 176
Cooling System 176
Torque Specifications 177
Troubleshooting 178
0700YRM626-524150775(03-2003)-EN 185
toc 185
Cooling System 185
Safety Precautions Maintenance and Repair 186
General 189
Description 190
Radiator 190
Radiator Cap 190
Thermostat 190
Water Pump 191
Fan and Fan Shroud 191
Cooling System Checks 191
Radiator 191
Thermostat 191
Water Pump 192
Exhaust Leaks 192
Fan and Fan Shroud 192
Radiator Cleaning 192
Drain 192
Clean 192
Fill 193
Troubleshooting 194
0900YRM498-524158744(12-2003)-EN 197
toc 197
LPG Fuel System 197
Safety Precautions Maintenance and Repair 198
General 201
Description and Operation 201
Fuel Tank 202
Fuel Filter and Fuel Valve Unit 202
Vaporizer 202
Carburetor 204
Solenoid Valve 205
Idle Control Actuator 206
Governor System 206
Hose Replacement 206
LPG Tank Repair 207
Remove 207
Install 207
Hydrostatic Relief Valve Repair 208
Remove and Install 208
Filter Unit Repair 208
Fuel Filter Element, Replace 208
Diaphragm and Fuel Valve, Replace 210
Vaporizer Repair 210
Remove 210
Disassemble 210
Clean 210
Inspect 210
Assemble 212
Install 216
Carburetor Repair 216
Remove 216
Disassemble 216
Clean 216
Assemble 218
Install 218
Solenoid Valve Repair 218
Governor System Check 219
Filter Unit Check 219
Vaporizer Check 220
Pressure Reducer Valve 220
Vapor Valve 220
Carburetor Adjustment 220
Idle, Adjust 220
Power Mixture 221
Throttle Linkage Adjustment 222
Foot Directional Control Pedal, Check 223
Troubleshooting 224
0900YRM523-524158746(12-2003)-EN 231
toc 231
LPG Fuel System 231
Safety Precautions Maintenance and Repair 232
General 235
Description and Operation 235
Fuel Tank 237
Fuel Filter and Fuel Valve Unit 237
Vaporizer 238
Carburetor 240
Solenoid Valve 242
Idle Control Actuator 242
Governor 242
Hose Replacement 242
LPG Tank Repair 243
Remove 243
Install 243
Hydrostatic Relief Valve Repair 244
Remove and Install 244
Filter Unit Repair 244
Fuel Filter Element, Replace 244
Diaphragm and Fuel Valve, Replace 246
Vaporizer Repair 246
Remove 246
Disassemble 246
Clean 246
Inspect 246
Assemble 248
Install 251
Carburetor Repair 252
Remove 252
Disassemble 252
Clean 252
Assemble 255
Install 255
Solenoid Valve Repair 255
Governor Repair 255
Filter Unit Check 256
Vaporizer Check 256
Pressure Reducer Valve 256
Vapor Valve 256
Carburetor Adjustment 256
Idle Mixture 256
Idle, Adjust 256
Power Mixture, Adjust 257
Governor Check and Adjustment 258
Check 258
Adjust 258
Throttle Linkage Adjustment GC/GLC040-065RG/TG/ZG and GP/GLP/GDP 259
Throttle Linkage Adjustment GP/GLP/GDP16-20AF/BF (GP/GLP/GDP030- 260
Foot Directional Control Pedal Check 261
Troubleshooting 262
0900YRM925-524158747(12-2003)-EN LPG SYSTEM AISAN OPEN-LOOP 269
toc 269
LPG Fuel System 269
Safety Precautions Maintenance and Repair 270
General 273
Description and Operation 273
Fuel Tank 274
Regulator 274
Start Mode 276
Idle Mode 276
Run Mode 276
Resonator 276
Carburetor 277
Start Mode 277
Idle Mode 277
Run Mode 277
Governor 278
Hoses Replacement 279
LPG Tank Repair 279
Remove 279
Install 279
Relief Valve Repair 280
Remove and Install 280
Carburetor Repair 280
Remove 280
Disassemble 280
Clean 281
Assemble 281
Install 282
Governor Repair 282
Remove 282
Inspect 282
Install 282
Regulator Repair 283
Remove 283
Disassemble 283
Clean 283
Inspect 283
Assemble 285
Install 286
Regulator Adjustment 286
Regulator Height Adjustment 286
Regulator Assembly Air Tightness Test 287
Carburetor Adjustment 288
Idle Speed and Fuel Mixture 288
Idle Control Adjustment 288
Governor Adjustment 289
Checks 289
Adjustments 289
Throttle Linkage Adjustment 290
Foot Directional Control Pedal Check 291
Throttle Linkage Adjustment 292
Troubleshooting 293
tables 269
Table 1 Power Adjusting Screw 282
Table 2 Air Adjusting Screw 282
Table 3 Idle Mixture Adjusting Screw 285
Table 4 Idle Mixture Adjusting Screw 288
0900YRM1088-524208004(05-2006)-EN 301
toc 301
Electronic Controlled LPG/Gasoline Fuel System 301
Safety Precautions Maintenance and Repair 302
General 307
Fuel System Warnings and Cautions 307
Glossary 308
Description and Operation of LPG Fuel System 312
Propane Fuel System 312
LPG Fuel Tank 314
Service Line 314
Fuel Filter 314
Low Pressure Lock-Off (LPL) 314
Low Pressure Regulator (LPR) 315
Air Fuel Mixer 315
Throttle Control Device 316
Drive By Cable 316
Three-Way Catalytic (TWC) Muffler 317
Electronic Control Module (ECM) 317
Heated Exhaust Gas Oxygen (HEGO) Sensor 318
Description and Operation of Gasoline Fuel System 320
Gasoline Fuel System Throttle Body Injection (TBI), 3 0L Engine 320
Gasoline Multi-Point Fuel Injection (MPFI) System, 4 3L Only 320
Gasoline Fuel Storage Tank 320
Gasoline Fuel Pump 320
Fuel Filter 320
Fuel Pressure Regulator, 3 0L Only 323
Fuel Rail and Pressure Regulator, 4 3L Only 324
Fuel Injector 324
Throttle Control Device 324
Drive By Cable 324
Three-Way Catalytic Muffler 325
Electronic Control Module (ECM) 325
Heated Exhaust Gas Oxygen (HEGO) Sensor 327
LPG Fuel System Repair 327
Propane Fuel System Pressure Relief 327
Propane Fuel System Leak Test 327
Propane Fuel Filter Replacement 328
Remove 328
Install 328
Low Pressure Lock-Off (LPL) Replacement 328
Remove 328
Install 328
Pressure Trim Valve (PTV) Replacement 330
Remove 330
Install 330
Low Pressure Regulator 330
Remove 330
Install 330
Fuel Trim Valve (FTV) Solenoid Replacement 331
Remove 331
Install 331
Temperature Manifold Absolute Pressure (TMAP) 331
Remove 331
Install 331
Throttle Body Replacement 333
Remove 333
Install 333
Mixer Replacement 335
Remove 335
Install 335
Coolant Hose Replacement 335
Remove 335
Install 336
Vapor Hose Replacement 336
Remove 336
Install 336
Balance Line Hose Replacement 336
Remove 336
Install 336
PTV Hose Replacement 336
Remove 336
Install 336
FTV Hose Replacement 337
Remove 337
Install 337
Throttle Position Sensor (TPS) Replacement 337
Foot Pedal Position (FPP) Sensor Replacement 339
Electronic Control Module (ECM) Replacement 342
Remove 342
Install 342
Heated Exhaust Gas Oxygen (HEGO) Sensor Replacement 342
Remove 342
Install 343
Three-Way Catalytic Muffler (TWC) Replacement 343
Remove 343
Install 343
Restricted Exhaust System Diagnosis 343
Exhaust System Description 343
Tools Required 343
Diagnostic Tool 343
Check at Heated Exhaust Gas Oxygen Sensor (HEGO) 343
Gasoline Fuel System Repair 344
Gasoline MPFI and TBI Fuel System Pressure Relief 344
Gasoline Fuel System Leak Test 345
Throttle Body Injector (TBI) Assembly Replacement, 3 0L Only 345
Remove 345
Install 345
Throttle Body Assembly Replacement, 3 0L Only 347
Remove 347
Install 347
Throttle Body Assembly Replacement, 4 3L Only 348
Remove 348
Install 348
Fuel Rail Replacement, Gasoline 4 3L Only 349
Remove 349
Install 349
Injector Replacement, Gasoline 4 3L Only 349
Remove 349
Install 349
Injector Replacement, Gasoline 3 0L Only 351
Remove 351
