Hyster A917 (H40.00XM-12, H44.00XM-12, H48.00XM-12 Europe) Service Manual – PDF DOWNLOAD

Description

Hyster A917 (H40.00XM-12, H44.00XM-12, H48.00XM-12 Europe) Service Manual – PDF DOWNLOAD

DESCRIPTION:

Hyster A917 (H40.00XM-12, H44.00XM-12, H48.00XM-12 Europe) Service Manual – PDF DOWNLOAD

SAFETY PRECAUTIONS MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly
fastened, and that the load being lifted is balanced. Make sure the crane, cables, and
chains have the capacity to support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair
on electric lift trucks. Disconnect the battery ground cable on internal combustion lift
trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT
THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance
section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts
must meet or exceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before
using force to remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit whenmaking repairs,
or if the unit needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel
are flammable. Be sure to follow the necessary safety precautions when handling these
fuels and when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks
away from the area. Make sure the area is well ventilated.

TABLE OF CONTENTS:

Hyster A917 (H40.00XM-12, H44.00XM-12, H48.00XM-12 Europe) Service Manual – PDF DOWNLOAD

910072-1400SRM0046-(07-2007)-UK-EN....................................................................................................................................................................................................................................................   1
	toc...............................................................................................................................................................................................................................................................................   1
		Differential..................................................................................................................................................................................................................................................................   1
		Safety Precautions Maintenance and Repair.....................................................................................................................................................................................................................................   2
		General.......................................................................................................................................................................................................................................................................   5
		Description...................................................................................................................................................................................................................................................................   5
		Differential Repair...........................................................................................................................................................................................................................................................   6
			Remove....................................................................................................................................................................................................................................................................   6
				Differential Carrier From Axle Housing, Remove........................................................................................................................................................................................................................   6
				Differential and Ring Gear From Differential Carrier, Remove..........................................................................................................................................................................................................   8
				Drive Pinion and Pinion Carrier From Differential Carrier, Remov......................................................................................................................................................................................................  10
			Disassemble...............................................................................................................................................................................................................................................................  11
				Differential and Ring Gear Assembly, Disassemble......................................................................................................................................................................................................................  11
				Drive Pinion and Pinion Carrier, Disassemble..........................................................................................................................................................................................................................  13
			Clean and Inspect.........................................................................................................................................................................................................................................................  16
			Assemble..................................................................................................................................................................................................................................................................  17
				Pinion, Bearings, and Pinion Carrier, Assemble........................................................................................................................................................................................................................  17
				Pinion Bearings, Adjust Preload.......................................................................................................................................................................................................................................  17
					Press Method......................................................................................................................................................................................................................................................  17
					Yoke or Flange Method.............................................................................................................................................................................................................................................  18
				Triple-Lip Seal, Install..............................................................................................................................................................................................................................................  19
				Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion)...........................................................................................................................................................................................................  20
				Differential and Ring Gear, Assemble..................................................................................................................................................................................................................................  22
				Differential Gears Rotating Torque, Check.............................................................................................................................................................................................................................  24
				Differential and Ring Gear Assembly, Install..........................................................................................................................................................................................................................  25
				Differential Bearings, Preload Adjust.................................................................................................................................................................................................................................  27
				Ring Gear, Runout Check...............................................................................................................................................................................................................................................  28
				Ring Gear Backlash, Adjust............................................................................................................................................................................................................................................  28
				Gear Set, Tooth Contact Pattern Check.................................................................................................................................................................................................................................  30
				Thrust Screw, Install and Adjust......................................................................................................................................................................................................................................  33
			Install...................................................................................................................................................................................................................................................................  33
				Differential Assembly Into Axle Housing, Install......................................................................................................................................................................................................................  33
		Specifications................................................................................................................................................................................................................................................................  35
		Troubleshooting...............................................................................................................................................................................................................................................................  40
	tables............................................................................................................................................................................................................................................................................   1
		Table 1. Ring Gear Backlash Adjustment Specifications.........................................................................................................................................................................................................................  30
		Table 2. Ring and Pinion Tooth Contact Adjustment.............................................................................................................................................................................................................................  31
		Table 3. General Specifications...............................................................................................................................................................................................................................................  35
		Table 4. Rivet Installation Pressure..........................................................................................................................................................................................................................................  35
		Table 5. Pinion Adjustment....................................................................................................................................................................................................................................................  36
		Table 6. Pinion Preload Pressure..............................................................................................................................................................................................................................................  36
		Table 7. Torque Specifications................................................................................................................................................................................................................................................  37
		Table 8. Torque Specifications for Metric Hardware............................................................................................................................................................................................................................  38
		Table 9. Torque Specifications for Metric (Fine) Hardware.....................................................................................................................................................................................................................  39
910091-1900SRM0097-(07-2006)-UK-EN....................................................................................................................................................................................................................................................  43
	toc...............................................................................................................................................................................................................................................................................  43
		Hydraulic Gear Pumps..........................................................................................................................................................................................................................................................  43
		Safety Precautions Maintenance and Repair.....................................................................................................................................................................................................................................  44
		Description...................................................................................................................................................................................................................................................................  47
		Operation.....................................................................................................................................................................................................................................................................  48
			Flow Control Valve........................................................................................................................................................................................................................................................  48
			Relief Valve..............................................................................................................................................................................................................................................................  49
		Hydraulic Gear Pump Repair....................................................................................................................................................................................................................................................  49
			Remove....................................................................................................................................................................................................................................................................  49
			Disassemble...............................................................................................................................................................................................................................................................  50
			Clean.....................................................................................................................................................................................................................................................................  50
			Inspect...................................................................................................................................................................................................................................................................  51
			Assemble..................................................................................................................................................................................................................................................................  54
			Install...................................................................................................................................................................................................................................................................  56
		Pump Output Check.............................................................................................................................................................................................................................................................  56
			Method No. 1..............................................................................................................................................................................................................................................................  56
			Method No. 2..............................................................................................................................................................................................................................................................  57
		Hydraulic System Air Check....................................................................................................................................................................................................................................................  58
		Troubleshooting...............................................................................................................................................................................................................................................................  59
910442-8000SRM0231-(12-2004)-UK-EN....................................................................................................................................................................................................................................................  65
	toc...............................................................................................................................................................................................................................................................................  65
		Metric and Inch (SAE) Fasteners...............................................................................................................................................................................................................................................  65
		Safety Precautions Maintenance and Repair.....................................................................................................................................................................................................................................  66
		General.......................................................................................................................................................................................................................................................................  69
			Threaded Fasteners........................................................................................................................................................................................................................................................  69
			Nomenclature, Threads.....................................................................................................................................................................................................................................................  69
			Strength Identification...................................................................................................................................................................................................................................................  70
			Cotter (Split) Pins.......................................................................................................................................................................................................................................................  70
			Fastener Torque Tables....................................................................................................................................................................................................................................................  75
			Conversion Table..........................................................................................................................................................................................................................................................  77
	tables............................................................................................................................................................................................................................................................................  65
		Table 1. Bolts and Screws.....................................................................................................................................................................................................................................................  71
		Table 2. Studs and Nuts.......................................................................................................................................................................................................................................................  72
		Table 3. Torque Nuts..........................................................................................................................................................................................................................................................  73
		Table 4. Torque Nuts With Nylon Insert........................................................................................................................................................................................................................................  74
		Table 5. Torque Values for Metric Fasteners*..................................................................................................................................................................................................................................  75
		Table 6. Torque Values for Inch Fasteners*....................................................................................................................................................................................................................................  76
		Table 7. Conversion Table for Metric and English Units........................................................................................................................................................................................................................  77
		Table 8. Cotter Pin Dimensional Data..........................................................................................................................................................................................................................................  78
		Table 9. Cotter Pin Dimensional Data..........................................................................................................................................................................................................................................  79
		Table 10. Cotter Pin Dimensional Data.........................................................................................................................................................................................................................................  80
		Table 11. Cotter Pin Dimensional Data.........................................................................................................................................................................................................................................  82
1529749-1800SRM1036-(07-2007)-UK-EN...................................................................................................................................................................................................................................................  87
	toc...............................................................................................................................................................................................................................................................................  87
		Brake Accumulator.............................................................................................................................................................................................................................................................  87
		Safety Precautions Maintenance and Repair.....................................................................................................................................................................................................................................  88
		General.......................................................................................................................................................................................................................................................................  91
		Description and Operation.....................................................................................................................................................................................................................................................  91
		Accumulator Maintenance.......................................................................................................................................................................................................................................................  91
			Precharge Check...........................................................................................................................................................................................................................................................  91
			Precharge Filling.........................................................................................................................................................................................................................................................  92
			Remove....................................................................................................................................................................................................................................................................  93
			Disassemble...............................................................................................................................................................................................................................................................  93
			Clean.....................................................................................................................................................................................................................................................................  95
			Inspect...................................................................................................................................................................................................................................................................  95
			Repair....................................................................................................................................................................................................................................................................  95
			Assemble..................................................................................................................................................................................................................................................................  95
			Replace...................................................................................................................................................................................................................................................................  95
	tables............................................................................................................................................................................................................................................................................  87
		Table 1. Accumulator Pressures................................................................................................................................................................................................................................................  92
1531822-1800SRM1038-(07-2007)-UK-EN...................................................................................................................................................................................................................................................  99
	toc...............................................................................................................................................................................................................................................................................  99
		Service Brake.................................................................................................................................................................................................................................................................  99
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 100
		General....................................................................................................................................................................................................................................................................... 103
		Description and Operation..................................................................................................................................................................................................................................................... 103
			A917, E117, and F117 Only................................................................................................................................................................................................................................................. 103
			B222 Only................................................................................................................................................................................................................................................................. 103
		Repair........................................................................................................................................................................................................................................................................ 105
			General................................................................................................................................................................................................................................................................... 105
			Remove.................................................................................................................................................................................................................................................................... 105
				Drive Wheels and Tires................................................................................................................................................................................................................................................ 105
				Brake Housing......................................................................................................................................................................................................................................................... 106
				Spindle and Brake Cover............................................................................................................................................................................................................................................... 108
			Disassemble............................................................................................................................................................................................................................................................... 109
			Clean..................................................................................................................................................................................................................................................................... 111
				Ground and Polished Parts............................................................................................................................................................................................................................................. 111
				Parts With Rough Finish............................................................................................................................................................................................................................................... 111
				Wet Disc Brake and Axle Assembly...................................................................................................................................................................................................................................... 111
			Inspect................................................................................................................................................................................................................................................................... 111
				Face Seals............................................................................................................................................................................................................................................................ 111
				Disc.................................................................................................................................................................................................................................................................. 112
					Wear Limits....................................................................................................................................................................................................................................................... 112
			Replace................................................................................................................................................................................................................................................................... 112
				Parts................................................................................................................................................................................................................................................................. 112
			Assemble.................................................................................................................................................................................................................................................................. 113
				Brake Housings........................................................................................................................................................................................................................................................ 113
			Install................................................................................................................................................................................................................................................................... 115
				Hub Oil Seals......................................................................................................................................................................................................................................................... 115
					Double Seals...................................................................................................................................................................................................................................................... 115
					Single Seal....................................................................................................................................................................................................................................................... 116
				Spindle and Brake Cover............................................................................................................................................................................................................................................... 117
				Brake Housing......................................................................................................................................................................................................................................................... 118
				Drive Wheels and Tires................................................................................................................................................................................................................................................ 121
			Pressure Switch........................................................................................................................................................................................................................................................... 125
				Replace............................................................................................................................................................................................................................................................... 125
			Accumulator............................................................................................................................................................................................................................................................... 125
		Brake Pedal Valves (Treadle Valves) Repair.................................................................................................................................................................................................................................... 125
			All Models Except A917, B222, E117, and F117.............................................................................................................................................................................................................................. 125
				Remove................................................................................................................................................................................................................................................................ 125
				Clean and Inspect..................................................................................................................................................................................................................................................... 125
				Install............................................................................................................................................................................................................................................................... 126
			A917, B222, E117, and F117................................................................................................................................................................................................................................................ 129
				Remove................................................................................................................................................................................................................................................................ 129
				Clean and Inspect..................................................................................................................................................................................................................................................... 129
				Install............................................................................................................................................................................................................................................................... 129
		Brake System Air Removal...................................................................................................................................................................................................................................................... 129
		Specifications................................................................................................................................................................................................................................................................ 130
			Brake Coolant............................................................................................................................................................................................................................................................. 133
				Coolant Change Intervals.............................................................................................................................................................................................................................................. 133
					Normal Maintenance................................................................................................................................................................................................................................................ 133
			Hydraulic Fluid........................................................................................................................................................................................................................................................... 133
		Troubleshooting............................................................................................................................................................................................................................................................... 134
	tables............................................................................................................................................................................................................................................................................  99
		Table 1. Friction Disc........................................................................................................................................................................................................................................................ 112
		Table 2. Stationary Disc...................................................................................................................................................................................................................................................... 112
		Table 3. Wheel Hub and Brake Housing Torque Chart............................................................................................................................................................................................................................. 131
		Table 4. Brake Housing Cover Torque Chart..................................................................................................................................................................................................................................... 133
1564053-0600SRM1101-(11-2007)-UK-EN................................................................................................................................................................................................................................................... 139
	toc............................................................................................................................................................................................................................................................................... 139
		Cummins Diesel/LPG Engine Fault Code Guide.................................................................................................................................................................................................................................... 139
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 140
		General....................................................................................................................................................................................................................................................................... 143
		Fault Codes................................................................................................................................................................................................................................................................... 143
			Normal Mode............................................................................................................................................................................................................................................................... 143
			Fault Log Mode............................................................................................................................................................................................................................................................ 143
				Access................................................................................................................................................................................................................................................................ 143
				Exit.................................................................................................................................................................................................................................................................. 144
				Clear................................................................................................................................................................................................................................................................. 144
			Electronic Throttle Calibration........................................................................................................................................................................................................................................... 144
				Electronic Throttle Calibration Procedure............................................................................................................................................................................................................................. 144
	tables............................................................................................................................................................................................................................................................................ 139
		Table 1. Error Code Descriptions.............................................................................................................................................................................................................................................. 145
1565182-1600SRM1109-(07-2007)-UK-EN................................................................................................................................................................................................................................................... 161
	toc............................................................................................................................................................................................................................................................................... 161
		Steering System............................................................................................................................................................................................................................................................... 161
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 162
		General....................................................................................................................................................................................................................................................................... 165
		Description................................................................................................................................................................................................................................................................... 165
		Steering Wheel and Column Assembly Repair..................................................................................................................................................................................................................................... 167
			General................................................................................................................................................................................................................................................................... 167
			Steering Wheel and Horn................................................................................................................................................................................................................................................... 167
				Remove................................................................................................................................................................................................................................................................ 167
				Install............................................................................................................................................................................................................................................................... 167
		Steering Column............................................................................................................................................................................................................................................................... 169
			Remove.................................................................................................................................................................................................................................................................... 169
			Install................................................................................................................................................................................................................................................................... 169
		Steering Control Unit Repair.................................................................................................................................................................................................................................................. 170
			General................................................................................................................................................................................................................................................................... 170
			Description............................................................................................................................................................................................................................................................... 170
			Operation................................................................................................................................................................................................................................................................. 170
			Remove.................................................................................................................................................................................................................................................................... 170
			Disassemble............................................................................................................................................................................................................................................................... 172