Install 351
Temperature Manifold Absolute Pressure (TMAP) Replacement 351
Remove 351
Install 351
Throttle Position Sensor (TPS) Replacement 351
Foot Pedal Position (FPP) Sensor Replacement 354
Electronic Control Module (ECM) Replacement 357
Remove 357
Install 357
Heated Exhaust Gas Oxygen (HEGO) Sensor Replacement 358
Remove 358
Install 358
Three-Way Catalytic Muffler (TWC) Replacement 358
Remove 358
Install 358
Restricted Exhaust System Diagnosis 358
Exhaust System Description 358
Tools Required 358
Diagnostic Tool 358
Check at Heated Exhaust Gas Oxygen Sensor (HEGO) 359
LPG System Diagnosis 359
Fuel System Description 359
Diagnostic Aids 360
Tools Required 360
Duty Cycle Monitoring Tool 360
Diagnostic Tool 360
Pressure Gauges 360
Test Description 360
Gasoline System Diagnosis 368
Fuel System Description, 3 0L Only 368
Fuel System Description, 4 3L Only 368
Diagnostic Aids 369
Tools Required 369
Diagnostic Tool 369
Test Description 369
LPG Symptom Diagnosis 376
Gasoline Symptom Diagnosis 390
Wire Harness Repair 401
On Vehicle Service Wiring Harness Repair 401
Connectors and Terminals 401
Twisted/Shielded Cable Repair 402
Twisted Leads Repair 403
Micro-Pack 404
Metri-Pack 404
Remove 404
Weather-Pack 406
Weather-Pack Terminal Repair 407
tables 301
Table 1 TPS Replacement Procedure 337
Table 2 FPP Replacement Procedure 340
Table 3 TPS Replacement Procedure 352
Table 4 FPP Replacement Procedure 355
Table 5 LPG Fuel System Diagnosis 360
Table 6 Fuel Control Diagnosis 364
Table 7 Gasoline Fuel System Diagnosis, 3 0L Only 370
Table 8 Gasoline Fuel System Diagnosis, 4 3L Only 373
Table 9 Preliminary Checks 376
Table 10 Intermittent 377
Table 11 No Start 378
Table 12 Hard Start 380
Table 13 Cuts Out or Misses 381
Table 14 Hesitation, Sag, or Stumble 382
Table 15 Backfire 383
Table 16 Lack of Power, Sluggishness, or Sponginess 384
Table 17 Poor Fuel Economy 385
Table 18 Rough, Unstable, Incorrect Idle, or Stalling 387
Table 19 Surges or Chuggles 389
Table 20 Preliminary Checks 390
Table 21 Intermittent 391
Table 22 No Start 392
Table 23 Hard Start 393
Table 24 Cuts Out or Misses 394
Table 25 Hesitation, Sag, or Stumble 395
Table 26 Backfire 396
Table 27 Lack of Power, Sluggishness, or Sponginess 397
Table 28 Poor Fuel Economy 398
Table 29 Rough, Unstable, Incorrect Idle, or Stalling 399
Table 30 Surges or Chuggles 400
1300YRM500-524158749(08-2003)-EN 411
toc 411
Single-Speed Powershift Transmission 411
Safety Precautions Maintenance and Repair 412
General 415
Description and Operation 415
General 415
Torque Converter 416
Description 416
Operation 416
Clutch Assemblies 418
Description 418
Operation 419
Hydraulic System 422
General 422
Control Valve 423
General 423
Clutch Pressure Regulator 424
Inching Spool Assembly 425
Direction Spool 425
Modulator Circuit 425
Torque Converter Regulator 425
Foot Directional Control Pedal 425
Foot Directional Control Pedal Start Circuit 426
Direction Control Lever 426
Differential 426
Oil Flow Diagrams 428
Neutral 428
Modulator Operation 428
Forward 432
Forward-Inching 432
1300YRM501-524158750(03-2004)-EN 439
toc 439
Single-Speed Powershift Transmission 439
Safety Precautions Maintenance and Repair 440
General 443
Transmission Removal 447
Torque Converter and Housing Repair 447
Remove 447
Install 447
Transmission Pump Repair 449
Remove 449
Repair 449
Install 449
Front Cover and Pump Drive Repair 449
Remove and Disassemble 449
Assemble and Install 449
Clutch Assemblies Repair 452
Remove and Disassemble 455
Inspect 457
Assemble 458
Install 463
Differential Repair 464
Remove and Disassemble 464
Inspect 465
Assemble and Install 466
Control Valve Repair 473
Remove and Disassemble 473
Inspect 473
Assemble and Install 473
Foot Directional Control Pedal Repair 476
Remove and Disassemble 476
Assemble and Install 476
Direction Control Lever Repair 479
Remove and Disassemble 479
Assemble and Install 479
Stall Test 480
Inching/Brake Pedal Adjustment 481
Neutral Start Switch, Foot Directional Control Pedal Adjustment 485
Neutral Start Switch, Foot Directional Control Pedal Adjustment 486
Neutral Start Switch Test, Foot Directional Control Pedal 487
Oil Pressure Checks 487
Relief Valve for Transmission Pump Check, TEST PORT 1 487
Clutch Pressure Check, TEST PORTS 2 and 3 487
Torque Converter Regulator Check, TEST PORT 4 488
Lubrication Circuit Oil Pressure Check, TEST PORT 5 488
Modulator Pressure Check, TEST PORT 6 488
Troubleshooting 489
Troubleshooting – Pressure Tests 492
tables 439
Table 1 Adjustment of Shims for Pinion Assembly 466
Table 2 Ring and Pinion Tooth Contact Adjustment 467
Table 3 Stall Speeds 481
Table 4 Transmission Oil Pressures Test Ports 488
1300YRM717-524199506(07-2003)-EN 497
toc 497
Hydrostatic Transmission 497
Safety Precautions Maintenance and Repair 498
General 501
Hydrostatic Components 501
Location 501
Description 501
Theory of Operation 501
Features of the Hydrostatic Transmission 506
Travel Control 506
Dynamic Braking 506
Inching 506
Throttle-Up (Option) 506
Hydraulic Circuit 507
Loop 507
Charge 507
Control 507
Cooling 509
Repairs – General Information 511
Hydrostatic Transmission Fluid 511
Transmission Fluid Change Intervals 511
Operation Following Service or Repairs (Commissioning) 512
Towing the Lift Truck 512
Hydrostatic Transmission Repair 513
Remove 513
Clean and Inspect 515
Repairs 515
Install 518
Drive Axle Repair 519
Remove 519
Inspect 520
Install 521
Foot Directional Control Pedal Repair 522
Remove and Disassemble 522
Assemble and Install 522
Direction Control Lever Repair 525
Remove and Disassemble 525
Assemble and Install 525
Throttle-Up System Repair 526
Remove and Install 526
Switches 527
Module, Relays, and Fuse 528
Throttle Motor 528
Inching/Brake Pedal Adjustment 529
Variable Relief Valve Adjustment 529
Hydrostatic Pump Oil Pressure Check 530
Loop and Pilot Pressure Checks 531
Charge Pressure Check 531
Case Pressure Check 531
Axle Leakage 531
Inching Adjustment 532
Swashplate Positioning Cylinder Check and Adjustment 532
Throttle-Up System Checks 532
Check Switches 532
Check Throttle Motor 532
Check Control Module 533
Troubleshooting 534
Torque Specifications 542
tables 497
Table 1 Hydrostatic Transmission Oil 511
Table 2 Hydrostatic Transmission Pressure Tests 531
Table 3 Control Module Pin Voltages 533
1400YRM499-524158751(10-2004)-EN 545
toc 545
Drive Axle 545
Safety Precautions Maintenance and Repair 546
General 549
Description 549
Drive Axle Repair 549
Remove and Disassemble 549
Clean and Inspect 551
Assemble and Install 551
Torque Specifications 553
GP2 00-3 00RF/TF (GP040-060RG/TG/ZG) 553
GC040-065TF/RF 553
Troubleshooting 554
1600YRM316-524158752(03-2003)-EN 557
toc 557
Steering Axle 557
Safety Precautions Maintenance and Repair 558
General 561
Description 561
Steering Axle Assembly Repair 562