			Clean..................................................................................................................................................................................................................................................................... 175
			Assemble.................................................................................................................................................................................................................................................................. 175
			Install................................................................................................................................................................................................................................................................... 181
		Steering System Air Removal................................................................................................................................................................................................................................................... 181
		Steering Relief Pressure Check and Adjustments................................................................................................................................................................................................................................ 181
		Flow Amplifier Repair......................................................................................................................................................................................................................................................... 183
			General................................................................................................................................................................................................................................................................... 183
			Description............................................................................................................................................................................................................................................................... 183
			Operation................................................................................................................................................................................................................................................................. 183
				Neutral Position...................................................................................................................................................................................................................................................... 183
				During Steering Function.............................................................................................................................................................................................................................................. 183
				Manual Steering Function.............................................................................................................................................................................................................................................. 185
			Disassemble............................................................................................................................................................................................................................................................... 185
				Pressure Relief Valve................................................................................................................................................................................................................................................. 185
				End Cover at PP Port.................................................................................................................................................................................................................................................. 185
				End Cover at LS Port.................................................................................................................................................................................................................................................. 185
				Spools................................................................................................................................................................................................................................................................ 186
				Directional Valve Spool............................................................................................................................................................................................................................................... 186
				Priority Valve Spool.................................................................................................................................................................................................................................................. 186
				Pressure Control/Amplifier Valve Spool................................................................................................................................................................................................................................ 186
				Check Valve........................................................................................................................................................................................................................................................... 187
				Cushion/Suction Valves................................................................................................................................................................................................................................................ 187
			Clean..................................................................................................................................................................................................................................................................... 188
			Assemble.................................................................................................................................................................................................................................................................. 188
		Troubleshooting............................................................................................................................................................................................................................................................... 189
1565582-1600SRM1114-(07-2007)-UK-EN................................................................................................................................................................................................................................................... 193
	toc............................................................................................................................................................................................................................................................................... 193
		Steering Axle................................................................................................................................................................................................................................................................. 193
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 194
		General....................................................................................................................................................................................................................................................................... 197
		Description................................................................................................................................................................................................................................................................... 197
		How To Put Lift Truck On Blocks............................................................................................................................................................................................................................................... 198
			How to Lift Steer Tires................................................................................................................................................................................................................................................... 198
		Steering Axle Assembly........................................................................................................................................................................................................................................................ 200
			Remove.................................................................................................................................................................................................................................................................... 200
			Install................................................................................................................................................................................................................................................................... 201
		Wheels and Hubs............................................................................................................................................................................................................................................................... 202
			Remove and Disassemble.................................................................................................................................................................................................................................................... 202
			Clean..................................................................................................................................................................................................................................................................... 202
			Assemble and Install...................................................................................................................................................................................................................................................... 203
		Spindles, Bearings, and Tie Rods.............................................................................................................................................................................................................................................. 204
			Remove.................................................................................................................................................................................................................................................................... 204
			Install................................................................................................................................................................................................................................................................... 205
		Steering Cylinder............................................................................................................................................................................................................................................................. 207
			Remove and Disassemble.................................................................................................................................................................................................................................................... 207
			Clean and Inspect......................................................................................................................................................................................................................................................... 208
			Assemble and Install...................................................................................................................................................................................................................................................... 208
		Torque Specifications......................................................................................................................................................................................................................................................... 209
		Troubleshooting............................................................................................................................................................................................................................................................... 209
1565653-2100SRM1116-(01-2007)-UK-EN................................................................................................................................................................................................................................................... 213
	toc............................................................................................................................................................................................................................................................................... 213
		Tilt Cylinders................................................................................................................................................................................................................................................................ 213
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 214
		General....................................................................................................................................................................................................................................................................... 217
		Description................................................................................................................................................................................................................................................................... 217
		Tilt Cylinder Repair.......................................................................................................................................................................................................................................................... 217
			Remove.................................................................................................................................................................................................................................................................... 217
			Disassemble............................................................................................................................................................................................................................................................... 219
			Clean..................................................................................................................................................................................................................................................................... 220
			Inspect................................................................................................................................................................................................................................................................... 220
			Assemble.................................................................................................................................................................................................................................................................. 220
			Install................................................................................................................................................................................................................................................................... 220
		Tilt Cylinder Leak Check...................................................................................................................................................................................................................................................... 220
		Tilt Cylinder Stroke and Mast Tilt Angle Adjustment........................................................................................................................................................................................................................... 221
		Torque Specifications......................................................................................................................................................................................................................................................... 222
		Troubleshooting............................................................................................................................................................................................................................................................... 222
	tables............................................................................................................................................................................................................................................................................ 213
		Table 1. Movement Rate (Maximum) for Tilt Cylinders........................................................................................................................................................................................................................... 221
1565789-1800SRM1117-(07-2007)-UK-EN................................................................................................................................................................................................................................................... 225
	toc............................................................................................................................................................................................................................................................................... 225
		Parking Brake................................................................................................................................................................................................................................................................. 225
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 226
		General....................................................................................................................................................................................................................................................................... 229
		Description and Operation..................................................................................................................................................................................................................................................... 229
		Parking Brake Valve Replacement............................................................................................................................................................................................................................................... 229
			Remove.................................................................................................................................................................................................................................................................... 229
			Clean and Inspect......................................................................................................................................................................................................................................................... 230
			Install................................................................................................................................................................................................................................................................... 230
		Parking Brake Caliper Repair.................................................................................................................................................................................................................................................. 230
			Remove.................................................................................................................................................................................................................................................................... 230
			Disassemble............................................................................................................................................................................................................................................................... 230
			Inspect................................................................................................................................................................................................................................................................... 230
			Install................................................................................................................................................................................................................................................................... 231
			Bleed Brakes.............................................................................................................................................................................................................................................................. 233
			Adjust.................................................................................................................................................................................................................................................................... 233
		Brake Pad Repair.............................................................................................................................................................................................................................................................. 234
			Inspect................................................................................................................................................................................................................................................................... 234
			Remove.................................................................................................................................................................................................................................................................... 234
			Install................................................................................................................................................................................................................................................................... 235
		Seals Repair.................................................................................................................................................................................................................................................................. 235
			Remove.................................................................................................................................................................................................................................................................... 235
			Install................................................................................................................................................................................................................................................................... 235
		Specifications................................................................................................................................................................................................................................................................ 236
			Torque Requirements....................................................................................................................................................................................................................................................... 236
			Wear Limits............................................................................................................................................................................................................................................................... 236
			Lining to Disc Clearance.................................................................................................................................................................................................................................................. 236
		Troubleshooting............................................................................................................................................................................................................................................................... 237
	tables............................................................................................................................................................................................................................................................................ 225
		Table 1. Brake Pad Adjustment................................................................................................................................................................................................................................................. 234
		Table 2. Torque Requirements.................................................................................................................................................................................................................................................. 236
		Table 3. Wear Limits.......................................................................................................................................................................................................................................................... 236
		Table 4. Lining to Disc Clearance............................................................................................................................................................................................................................................. 236
1569718-4000SRM1160-(01-2007)-UK-EN................................................................................................................................................................................................................................................... 241
	toc............................................................................................................................................................................................................................................................................... 241
		Mast.......................................................................................................................................................................................................................................................................... 241
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 242
		General....................................................................................................................................................................................................................................................................... 245
		Description and Operation..................................................................................................................................................................................................................................................... 245
			General................................................................................................................................................................................................................................................................... 245
			Lifting................................................................................................................................................................................................................................................................... 246
			Lowering.................................................................................................................................................................................................................................................................. 246
		Safety Procedures When Working Near Mast...................................................................................................................................................................................................................................... 246
		Forks Repair.................................................................................................................................................................................................................................................................. 247
			Adjust.................................................................................................................................................................................................................................................................... 247
			Remove.................................................................................................................................................................................................................................................................... 247
			Install................................................................................................................................................................................................................................................................... 247
				Low-Mount Fork........................................................................................................................................................................................................................................................ 247
		Carriage Repair............................................................................................................................................................................................................................................................... 248
			General................................................................................................................................................................................................................................................................... 248
			Remove.................................................................................................................................................................................................................................................................... 248
			Disassemble............................................................................................................................................................................................................................................................... 251
			Clean and Inspect......................................................................................................................................................................................................................................................... 253
			Assemble.................................................................................................................................................................................................................................................................. 253
			Install................................................................................................................................................................................................................................................................... 255
			Carriage Side Blocks...................................................................................................................................................................................................................................................... 255
				Adjust................................................................................................................................................................................................................................................................ 255
		Mast Repair................................................................................................................................................................................................................................................................... 256
			Remove.................................................................................................................................................................................................................................................................... 256
			Disassemble............................................................................................................................................................................................................................................................... 257
			Clean and Inspect......................................................................................................................................................................................................................................................... 259
			Assemble.................................................................................................................................................................................................................................................................. 260
			Install................................................................................................................................................................................................................................................................... 262
		Lift Cylinders Repair......................................................................................................................................................................................................................................................... 262
			Remove.................................................................................................................................................................................................................................................................... 262
			Disassemble............................................................................................................................................................................................................................................................... 262
			Clean and Inspect......................................................................................................................................................................................................................................................... 263
			Assemble.................................................................................................................................................................................................................................................................. 263
			Install................................................................................................................................................................................................................................................................... 263
		Fork Positioner Cylinders Repair.............................................................................................................................................................................................................................................. 264
			Remove.................................................................................................................................................................................................................................................................... 264
			Disassemble............................................................................................................................................................................................................................................................... 264
			Clean and Inspect......................................................................................................................................................................................................................................................... 264
			Assemble.................................................................................................................................................................................................................................................................. 264
			Install................................................................................................................................................................................................................................................................... 264
		Sideshift Cylinder Repair..................................................................................................................................................................................................................................................... 265
			Remove.................................................................................................................................................................................................................................................................... 265
			Disassemble............................................................................................................................................................................................................................................................... 265
			Clean and Inspect......................................................................................................................................................................................................................................................... 265
			Assemble.................................................................................................................................................................................................................................................................. 265
			Install................................................................................................................................................................................................................................................................... 265
		Header Hoses Replacement...................................................................................................................................................................................................................................................... 265
		Carriage Side Blocks Adjustment............................................................................................................................................................................................................................................... 267
		Mast Side Blocks Adjustment................................................................................................................................................................................................................................................... 267
		Mast Load Rollers Adjustment.................................................................................................................................................................................................................................................. 267
		Lift Chains Adjustment........................................................................................................................................................................................................................................................ 268
		Lift and Tilt Cylinders Leak Check............................................................................................................................................................................................................................................ 268
		Troubleshooting............................................................................................................................................................................................................................................................... 269
1574068-1400SRM1171-(02-2008)-UK-EN................................................................................................................................................................................................................................................... 273
	toc............................................................................................................................................................................................................................................................................... 273
		Planetary Gear Axle........................................................................................................................................................................................................................................................... 273
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 274
		General....................................................................................................................................................................................................................................................................... 277
		Description................................................................................................................................................................................................................................................................... 277
		Operation..................................................................................................................................................................................................................................................................... 277
		Planetary Gear Axle Repair.................................................................................................................................................................................................................................................... 281
			Remove.................................................................................................................................................................................................................................................................... 281
				Drive Wheels and Tires................................................................................................................................................................................................................................................ 281
			Disassemble............................................................................................................................................................................................................................................................... 282
				Drive Axle............................................................................................................................................................................................................................................................ 282
				Planetary Gear Carrier................................................................................................................................................................................................................................................ 283
				Ring Gear, Ring Gear Hub, and Wheel Hub............................................................................................................................................................................................................................... 284
				Hub Oil Seal and Bearings............................................................................................................................................................................................................................................. 286
				Axle Shaft............................................................................................................................................................................................................................................................ 286
				Spindle............................................................................................................................................................................................................................................................... 286
			Repair.................................................................................................................................................................................................................................................................... 287
				Repairing or Replacing Parts.......................................................................................................................................................................................................................................... 287
				Welding............................................................................................................................................................................................................................................................... 287
			Clean..................................................................................................................................................................................................................................................................... 288
				Ground or Polished Parts.............................................................................................................................................................................................................................................. 288
				Parts With Rough Finishes............................................................................................................................................................................................................................................. 288
				Axle Assemblies....................................................................................................................................................................................................................................................... 288
				Drying Cleaned Parts.................................................................................................................................................................................................................................................. 288
			Preventing Corrosion...................................................................................................................................................................................................................................................... 288
			Parts Inspection.......................................................................................................................................................................................................................................................... 288
			Assemble.................................................................................................................................................................................................................................................................. 289
				Spindle............................................................................................................................................................................................................................................................... 289
				Axle Shaft............................................................................................................................................................................................................................................................ 289
				Hub Oil Seal and Bearings............................................................................................................................................................................................................................................. 289
				Ring Gear, Ring Gear Hub, and Wheel Hub............................................................................................................................................................................................................................... 290
				Wheel Bearing Preload................................................................................................................................................................................................................................................. 290
					Adjust............................................................................................................................................................................................................................................................ 290
				Planetary Gear Carrier................................................................................................................................................................................................................................................ 292
				Drive Axle............................................................................................................................................................................................................................................................ 293
				Wheel Ends............................................................................................................................................................................................................................................................ 294
					Fill.............................................................................................................................................................................................................................................................. 294
			Install................................................................................................................................................................................................................................................................... 294
				Drive Wheels and Tires................................................................................................................................................................................................................................................ 294
		Torque Specifications......................................................................................................................................................................................................................................................... 298
		Troubleshooting............................................................................................................................................................................................................................................................... 299
	tables............................................................................................................................................................................................................................................................................ 273
		Table 1. Wheel Bearing Adjustment Torque...................................................................................................................................................................................................................................... 291
		Table 2. Planetary Gear Carrier Capscrew and Stud Torque Specifi.............................................................................................................................................................................................................. 293
		Table 3. Standard Torque Values for Axle Fasteners............................................................................................................................................................................................................................ 298
1616438-2000SRM1233-(01-2007)-UK-EN................................................................................................................................................................................................................................................... 303
	toc............................................................................................................................................................................................................................................................................... 303