Remove 562
Install 562
Wheels and Hubs Repair 563
Remove and Disassemble 563
Clean 563
Assemble and Install 563
Spindles, Bearings, and Tie Rods Repair 565
Remove 565
Install 565
Steering Cylinder Repair 566
Remove and Disassemble 566
Clean and Inspect 566
Assemble and Install 566
Torque Specifications 567
Troubleshooting 568
1600YRM720-524158753(03-2006)-EN 573
toc 573
Steering Housing and Control Unit 573
Safety Precautions Maintenance and Repair 574
General 577
Description 577
Operation 578
Steering Wheel and Column Assembly Repair 579
Assembly Components, Remove 579
Steering Control Unit, Disassemble 584
Steering Control Unit, Clean 584
Steering Control Unit, Assemble 584
Assembly Components, Install 586
System Air Removal 587
Troubleshooting 588
1800YRM506-524158754(05-2005)-EN 591
toc 591
Brake System 591
Safety Precautions Maintenance and Repair 592
General 595
Description and Operation 595
Service Brakes 595
Master Cylinder 595
Parking Brake 597
Service Brakes Repair 597
Remove and Disassemble 597
Clean 599
Inspect 599
Assemble and Install 601
Adjust 605
Parking Brake Repair 605
Remove and Disassemble 605
Assemble and Install 605
Adjust 605
Master Cylinder Repair 607
Remove 607
Clean and Inspect 607
Repair 608
Install 610
Service Brakes Adjustment 610
Brake System Air Removal 611
Parking Brake Not Applied Switch Test 611
Parking Brake Switch Test (Foot Directional Control Pedal Only) 611
Inching/Brake Pedal Adjustment 612
Neutral Start Switch Adjustment, Foot Directional Control Pedal 616
Neutral Start Switch Adjustment, Foot Directional Control Pedal 617
Neutral Start Switch Test (Foot Directional Control Pedal) 618
Torque Specifications 618
GP2 00-3 00RF/TF (GP040-060RG/TG/ZG) 618
GC040-065RG/TG/ZG 618
Troubleshooting 618
1900YRM513-524158755(06-2004)-EN 625
toc 625
Hydraulic System 625
Safety Precautions Maintenance and Repair 626
General 629
Description 629
Hydraulic System 629
Gear Pump Assembly 629
Flow Control Valve 629
Relief Valve 629
Operation 636
Hydraulic System 636
Gear Pump 636
Flow Control Valve 636
Relief Valve 636
Gear Pump Assembly Repair 638
Remove and Disassemble 638
Assemble and Install 639
Steering Relief Pressure Check and Adjustment 639
Gear Pump Flow Check 640
Troubleshooting 640
2000YRM516-524158756(12-2003)-EN 645
toc 645
Main Control Valve 645
Safety Precautions Maintenance and Repair 646
General 649
Description 649
Operation 650
Lift Section 650
Tilt Section 650
Tilt Backward 650
Tilt Forward 650
Relief Valve 654
Main Control Valve Repair 655
Remove 655
Disassemble 655
Clean and Inspect 655
Assemble 655
Install 661
Pressure Relief Valve Check and Adjustment 662
Primary Relief Valve 662
Secondary Relief Valve 662
Troubleshooting 663
2100YRM103-524150790(03-2005)-EN 667
toc 667
Tilt Cylinders 667
Safety Precautions Maintenance and Repair 668
General 671
Description 671
Tilt Cylinder Repair 671
Remove 671
Disassemble 671
Clean 671
Assemble 671
Tilt Cylinders With O-Ring or Single-Lip Seals 671
Tilt Cylinders 672
Install 674
Tilt Cylinder Leak Check 676
Tilt Cylinder Stroke and Mast Tilt Angle Adjustment 677
Torque Specifications 677
Piston Rod Nut 677
Retainer 677
Troubleshooting 678
tables 667
Table 1 Movement Rates (Maximum) for Tilt Cylinders 676
2200YRM002-524150791(10-2003)-EN 683
toc 683
Alternator with Regulator 683
Safety Precautions Maintenance and Repair 684
General 687
Description 687
Alternator Repair 689
Alternator Type A 689
Remove and Disassemble 689
Clean 690
Assemble 690
Install 691
Alternator Type B 694
Remove and Disassemble 694
Clean 694
Assemble 695
Install 696
General Check and Adjustment 697
Low Output Check (Type A or Type B) 697
High Output Check (Type A or Type B) 699
Brushes Circuit Check 700
Delco Alternators 700
Motorola Alternators 701
Diodes Check 702
Diode Bridge Check 702
Delco and Leece-Neville Alternators 702
Motorola Alternators 702
Rotor Field Winding Check 703
Stator Windings Check 704
Voltage Regulator Check 704
Troubleshooting 704
2200YRM106-524150792(03-2003)-EN 709
toc 709
Starter 709
Safety Precautions Maintenance and Repair 710
General 713
Description and Operation 713
Starter Repair 715
Remove 715
Disassemble 716
Clean 716
Assemble 716
Install 717
General Checks and Adjustments 717
Troubleshooting 720
2200YRM514-524158757(01-2004)-EN 725
toc 725
Instrument Cluster 725
Safety Precautions Maintenance and Repair 726
General 729
Description 729
Instrument Cluster Display Panel, Internal Combustion Lift Truck 729
Instrument Cluster Display Panel, Electric Lift Truck Models 736
Optional Basic Display Panel 736
Features of the Optional Basic Display Panel 736
Description of Features on the Optional Basic Display Panel 736
Standard Display Panel 737
Features of the Standard Display Panel 737
Description of Features on the Standard Display Panel 737
Premium Display Panel 738
Features on the Premium Display Panel 738
Description of Features on the Premium Display Panel 739
Curtis 1215 Display Panel 741
Description and Features 741
Operation 742
Cluster-Type Display Panel (Internal Combustion) Replacement 743
Remove 743
Install 743
Cluster Display Panel (Electric Lift Truck) Replacement 746
Curtis 1215 Display Panel Replacement 751
Remove 751
Install 751
tables 725
Table 1 Instrument Cluster, Internal Combustion 730
2200YRM524-524158758(12-2003)-EN 755
toc 755
Electrical System 755
Safety Precautions Maintenance and Repair 756
General 759
Description 759
Starting System 759
Ignition System 759
Charging System 760
Starter Repair 761
Remove and Disassemble 761
Assemble and Install 761
Coil Replacement 763
Distributor Repair 764
Remove and Disassemble 764
Assemble and Install 764
Distributor Repair 766
Remove and Disassemble 766
Assemble and Install 768
Alternator Repair 768
Remove and Disassemble 768
Assemble and Install 769
General Checks and Adjustments 770
Starter Checks 770
Operation, Check 770
Brush Holder, Check 771
Armature, Check 771
Field Windings, Check 771
Clutch and Bearing, Check 771
Ignition System Check and Adjustment 772
Engine Timing, Adjust 772
Spark Plugs, Check 772
Charging Circuit Checks 773
Low Output, Check 773
High Output, Check 774
Diodes, Check 774
Rotor Field Winding, Check 775
Stator Windings, Check 775
Brushes and Bearings, Check 775
Voltage Regulator, Check 775
Troubleshooting 776
2200YRM603-524158759(12-2003)-EN 781
toc 781
Microprocessor Spark Timing System (MSTS) 781
Safety Precautions Maintenance and Repair 782
General 785
Description 785
What MSTS Does 785
How MSTS Begins Operation 785
Operation 786
Distributor 786
Ignition Module 787
When Engine is Being Started 788
When Engine is Running 788
Manifold Absolute Pressure (MAP) Sensor 789
Engine Coolant Temperature (ECT) Sensor 790
MSTS Module Corrections 790
Initial Timing Connector 792
Governor System Operation 792
Troubleshooting 794
General 794
Tools and Test Equipment 795
MSTS 795
Test Description 795
Ignition System 797
Test Description 797
Electronic Spark Timing (EST) 800
Circuit Description 800
Test Description 801
Manifold Absolute Pressure (MAP) Sensor 804
Circuit Description 804
Test Description 804
Test 1 805
Test 2 806
Engine Coolant Temperature (ECT) Sensor 807
Circuit Description 807
Test Description 807
Distributor Repair 809
Remove 809
Disassemble 809
Inspect 810
Assemble 810
Install 810
Ignition Timing 810
Ignition Module Replacement 811
Test for a Fault 811
Replace 812
Sensing Coil Replacement 812
Test for a Fault 812
Replace 812
Ignition Coil Replacement 813
Test for a Fault 813
Remove 813
Install 813
MSTS Module Replacement 814
Remove 814
Install 814
ECT Sensor Replacement 814
MAP Sensor Replacement 815
tables 781
Table 1 MSTS Module Connections 792
Table 2 Voltage and Pressure for MAP Sensor Troubleshooting 805
Table 3 Pressure Conversion Chart 806
2200YRM765-524153916(03-2003)-EN 819
toc 819
Microprocessor Spark Timing System (MSTS) 819
Safety Precautions Maintenance and Repair 820
General 823
Description 824
What MSTS Does 824
How MSTS Begins Operation 824
Operation 825
Distributor 825
Ignition Coil 826
Ignition Module 826
When Engine Is Being Started 826
When Engine Is Running 828
Manifold Absolute Pressure (MAP) Sensor 829
Engine Coolant Temperature (ECT) Sensor 829
MSTS Module Corrections 830
Troubleshooting 831
General 831
Tools and Test Equipment 833
MSTS 834
Troubleshooting Procedure 834
Where to Start 834
Visual/Physical Inspection 834
Knowledge/Tools Required 834
Damage From Static Discharge (Static Electricity) 835
Troubleshooting Information 835
Malfunction Indicator Lamp (MIL) 835
Connecting CodeMate Tester 835
Reading Diagnostic Trouble Codes (DTC) 836
Clearing Diagnostic Trouble Codes (DTC’s) 837
On-Board Diagnostic (OBD) System Check 837
Test Description 837
No Malfunction Indicator Lamp 839
Circuit Description 839
Test Description 839
No DTC-12, Malfunction Indicator Lamp ON 841
Circuit Description 841
Test Description 841
Starter Rotates Engine, Engine Does Not Run 842
Test Description 842
DTC-14 Engine Coolant Temperature (ECT) (Low Temperature Indicat 846
Circuit Description 846
Test Description 846
DTC-15 Engine Coolant Temperature Sensor (ECT) (High Temperature 848
Circuit Description 848
Test Description 848
DTC-34 Manifold Absolute Pressure (MAP) Sensor 850
Circuit Description 850
Test Description 850
DTC-41 Electronic Spark Timing (EST) Open Circuit 853
Circuit Description 853
Test Description 853
DTC-42 Electronic Spark Timing (EST) Grounded Circuit 855
Circuit Description 855
Test Description 855
DTC-51 MSTS Failure 857
Circuit Description 857
Distributor Repair 857
Remove 857
Disassemble 858
Inspect 858
Assemble 858
Install 859
Ignition Timing 859
Ignition Module Repair 860
Test For Fault 860
Replace 860
Sensing Coil Repair 861
Test For Fault 861
Replace 861
Ignition Coil Repair 862
Test For Fault 862
Remove 862
Install 862
MSTS Module Repair 863
Remove 863
Install 863
ECT Sensor Replacement 863
MAP Sensor Replacement 864
tables 819
Table 1 MSTS Module Connections 832
Table 2 Pressure Conversion Chart 833
Table 3 MSTS Diagnostic Codes 835
2200YRM1090-524208009(04-2005)-EN 867
toc 867
Electronic Control Module (ECM) Diagnostic Troubleshooting 867
Safety Precautions Maintenance and Repair 868
General 877
Description of ECM Based Diagnostics 877
Definition of Terms 877
Diagnostics Overview of the Spectrum Fuel System 877
Malfunction Indicator Lamp (MIL) 877
Spectrum Diagnostic Trouble Codes (DTC) 878
Using a Laptop Computer to Diagnose the Spectrum System 878
Installing the Spectrum Diagnostic Software 878
Connecting a Laptop Computer to the Spectrum System 878
Diagnostic Communication Error 879
Diagnostic Trouble Codes 879
Checking Diagnostic Trouble Codes 880
Clearing Diagnostic Trouble Codes 880
DATA Stream 880
Reading Sensor and Actuator Values 880
Graphing and Data Logging 881
Ignition System Test 882
Disabling Ignition Outputs 882
Injector Test 883
Disabling Injectors 883
Throttle Test 884
Using a Diagnostic Jumper to Diagnose the ECI System 885
On-Board Diagnostics System Check/Malfunction Indicator Lamp 886
Circuit Description 886
Preliminary and Intermittent Checks 889
GM 3 0L Wiring Schematics and Connectors 891
GM 3 0L Diagnostic Trouble Codes 905
DTC 111 – IAT High Voltage Motorola® TMAP 905
Circuit Description 905
Conditions for Setting the DTC 905
DTC 112 – IAT Low Voltage Motorola® TMAP 908
Circuit Description 908
Conditions for Setting the DTC 908
DTC 113 – IAT Higher Than Expected 1 Motorola® TMAP 911
Circuit Description 911
Conditions for Setting the DTC 911
Diagnostic Aids 911
DTC 114 – IAT Higher Than Expected 2 Motorola® TMAP 912
Circuit Description 912
Conditions for Setting the DTC 912
Diagnostic Aids 912
DTC 115 – Oil Pressure Low 913
Circuit Description 913
Conditions for Setting the DTC 913
DTC 121 – ECT Voltage High 916
Circuit Description 916
Conditions for Setting the DTC 917
DTC 122 – ECT Voltage Low 920
Circuit Description 920
Conditions for Setting the DTC 920
DTC 123 – ECT Higher Than Expected 1 922
Circuit Description 922
Conditions for Setting the DTC 922
DTC 124 – ECT Higher Than Expected 2 924
Circuit Description 924
Conditions for Setting the DTC 924
DTC 131 – MAP High Pressure Motorola® TMAP 926
Circuit Description 926
Conditions for Setting the DTC 926
Diagnostic Aids 926
DTC 132 – MAP Low Voltage Motorola® TMAP 928
Circuit Description 928
Conditions for Setting the DTC 928
DTC 134 – BP High Pressure Motorola® TMAP 932
Circuit Description 932
Conditions for Setting the DTC 932
DTC 135 – BP Low Pressure Motorola® TMAP 934
Circuit Description 934
Conditions for Setting the DTC 934
DTC 142 – Crank Sync Noise 938
Circuit Description 938
Conditions for setting the DTC 938
DTC 143 – Never Crank Synced At Start 941
Circuit Description 941
Conditions for Setting the DTC 941
DTC 144 – Camshaft Sensor Loss 944
Circuit Description 944
Conditions for Setting the DTC 944
DTC 145 – Camshaft Sensor Noise 947
Circuit Description 947
Conditions for Setting the DTC 947
DTC 211 – Closed Loop Multiplier High (LPG) 950
Circuit Description 950
Conditions for Setting the DTC 950
Diagnostic Aids 950
DTC 212 – HO 2 S Open/Inactive 952
Circuit Description 952
Conditions for Setting the DTC 952
DTC 221 – Closed Loop Multiplier High (Gasoline) 956
Circuit Description 956
Conditions for Setting the DTC 956
Diagnostic Aids 957
DTC 222 – Closed Loop Multiplier Low (Gasoline) 958
Circuit Description 958
Conditions for Setting the DTC 958
Diagnostic Aids 958
DTC 224 – Closed Loop Multiplier Low (LPG) 960
Circuit Description 960
Conditions for Setting the DTC 960
Diagnostic Aids 961
DTC 241 – Adaptive Lean Fault (High Limit-Gasoline) 962