		Hydraulic Plate............................................................................................................................................................................................................................................................... 303
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 304
		General....................................................................................................................................................................................................................................................................... 307
		Description and Operation..................................................................................................................................................................................................................................................... 308
			Hydraulic Oil Supply...................................................................................................................................................................................................................................................... 308
			Manifold, Section 1 of Hydraulic Plate.................................................................................................................................................................................................................................... 308
			Main Control Valve, Section 2 of Hydraulic Plate.......................................................................................................................................................................................................................... 308
				Description........................................................................................................................................................................................................................................................... 308
				Operation............................................................................................................................................................................................................................................................. 309
					Auxiliary Section................................................................................................................................................................................................................................................. 309
					Tilt Section...................................................................................................................................................................................................................................................... 309
					Lift Section...................................................................................................................................................................................................................................................... 309
			Return Manifold, Section 3 of Hydraulic Plate............................................................................................................................................................................................................................. 309
			Brake Manifold, Section 4 of Hydraulic Plate.............................................................................................................................................................................................................................. 313
				Cooling Circuit....................................................................................................................................................................................................................................................... 313
				Service Brake......................................................................................................................................................................................................................................................... 313
				Parking Brake......................................................................................................................................................................................................................................................... 313
			Flow Amplifier, Section 5 of Hydraulic Plate.............................................................................................................................................................................................................................. 313
		Manifold, Section 1 of Hydraulic Plate........................................................................................................................................................................................................................................ 313
			General................................................................................................................................................................................................................................................................... 313
			Valves and Pressure Switches.............................................................................................................................................................................................................................................. 314
		Main Control Valve, Section 2 of Hydraulic Plate.............................................................................................................................................................................................................................. 317
			Remove.................................................................................................................................................................................................................................................................... 317
			Disassemble............................................................................................................................................................................................................................................................... 317
				Auxiliary Section..................................................................................................................................................................................................................................................... 317
				Lift Section.......................................................................................................................................................................................................................................................... 318
				Lift/Tilt Section..................................................................................................................................................................................................................................................... 320
			Clean and Inspect......................................................................................................................................................................................................................................................... 321
			Assemble.................................................................................................................................................................................................................................................................. 321
				Auxiliary Section..................................................................................................................................................................................................................................................... 321
				Lift Section.......................................................................................................................................................................................................................................................... 321
				Lift/Tilt Section..................................................................................................................................................................................................................................................... 322
			Install................................................................................................................................................................................................................................................................... 322
		Return Manifold, Section 3 of Hydraulic Plate................................................................................................................................................................................................................................. 323
			Remove.................................................................................................................................................................................................................................................................... 323
			Disassemble............................................................................................................................................................................................................................................................... 323
			Clean and Inspect......................................................................................................................................................................................................................................................... 324
			Assemble.................................................................................................................................................................................................................................................................. 324
			Install................................................................................................................................................................................................................................................................... 324
		Brake Manifold, Section 4 of Hydraulic Plate.................................................................................................................................................................................................................................. 325
			Remove.................................................................................................................................................................................................................................................................... 325
			Clean and Inspect......................................................................................................................................................................................................................................................... 325
			Install................................................................................................................................................................................................................................................................... 325
		Flow Amplifier, Section 5 of Hydraulic Plate.................................................................................................................................................................................................................................. 326
		Hydraulic Hose Repair......................................................................................................................................................................................................................................................... 326
		Hydraulic Hose Identification................................................................................................................................................................................................................................................. 326
		Torque Values................................................................................................................................................................................................................................................................. 328
		Measurements and Adjustments.................................................................................................................................................................................................................................................. 329
			Measurements.............................................................................................................................................................................................................................................................. 329
			Adjustments............................................................................................................................................................................................................................................................... 329
		Troubleshooting............................................................................................................................................................................................................................................................... 330
	tables............................................................................................................................................................................................................................................................................ 303
		Table 1. Pilot Hoses.......................................................................................................................................................................................................................................................... 327
		Table 2. Brake Hoses.......................................................................................................................................................................................................................................................... 327
		Table 3. Auxiliary Hoses With Alternating P and T............................................................................................................................................................................................................................. 327
		Table 4. Steer Hoses.......................................................................................................................................................................................................................................................... 327
		Table 5. Pressure Settings at 2100 RPM........................................................................................................................................................................................................................................ 329
1616439-2200SRM1234-(07-2007)-UK-EN................................................................................................................................................................................................................................................... 339
	toc............................................................................................................................................................................................................................................................................... 339
		Instrument Panel Indicators and Senders....................................................................................................................................................................................................................................... 339
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 340
		General....................................................................................................................................................................................................................................................................... 343
		Description................................................................................................................................................................................................................................................................... 343
			General................................................................................................................................................................................................................................................................... 343
			Instrument Panel Meters, Indicators, and LCD Display...................................................................................................................................................................................................................... 343
			Connector................................................................................................................................................................................................................................................................. 348
				Seat Switch Logic..................................................................................................................................................................................................................................................... 349
				Central Warning Light Output.......................................................................................................................................................................................................................................... 349
				Buzzer Output......................................................................................................................................................................................................................................................... 349
		Instrument Panel Component Replacement........................................................................................................................................................................................................................................ 351
			Instrument Panel.......................................................................................................................................................................................................................................................... 351
				Remove................................................................................................................................................................................................................................................................ 351
			Light..................................................................................................................................................................................................................................................................... 352
				Replace............................................................................................................................................................................................................................................................... 352
		Sender Replacement............................................................................................................................................................................................................................................................ 352
			Fuel Level Sender......................................................................................................................................................................................................................................................... 352
			Pressure Sender........................................................................................................................................................................................................................................................... 353
			Temperature Sender........................................................................................................................................................................................................................................................ 353
			Low Coolant Sender........................................................................................................................................................................................................................................................ 354
			Vacuum Switch............................................................................................................................................................................................................................................................. 354
			Crankshaft Position Sensor................................................................................................................................................................................................................................................ 354
	tables............................................................................................................................................................................................................................................................................ 339
		Table 1. Instrument Panel and Indicators...................................................................................................................................................................................................................................... 344
		Table 2. Pin Description...................................................................................................................................................................................................................................................... 348
		Table 3. Sender Description................................................................................................................................................................................................................................................... 349
1616442-8000SRM1236-(03-2007)-UK-EN................................................................................................................................................................................................................................................... 357
	toc............................................................................................................................................................................................................................................................................... 357
		Diagrams...................................................................................................................................................................................................................................................................... 357
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 358
1616443-8000SRM1237-(01-2007)-UK-EN................................................................................................................................................................................................................................................... 421
	toc............................................................................................................................................................................................................................................................................... 421
		Periodic Maintenance.......................................................................................................................................................................................................................................................... 421
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 422
		General....................................................................................................................................................................................................................................................................... 427
			Serial Number Data........................................................................................................................................................................................................................................................ 427
			How to Move Disabled Lift Truck........................................................................................................................................................................................................................................... 427
				How to Tow Lift Truck................................................................................................................................................................................................................................................. 428
			How to Put Lift Truck on Blocks........................................................................................................................................................................................................................................... 428
				How to Raise Drive Tires.............................................................................................................................................................................................................................................. 428
				How to Raise Steering Tires........................................................................................................................................................................................................................................... 429
		Maintenance Schedule.......................................................................................................................................................................................................................................................... 430
			Spreader Maintenance...................................................................................................................................................................................................................................................... 440
		Maintenance Procedures Every 8 Hours or Daily................................................................................................................................................................................................................................. 441
			How to Make Checks With the Engine Stopped................................................................................................................................................................................................................................ 441
				Safety Labels......................................................................................................................................................................................................................................................... 441
				Operator Restraint System............................................................................................................................................................................................................................................. 442
					Safety Belt and Seat Rails........................................................................................................................................................................................................................................ 442
					Steering Column Latch............................................................................................................................................................................................................................................. 442
				Tires and Wheels...................................................................................................................................................................................................................................................... 442
				Forks................................................................................................................................................................................................................................................................. 443
					Adjust............................................................................................................................................................................................................................................................ 443
					Remove............................................................................................................................................................................................................................................................ 443
					Low Mount Forks, Install.......................................................................................................................................................................................................................................... 443
				Forks, Mast, and Lift Chains, Inspect................................................................................................................................................................................................................................. 444
				Drive Belt............................................................................................................................................................................................................................................................ 445
				Crankcase Breather Tube............................................................................................................................................................................................................................................... 445
				Air Intake Piping and Charge Air Piping............................................................................................................................................................................................................................... 445
				Cooling Fan........................................................................................................................................................................................................................................................... 446
				Pre-Cleaner for Air Filter............................................................................................................................................................................................................................................ 446
				Fuel, Oil, or Coolant Leaks........................................................................................................................................................................................................................................... 447
				Hydraulic Tank Breather............................................................................................................................................................................................................................................... 447
				Engine Oil............................................................................................................................................................................................................................................................ 447
				Hydraulic System Oil.................................................................................................................................................................................................................................................. 448
				Hydraulic High Pressure Oil Filter.................................................................................................................................................................................................................................... 448
				Battery............................................................................................................................................................................................................................................................... 449
				Fuel Filter/Water Separator........................................................................................................................................................................................................................................... 449
				Cooling System........................................................................................................................................................................................................................................................ 450
			How to Add Fuel to Lift Truck............................................................................................................................................................................................................................................. 451
			How to Make Checks With Engine Running.................................................................................................................................................................................................................................... 451
				Gauges, Lights, Horn, Fuses, and Relays............................................................................................................................................................................................................................... 451
					Sealed Fuses...................................................................................................................................................................................................................................................... 454
				Transmission Oil...................................................................................................................................................................................................................................................... 454
				Engine Air Filter..................................................................................................................................................................................................................................................... 454
				Engine Oil Pressure................................................................................................................................................................................................................................................... 455
				Electrical System..................................................................................................................................................................................................................................................... 455
				Steering System....................................................................................................................................................................................................................................................... 455
				Service Brakes........................................................................................................................................................................................................................................................ 455
				Parking Brake......................................................................................................................................................................................................................................................... 455
				Control Levers and Pedals............................................................................................................................................................................................................................................. 455
				Lift System Operation................................................................................................................................................................................................................................................. 455
				Attachments........................................................................................................................................................................................................................................................... 456
		First Inspection After First 100 Hours of Operation........................................................................................................................................................................................................................... 456
			Engine Oil Filter......................................................................................................................................................................................................................................................... 456
			Drive Axle and Differential............................................................................................................................................................................................................................................... 456
			Lift Chains............................................................................................................................................................................................................................................................... 456
			Transmission Oil Filter................................................................................................................................................................................................................................................... 456
			Air Conditioning.......................................................................................................................................................................................................................................................... 456
			Steer Wheel Hubs.......................................................................................................................................................................................................................................................... 456
		Maintenance Procedures Every 250 Hours Or Monthly............................................................................................................................................................................................................................. 457
			Transmission Oil Filter................................................................................................................................................................................................................................................... 457
			Twist Locks (F117 Only)................................................................................................................................................................................................................................................... 457
			Gantry Carriage and Container Attachments (F117 Only)..................................................................................................................................................................................................................... 457
		Maintenance Procedures Every 500 Hours or 3 Months............................................................................................................................................................................................................................ 457
			Drive Belt................................................................................................................................................................................................................................................................ 457
			Lift Chains............................................................................................................................................................................................................................................................... 457
			Hydraulic Return Line Oil Filter.......................................................................................................................................................................................................................................... 458
			Air Conditioning.......................................................................................................................................................................................................................................................... 458
			Wheel Nuts................................................................................................................................................................................................................................................................ 458
			Heater Air Filter......................................................................................................................................................................................................................................................... 458
			Steering Axle Kingpins.................................................................................................................................................................................................................................................... 458
			Steering Axle Tie Rods.................................................................................................................................................................................................................................................... 459
			Drive Shaft............................................................................................................................................................................................................................................................... 459
			Steering Axle Pivots...................................................................................................................................................................................................................................................... 459
			Mast and Carriage Load Rollers............................................................................................................................................................................................................................................ 459
			Mast Pivots, Sliding Surfaces............................................................................................................................................................................................................................................. 459
			Sideshift Carriage........................................................................................................................................................................................................................................................ 459
		Maintenance Procedures Every 500 Hours or 6 Months............................................................................................................................................................................................................................ 460
			Fuel Filter............................................................................................................................................................................................................................................................... 460
			Engine Oil and Filter..................................................................................................................................................................................................................................................... 460
			Oil Filter for Oil-Cooled Brakes (Brake Filter)........................................................................................................................................................................................................................... 460
			Transmission Oil.......................................................................................................................................................................................................................................................... 460
				Change................................................................................................................................................................................................................................................................ 460
		Maintenance Procedures Every 1000 Hours or 6 Months........................................................................................................................................................................................................................... 461
			Drive Axle and Differential Oil........................................................................................................................................................................................................................................... 461
			Service Brake System...................................................................................................................................................................................................................................................... 461
			Brake System Accumulator.................................................................................................................................................................................................................................................. 461
			Hub Bearings, Steer Wheel s............................................................................................................................................................................................................................................... 461
			General Lubrication....................................................................................................................................................................................................................................................... 461
		Maintenance Procedures Every 1500 Hours or 1 Year............................................................................................................................................................................................................................. 461
			Engine.................................................................................................................................................................................................................................................................... 461
			Water Pump................................................................................................................................................................................................................................................................ 461
			Turbocharger.............................................................................................................................................................................................................................................................. 462
			Engine Mounting Bolts..................................................................................................................................................................................................................................................... 462
			Air Leaks, Air Intake and Exhaust......................................................................................................................................................................................................................................... 463
			Valve and Injector Adjustments............................................................................................................................................................................................................................................ 464
				General............................................................................................................................................................................................................................................................... 464
				Adjust................................................................................................................................................................................................................................................................ 465
					Injector Adjustment............................................................................................................................................................................................................................................... 465
					Valve Adjustment.................................................................................................................................................................................................................................................. 466
		Maintenance Procedures Every 2000 Hours or 1 Year............................................................................................................................................................................................................................. 468
			Parking Brake Assembly.................................................................................................................................................................................................................................................... 468
				Clean................................................................................................................................................................................................................................................................. 468
				Inspect............................................................................................................................................................................................................................................................... 468
		Maintenance Procedures Every 3000 Hours or 18 Months.......................................................................................................................................................................................................................... 470
			Hydraulic Suction Oil Filters............................................................................................................................................................................................................................................. 470
		Maintenance Procedures Every 5000 Hours....................................................................................................................................................................................................................................... 470
			Container Attachment (F117)............................................................................................................................................................................................................................................... 470
		Maintenance Procedures Every 6000 Hours or 2 Years............................................................................................................................................................................................................................ 470
			Vibration Damper.......................................................................................................................................................................................................................................................... 470
			Fan Drive Idler Pulley.................................................................................................................................................................................................................................................... 471
			Fan Hub................................................................................................................................................................................................................................................................... 472
			Turbocharger.............................................................................................................................................................................................................................................................. 472
			Cooling System Fluid...................................................................................................................................................................................................................................................... 472
		Maintenance Procedures Every 10,000 Hours or 5 Years.......................................................................................................................................................................................................................... 473
			High Pressure Hydraulic Oil Filter........................................................................................................................................................................................................................................ 473
		Safety Procedures When Working Near Mast...................................................................................................................................................................................................................................... 474
		Lift and Tilt System Leaks Check.............................................................................................................................................................................................................................................. 475
			Lift System............................................................................................................................................................................................................................................................... 475
			Tilt System............................................................................................................................................................................................................................................................... 475
		Pneumatic Tires and Wheels.................................................................................................................................................................................................................................................... 476
			Remove Wheels From Lift Truck............................................................................................................................................................................................................................................. 476
			Remove Tire From Wheel.................................................................................................................................................................................................................................................... 476
				Remove Tire From Five-Piece Wheel..................................................................................................................................................................................................................................... 477
			Install Tire on Wheel..................................................................................................................................................................................................................................................... 478
				Install Tire on Five-Piece Wheel...................................................................................................................................................................................................................................... 479
			Add Air Pressure to Tires................................................................................................................................................................................................................................................. 480
			Install Wheels on Lift Truck.............................................................................................................................................................................................................................................. 481
	tables............................................................................................................................................................................................................................................................................ 421
		Table 1. Condition Check...................................................................................................................................................................................................................................................... 432
		Table 2. Daily Inspections − Fluid Level Check................................................................................................................................................................................................................................ 433
		Table 3. Daily Inspections − Checks With the Engine Running................................................................................................................................................................................................................... 434
		Table 4. First Inspection After First 100 Hours of Operation.................................................................................................................................................................................................................. 435
		Table 5. Periodic Maintenance Schedule − Inspect and Adjust................................................................................................................................................................................................................... 436
		Table 6. Periodic Maintenance Schedule − Lubricate............................................................................................................................................................................................................................ 438
		Table 7. Periodic Maintenance Schedule − Change............................................................................................................................................................................................................................... 439
		Table 8. Container Attachment Maintenance - Lubricate......................................................................................................................................................................................................................... 441
		Table 9. Container Attachment Maintenance − Replace........................................................................................................................................................................................................................... 441
		Table 10. Valve and Injector Adjustment Specifications........................................................................................................................................................................................................................ 464
		Table 11. Injector and Valve Measurement Sequence............................................................................................................................................................................................................................. 465
1616703-1300SRM1220-(07-2007)-UK-EN................................................................................................................................................................................................................................................... 485
	toc............................................................................................................................................................................................................................................................................... 485
		Transmission.................................................................................................................................................................................................................................................................. 485
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 486
		Description of Operation...................................................................................................................................................................................................................................................... 491
			General................................................................................................................................................................................................................................................................... 491
			Torque Convertor, Pump Drive, and Pressure Regulating Valve............................................................................................................................................................................................................... 492
			Input Shaft and Directional Clutches...................................................................................................................................................................................................................................... 492
			Range Clutches............................................................................................................................................................................................................................................................ 493
			Output Section............................................................................................................................................................................................................................................................ 493
			Transmission Controls..................................................................................................................................................................................................................................................... 494
				Valve Operation....................................................................................................................................................................................................................................................... 494
				Directional Selection................................................................................................................................................................................................................................................. 494
				Range Selection....................................................................................................................................................................................................................................................... 495
				Neutral Selection..................................................................................................................................................................................................................................................... 495
				Total Neutral Selection............................................................................................................................................................................................................................................... 495
				Pressure Switch....................................................................................................................................................................................................................................................... 496
			Electric Solenoid Controls................................................................................................................................................................................................................................................ 496
			Transmission Specifications............................................................................................................................................................................................................................................... 525
				Transmission Identification........................................................................................................................................................................................................................................... 525
				Weight, Dimensions, and Oil Capacity.................................................................................................................................................................................................................................. 525
		Transmission Repair........................................................................................................................................................................................................................................................... 526
			Remove.................................................................................................................................................................................................................................................................... 526
			Disassemble............................................................................................................................................................................................................................................................... 528
				Transmission Case, Disassemble........................................................................................................................................................................................................................................ 528
				Converter Housing, Disassemble........................................................................................................................................................................................................................................ 552
				Reverse and Second-Speed Clutch....................................................................................................................................................................................................................................... 554
					Reverse, Disassemble.............................................................................................................................................................................................................................................. 554
					Second-Speed Clutch, Disassemble.................................................................................................................................................................................................................................. 558
				Forward Clutch, Disassemble........................................................................................................................................................................................................................................... 560
				Third-Speed Clutch, Disassemble....................................................................................................................................................................................................................................... 566
				Fourth-Speed Clutch, Disassemble...................................................................................................................................................................................................................................... 570
				First-Speed Clutch, Disassemble....................................................................................................................................................................................................................................... 573
				Output Shaft, Disassemble............................................................................................................................................................................................................................................. 579
				Turbine Shaft, Disassemble............................................................................................................................................................................................................................................ 580
				Impeller and Baffle, Disassemble...................................................................................................................................................................................................................................... 582
				Impeller Cover and Turbine Assembly, Disassemble...................................................................................................................................................................................................................... 585
				Pump Drive Gear, Disassemble.......................................................................................................................................................................................................................................... 586
			Clean and Inspect......................................................................................................................................................................................................................................................... 587
				Housings.............................................................................................................................................................................................................................................................. 587
				Oil Seals and Gaskets................................................................................................................................................................................................................................................. 587
				Bearings.............................................................................................................................................................................................................................................................. 588
				Gears and Shafts...................................................................................................................................................................................................................................................... 588
			Assemble.................................................................................................................................................................................................................................................................. 588
				Pump Drive Gear, Assemble............................................................................................................................................................................................................................................. 588
				Impeller Cover and Turbine, Assemble.................................................................................................................................................................................................................................. 589
				Impeller and Baffle, Assemble......................................................................................................................................................................................................................................... 591
				Turbine Shaft, Assemble............................................................................................................................................................................................................................................... 594
				Output Shaft, Assemble................................................................................................................................................................................................................................................ 595
				First-Speed Clutch, Assemble.......................................................................................................................................................................................................................................... 597
				Fourth-Speed Clutch, Assemble......................................................................................................................................................................................................................................... 604
				Third-Speed Clutch, Assemble.......................................................................................................................................................................................................................................... 608
				Forward Clutch, Assemble.............................................................................................................................................................................................................................................. 614
				Reverse and Second-Speed Clutch....................................................................................................................................................................................................................................... 620
					Second-Speed Clutch, Assemble..................................................................................................................................................................................................................................... 620
					Reverse Clutch, Assemble.......................................................................................................................................................................................................................................... 624
				Converter Housing, Assemble........................................................................................................................................................................................................................................... 630
				Transmission Case, Assemble........................................................................................................................................................................................................................................... 633
			Install................................................................................................................................................................................................................................................................... 654
		Speed Sensors................................................................................................................................................................................................................................................................. 657
			Type of Sensors........................................................................................................................................................................................................................................................... 657
				Speed Sensor With 2-Pin Connector..................................................................................................................................................................................................................................... 657
				Speed Sensor With 3-Pin Connector..................................................................................................................................................................................................................................... 657
			Speed Sensor, Install..................................................................................................................................................................................................................................................... 658
		Control Valve Repair.......................................................................................................................................................................................................................................................... 659
			Remove.................................................................................................................................................................................................................................................................... 659
			Disassemble and Assemble.................................................................................................................................................................................................................................................. 659
			Clean and Inspect......................................................................................................................................................................................................................................................... 659
				Housings.............................................................................................................................................................................................................................................................. 661
				Oil Seals and Gaskets................................................................................................................................................................................................................................................. 661
			Install................................................................................................................................................................................................................................................................... 661
		Stall Test.................................................................................................................................................................................................................................................................... 663
		Transmission Calibration and Electrical Troubleshooting....................................................................................................................................................................................................................... 664
			Userlink®................................................................................................................................................................................................................................................................. 664
			Connection................................................................................................................................................................................................................................................................ 664
			Clutch Filling Calibration................................................................................................................................................................................................................................................ 664
				Purpose............................................................................................................................................................................................................................................................... 664
				Clutch Filling Calibration Procedure.................................................................................................................................................................................................................................. 664
				Alternative Clutch Filling Calibration Procedure...................................................................................................................................................................................................................... 665
				Heat-up Mode.......................................................................................................................................................................................................................................................... 666
				Heat-up Mode Stall Test............................................................................................................................................................................................................................................... 666
			Inching Pedal Calibration................................................................................................................................................................................................................................................. 667
				Purpose............................................................................................................................................................................................................................................................... 667
				Brake Pedal Adjustment................................................................................................................................................................................................................................................ 667
				Inching Pedal Adjustment (Except for C227)............................................................................................................................................................................................................................ 667
				Inching Pedal Sensor Adjustment (Except for C227)..................................................................................................................................................................................................................... 668
				Inching Pedal Calibration Procedure (Except for C227)................................................................................................................................................................................................................. 668
				Verification/Adjustment of Inching Pedal Sensor When Pedal is Fu...................................................................................................................................................................................................... 669
				Manual Inching Pedal Sensor Calibration Procedure (Except for C2...................................................................................................................................................................................................... 669
			Troubleshooting........................................................................................................................................................................................................................................................... 669
			Transmission Display Warning Codes........................................................................................................................................................................................................................................ 670
				Access................................................................................................................................................................................................................................................................ 670
				Clear................................................................................................................................................................................................................................................................. 670
				Exit.................................................................................................................................................................................................................................................................. 670
				Limp Home Mode........................................................................................................................................................................................................................................................ 706
				Shutdown Mode......................................................................................................................................................................................................................................................... 707
				Pressure Feedback Sensor.............................................................................................................................................................................................................................................. 707
		Transmission Oil Pressure Check............................................................................................................................................................................................................................................... 707
			Pressure and Temperature Specifications................................................................................................................................................................................................................................... 707
		Clutch Discs.................................................................................................................................................................................................................................................................. 711
		Electrical Specifications..................................................................................................................................................................................................................................................... 713
		Hydraulic Cooler Lines Specifications......................................................................................................................................................................................................................................... 713
		Torque Specifications......................................................................................................................................................................................................................................................... 714
			Torque Specifications for Lubricated or Plated Screw Threads.............................................................................................................................................................................................................. 714
		Troubleshooting............................................................................................................................................................................................................................................................... 716
	tables............................................................................................................................................................................................................................................................................ 485
		Table 1. Electric Solenoid Controls........................................................................................................................................................................................................................................... 497
		Table 2. 2-Pin Connector Wiring............................................................................................................................................................................................................................................... 657
		Table 3. 3-Pin Connector Wiring............................................................................................................................................................................................................................................... 657
		Table 4. Controller Connector J2 Wire to Pin Number Cross Refere.............................................................................................................................................................................................................. 671
		Table 5. Controller Connector J1 Wire to Pin Number Cross Refere.............................................................................................................................................................................................................. 672
		Table 6. Common Calibration Condition Messages................................................................................................................................................................................................................................ 674
		Table 7. Calibration Codes During Calibration................................................................................................................................................................................................................................. 675
		Table 8. Error Codes During Calibration....................................................................................................................................................................................................................................... 675
		Table 9. Display Warning Codes................................................................................................................................................................................................................................................ 676
		Table 10. Display Warning Exceed Codes........................................................................................................................................................................................................................................ 705
		Table 11. Type of Warning Codes............................................................................................................................................................................................................................................... 706
		Table 12. Forward/Reverse Clutch.............................................................................................................................................................................................................................................. 711
		Table 13. First-Speed Clutch.................................................................................................................................................................................................................................................. 711
		Table 14. Second-Speed Clutch................................................................................................................................................................................................................................................. 712
		Table 15. Third-Speed Clutch.................................................................................................................................................................................................................................................. 712
		Table 16. Fourth-Speed Clutch................................................................................................................................................................................................................................................. 713
		Table 17. Grade 5............................................................................................................................................................................................................................................................. 714
		Table 18. Grade 8............................................................................................................................................................................................................................................................. 714
		Table 19. Grades 8.8, 10.9, and 12.9.......................................................................................................................................................................................................................................... 715
		Table 20. Elastic Stop Nut Torque............................................................................................................................................................................................................................................. 716
		Table 21. O-ring Port Plug Torque Chart....................................................................................................................................................................................................................................... 716
		Table 22. Pipe Plug Torque Chart.............................................................................................................................................................................................................................................. 716
		Table 23. Pipe Plug Torque Chart.............................................................................................................................................................................................................................................. 716
1616924-1900SRM1239-(01-2007)-UK-EN................................................................................................................................................................................................................................................... 721
	toc............................................................................................................................................................................................................................................................................... 721
		Hydraulic System.............................................................................................................................................................................................................................................................. 721
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 722
		General....................................................................................................................................................................................................................................................................... 727
		Description and Operation..................................................................................................................................................................................................................................................... 727
			Hydraulic Plate........................................................................................................................................................................................................................................................... 727
			Hydraulic Pumps........................................................................................................................................................................................................................................................... 728
			Cab Manifold.............................................................................................................................................................................................................................................................. 728
				Oil Cooled Brakes (Service Brakes).................................................................................................................................................................................................................................... 728
				Lift/Tilt Functions................................................................................................................................................................................................................................................... 728
				Over Lower Interrupt.................................................................................................................................................................................................................................................. 729
				Lift Interrupt........................................................................................................................................................................................................................................................ 729
			Accumulator Charge Disabling Solenoid (ACDS).............................................................................................................................................................................................................................. 729
			Heat Exchanger System..................................................................................................................................................................................................................................................... 729
			Steering Control System................................................................................................................................................................................................................................................... 729
			Brake System.............................................................................................................................................................................................................................................................. 729
		Hydraulic Pump Repair......................................................................................................................................................................................................................................................... 730
			Remove.................................................................................................................................................................................................................................................................... 730
			Disassemble............................................................................................................................................................................................................................................................... 730
				Tandem Gear Pump...................................................................................................................................................................................................................................................... 730
				Tri-Section Gear Pump................................................................................................................................................................................................................................................. 731
			Clean and Inspect......................................................................................................................................................................................................................................................... 732
			Assemble.................................................................................................................................................................................................................................................................. 732
				Tandem Gear Pump...................................................................................................................................................................................................................................................... 732
				Tri-Section Gear Pump................................................................................................................................................................................................................................................. 733
			Install................................................................................................................................................................................................................................................................... 733
			Pump Output Check......................................................................................................................................................................................................................................................... 733
				First Method.......................................................................................................................................................................................................................................................... 733
				Second Method......................................................................................................................................................................................................................................................... 734
		Cab Manifold.................................................................................................................................................................................................................................................................. 736
			Remove.................................................................................................................................................................................................................................................................... 736
			Disassemble Valves and Pressure Switches.................................................................................................................................................................................................................................. 736
			Clean and Inspect......................................................................................................................................................................................................................................................... 738
			Assemble Valves and Pressure Switches..................................................................................................................................................................................................................................... 738
			Install................................................................................................................................................................................................................................................................... 738
		Lift and Lower Circuit........................................................................................................................................................................................................................................................ 739
			Description............................................................................................................................................................................................................................................................... 739
			Operation................................................................................................................................................................................................................................................................. 739
				Lift Circuit.......................................................................................................................................................................................................................................................... 740
				Lowering.............................................................................................................................................................................................................................................................. 740
				Lowering Control Valves............................................................................................................................................................................................................................................... 740
			Repairs................................................................................................................................................................................................................................................................... 740
				General............................................................................................................................................................................................................................................................... 740
				Remote Control Valve.................................................................................................................................................................................................................................................. 740
					Description and Operation......................................................................................................................................................................................................................................... 740
					Remove............................................................................................................................................................................................................................................................ 740
					Disassemble....................................................................................................................................................................................................................................................... 741
					Clean and Inspect................................................................................................................................................................................................................................................. 742
					Assemble.......................................................................................................................................................................................................................................................... 742
					Install........................................................................................................................................................................................................................................................... 742