Circuit Description 962
Conditions for Setting the DTC 962
Diagnostic Aids 963
DTC 242 – Adaptive Rich Fault (Low Limit-Gasoline) 966
Circuit Description 966
Conditions for Setting the DTC 966
Diagnostic Aids 966
DTC 243 – Adaptive Learn High (LPG) 968
Circuit Description 968
Conditions for Setting the DTC 968
Diagnostic Aids 968
DTC 244 – Adaptive Learn Low (LPG) 972
Circuit Description 972
Conditions for Setting the DTC 972
Diagnostic Aids 972
DTC 261 – System Voltage High 974
Circuit Description 974
Conditions for Setting the DTC 974
DTC 262 – System Voltage Low 976
Circuit Description 976
Conditions for Setting the DTC 976
DTC 411 – Injector Driver 1 Open 979
Circuit Description 979
Conditions for Setting the DTC 979
DTC 412 – Injector Driver 1 Shorted 982
Circuit Description 982
Conditions for Setting the DTC 982
DTC 511 – COP Failure 985
Circuit Description 985
Conditions for Setting the DTC 985
DTC 512 – Invalid Interrupt 987
Circuit Description 987
Conditions for Setting the DTC 987
DTC 513 – A/D Loss 989
Circuit Description 989
Conditions for Setting the DTC 989
DTC 514 – RTI 1 Loss 991
Circuit Description 991
Conditions for Setting the DTC 991
DTC 515 – Flash Checksum Invalid 993
Circuit Description 993
Conditions for Setting the DTC 993
DTC 516 – Ram Failure 995
Circuit Description 995
Conditions for Setting the DTC 995
DTC 531 – External 5V Ref Lower Than Expected 997
Circuit Description 997
Conditions for Setting the DTC 997
DTC 532 – External 5V Ref Higher Than Expected 1000
Circuit Description 1000
Conditions for Setting the DTC 1000
DTC 555 – RTI 2 Loss 1002
Circuit Description 1002
Conditions for Setting the DTC 1002
DTC 556 – RTI 3 Loss 1004
Circuit Description 1004
Conditions for Setting the DTC 1004
DTC 611 – FPP High Voltage 1006
Circuit Description 1006
Conditions for Setting the DTC 1006
DTC 612 – FPP Low Voltage 1009
Circuit Description 1009
Conditions for Setting the DTC 1009
DTC 631 – TPS1 Signal Voltage High 1013
Circuit Description 1013
Conditions for Setting the DTC 1013
DTC 632 – TPS1 Signal Voltage Low 1016
Circuit Description 1016
Conditions for Setting the DTC 1016
DTC 638 – Throttle Unable To Close 1018
Circuit Description 1018
Conditions for Setting the DTC 1018
Diagnostic Aids 1018
DTC 651 – Maximum Govern Speed Override 1022
Circuit Description 1022
Conditions for Setting the DTC 1022
Diagnostic Aids 1022
DTC 652 – Fuel Rev Limit 1024
Circuit Description 1024
Conditions for Setting the DTC 1024
Diagnostic Aids 1024
DTC 653 – Spark Rev Limit 1027
Circuit Description 1027
Conditions for Setting the DTC 1027
Diagnostic Aids 1027
GM 4 3L Wiring Schematics and Connectors 1030
GM 4 3L Diagnostic Trouble Codes 1047
DTC 111 – IAT High Voltage Bosch® TMAP 1047
Circuit Description 1047
Conditions for Setting the DTC 1047
DTC 111 – IAT High Voltage Motorola® TMAP 1050
Circuit Description 1050
Conditions for Setting the DTC 1050
DTC 112 – IAT Low Voltage Bosch® TMap 1052
Circuit Description 1052
Conditions for Setting the DTC 1052
DTC 112 – IAT Low Voltage Motorola® TMAP 1055
Circuit Description 1055
Conditions for Setting the DTC 1055
DTC 113 – IAT Higher Than Expected 1 Bosch® TMAP 1058
Circuit Description 1058
Conditions for Setting the DTC 1058
Diagnostic Aids 1058
DTC 113 – IAT Higher Than Expected 1 Motorola® TMAP 1059
Circuit Description 1059
Conditions for Setting the DTC 1059
Diagnostic Aids 1059
DTC 114 – IAT Higher Than Expected 2 Bosch® TMAP€ 1060
Circuit Description 1060
Conditions for Setting the DTC 1060
Diagnostic Aids 1060
DTC 114 – IAT Higher Than Expected 2 Motorola® TMAP 1061
Circuit Description 1061
Conditions for Setting the DTC 1061
Diagnostic Aids 1061
DTC 115 – Oil Pressure Low 1062
Circuit Description 1062
Conditions for Setting the DTC 1062
DTC 121 – ECT Voltage High 1065
Circuit Description 1065
Conditions for Setting the DTC 1066
DTC 122 – ECT Voltage Low 1068
Circuit Description 1068
Conditions for Setting the DTC 1068
DTC 123 – ECT Higher Than Expected 1 1071
Circuit Description 1071
Conditions for Setting the DTC 1071
DTC 124 – ECT Higher Than Expected 2 1073
Circuit Description 1073
Conditions for Setting the DTC 1073
DTC 131 – MAP High Pressure Bosch® TMAP 1074
Circuit Description 1074
Conditions for Setting the DTC 1074
Diagnostic Aids 1074
DTC 131 – MAP High Pressure Motorola® TMAP 1078
Circuit Description 1078
Conditions for Setting the DTC 1078
Diagnostic Aids 1078
DTC 132 – MAP Low Voltage Bosch® TMAP 1081
Circuit Description 1081
Conditions for Setting the DTC 1081
DTC 132 – MAP Low Voltage Motorola® TMAP 1084
Circuit Description 1084
Conditions for Setting the DTC 1084
DTC 134 – BP High Pressure Bosch® TMAP 1088
Circuit Description 1088
Conditions for Setting the DTC 1088
DTC 134 – BP High Pressure Motorola® TMAP 1090
Circuit Description 1090
Conditions for Setting the DTC 1090
DTC 135 – BP Low Pressure Bosch® TMAP 1092
Circuit Description 1092
Conditions for Setting the DTC 1092
DTC 135 – BP Low Pressure Motorola® TMAP 1096
Circuit Description 1096
Conditions for Setting the DTC 1096
DTC 142 – Crank Sync Noise 1100
Circuit Description 1100
Conditions for setting the DTC 1100
DTC 143 – Never Crank Synced At Start 1103
Circuit Description 1103
Conditions for Setting the DTC 1103
DTC 144 – Camshaft Sensor Loss 1106
Circuit Description 1106
Conditions for Setting the DTC 1106
DTC 145 – Camshaft Sensor Noise 1109
Circuit Description 1109
Conditions for Setting the DTC 1109
DTC 211 – Closed Loop Multiplier High (LPG) 1112
Circuit Description 1112
Conditions for Setting the DTC 1112
Diagnostic Aids 1112
DTC 212 – HO 2 S Open/Inactive 1114
Circuit Description 1114
Conditions for Setting the DTC 1114
DTC 221 – Closed Loop Multiplier High (Gasoline) 1118
Circuit Description 1118
Conditions for Setting the DTC 1118
Diagnostic Aids 1118
DTC 222 – Closed Loop Multiplier Low (Gasoline) 1120
Circuit Description 1120
Conditions for Setting the DTC 1120
Diagnostic Aids 1121
DTC 224 – Closed Loop Multiplier Low (LPG) 1122
Circuit Description 1122
Conditions for Setting the DTC 1122
Diagnostic Aids 1123
DTC 241 – Adaptive Lean Fault (High Limit-Gasoline) 1124
Circuit Description 1124
Conditions for Setting the DTC 1124
Diagnostic Aids 1125
DTC 242 – Adaptive Rich Fault (Low Limit-Gasoline) 1128
Circuit Description 1128
Conditions for Setting the DTC 1128
Diagnostic Aids 1129
DTC 243 – Adaptive Learn High (LPG) 1131
Circuit Description 1131
Conditions for Setting the DTC 1131
Diagnostic Aids 1132
DTC 244 – Adaptive Learn Low (LPG) 1134
Circuit Description 1134
Conditions for Setting the DTC 1134
Diagnostic Aids 1135
DTC 261 – System Voltage High 1136
Circuit Description 1136
Conditions for Setting the DTC 1136
DTC 262 – System Voltage Low 1138
Circuit Description 1138
Conditions for Setting the DTC 1138