					Adjust............................................................................................................................................................................................................................................................ 743
				Lift Manifold......................................................................................................................................................................................................................................................... 743
					Description and Operation......................................................................................................................................................................................................................................... 743
					Remove............................................................................................................................................................................................................................................................ 743
					Clean and Inspect................................................................................................................................................................................................................................................. 743
					Assemble and Install.............................................................................................................................................................................................................................................. 743
			Checks and Adjustments.................................................................................................................................................................................................................................................... 745
		Tilt Control Circuit.......................................................................................................................................................................................................................................................... 746
			Description............................................................................................................................................................................................................................................................... 746
			Operation................................................................................................................................................................................................................................................................. 746
				Tilt /Lift Spool...................................................................................................................................................................................................................................................... 746
				Relief Valves in Main Control Valve................................................................................................................................................................................................................................... 747
				Relief Valves, Tilt Lock.............................................................................................................................................................................................................................................. 747
			Repairs................................................................................................................................................................................................................................................................... 747
				General............................................................................................................................................................................................................................................................... 747
				Relief Valves, Tilt Lock, Disassemble................................................................................................................................................................................................................................. 747
				Clean and Inspect..................................................................................................................................................................................................................................................... 747
				Checks and Adjustments................................................................................................................................................................................................................................................ 748
		Attachment Circuit Valves..................................................................................................................................................................................................................................................... 748
			General................................................................................................................................................................................................................................................................... 748
				Selector Valves Auxiliary Functions................................................................................................................................................................................................................................... 748
				Carriage Solenoid Valve............................................................................................................................................................................................................................................... 748
			Repairs................................................................................................................................................................................................................................................................... 748
				Carriage Solenoid Valve............................................................................................................................................................................................................................................... 748
					Remove............................................................................................................................................................................................................................................................ 748
					Disassemble....................................................................................................................................................................................................................................................... 748
					Clean and Inspect................................................................................................................................................................................................................................................. 750
					Assemble.......................................................................................................................................................................................................................................................... 750
					Install........................................................................................................................................................................................................................................................... 750
			Checks and Adjustments.................................................................................................................................................................................................................................................... 750
		Other Hydraulic Components.................................................................................................................................................................................................................................................... 750
			Description and Operation................................................................................................................................................................................................................................................. 750
				Relief Valves in Steering and Lift Circuits........................................................................................................................................................................................................................... 750
				Reducer Valve......................................................................................................................................................................................................................................................... 750
				Hydraulic Filters..................................................................................................................................................................................................................................................... 750
			Hydraulic Filters......................................................................................................................................................................................................................................................... 751
				Suction Filters....................................................................................................................................................................................................................................................... 751
				High Pressure Filter.................................................................................................................................................................................................................................................. 752
				Brake Filter.......................................................................................................................................................................................................................................................... 752
				Return Line Filters................................................................................................................................................................................................................................................... 753
			Hydraulic Hose Repair..................................................................................................................................................................................................................................................... 754
			Checks and Adjustments.................................................................................................................................................................................................................................................... 754
				Pilot Setting, Check.................................................................................................................................................................................................................................................. 754
				Return Pressure, Check................................................................................................................................................................................................................................................ 754
				Main Function Relief Valve Pressure, Check............................................................................................................................................................................................................................ 754
				Hydraulic Tank Breathers.............................................................................................................................................................................................................................................. 756
		Specifications................................................................................................................................................................................................................................................................ 756
			Hydraulic Pumps Output at 2100 rpm (Governed Speed)....................................................................................................................................................................................................................... 756
				Cummins 300 Hp (224 kW)/335 Hp (250 kW) Engine........................................................................................................................................................................................................................ 756
			Relief Valves (Approximate Operating Pressures)........................................................................................................................................................................................................................... 757
			Check Port Pressures...................................................................................................................................................................................................................................................... 757
			Main Hydraulic Filters.................................................................................................................................................................................................................................................... 757
			Tank Capacity............................................................................................................................................................................................................................................................. 757
		Torque Specifications......................................................................................................................................................................................................................................................... 758
			Remote Control Valves..................................................................................................................................................................................................................................................... 758
			Attachment Control Valve.................................................................................................................................................................................................................................................. 758
			Carriage Solenoid Valve................................................................................................................................................................................................................................................... 758
		Troubleshooting............................................................................................................................................................................................................................................................... 759
			Lift and Lower Circuit.................................................................................................................................................................................................................................................... 759
			Tilt Circuit.............................................................................................................................................................................................................................................................. 762
			Attachment Circuit Valves................................................................................................................................................................................................................................................. 764
			Attachment Control Valve.................................................................................................................................................................................................................................................. 765
			Carriage Solenoid Valve................................................................................................................................................................................................................................................... 765
			Other Hydraulic Components................................................................................................................................................................................................................................................ 766
			Accumulator Circuit....................................................................................................................................................................................................................................................... 766
			5 MPa ( 725 psi) Pilot Circuit............................................................................................................................................................................................................................................ 766
			Park Brake Circuit........................................................................................................................................................................................................................................................ 767
	tables............................................................................................................................................................................................................................................................................ 721
		Table 1. Brake Treadle Settings............................................................................................................................................................................................................................................... 730
		Table 2. Gauge Ranges......................................................................................................................................................................................................................................................... 755
		Table 3. Pressure Settings.................................................................................................................................................................................................................................................... 755
1648455-0100SRM1301-(01-2007)-UK-EN................................................................................................................................................................................................................................................... 777
	toc............................................................................................................................................................................................................................................................................... 777
		Operator's Cab................................................................................................................................................................................................................................................................ 777
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 778
		General....................................................................................................................................................................................................................................................................... 781
		Cab Repair.................................................................................................................................................................................................................................................................... 783
			Rear Cab Assembly......................................................................................................................................................................................................................................................... 783
			Bottom Cab Assembly....................................................................................................................................................................................................................................................... 784
			Raising and Lowering...................................................................................................................................................................................................................................................... 784
				Raise Cab............................................................................................................................................................................................................................................................. 784
				Lower Cab............................................................................................................................................................................................................................................................. 785
			Cab Repair................................................................................................................................................................................................................................................................ 785
				Remove................................................................................................................................................................................................................................................................ 785
				Install............................................................................................................................................................................................................................................................... 786
			Oil Filling for Tilt System............................................................................................................................................................................................................................................... 787
		Inching/Brake and Brake Pedals................................................................................................................................................................................................................................................ 788
			Brake Pedal, Adjust....................................................................................................................................................................................................................................................... 788
			Inching Pedal, Adjust..................................................................................................................................................................................................................................................... 788
			Inching Pedal Sensor, Adjust.............................................................................................................................................................................................................................................. 788
			Inching Cable, Adjust..................................................................................................................................................................................................................................................... 789
		Throttle Pedal Sensor Adjustment.............................................................................................................................................................................................................................................. 789
			Cable Alignment........................................................................................................................................................................................................................................................... 789
				Engine Side........................................................................................................................................................................................................................................................... 789
				Pedal Housing Side.................................................................................................................................................................................................................................................... 790
			Check..................................................................................................................................................................................................................................................................... 790
			Adjust.................................................................................................................................................................................................................................................................... 790
		Seat Assembly Removal......................................................................................................................................................................................................................................................... 790
		Power-Assist Armrest.......................................................................................................................................................................................................................................................... 791
			Adjust.................................................................................................................................................................................................................................................................... 791
		Steering Column Repair........................................................................................................................................................................................................................................................ 792
			Remove.................................................................................................................................................................................................................................................................... 792
			Install................................................................................................................................................................................................................................................................... 792
		Window Wipers Replacement..................................................................................................................................................................................................................................................... 793
			Window Wiper Assembly, Replace............................................................................................................................................................................................................................................ 793
			Front Window Wiper Motor Assembly, Replace................................................................................................................................................................................................................................ 793
			Rear Window Wiper Motor Assembly, Replace................................................................................................................................................................................................................................. 794
			Top Window Wiper Motor Assembly, Replace.................................................................................................................................................................................................................................. 794
		Window Washer Motors and Pumps................................................................................................................................................................................................................................................ 795
			Window Wiper and Washer Operating Switches................................................................................................................................................................................................................................ 795
		Window Replacement............................................................................................................................................................................................................................................................ 796
			Front Window, Replace..................................................................................................................................................................................................................................................... 797
			Rear Window, Replace...................................................................................................................................................................................................................................................... 797
			Top Window, Replace....................................................................................................................................................................................................................................................... 797
			Door Window, Replace...................................................................................................................................................................................................................................................... 798
		Heater and Air Conditioning Assembly.......................................................................................................................................................................................................................................... 798
			Heater Parts, Replace..................................................................................................................................................................................................................................................... 800
			Heat Control Knob/Switches................................................................................................................................................................................................................................................ 801
			Heat Control Knob/Cable................................................................................................................................................................................................................................................... 801
				Adjust................................................................................................................................................................................................................................................................ 801
			Air Control Knob/Cable.................................................................................................................................................................................................................................................... 802
				Adjust................................................................................................................................................................................................................................................................ 802
			Air Filter, Replace....................................................................................................................................................................................................................................................... 802
			Air Conditioning Condenser Fan(s)......................................................................................................................................................................................................................................... 802
				Remove................................................................................................................................................................................................................................................................ 802
				Install............................................................................................................................................................................................................................................................... 802
		Instruments, Switches, and Controls........................................................................................................................................................................................................................................... 803
			Switches.................................................................................................................................................................................................................................................................. 803
			Controls.................................................................................................................................................................................................................................................................. 804
		Fuses, Relays, and Power Sources.............................................................................................................................................................................................................................................. 806
			Fuse Panel................................................................................................................................................................................................................................................................ 806
			Fuses..................................................................................................................................................................................................................................................................... 806
			Relays.................................................................................................................................................................................................................................................................... 807
			Power Sources............................................................................................................................................................................................................................................................. 808
		Label Replacement............................................................................................................................................................................................................................................................. 809
1648456-0100SRM1302-(01-2007)-UK-EN................................................................................................................................................................................................................................................... 813
	toc............................................................................................................................................................................................................................................................................... 813
		Frame......................................................................................................................................................................................................................................................................... 813
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 814
		General....................................................................................................................................................................................................................................................................... 817
		Description................................................................................................................................................................................................................................................................... 817
		Counterweight Repair.......................................................................................................................................................................................................................................................... 818
			General................................................................................................................................................................................................................................................................... 818
			Remove.................................................................................................................................................................................................................................................................... 818
			Install................................................................................................................................................................................................................................................................... 819
		Covers........................................................................................................................................................................................................................................................................ 820
			Remove.................................................................................................................................................................................................................................................................... 820
			Install................................................................................................................................................................................................................................................................... 820
		Floor Plates, Handrails, and Steps............................................................................................................................................................................................................................................ 822
		Hydraulic Tank Repair......................................................................................................................................................................................................................................................... 824
			Remove.................................................................................................................................................................................................................................................................... 824
			Repair.................................................................................................................................................................................................................................................................... 826
				Small Leaks........................................................................................................................................................................................................................................................... 826
				Large Leaks........................................................................................................................................................................................................................................................... 826
			Clean..................................................................................................................................................................................................................................................................... 826
				Steam Method.......................................................................................................................................................................................................................................................... 826
				Chemical Solution Method.............................................................................................................................................................................................................................................. 826
			Other Methods of Preparation for Repair................................................................................................................................................................................................................................... 827
			Install................................................................................................................................................................................................................................................................... 827
			Suction Screen and Inspection Cover....................................................................................................................................................................................................................................... 828
				Remove................................................................................................................................................................................................................................................................ 828
				Clean and Inspect..................................................................................................................................................................................................................................................... 828
				Install............................................................................................................................................................................................................................................................... 829
		Fuel Tank Repair.............................................................................................................................................................................................................................................................. 829
			Remove.................................................................................................................................................................................................................................................................... 829
			Repair.................................................................................................................................................................................................................................................................... 829
			Install................................................................................................................................................................................................................................................................... 829
		Exhaust System Repair......................................................................................................................................................................................................................................................... 832
			Remove.................................................................................................................................................................................................................................................................... 832
			Install................................................................................................................................................................................................................................................................... 833
		Engine Repair................................................................................................................................................................................................................................................................. 833
			Remove.................................................................................................................................................................................................................................................................... 833
			Install................................................................................................................................................................................................................................................................... 834
		Label Replacement............................................................................................................................................................................................................................................................. 836
	tables............................................................................................................................................................................................................................................................................ 813
		Table 1. Counterweight Weights (Up to February 2007).......................................................................................................................................................................................................................... 818
		Table 2. Counterweight Weights (February 2007 and Up)......................................................................................................................................................................................................................... 818
		Table 3. Counterweight Weights................................................................................................................................................................................................................................................ 818
1648457-0700SRM1303-(01-2007)-UK-EN................................................................................................................................................................................................................................................... 839
	toc............................................................................................................................................................................................................................................................................... 839
		Multiple Aligned Cooling System............................................................................................................................................................................................................................................... 839
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 840
		General....................................................................................................................................................................................................................................................................... 843
		Description................................................................................................................................................................................................................................................................... 844
			Radiator.................................................................................................................................................................................................................................................................. 844
			Radiator Cap.............................................................................................................................................................................................................................................................. 844
			Thermostat................................................................................................................................................................................................................................................................ 844
			Water Pump................................................................................................................................................................................................................................................................ 845
			Fan and Fan Shroud........................................................................................................................................................................................................................................................ 845
		Cooling System Checks......................................................................................................................................................................................................................................................... 845
			Radiator.................................................................................................................................................................................................................................................................. 845
			Thermostat................................................................................................................................................................................................................................................................ 845
			Water Pump................................................................................................................................................................................................................................................................ 846
			Exhaust Leaks............................................................................................................................................................................................................................................................. 846
			Fan and Fan Shroud........................................................................................................................................................................................................................................................ 846
		Cooling System Repair......................................................................................................................................................................................................................................................... 846
			Remove.................................................................................................................................................................................................................................................................... 846
			Install................................................................................................................................................................................................................................................................... 848
		Core Repair................................................................................................................................................................................................................................................................... 848
			Remove.................................................................................................................................................................................................................................................................... 848
			Install................................................................................................................................................................................................................................................................... 848
		Radiator Cleaning............................................................................................................................................................................................................................................................. 849
			Drain..................................................................................................................................................................................................................................................................... 849
			Clean..................................................................................................................................................................................................................................................................... 849
			Fill...................................................................................................................................................................................................................................................................... 849
		Troubleshooting............................................................................................................................................................................................................................................................... 850
1648458-2200SRM1304-(01-2007)-UK-EN................................................................................................................................................................................................................................................... 853
	toc............................................................................................................................................................................................................................................................................... 853
		Electrical System............................................................................................................................................................................................................................................................. 853
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 854
		Description................................................................................................................................................................................................................................................................... 857
		Warning Devices............................................................................................................................................................................................................................................................... 861
			General................................................................................................................................................................................................................................................................... 861
			Description............................................................................................................................................................................................................................................................... 861
				Operator-Controlled Air Horn.......................................................................................................................................................................................................................................... 861
				Reverse Warning Horns/Lights.......................................................................................................................................................................................................................................... 862
				Warning Lights........................................................................................................................................................................................................................................................ 862
					Strobe Lights..................................................................................................................................................................................................................................................... 862
					Brake Lights...................................................................................................................................................................................................................................................... 862
					Hazard Lights..................................................................................................................................................................................................................................................... 862
				Replace............................................................................................................................................................................................................................................................... 864
					General........................................................................................................................................................................................................................................................... 864
					Horns............................................................................................................................................................................................................................................................. 864
					Horn Relay........................................................................................................................................................................................................................................................ 864
					Light Assemblies.................................................................................................................................................................................................................................................. 864
					Flashing Unit..................................................................................................................................................................................................................................................... 864
		Meters, Senders, and Switches................................................................................................................................................................................................................................................. 865
			General................................................................................................................................................................................................................................................................... 865
1648459-8000SRM1305-(01-2007)-UK-EN................................................................................................................................................................................................................................................... 873
	toc............................................................................................................................................................................................................................................................................... 873
		Capacities and Specifications................................................................................................................................................................................................................................................. 873
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 874
		Counterweight Weights......................................................................................................................................................................................................................................................... 877
		Carriage Weights.............................................................................................................................................................................................................................................................. 878
		Vehicle Weight................................................................................................................................................................................................................................................................ 878
		Capacities.................................................................................................................................................................................................................................................................... 878
		Electrical System............................................................................................................................................................................................................................................................. 878
		Engine Specifications (Cummins QSM11)......................................................................................................................................................................................................................................... 879
		Mast Weights.................................................................................................................................................................................................................................................................. 879
		Lifting and Lowering Speeds................................................................................................................................................................................................................................................... 880
		Tires......................................................................................................................................................................................................................................................................... 880
		Forks......................................................................................................................................................................................................................................................................... 880
		Hydraulic System Specifications............................................................................................................................................................................................................................................... 881
		Torque Specifications......................................................................................................................................................................................................................................................... 882
			Control Valves............................................................................................................................................................................................................................................................ 882
			Electrical System......................................................................................................................................................................................................................................................... 882
			Counterweight (Fabricated)................................................................................................................................................................................................................................................ 882
			Counterweight (Secondary)................................................................................................................................................................................................................................................. 882
			Counterweight (Slab)...................................................................................................................................................................................................................................................... 882
			Drive Axle................................................................................................................................................................................................................................................................ 882
			Wheel Bearing Adjusting Nut............................................................................................................................................................................................................................................... 882
			Differential.............................................................................................................................................................................................................................................................. 882
			Transmission.............................................................................................................................................................................................................................................................. 882
			Torque Converter.......................................................................................................................................................................................................................................................... 882
			Steering.................................................................................................................................................................................................................................................................. 882
			Wheel Nuts................................................................................................................................................................................................................................................................ 883
			Carriages (All)........................................................................................................................................................................................................................................................... 883
	tables............................................................................................................................................................................................................................................................................ 873
		Table 1. Up to February 2007.................................................................................................................................................................................................................................................. 877
		Table 2. February 2007 and Up................................................................................................................................................................................................................................................. 877
		Table 3. March 2007 and Up.................................................................................................................................................................................................................................................... 877
		Table 4. Slab Counterweight (Up to February 2007)............................................................................................................................................................................................................................. 877
1648460-8000SRM1306-(01-2007)-UK-EN................................................................................................................................................................................................................................................... 887
	toc............................................................................................................................................................................................................................................................................... 887
		Assembly Guide................................................................................................................................................................................................................................................................ 887
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 888
		List of All Special Tools and Equipment Needed for the Assembly............................................................................................................................................................................................................... 891
		General Considerations Before Starting the Job................................................................................................................................................................................................................................ 891
		Preparation of the Components Before Assembly................................................................................................................................................................................................................................. 892
		Wheels Check.................................................................................................................................................................................................................................................................. 892
			Air Pressure.............................................................................................................................................................................................................................................................. 892
				Drive Wheels.......................................................................................................................................................................................................................................................... 893
				Steer Wheels.......................................................................................................................................................................................................................................................... 898
			Wheel Nut Torque.......................................................................................................................................................................................................................................................... 901
		Installation of the Exhaust Extension Pipe.................................................................................................................................................................................................................................... 903
		Preparation of the Mast....................................................................................................................................................................................................................................................... 904
			Mast...................................................................................................................................................................................................................................................................... 904
			Mast Label Placement...................................................................................................................................................................................................................................................... 906
		Safety Procedures When Working Near Mast...................................................................................................................................................................................................................................... 907
		Mast Installation............................................................................................................................................................................................................................................................. 907
			Mast...................................................................................................................................................................................................................................................................... 907
			Tilt Cylinder Pin Installation............................................................................................................................................................................................................................................ 909
			Truck Header Hoses and Electrical Cable Connections....................................................................................................................................................................................................................... 910
		Lights Installation - Operator Compartment.................................................................................................................................................................................................................................... 913
		General Procedures After Assembly............................................................................................................................................................................................................................................. 914
		Hydraulic Oil Check........................................................................................................................................................................................................................................................... 914
		Lubrication Points............................................................................................................................................................................................................................................................ 915
		Check Points.................................................................................................................................................................................................................................................................. 915
			Checkpoint 1.............................................................................................................................................................................................................................................................. 915
			Checkpoint 2.............................................................................................................................................................................................................................................................. 915
			Checkpoint 3.............................................................................................................................................................................................................................................................. 915
			Checkpoint 4.............................................................................................................................................................................................................................................................. 915
			Checkpoint 5.............................................................................................................................................................................................................................................................. 915
		General Truck Install Procedures.............................................................................................................................................................................................................................................. 915
ACCUMULATOR........................................................................................................................................................................................................................................................................... 921
	toc............................................................................................................................................................................................................................................................................... 921
		Brake Accumulator............................................................................................................................................................................................................................................................. 921
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 922
		General....................................................................................................................................................................................................................................................................... 925
		Description and Operation..................................................................................................................................................................................................................................................... 925
		Accumulator Maintenance....................................................................................................................................................................................................................................................... 925
			Precharge Check........................................................................................................................................................................................................................................................... 925
			Precharge Filling......................................................................................................................................................................................................................................................... 926
			Remove.................................................................................................................................................................................................................................................................... 927
			Disassemble............................................................................................................................................................................................................................................................... 927
			Clean..................................................................................................................................................................................................................................................................... 929
			Inspect................................................................................................................................................................................................................................................................... 929
			Repair.................................................................................................................................................................................................................................................................... 929
			Assemble.................................................................................................................................................................................................................................................................. 929
			Replace................................................................................................................................................................................................................................................................... 929
	tables............................................................................................................................................................................................................................................................................ 921
		Table 1. Accumulator Pressures................................................................................................................................................................................................................................................ 926
Aurora_AC............................................................................................................................................................................................................................................................................. 933
	912-100-0148_engl_1.pdf........................................................................................................................................................................................................................................................... 934
		Compressors - Applications, Conditions of Use and Liability................................................................................................................................................................................................................... 934
			.......................................................................................................................................................................................................................................................................... 940
				Filling procedure for refrigerants.................................................................................................................................................................................................................................... 940
					Do not exceed the maximum operating pressure of the compressor. (see type label).................................................................................................................................................................................. 940
					Compressors are machines under pressure and as such require special care in handling.............................................................................................................................................................................. 940
					Only qualified personnel are allowed to perform any work on refrigeration compressors............................................................................................................................................................................. 940
					The national safety regulations, accident prevention regulations, technical rules and specific regulations must be taken into account abolutely................................................................................................................... 940
					Never put the safety switch out of action......................................................................................................................................................................................................................... 940
					Prior to commissioning, check wether all teh components installed by the user have been fastened expertly and connected pressure-tight with the compressor........................................................................................................ 940
					Prior to starting the compressor open discharge shut-off valve and suction shut-off valve......................................................................................................................................................................... 940
					Do not start the cmpressor in vacuum. Operate the compressor only when the system is charged...................................................................................................................................................................... 940
					Caution! Danger of burning because of high surface temperatures................................................................................................................................................................................................... 940
					Never grab rotating parts during operation. Danger of injury!..................................................................................................................................................................................................... 940
					Avoid all contact with the liquid refrigerant. Any parts of skin that come into contact with it must be treated like chilblains. Wear goggles to protect eyes. If refrigerant nevertheless gets into the eyes, consult a doctor immediately. Wear leather glov.... 940
					Before repairing refrigerant circuits, all refrigerant must be suctioned off as instructed. Note: Even when the unit is empty, there may be some residual pressure. It is advisable to loosen the screws slowly to allow residual pressure to subside. Refri.... 940
					No welding may be performed on any part of the unit or in the near vicinity while it is closed. Regardless whether the unit is filled with refrigerant or empty, heating causes excess pressure which can damage the unit or cause an explosion................... 940
					Full bottles of refrigerant must not be thrown or................................................................................................................................................................................................................. 940
					It is essential to ensure that the refrigerant system is does not become contaminated with chlorine, substances containing chlorine, oil or grease. Evacuation and filling units must be used for R 134a only..................................................... 940
		4. Troubleshooting............................................................................................................................................................................................................................................................ 941
			.......................................................................................................................................................................................................................................................................... 941
				...................................................................................................................................................................................................................................................................... 941
					Check refrigerant level and pressure as instructed in the Technical Information sheet for the unit................................................................................................................................................................ 941
					By wrong refrigerant level there is a danger of compressor malfunction............................................................................................................................................................................................ 941
					The outcome of too much refrigerant is a oil attenuation and reflux of the refrigerant can cause damages on the valve plate....................................................................................................................................... 941
					With undercharged refrigerant the compressor will become hotwhich caused a failure. The sealing will be damaged................................................................................................................................................... 941
					Faulty shaft seals:On older compressors the shaft seal can be damaged when the unit is switched on for first time after a prolonged period of disuse, e.g. if the air-conditioner has not been used during the winter. Seals may become brittle as a result o.... 941
					NoisesMechanical faults in compressors are generally indicated by unusual noises or by unusually quiet or noisy operation. The normal noise made by the seals during operation does not indicate a fault. The most common noises are caused by problems with..... 941
					Electrical faultsA 5A fuse is used for the magnetic coupling on the compressor. The magnetic coupling can be checked by applying the required voltage to the connection socket while the vehicle engine is running. The coupling should start up with a click.... 941
	912-100-0007_e.pdf................................................................................................................................................................................................................................................................ 942
		Technical modifications reserved.............................................................................................................................................................................................................................................. 942
	912-100-0258_e.pdf................................................................................................................................................................................................................................................................ 953
		Condenser unit, 24V........................................................................................................................................................................................................................................................... 953
			.......................................................................................................................................................................................................................................................................... 953
				...................................................................................................................................................................................................................................................................... 953
					.................................................................................................................................................................................................................................................................. 953
						.............................................................................................................................................................................................................................................................. 953
							part no.:175-FR2-0002..................................................................................................................................................................................................................................... 953
						Safety advices................................................................................................................................................................................................................................................ 953
			- we reserve the right to make technical modifications -.................................................................................................................................................................................................................. 953
		1Safety advices............................................................................................................................................................................................................................................................... 954
			Maintenance work on the refrigeration circuit:............................................................................................................................................................................................................................ 954
				...................................................................................................................................................................................................................................................................... 955
					2.2Condenser blowers.............................................................................................................................................................................................................................................. 955
					5Electrical connection............................................................................................................................................................................................................................................ 956
			every six months – authorised workshop:................................................................................................................................................................................................................................... 957
				...................................................................................................................................................................................................................................................................... 957
					.................................................................................................................................................................................................................................................................. 957
						.............................................................................................................................................................................................................................................................. 957
							State of the refrigerant hoses............................................................................................................................................................................................................................ 957
				State of the condenser................................................................................................................................................................................................................................................ 957
			A contaminated condenser has a minimised condensing performance. The cleaning is carried out by blow-out or spraying (do not use a high-pressure cleaner)................................................................................................................. 957
			every month sight checks - Operator....................................................................................................................................................................................................................................... 958
				...................................................................................................................................................................................................................................................................... 958
					.................................................................................................................................................................................................................................................................. 958
						.............................................................................................................................................................................................................................................................. 958
							State of the refrigerant hoses............................................................................................................................................................................................................................ 958
				State of the condenser................................................................................................................................................................................................................................................ 958
			Check condenser of contamination by dust, insects or parts of plants...................................................................................................................................................................................................... 958
			A contaminated condenser has a minimised condensing performance. The cleaning is carried out by blow-out or spraying (do not use a high-pressure cleaner)................................................................................................................. 958
				Installation of replacement parts..................................................................................................................................................................................................................................... 958
					8Technical data................................................................................................................................................................................................................................................... 958
					9Fault diagnosis.................................................................................................................................................................................................................................................. 959
CUMMINS DIESEL ENGINE FAULT CODE GUIDE................................................................................................................................................................................................................................................ 964
	toc............................................................................................................................................................................................................................................................................... 964
		Cummins Diesel/LPG Engine Fault Code Guide.................................................................................................................................................................................................................................... 964
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 965
		General....................................................................................................................................................................................................................................................................... 968
		Fault Codes................................................................................................................................................................................................................................................................... 968
			Normal Mode............................................................................................................................................................................................................................................................... 968
			Fault Log Mode............................................................................................................................................................................................................................................................ 968
				Access................................................................................................................................................................................................................................................................ 968
				Exit.................................................................................................................................................................................................................................................................. 969
				Clear................................................................................................................................................................................................................................................................. 969
			Electronic Throttle Calibration........................................................................................................................................................................................................................................... 969
				Electronic Throttle Calibration Procedure............................................................................................................................................................................................................................. 969
	tables............................................................................................................................................................................................................................................................................ 964
		Table 1. Error Code Descriptions.............................................................................................................................................................................................................................................. 970
DIFFERENTIAL.......................................................................................................................................................................................................................................................................... 986
	toc............................................................................................................................................................................................................................................................................... 986
		Differential.................................................................................................................................................................................................................................................................. 986
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 987
		General....................................................................................................................................................................................................................................................................... 990
		Description................................................................................................................................................................................................................................................................... 990
		Differential Repair........................................................................................................................................................................................................................................................... 991
			Remove.................................................................................................................................................................................................................................................................... 991
				Differential Carrier From Axle Housing, Remove........................................................................................................................................................................................................................ 991
				Differential and Ring Gear From Differential Carrier, Remove.......................................................................................................................................................................................................... 993
				Drive Pinion and Pinion Carrier From Differential Carrier, Remov...................................................................................................................................................................................................... 995
			Disassemble............................................................................................................................................................................................................................................................... 996
				Differential and Ring Gear Assembly, Disassemble...................................................................................................................................................................................................................... 996
				Drive Pinion and Pinion Carrier, Disassemble.......................................................................................................................................................................................................................... 998
			Clean and Inspect.........................................................................................................................................................................................................................................................1001
			Assemble..................................................................................................................................................................................................................................................................1002
				Pinion, Bearings, and Pinion Carrier, Assemble........................................................................................................................................................................................................................1002
				Pinion Bearings, Adjust Preload.......................................................................................................................................................................................................................................1002
					Press Method......................................................................................................................................................................................................................................................1002
					Yoke or Flange Method.............................................................................................................................................................................................................................................1003