DTC 511 – COP Failure 1141
Circuit Description 1141
Conditions for Setting the DTC 1141
DTC 512 – Invalid Interrupt 1143
Circuit Description 1143
Conditions for Setting the DTC 1143
DTC 513 – A/D Loss 1145
Circuit Description 1145
Conditions for Setting the DTC 1145
DTC 514 – RTI 1 Loss 1147
Circuit Description 1147
Conditions for Setting the DTC 1147
DTC 515 – Flash Checksum Invalid 1149
Circuit Description 1149
Conditions for Setting the DTC 1149
DTC 516 – Ram Failure 1151
Circuit Description 1151
Conditions for Setting the DTC 1151
DTC 531 – External 5V Ref Lower Than Expected 1153
Circuit Description 1153
Conditions for Setting the DTC 1153
DTC 532 – External 5V Ref Higher Than Expected 1156
Circuit Description 1156
Conditions for Setting the DTC 1156
DTC 555 – RTI 2 Loss 1158
Circuit Description 1158
Conditions for Setting the DTC 1158
DTC 556 – RTI 3 Loss 1160
Circuit Description 1160
Conditions for Setting the DTC 1160
DTC 611 – FPP High Voltage 1162
Circuit Description 1162
Conditions for Setting the DTC 1162
DTC 612 – FPP Low Voltage 1166
Circuit Description 1166
Conditions for Setting the DTC 1166
DTC 631 – TPS1 Signal Voltage High 1170
Circuit Description 1170
Conditions for Setting the DTC 1170
DTC 632 – TPS1 Signal Voltage Low 1173
Circuit Description 1173
Conditions for Setting the DTC 1173
DTC 638 – Throttle Unable To Close 1176
Circuit Description 1176
Conditions for Setting the DTC 1176
Diagnostic Aids 1177
DTC 651 – Maximum Govern Speed Override 1179
Circuit Description 1179
Conditions for Setting the DTC 1179
Diagnostic Aids 1179
DTC 652 – Fuel Rev Limit 1182
Circuit Description 1182
Conditions for Setting the DTC 1182
Diagnostic Aids 1182
DTC 653 – Spark Rev Limit 1184
Circuit Description 1184
Conditions for Setting the DTC 1184
Diagnostic Aids 1184
Wire Harness Repair 1187
On Vehicle Service Wiring Harness Repair 1187
Connectors and Terminals 1187
Twisted/Shielded Cable Repair 1188
Twisted Leads Repair 1189
Micro-Pack 1190
Metri-Pack 1190
Remove 1190
Weather-Pack 1192
Weather-Pack Terminal Repair 1192
tables 867
Table 1 OBD System Check 887
Table 2 Preliminary Checks 889
Table 3 Intermittent Checks 890
Table 4 Communication Port C002 891
Table 5 Coil Connector C003 891
Table 6 Fuel System Interface C004 891
Table 7 Oil Pressure Connector C005 892
Table 8 Distributor Connector C006 892
Table 9 Magnetic Pickup Connector C007 892
Table 10 Heated Oxygen Sensor C008 892
Table 11 Throttle Position Sensor Connector C009 893
Table 12 Foot Pedal Position Connector C010 893
Table 13 Governor Motor Connector C011 893
Table 14 TMAP Connector C012 893
Table 15 Starter Solenoid C013 894
Table 16 Engine Coolant Temperature C014 894
Table 17 Battery Connector C015 894
Table 18 Alternator Connection C016 894
Table 19 Battery Connector C017 894
Table 20 Alternator Connector C018 895
Table 21 Instrument Panel Connector C019 895
Table 22 Instrument Panel Connector C020 895
Table 23 Instrument Panel Connector C021 896
Table 24 Fuel Trim Valve Connector C022 896
Table 25 Fuel Lockoff Connector C023 896
Table 26 Pressure Trim Valve Connector C024 897
Table 27 Throttle Body Injector Connector C025 897
Table 28 Relay and Fuse Center 897
Table 29 DTC 111 – IAT Voltage High (Motorola® TMAP) 906
Table 30 DTC 112 – IAT Low Voltage (Motorola® TMAP) 909
Table 31 DTC 115 – Oil Pressure Low 914
Table 32 Temperature Resistance 916
Table 33 DTC 121 – ECT VOLTAGE HIGH 917
Table 34 DTC 122 – ECT Voltage Low 921
Table 35 DTC 123 – ECT Higher Than Expected 1 923
Table 36 DTC 124 – ECT Higher Than Expected 2 925
Table 37 DTC 131 – MAP HIGH PRESSURE (Motorola® TMAP) 927
Table 38 DTC 132 – MAP Low Voltage (Motorola® TMAP) 929
Table 39 DTC 134 – BP High Pressure (Motorola® TMAP) 933
Table 40 DTC 135 – BP Low Pressure (Motorola® TMAP) 934
Table 41 DTC 142 – Crank Sync Noise 938
Table 42 DTC 143 – Never Crank Synced At Start 941
Table 43 DTC 144 – Camshaft Sensor Loss 944
Table 44 DTC 145 – Camshaft Sensor Noise 947
Table 45 DTC 211 – Closed Loop Multiplier High (LPG) 951
Table 46 DTC 212 – HO 2 S Open/Inactive 953
Table 47 DTC 221 – Closed Loop Multiplier High (Gasoline) 957
Table 48 DTC 222 – Closed Loop Multiplier Low (Gasoline) 960
Table 49 DTC 224 – Closed Loop Multiplier Low (LPG) 962
Table 50 DTC 241 – Adaptive Lean Fault (High Limit-Gasoline) 964
Table 51 DTC 242 – Adaptive Rich Fault (Low Limit-Gasoline) 967
Table 52 DTC 243 – Adaptive Learn High (LPG) 970
Table 53 DTC 244 – Adaptive Learn Low (LPG) 973
Table 54 DTC 261 – System Voltage High 975
Table 55 DTC 262 – System Voltage Low 977
Table 56 DTC 411 – Injector Driver 1 Open 980
Table 57 DTC 412 – Injector Driver 1 Shorted 983
Table 58 DTC 511 – COP Failure 986
Table 59 DTC 512 – Invalid Interrupt 988
Table 60 DTC 513 – A/D Loss 990
Table 61 DTC 514 – RTI 1 Loss 992
Table 62 DTC 515 – Flash Checksum Invalid 994
Table 63 DTC 516 – Ram Failure 996
Table 64 DTC 531 – External 5V Ref Lower Than Expected 998
Table 65 DTC 532 – External 5 V Ref Higher Than Expected 1000
Table 66 DTC 555 – RTI 2 Loss 1003
Table 67 DTC 556 – RTI 3 Loss 1005
Table 68 DTC 611 – FPP High Voltage 1006
Table 69 DTC 612 – FPP Low Voltage 1010
Table 70 DTC 631 – TPS1 Signal Voltage High 1014
Table 71 DTC 632 – TPS1 Signal Voltage Low 1017
Table 72 DTC 638 – Throttle Unable To Close 1019
Table 73 DTC 651 – Maximum Govern Speed Override 1023
Table 74 DTC 652 – Fuel Rev Limit 1025
Table 75 DTC 653 – Spark Rev Limit 1028
Table 76 Communication Port C002 1030
Table 77 Injector Connector C003 1030
Table 78 Injector Connector C004 1030
Table 79 Oil Pressure Connector C005 1031
Table 80 Throttle Position Sensor 1 Connector C006 1031
Table 81 Foot Pedal Position Connector C006A 1031
Table 82 Coil Connector C007 1031
Table 83 Module Connector C008 1032
Table 84 Crank Sensor Connector C009 1032
Table 85 EGO Sensor Connector C010 1032
Table 86 Cam Connector C011 1032
Table 87 Throttle Connector C012 1033
Table 88 Bosch TMAP Connector C013 (Gasoline Fuel System Only) 1033
Table 89 Motorola TMAP Connector C013 (LPG Fuel System Only) 1033
Table 90 Starter Solenoid Connector C014 1033
Table 91 ECT Connector C015 1034
Table 92 Starter Relay C016 1034
Table 93 Power Relay C017 1034
Table 94 Fuel Pump Relay C018 1034
Table 95 Battery Connector C019 1034
Table 96 Alternator Connector C020 1034
Table 97 Alternator Connector C021 1035
Table 98 Instrument Panel Connector C022 1035
Table 99 Instrument Panel Connector C023 1035
Table 100 Instrument Panel Connector C024 1036
Table 101 Fuel Trim Valve Connector C025 1036
Table 102 Fuel Lockoff Connector C026 1036
Table 103 Pressure Trim Valve Connector C027 1037
Table 104 Injector 1 Connector C028 1037
Table 105 Injector 2 Connector C029 1037
Table 106 Injector 3 Connector C030 1037
Table 107 Injector 4 Connector C031 1038