				Triple-Lip Seal, Install..............................................................................................................................................................................................................................................1004
				Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion)...........................................................................................................................................................................................................1005
				Differential and Ring Gear, Assemble..................................................................................................................................................................................................................................1007
				Differential Gears Rotating Torque, Check.............................................................................................................................................................................................................................1009
				Differential and Ring Gear Assembly, Install..........................................................................................................................................................................................................................1010
				Differential Bearings, Preload Adjust.................................................................................................................................................................................................................................1012
				Ring Gear, Runout Check...............................................................................................................................................................................................................................................1013
				Ring Gear Backlash, Adjust............................................................................................................................................................................................................................................1013
				Gear Set, Tooth Contact Pattern Check.................................................................................................................................................................................................................................1015
				Thrust Screw, Install and Adjust......................................................................................................................................................................................................................................1018
			Install...................................................................................................................................................................................................................................................................1018
				Differential Assembly Into Axle Housing, Install......................................................................................................................................................................................................................1018
		Specifications................................................................................................................................................................................................................................................................1020
		Troubleshooting...............................................................................................................................................................................................................................................................1025
	tables............................................................................................................................................................................................................................................................................ 986
		Table 1. Ring Gear Backlash Adjustment Specifications.........................................................................................................................................................................................................................1015
		Table 2. Ring and Pinion Tooth Contact Adjustment.............................................................................................................................................................................................................................1016
		Table 3. General Specifications...............................................................................................................................................................................................................................................1020
		Table 4. Rivet Installation Pressure..........................................................................................................................................................................................................................................1020
		Table 5. Pinion Adjustment....................................................................................................................................................................................................................................................1021
		Table 6. Pinion Preload Pressure..............................................................................................................................................................................................................................................1021
		Table 7. Torque Specifications................................................................................................................................................................................................................................................1022
		Table 8. Torque Specifications for Metric Hardware............................................................................................................................................................................................................................1023
		Table 9. Torque Specifications for Metric (Fine) Hardware.....................................................................................................................................................................................................................1024
FRAME.................................................................................................................................................................................................................................................................................1028
	toc...............................................................................................................................................................................................................................................................................1028
		Frame.........................................................................................................................................................................................................................................................................1028
		Safety Precautions Maintenance and Repair.....................................................................................................................................................................................................................................1029
		General.......................................................................................................................................................................................................................................................................1032
		Description...................................................................................................................................................................................................................................................................1032
		Counterweight Repair..........................................................................................................................................................................................................................................................1033
			General...................................................................................................................................................................................................................................................................1033
			Remove....................................................................................................................................................................................................................................................................1033
			Install...................................................................................................................................................................................................................................................................1034
		Covers........................................................................................................................................................................................................................................................................1035
			Remove....................................................................................................................................................................................................................................................................1035
			Install...................................................................................................................................................................................................................................................................1035
		Floor Plates, Handrails, and Steps............................................................................................................................................................................................................................................1037
		Hydraulic Tank Repair.........................................................................................................................................................................................................................................................1039
			Remove....................................................................................................................................................................................................................................................................1039
			Repair....................................................................................................................................................................................................................................................................1041
				Small Leaks...........................................................................................................................................................................................................................................................1041
				Large Leaks...........................................................................................................................................................................................................................................................1041
			Clean.....................................................................................................................................................................................................................................................................1041
				Steam Method..........................................................................................................................................................................................................................................................1041
				Chemical Solution Method..............................................................................................................................................................................................................................................1041
			Other Methods of Preparation for Repair...................................................................................................................................................................................................................................1042
			Install...................................................................................................................................................................................................................................................................1042
			Suction Screen and Inspection Cover.......................................................................................................................................................................................................................................1043
				Remove................................................................................................................................................................................................................................................................1043
				Clean and Inspect.....................................................................................................................................................................................................................................................1043
				Install...............................................................................................................................................................................................................................................................1044
		Fuel Tank Repair..............................................................................................................................................................................................................................................................1044
			Remove....................................................................................................................................................................................................................................................................1044
			Repair....................................................................................................................................................................................................................................................................1044
			Install...................................................................................................................................................................................................................................................................1044
		Exhaust System Repair.........................................................................................................................................................................................................................................................1047
			Remove....................................................................................................................................................................................................................................................................1047
			Install...................................................................................................................................................................................................................................................................1048
		Engine Repair.................................................................................................................................................................................................................................................................1048
			Remove....................................................................................................................................................................................................................................................................1048
			Install...................................................................................................................................................................................................................................................................1049
		Label Replacement.............................................................................................................................................................................................................................................................1051
	tables............................................................................................................................................................................................................................................................................1028
		Table 1. Counterweight Weights (Up to February 2007)..........................................................................................................................................................................................................................1033
		Table 2. Counterweight Weights (February 2007 and Up).........................................................................................................................................................................................................................1033
		Table 3. Counterweight Weights................................................................................................................................................................................................................................................1033
MULTIPLE ALIGNED COOLING SYSTEM.......................................................................................................................................................................................................................................................1054
	toc...............................................................................................................................................................................................................................................................................1054
		Multiple Aligned Cooling System...............................................................................................................................................................................................................................................1054
		Safety Precautions Maintenance and Repair.....................................................................................................................................................................................................................................1055
		General.......................................................................................................................................................................................................................................................................1058
		Description...................................................................................................................................................................................................................................................................1059
			Radiator..................................................................................................................................................................................................................................................................1059
			Radiator Cap..............................................................................................................................................................................................................................................................1059
			Thermostat................................................................................................................................................................................................................................................................1059
			Water Pump................................................................................................................................................................................................................................................................1060
			Fan and Fan Shroud........................................................................................................................................................................................................................................................1060
		Cooling System Checks.........................................................................................................................................................................................................................................................1060
			Radiator..................................................................................................................................................................................................................................................................1060
			Thermostat................................................................................................................................................................................................................................................................1060
			Water Pump................................................................................................................................................................................................................................................................1061
			Exhaust Leaks.............................................................................................................................................................................................................................................................1061
			Fan and Fan Shroud........................................................................................................................................................................................................................................................1061
		Cooling System Repair.........................................................................................................................................................................................................................................................1061
			Remove....................................................................................................................................................................................................................................................................1061
			Install...................................................................................................................................................................................................................................................................1063
		Core Repair...................................................................................................................................................................................................................................................................1063
			Remove....................................................................................................................................................................................................................................................................1063
			Install...................................................................................................................................................................................................................................................................1063
		Radiator Cleaning.............................................................................................................................................................................................................................................................1064
			Drain.....................................................................................................................................................................................................................................................................1064
			Clean.....................................................................................................................................................................................................................................................................1064
			Fill......................................................................................................................................................................................................................................................................1064
		Troubleshooting...............................................................................................................................................................................................................................................................1065
OPERATOR''S CAB.......................................................................................................................................................................................................................................................................1068
	toc...............................................................................................................................................................................................................................................................................1068
		Operator's Cab................................................................................................................................................................................................................................................................1068
		Safety Precautions Maintenance and Repair.....................................................................................................................................................................................................................................1069
		General.......................................................................................................................................................................................................................................................................1072
		Cab Repair....................................................................................................................................................................................................................................................................1074
			Rear Cab Assembly.........................................................................................................................................................................................................................................................1074
			Bottom Cab Assembly.......................................................................................................................................................................................................................................................1075
			Raising and Lowering......................................................................................................................................................................................................................................................1075
				Raise Cab.............................................................................................................................................................................................................................................................1075
				Lower Cab.............................................................................................................................................................................................................................................................1076
			Cab Repair................................................................................................................................................................................................................................................................1076
				Remove................................................................................................................................................................................................................................................................1076
				Install...............................................................................................................................................................................................................................................................1077
			Oil Filling for Tilt System...............................................................................................................................................................................................................................................1078
		Inching/Brake and Brake Pedals................................................................................................................................................................................................................................................1079
			Brake Pedal, Adjust.......................................................................................................................................................................................................................................................1079
			Inching Pedal, Adjust.....................................................................................................................................................................................................................................................1079
			Inching Pedal Sensor, Adjust..............................................................................................................................................................................................................................................1079
			Inching Cable, Adjust.....................................................................................................................................................................................................................................................1080
		Throttle Pedal Sensor Adjustment..............................................................................................................................................................................................................................................1080
			Cable Alignment...........................................................................................................................................................................................................................................................1080
				Engine Side...........................................................................................................................................................................................................................................................1080
				Pedal Housing Side....................................................................................................................................................................................................................................................1081
			Check.....................................................................................................................................................................................................................................................................1081
			Adjust....................................................................................................................................................................................................................................................................1081
		Seat Assembly Removal.........................................................................................................................................................................................................................................................1081
		Power-Assist Armrest..........................................................................................................................................................................................................................................................1082
			Adjust....................................................................................................................................................................................................................................................................1082
		Steering Column Repair........................................................................................................................................................................................................................................................1083
			Remove....................................................................................................................................................................................................................................................................1083
			Install...................................................................................................................................................................................................................................................................1083
		Window Wipers Replacement.....................................................................................................................................................................................................................................................1084
			Window Wiper Assembly, Replace............................................................................................................................................................................................................................................1084
			Front Window Wiper Motor Assembly, Replace................................................................................................................................................................................................................................1084
			Rear Window Wiper Motor Assembly, Replace.................................................................................................................................................................................................................................1085
			Top Window Wiper Motor Assembly, Replace..................................................................................................................................................................................................................................1085
		Window Washer Motors and Pumps................................................................................................................................................................................................................................................1086
			Window Wiper and Washer Operating Switches................................................................................................................................................................................................................................1086
		Window Replacement............................................................................................................................................................................................................................................................1087
			Front Window, Replace.....................................................................................................................................................................................................................................................1088
			Rear Window, Replace......................................................................................................................................................................................................................................................1088
			Top Window, Replace.......................................................................................................................................................................................................................................................1088
			Door Window, Replace......................................................................................................................................................................................................................................................1089
		Heater and Air Conditioning Assembly..........................................................................................................................................................................................................................................1089
			Heater Parts, Replace.....................................................................................................................................................................................................................................................1091
			Heat Control Knob/Switches................................................................................................................................................................................................................................................1092
			Heat Control Knob/Cable...................................................................................................................................................................................................................................................1092
				Adjust................................................................................................................................................................................................................................................................1092
			Air Control Knob/Cable....................................................................................................................................................................................................................................................1093
				Adjust................................................................................................................................................................................................................................................................1093
			Air Filter, Replace.......................................................................................................................................................................................................................................................1093
			Air Conditioning Condenser Fan(s).........................................................................................................................................................................................................................................1093
				Remove................................................................................................................................................................................................................................................................1093
				Install...............................................................................................................................................................................................................................................................1093
		Instruments, Switches, and Controls...........................................................................................................................................................................................................................................1094
			Switches..................................................................................................................................................................................................................................................................1094
			Controls..................................................................................................................................................................................................................................................................1095
		Fuses, Relays, and Power Sources..............................................................................................................................................................................................................................................1097
			Fuse Panel................................................................................................................................................................................................................................................................1097
			Fuses.....................................................................................................................................................................................................................................................................1097
			Relays....................................................................................................................................................................................................................................................................1098
			Power Sources.............................................................................................................................................................................................................................................................1099
		Label Replacement.............................................................................................................................................................................................................................................................1100
PLANETARY GEAR AXLE...................................................................................................................................................................................................................................................................1104
	toc...............................................................................................................................................................................................................................................................................1104
		Planetary Gear Axle...........................................................................................................................................................................................................................................................1104
		Safety Precautions Maintenance and Repair.....................................................................................................................................................................................................................................1105
		General.......................................................................................................................................................................................................................................................................1108
		Description...................................................................................................................................................................................................................................................................1108
		Operation.....................................................................................................................................................................................................................................................................1108
		Planetary Gear Axle Repair....................................................................................................................................................................................................................................................1112
			Remove....................................................................................................................................................................................................................................................................1112
				Drive Wheels and Tires................................................................................................................................................................................................................................................1112
			Disassemble...............................................................................................................................................................................................................................................................1113
				Drive Axle............................................................................................................................................................................................................................................................1113
				Planetary Gear Carrier................................................................................................................................................................................................................................................1114
				Ring Gear, Ring Gear Hub, and Wheel Hub...............................................................................................................................................................................................................................1115
				Hub Oil Seal and Bearings.............................................................................................................................................................................................................................................1117
				Axle Shaft............................................................................................................................................................................................................................................................1117
				Spindle...............................................................................................................................................................................................................................................................1117
			Repair....................................................................................................................................................................................................................................................................1118
				Repairing or Replacing Parts..........................................................................................................................................................................................................................................1118
				Welding...............................................................................................................................................................................................................................................................1118
			Clean.....................................................................................................................................................................................................................................................................1119
				Ground or Polished Parts..............................................................................................................................................................................................................................................1119
				Parts With Rough Finishes.............................................................................................................................................................................................................................................1119
				Axle Assemblies.......................................................................................................................................................................................................................................................1119
				Drying Cleaned Parts..................................................................................................................................................................................................................................................1119
			Preventing Corrosion......................................................................................................................................................................................................................................................1119
			Parts Inspection..........................................................................................................................................................................................................................................................1119
			Assemble..................................................................................................................................................................................................................................................................1120
				Spindle...............................................................................................................................................................................................................................................................1120
				Axle Shaft............................................................................................................................................................................................................................................................1120
				Hub Oil Seal and Bearings.............................................................................................................................................................................................................................................1120
				Ring Gear, Ring Gear Hub, and Wheel Hub...............................................................................................................................................................................................................................1121
				Wheel Bearing Preload.................................................................................................................................................................................................................................................1121
					Adjust............................................................................................................................................................................................................................................................1121
				Planetary Gear Carrier................................................................................................................................................................................................................................................1123
				Drive Axle............................................................................................................................................................................................................................................................1124
				Wheel Ends............................................................................................................................................................................................................................................................1125
					Fill..............................................................................................................................................................................................................................................................1125
			Install...................................................................................................................................................................................................................................................................1125
				Drive Wheels and Tires................................................................................................................................................................................................................................................1125
		Torque Specifications.........................................................................................................................................................................................................................................................1129
		Troubleshooting...............................................................................................................................................................................................................................................................1130
	tables............................................................................................................................................................................................................................................................................1104
		Table 1. Wheel Bearing Adjustment Torque......................................................................................................................................................................................................................................1122
		Table 2. Planetary Gear Carrier Capscrew and Stud Torque Specifi..............................................................................................................................................................................................................1124
		Table 3. Standard Torque Values for Axle Fasteners............................................................................................................................................................................................................................1129
STEERING AXLE.........................................................................................................................................................................................................................................................................1134
	toc...............................................................................................................................................................................................................................................................................1134
		Steering Axle.................................................................................................................................................................................................................................................................1134
		Safety Precautions Maintenance and Repair.....................................................................................................................................................................................................................................1135
		General.......................................................................................................................................................................................................................................................................1138
		Description...................................................................................................................................................................................................................................................................1138
		How To Put Lift Truck On Blocks...............................................................................................................................................................................................................................................1139
			How to Lift Steer Tires...................................................................................................................................................................................................................................................1139
		Steering Axle Assembly........................................................................................................................................................................................................................................................1141
			Remove....................................................................................................................................................................................................................................................................1141
			Install...................................................................................................................................................................................................................................................................1142
		Wheels and Hubs...............................................................................................................................................................................................................................................................1143
			Remove and Disassemble....................................................................................................................................................................................................................................................1143
			Clean.....................................................................................................................................................................................................................................................................1143
			Assemble and Install......................................................................................................................................................................................................................................................1144
		Spindles, Bearings, and Tie Rods..............................................................................................................................................................................................................................................1145
			Remove....................................................................................................................................................................................................................................................................1145
			Install...................................................................................................................................................................................................................................................................1146
		Steering Cylinder.............................................................................................................................................................................................................................................................1148
			Remove and Disassemble....................................................................................................................................................................................................................................................1148
			Clean and Inspect.........................................................................................................................................................................................................................................................1149
			Assemble and Install......................................................................................................................................................................................................................................................1149
		Torque Specifications.........................................................................................................................................................................................................................................................1150
		Troubleshooting...............................................................................................................................................................................................................................................................1150
STEERING SYSTEM.......................................................................................................................................................................................................................................................................1154
	toc...............................................................................................................................................................................................................................................................................1154
		Steering System...............................................................................................................................................................................................................................................................1154
		Safety Precautions Maintenance and Repair.....................................................................................................................................................................................................................................1155
		General.......................................................................................................................................................................................................................................................................1158
		Description...................................................................................................................................................................................................................................................................1158
		Steering Wheel and Column Assembly Repair.....................................................................................................................................................................................................................................1160
			General...................................................................................................................................................................................................................................................................1160
			Steering Wheel and Horn...................................................................................................................................................................................................................................................1160
				Remove................................................................................................................................................................................................................................................................1160
				Install...............................................................................................................................................................................................................................................................1160
		Steering Column...............................................................................................................................................................................................................................................................1162
			Remove....................................................................................................................................................................................................................................................................1162
			Install...................................................................................................................................................................................................................................................................1162
		Steering Control Unit Repair..................................................................................................................................................................................................................................................1163
			General...................................................................................................................................................................................................................................................................1163
			Description...............................................................................................................................................................................................................................................................1163
			Operation.................................................................................................................................................................................................................................................................1163
			Remove....................................................................................................................................................................................................................................................................1163
			Disassemble...............................................................................................................................................................................................................................................................1165
			Clean.....................................................................................................................................................................................................................................................................1168
			Assemble..................................................................................................................................................................................................................................................................1168
			Install...................................................................................................................................................................................................................................................................1174
		Steering System Air Removal...................................................................................................................................................................................................................................................1174
		Steering Relief Pressure Check and Adjustments................................................................................................................................................................................................................................1174
		Flow Amplifier Repair.........................................................................................................................................................................................................................................................1176
			General...................................................................................................................................................................................................................................................................1176
			Description...............................................................................................................................................................................................................................................................1176
			Operation.................................................................................................................................................................................................................................................................1176
				Neutral Position......................................................................................................................................................................................................................................................1176
				During Steering Function..............................................................................................................................................................................................................................................1176
				Manual Steering Function..............................................................................................................................................................................................................................................1178
			Disassemble...............................................................................................................................................................................................................................................................1178
				Pressure Relief Valve.................................................................................................................................................................................................................................................1178
				End Cover at PP Port..................................................................................................................................................................................................................................................1178
				End Cover at LS Port..................................................................................................................................................................................................................................................1178
				Spools................................................................................................................................................................................................................................................................1179
				Directional Valve Spool...............................................................................................................................................................................................................................................1179
				Priority Valve Spool..................................................................................................................................................................................................................................................1179
				Pressure Control/Amplifier Valve Spool................................................................................................................................................................................................................................1179
				Check Valve...........................................................................................................................................................................................................................................................1180
				Cushion/Suction Valves................................................................................................................................................................................................................................................1180
			Clean.....................................................................................................................................................................................................................................................................1181
			Assemble..................................................................................................................................................................................................................................................................1181
		Troubleshooting...............................................................................................................................................................................................................................................................1182
TRANSMISSION TE27 AND TE32............................................................................................................................................................................................................................................................1186
	toc...............................................................................................................................................................................................................................................................................1186
		Transmission..................................................................................................................................................................................................................................................................1186
		Safety Precautions Maintenance and Repair.....................................................................................................................................................................................................................................1187
		Description of Operation......................................................................................................................................................................................................................................................1192
			General...................................................................................................................................................................................................................................................................1192
			Torque Convertor, Pump Drive, and Pressure Regulating Valve...............................................................................................................................................................................................................1193
			Input Shaft and Directional Clutches......................................................................................................................................................................................................................................1193
			Range Clutches............................................................................................................................................................................................................................................................1194
			Output Section............................................................................................................................................................................................................................................................1194
			Transmission Controls.....................................................................................................................................................................................................................................................1195
				Valve Operation.......................................................................................................................................................................................................................................................1195
				Directional Selection.................................................................................................................................................................................................................................................1195
				Range Selection.......................................................................................................................................................................................................................................................1196
				Neutral Selection.....................................................................................................................................................................................................................................................1196
				Total Neutral Selection...............................................................................................................................................................................................................................................1196
				Pressure Switch.......................................................................................................................................................................................................................................................1197
			Electric Solenoid Controls................................................................................................................................................................................................................................................1197
			Transmission Specifications...............................................................................................................................................................................................................................................1226
				Transmission Identification...........................................................................................................................................................................................................................................1226
				Weight, Dimensions, and Oil Capacity..................................................................................................................................................................................................................................1226
		Transmission Repair...........................................................................................................................................................................................................................................................1227
			Remove....................................................................................................................................................................................................................................................................1227
			Disassemble...............................................................................................................................................................................................................................................................1229
				Transmission Case, Disassemble........................................................................................................................................................................................................................................1229
				Converter Housing, Disassemble........................................................................................................................................................................................................................................1253
				Reverse and Second-Speed Clutch.......................................................................................................................................................................................................................................1255
					Reverse, Disassemble..............................................................................................................................................................................................................................................1255
					Second-Speed Clutch, Disassemble..................................................................................................................................................................................................................................1259
				Forward Clutch, Disassemble...........................................................................................................................................................................................................................................1261
				Third-Speed Clutch, Disassemble.......................................................................................................................................................................................................................................1267
				Fourth-Speed Clutch, Disassemble......................................................................................................................................................................................................................................1271
				First-Speed Clutch, Disassemble.......................................................................................................................................................................................................................................1274
				Output Shaft, Disassemble.............................................................................................................................................................................................................................................1280
				Turbine Shaft, Disassemble............................................................................................................................................................................................................................................1281
				Impeller and Baffle, Disassemble......................................................................................................................................................................................................................................1283
				Impeller Cover and Turbine Assembly, Disassemble......................................................................................................................................................................................................................1286
				Pump Drive Gear, Disassemble..........................................................................................................................................................................................................................................1287
			Clean and Inspect.........................................................................................................................................................................................................................................................1288
				Housings..............................................................................................................................................................................................................................................................1288
				Oil Seals and Gaskets.................................................................................................................................................................................................................................................1288
				Bearings..............................................................................................................................................................................................................................................................1289
				Gears and Shafts......................................................................................................................................................................................................................................................1289
			Assemble..................................................................................................................................................................................................................................................................1289
				Pump Drive Gear, Assemble.............................................................................................................................................................................................................................................1289
				Impeller Cover and Turbine, Assemble..................................................................................................................................................................................................................................1290
				Impeller and Baffle, Assemble.........................................................................................................................................................................................................................................1292
				Turbine Shaft, Assemble...............................................................................................................................................................................................................................................1295
				Output Shaft, Assemble................................................................................................................................................................................................................................................1296
				First-Speed Clutch, Assemble..........................................................................................................................................................................................................................................1298
				Fourth-Speed Clutch, Assemble.........................................................................................................................................................................................................................................1305
				Third-Speed Clutch, Assemble..........................................................................................................................................................................................................................................1309
				Forward Clutch, Assemble..............................................................................................................................................................................................................................................1315
				Reverse and Second-Speed Clutch.......................................................................................................................................................................................................................................1321
					Second-Speed Clutch, Assemble.....................................................................................................................................................................................................................................1321
					Reverse Clutch, Assemble..........................................................................................................................................................................................................................................1325
				Converter Housing, Assemble...........................................................................................................................................................................................................................................1331
				Transmission Case, Assemble...........................................................................................................................................................................................................................................1334
			Install...................................................................................................................................................................................................................................................................1355
		Speed Sensors.................................................................................................................................................................................................................................................................1358
			Type of Sensors...........................................................................................................................................................................................................................................................1358
				Speed Sensor With 2-Pin Connector.....................................................................................................................................................................................................................................1358
				Speed Sensor With 3-Pin Connector.....................................................................................................................................................................................................................................1358
			Speed Sensor, Install.....................................................................................................................................................................................................................................................1359
		Control Valve Repair..........................................................................................................................................................................................................................................................1360
			Remove....................................................................................................................................................................................................................................................................1360
			Disassemble and Assemble..................................................................................................................................................................................................................................................1360
			Clean and Inspect.........................................................................................................................................................................................................................................................1360
				Housings..............................................................................................................................................................................................................................................................1362
				Oil Seals and Gaskets.................................................................................................................................................................................................................................................1362
			Install...................................................................................................................................................................................................................................................................1362
		Stall Test....................................................................................................................................................................................................................................................................1364
		Transmission Calibration and Electrical Troubleshooting.......................................................................................................................................................................................................................1365
			Userlink®.................................................................................................................................................................................................................................................................1365
			Connection................................................................................................................................................................................................................................................................1365
			Clutch Filling Calibration................................................................................................................................................................................................................................................1365
				Purpose...............................................................................................................................................................................................................................................................1365
				Clutch Filling Calibration Procedure..................................................................................................................................................................................................................................1365
				Alternative Clutch Filling Calibration Procedure......................................................................................................................................................................................................................1366
				Heat-up Mode..........................................................................................................................................................................................................................................................1367
				Heat-up Mode Stall Test...............................................................................................................................................................................................................................................1367
			Inching Pedal Calibration.................................................................................................................................................................................................................................................1368
				Purpose...............................................................................................................................................................................................................................................................1368
				Brake Pedal Adjustment................................................................................................................................................................................................................................................1368
				Inching Pedal Adjustment (Except for C227)............................................................................................................................................................................................................................1368
				Inching Pedal Sensor Adjustment (Except for C227).....................................................................................................................................................................................................................1369
				Inching Pedal Calibration Procedure (Except for C227).................................................................................................................................................................................................................1369
				Verification/Adjustment of Inching Pedal Sensor When Pedal is Fu......................................................................................................................................................................................................1370
				Manual Inching Pedal Sensor Calibration Procedure (Except for C2......................................................................................................................................................................................................1370
			Troubleshooting...........................................................................................................................................................................................................................................................1370
			Transmission Display Warning Codes........................................................................................................................................................................................................................................1371
				Access................................................................................................................................................................................................................................................................1371
				Clear.................................................................................................................................................................................................................................................................1371
				Exit..................................................................................................................................................................................................................................................................1371
				Limp Home Mode........................................................................................................................................................................................................................................................1407
				Shutdown Mode.........................................................................................................................................................................................................................................................1408
				Pressure Feedback Sensor..............................................................................................................................................................................................................................................1408
		Transmission Oil Pressure Check...............................................................................................................................................................................................................................................1408
			Pressure and Temperature Specifications...................................................................................................................................................................................................................................1408
		Clutch Discs..................................................................................................................................................................................................................................................................1412
		Electrical Specifications.....................................................................................................................................................................................................................................................1414
		Hydraulic Cooler Lines Specifications.........................................................................................................................................................................................................................................1414
		Torque Specifications.........................................................................................................................................................................................................................................................1415
			Torque Specifications for Lubricated or Plated Screw Threads..............................................................................................................................................................................................................1415
		Troubleshooting...............................................................................................................................................................................................................................................................1417
	tables............................................................................................................................................................................................................................................................................1186
		Table 1. Electric Solenoid Controls...........................................................................................................................................................................................................................................1198
		Table 2. 2-Pin Connector Wiring...............................................................................................................................................................................................................................................1358
		Table 3. 3-Pin Connector Wiring...............................................................................................................................................................................................................................................1358
		Table 4. Controller Connector J2 Wire to Pin Number Cross Refere..............................................................................................................................................................................................................1372
		Table 5. Controller Connector J1 Wire to Pin Number Cross Refere..............................................................................................................................................................................................................1373
		Table 6. Common Calibration Condition Messages................................................................................................................................................................................................................................1375
		Table 7. Calibration Codes During Calibration.................................................................................................................................................................................................................................1376
		Table 8. Error Codes During Calibration.......................................................................................................................................................................................................................................1376
		Table 9. Display Warning Codes................................................................................................................................................................................................................................................1377
		Table 10. Display Warning Exceed Codes........................................................................................................................................................................................................................................1406
		Table 11. Type of Warning Codes...............................................................................................................................................................................................................................................1407
		Table 12. Forward/Reverse Clutch..............................................................................................................................................................................................................................................1412
		Table 13. First-Speed Clutch..................................................................................................................................................................................................................................................1412
		Table 14. Second-Speed Clutch.................................................................................................................................................................................................................................................1413
		Table 15. Third-Speed Clutch..................................................................................................................................................................................................................................................1413
		Table 16. Fourth-Speed Clutch.................................................................................................................................................................................................................................................1414
		Table 17. Grade 5.............................................................................................................................................................................................................................................................1415
		Table 18. Grade 8.............................................................................................................................................................................................................................................................1415
		Table 19. Grades 8.8, 10.9, and 12.9..........................................................................................................................................................................................................................................1416
		Table 20. Elastic Stop Nut Torque.............................................................................................................................................................................................................................................1417
		Table 21. O-ring Port Plug Torque Chart.......................................................................................................................................................................................................................................1417
		Table 22. Pipe Plug Torque Chart..............................................................................................................................................................................................................................................1417
		Table 23. Pipe Plug Torque Chart..............................................................................................................................................................................................................................................1417

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