Table 108 Injector 5 Connector C032 1038
Table 109 Injector 6 Connector C033 1038
Table 110 Relay and Fuse Center 1039
Table 111 DTC 111 – IAT Voltage High (Bosch® TMAP) 1048
Table 112 DTC 111 – IAT Voltage High (Motorola® TMAP) 1051
Table 113 DTC 112 – IAT Low Voltage (Bosch® TMAP) 1053
Table 114 DTC 112 – IAT Low Voltage (Motorola® TMAP) 1056
Table 115 DTC 115 – Oil Pressure Low 1063
Table 116 Temperature Resistance 1065
Table 117 DTC 121 – ECT VOLTAGE HIGH 1066
Table 118 DTC 122 – ECT Voltage Low 1069
Table 119 DTC 123 – ECT Higher Than Expected 1 1072
Table 120 DTC 124 – ECT Higher Than Expected 2 1074
Table 121 DTC 131 – MAP High Pressure (Bosch® TMAP) 1075
Table 122 DTC 131 – MAP HIGH PRESSURE (Motorola® TMAP) 1079
Table 123 DTC 132 – MAP Low Voltage (Bosch® TMAP) 1082
Table 124 DTC 132 – MAP Low Voltage (Motorola® TMAP) 1085
Table 125 DTC 134 – BP High Pressure (Bosch® TMAP) 1089
Table 126 DTC 134 – BP High Pressure (Motorola® TMAP) 1091
Table 127 DTC 135 – BP Low Pressure (Bosch® TMAP) 1092
Table 128 DTC 135 – BP Low Pressure (Motorola® TMAP) 1096
Table 129 DTC 142 – Crank Sync Noise 1100
Table 130 DTC 143 – Never Crank Synced At Start 1103
Table 131 DTC 144 – Camshaft Sensor Loss 1106
Table 132 DTC 145 – Camshaft Sensor Noise 1109
Table 133 DTC 211 – Closed Loop Multiplier High (LPG) 1113
Table 134 DTC 212 – HO 2 S Open/Inactive 1115
Table 135 DTC 221 – Closed Loop Multiplier High (Gasoline) 1119
Table 136 DTC 222 – Closed Loop Multiplier Low (Gasoline) 1122
Table 137 DTC 224 – Closed Loop Multiplier Low (LPG) 1124
Table 138 DTC 241 – Adaptive Lean Fault (High Limit-Gasoline) 1126
Table 139 DTC 242 – Adaptive Rich Fault (Low Limit-Gasoline) 1129
Table 140 DTC 243 – Adaptive Learn High (LPG) 1132
Table 141 DTC 244 – Adaptive Learn Low (LPG) 1135
Table 142 DTC 261 – System Voltage High 1137
Table 143 DTC 262 – System Voltage Low 1139
Table 144 DTC 511 – COP Failure 1142
Table 145 DTC 512 – Invalid Interrupt 1144
Table 146 DTC 513 – A/D Loss 1146
Table 147 DTC 514 – RTI 1 Loss 1148
Table 148 DTC 515 – Flash Checksum Invalid 1150
Table 149 DTC 516 – Ram Failure 1152
Table 150 DTC 531 – External 5V Ref Lower Than Expected 1154
Table 151 DTC 532 – External 5 V Ref Higher Than Expected 1156
Table 152 DTC 555 – RTI 2 Loss 1159
Table 153 DTC 556 – RTI 3 Loss 1161
Table 154 DTC 611 – FPP High Voltage 1163
Table 155 DTC 612 – FPP Low Voltage 1167
Table 156 DTC 631 – TPS1 Signal Voltage High 1171
Table 157 DTC 632 – TPS1 Signal Voltage Low 1174
Table 158 DTC 638 – Throttle Unable To Close 1177
Table 159 DTC 651 – Maximum Govern Speed Override 1180
Table 160 DTC 652 – Fuel Rev Limit 1183
Table 161 DTC 653 – Spark Rev Limit 1185
2200YRM1097-524208014(06-2006)-EN 1197
toc 1197
High Voltage Switch (HVS) Ignition 1197
Safety Precautions Maintenance and Repair 1198
Description 1201
Distributor Ignition (DI) System 1201
Crankshaft Position (CKP) Sensor 1201
Camshaft Position (CMP) Sensor 1201
Ignition Coil and Ignition Control Module (ICM) 1201
Secondary Ignition Components 1201
Spark Plugs and Wires 1201
Spark Plug Wire Inspection 1201
Spark Plug Wire Replacement 1201
Remove 1201
Install 1202
Spark Plug Inspection 1202
Usage 1202
Inspection 1202
Visual Inspection 1204
Spark Plug Replacement 1204
Remove 1204
Install 1204
Distributor Repair 1205
Inspect 1205
Overhaul 1205
Disassemble 1205
Assemble 1208
Replace 1208
Remove 1208
Install Procedure 1 1210
Install Procedure 2 1211
Ignition Coil Replacement 1212
Remove 1212
Install 1212
Ignition Control Module Replacement 1214
Remove 1214
Install 1214
Camshaft Position (CMP) Sensor Replacement 1214
Remove 1214
Install 1216
Crankshaft Position (CKP) Sensor Replacement 1216
Remove 1216
Install 1216
Wire Harness Repair 1218
On Vehicle Service Wiring Harness Repair 1218
Connectors and Terminals 1218
Twisted/Shielded Cable Repair 1219
Twisted Leads Repair 1220
Micro-Pack 1220
Metri-Pack 1221
Remove 1221
Weather-Pack 1223
Weather-Pack Terminal Repair 1223
Specifications and Special Tools 1224
System Diagnosis 1226
tables 1197
Table 1 Ignition System Specifications 1224
Table 2 Fastener Tightening Specifications 1225
Table 3 Special Tools 1225
Table 4 Distributor Ignition (DI) 1226
4000YRM521-524158890(03-2006)-EN 1235
toc 1235
Mast 1235
Safety Precautions Maintenance and Repair 1236
General 1239
Description and Operation 1239
Carriages 1239
Mast Mounts 1241
Two-Stage Mast, Limited Free-Lift (LFL) 1242
Description and Operation 1242
Two-Stage Mast, Full Free-Lift (FFL) 1244
Description and Operation 1244
Three-Stage Mast, Full Free-Lift (FFL) 1246
Description and Operation 1246
Four-Stage Mast 1248
Description and Operation 1248
Cylinder Cushion During Lifting Sequence 1252
Cylinder Cushion During Lowering Sequence 1253
4000YRM522-524158891(05-2004)-EN 1257
toc 1257
Mast 1257
Safety Precautions Maintenance and Repair 1258
General 1261
Safety Procedures When Working Near Mast 1261
Forks Repair 1263
Remove 1263
Install 1263
Carriages Repair 1264
Standard Carriage, Remove 1264
Hang-On Sideshift Carriage, Remove 1265
Standard Carriage and Hang-On Sideshift Carriage, Repair 1266
Standard Carriage, Install 1266
Hang-On Sideshift Carriage, Install 1267
Integral Sideshift Carriage 1267
Remove 1267
Clean and Inspect 1269
Repair 1269
Install 1270
Mast Repair 1270
Remove 1270
Two-Stage LFL and Two-Stage FFL Masts, Disassemble 1272
Three-Stage FFL Mast 1279
Disassemble 1279
Mast and Chains, Clean and Inspect 1282
Two-Stage LFL and Two-Stage FFL Mast, Assemble 1283
Three-Stage FFL Mast, Assemble 1284
Install 1285
Lift Cylinders Repair 1287
Main Lift Cylinders, Remove 1287
Free-Lift Cylinder, Remove 1287
Lift Cylinders, Disassemble 1288
Lift Cylinders, Assemble 1289
Main Lift Cylinders, Install 1291
Free-Lift Cylinder, Install 1291
Header Hose Arrangements 1292
Two-Stage LFL Mast, New Hose Install 1292
Two-Stage LFL Mast, Adjust Hoses After Installation 1297
Two-Stage FFL Mast, New Hose Install 1297
Two-Stage FFL Mast, Adjust Hoses After Installation 1302
Three-Stage FFL Mast, New Hose Install 1302
Three-Stage FFL Mast, Adjust Hoses After Installation 1314
Header Hose Arrangement 1315
Two-Stage LFL Mast, New Hose Install 1315
Two-Stage LFL Mast, Adjust Hoses After Installation 1319
Two-Stage FFL Mast, New Hose Install 1319
Two-Stage FFL Mast, Adjust Hoses After Installation 1324
Three-Stage FFL Mast, New Hose Install 1326
Three-Stage FFL Mast, Adjust Hoses After Install 1334
Lift and Tilt System Leak Check 1334
Lift Cylinders Leak Check 1334
Tilt Cylinders Leak Check 1334
Tilt Cylinders Adjustment 1335
Lift Chains Adjustment 1336
Mast Adjustment 1338
Carriage Adjustment 1340
Troubleshooting 1340
tables 1257
Table 1 Hook-Type Carriage Chain Adjustment 1337
Table 2 Pin-Type Carriage Chain Adjustment 1337
8000YRM231-524150797(12-2004)-EN 1345
toc 1345
Metric and Inch (SAE) Fasteners 1345
Safety Precautions Maintenance and Repair 1346
General 1349
Threaded Fasteners 1349
Nomenclature, Threads 1349
Strength Identification 1350
Cotter (Split) Pins 1350
Fastener Torque Tables 1355
Conversion Table 1357
tables 1345
Table 1 Bolts and Screws 1351
Table 2 Studs and Nuts 1352
Table 3 Torque Nuts 1353
Table 4 Torque Nuts with Nylon Insert 1354
Table 5 Torque Values for Metric Fasteners* 1355
Table 6 Torque Values for Inch Fasteners* 1356
Table 7 Conversion Table for Metric and English Units 1357
Table 8 Cotter Pin Dimensional Data 1358
Table 9 Cotter Pin Dimensional Data 1359
Table 10 Cotter Pin Dimensional Data 1360
Table 11 Cotter Pin Dimensional Data 1362
8000YRM707-524175194(07-2006)-EN 1365
toc 1365
Periodic Maintenance 1365
Safety Precautions Maintenance and Repair 1366
General 1371
Serial Number 1371
How to Move Disabled Lift Truck 1371
How to Tow Lift Truck 1371
How to Put Lift Truck on Blocks 1372
How to Raise Drive Tires 1372
How to Raise Steering Tires 1372
Maintenance Schedule 1373
Maintenance Procedures Every 8 Hours or Daily 1381
How to Make Checks With Engine Stopped 1381
Tires and Wheels 1382
Forks 1382
Adjust 1382
Remove 1383
Install 1384
Forks, Mast, and Lift Chains, Inspect 1384
Safety Labels 1385
Operator Restraint System 1385
Steering Column Latch 1385
Fuel, Oil, or Coolant Leaks, Check 1385
Drive Belt 1386
Intake Manifold Rubber Cap 1386
Powershift Transmission Oil Temperature 1386
Powershift Transmission Oil Level 1386
Hydrostatic Transmission Oil Level 1387
Engine Oil 1387
Hydraulic System 1387
Air Filter 1389
How to Make Checks With Engine Running 1389
Gauges, Indicator Lights, Horn, Fuses, and Relays 1389
Engine Oil Pressure 1389
Cooling System 1390
Steering System 1390
Service Brakes 1391
Brake Fluid Level 1391
Operation, Check 1391
Parking Brake 1391
Water Separator, Diesel Engine 1392
Drain Water from Water Separator 1392
Fuel Filter, Diesel Engine 1392
Diesel Fuel System, Remove Air 1392
Control Levers and Pedals 1392
Lift System, Operate 1393
Cooling System 1393
Maintenance Procedures Every 250 Hours or 6 Weeks 1394
Drive Belt 1394
GM 3 0L 1394
Engine Oil and Filter, GM 3 0L 1395
Fuel System, GM 3 0L 1395
Engine Speed, LPG Carburetor, GM (Aisan Open-Loop) 1395
Engine Speed, LPG Carburetor, GM 3 0L (Impco) 1395
Cooling System, Clean Debris From Radiator Core 1396
Air Filter 1396
GM 3 0L EPA Compliant Engine 1396
Maintenance Procedures Every 500 Hours or 3 Months 1396
Air Filter 1396
Drive Belt 1396
Mazda FE and F2 Engines 1396
Fan and Alternator Drive Belt 1396
Timing Belt 1397
Mazda XA and HA Diesel Engines 1397
Engine Oil and Filter 1397
Brake Fluid 1398
Hydraulic Tank Breather 1398
Battery 1398
Forks 1398
Lift Chains 1398
Lubrication 1398
Wear, Check 1398
Mast 1399
Steering Axle 1399
Fuel System 1399
Engine Speed, Diesel, Mazda XA and HA Engines 1399
Engine Speed, LPG Carburetor, Mazda (Aisan Open-Loop) 1400
Engine Speed, LPG Carburetor, Mazda (Impco) 1400
Hydraulic System 1401
Drain Tar From Aisan LPG Regulator 1402
Maintenance Procedures Every 1000 Hours or 6 Months 1402
Diesel Fuel System 1402
Fuel Filter, Replace 1402
Check Water Sensor 1403
Diesel Fuel System Air Removal 1403
Differential and Drive Axle, Powershift Transmission 1404
Drive Axle, Hydrostatic Transmission 1404
Valve Clearance, Check and Adjust 1404
Ignition System 1404
GM 3 0L LPG (IMPCO) 1404
GM 3 0L LPG (Aisan) 1404
Mazda FE and F2 1404
Mazda XA and HA Diesel Engines 1405
Aisan Regulator Pressure/Diaphragm and O-Ring Checks 1405
PCV Valve 1405
Integral Sideshift Carriage, Check Bearings 1405
Control Levers and Pedals 1406
Cooling System, GM 3 0L EPA Compliant Engine 1406
LPG Fuel Filter (IMPCO), GM 3 0L EPA Compliant Engine, Replace 1406
Inspect Engine Electrical System, Connectors, and FCVS Connectio 1407
Maintenance Procedures Every 2000 Hours or Yearly 1407
Hydraulic System 1407
Hydraulic Oil and Filter, Replace 1407
Powershift Transmission Oil and Filter 1408
Replace 1408
Hydrostatic Transmission Oil and Filter 1409
Replace 1409
Cooling System 1410
Service Brakes 1410
Differential 1410
Transmission Axle Shaft Oil (Hydrostatic Transmission) 1410
LPG Fuel Filter, Replace (Pre-2004) 1411
PCV Valve 1411
Fuel Filter, Replace (Aisan LPG System) 1411
Integral Sideshift Carriage, Replace Bearings 1411
Oxygen Sensor, GM 3 0L EPA Compliant Engine 1411
Air Filter Element, GM 3 0L EPA Compliant Engine 1412
Inspect Low Pressure Regulator (LPR) for Oil Buildup and Leaks 1412
Check Throttle Shaft for Sticking 1413
Inspect Exhaust Manifold and Piping for Leaks 1413
Test LPG Regulator Pressure 1413
Safety Procedures When Working Near Mast 1413
Hood Latch Check 1416
Lift Chain Adjustments 1417
Lift and Tilt System Leak Check 1419
Lift Cylinder, Leak Check 1419
Tilt Cylinder, Leak Check 1420
Charging Battery 1420
Diesel Engine Fuel Injector Check 1421
Welding Repairs 1421
Overhead Guard Changes 1422
Wheel and Tire Replacement 1422
Pneumatic Tire, Repair GLP/GDP20-30RF/TF Models 1422
Remove Wheels From Lift Truck 1422
Remove Wheel From Tire 1422
Remove Tire From Two-Piece Wheel 1423
Remove Tire From Three- and Four-Piece Wheels 1424
Install Wheel on Tire 1425
Install Tire on Three- or Four-Piece Wheels 1425
Install Three-Piece or Four-Piece Wheel in Tire 1426
Install Tire on Two-Piece Wheel 1427
Install Two-Piece Wheel in Tire 1427
Add Air to Pneumatic Tires 1428
Wheels, Install 1428
Dual Drive Wheels, Install 1428
Solid Rubber Tire, Change GLP/GDP20-30RF/TF Models 1429
Remove Wheel From Tire 1429
Install Wheel in Tire 1431
SIT Tire, Change 1432
Remove SIT Solid Tire From Wheel 1433
Install SIT Solid Tire on Wheel 1434
tables 1365
Table 1 Maintenance Schedule 1374
Table 2 Hook-Type Carriage Chain Adjustment 1418
Table 3 Pin-Type Carriage Chain Adjustment 1418
8000YRM708-524158901(10-2004)-EN 1437
toc 1437
Capacities and Specifications 1437
Safety Precautions Maintenance and Repair 1438
Lift Truck Weights 1441
Tire Pressure 1441
Tire Sizes 1442
Capacities 1442
Electrical System 1443
Gasoline/LPG 1443
Diesel 1443
Transmission Oil Pressures 1444
Hydraulic System 1444
Stall Speeds 1445
Engine Specifications 1445
Gasoline/LPG 1445
Diesel 1447
Mast Speeds 1448
Gasoline/LPG Engines (US Models) 1448
Diesel Engines (US Models) 1452
Gasoline/LPG Engines (US Models) 1454
Gasoline/LPG Engines (European Models) 1459
Diesel Engines (European Models) 1463
Torque Specifications 1465
Frame 1465
Brake System 1465
Mast 1465
Steering System 1465
Drive Axle 1465
Transmission and Differential 1466
Engine – Mazda FE and F2 1466
Engine – GM 3 0L 1467
Engine – Mazda XA and HA Diesel 1467
8000YRM709-524158902(10-2004)-EN 1471
toc 1471
Diagrams 1471
Safety Precautions Maintenance and Repair 1472

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