Hyster A917 (H800-900-1050HD, H800-900-970-1050HDS) Service Manual – PDF DOWNLOAD

Description

Hyster A917 (H800-900-1050HD, H800-900-970-1050HDS) Service Manual – PDF DOWNLOAD

DESCRIPTION:

Hyster A917 (H800-900-1050HD, H800-900-970-1050HDS) 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 (H800-900-1050HD, H800-900-970-1050HDS) Service Manual – PDF DOWNLOAD

910072-1400SRM0046-(07-2007)-US-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)-US-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)-US-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)-US-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)-US-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)-US-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)-US-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)-US-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)-US-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)-US-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)-US-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)-US-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................................................................................................................................................................................................................................................291
				Drive Axle............................................................................................................................................................................................................................................................292
				Wheel Ends............................................................................................................................................................................................................................................................293
					Fill..............................................................................................................................................................................................................................................................293
			Install...................................................................................................................................................................................................................................................................293
				Drive Wheels and Tires................................................................................................................................................................................................................................................293
		Torque Specifications.........................................................................................................................................................................................................................................................297
		Troubleshooting...............................................................................................................................................................................................................................................................298
	tables............................................................................................................................................................................................................................................................................273
		Table 1. Wheel Bearing Adjustment Torque......................................................................................................................................................................................................................................290
		Table 2. Planetary Gear Carrier Capscrew and Stud Torque Specifi..............................................................................................................................................................................................................292
		Table 3. Standard Torque Values for Axle Fasteners............................................................................................................................................................................................................................297
1616438-2000SRM1233-(01-2007)-US-EN...................................................................................................................................................................................................................................................301
	toc...............................................................................................................................................................................................................................................................................301
		Hydraulic Plate...............................................................................................................................................................................................................................................................301
		Safety Precautions Maintenance and Repair.....................................................................................................................................................................................................................................302
		General.......................................................................................................................................................................................................................................................................305
		Description and Operation.....................................................................................................................................................................................................................................................306
			Hydraulic Oil Supply......................................................................................................................................................................................................................................................306
			Manifold, Section 1 of Hydraulic Plate....................................................................................................................................................................................................................................306
			Main Control Valve, Section 2 of Hydraulic Plate..........................................................................................................................................................................................................................306
				Description...........................................................................................................................................................................................................................................................306
				Operation.............................................................................................................................................................................................................................................................307
					Auxiliary Section.................................................................................................................................................................................................................................................307
					Tilt Section......................................................................................................................................................................................................................................................307
					Lift Section......................................................................................................................................................................................................................................................307
			Return Manifold, Section 3 of Hydraulic Plate.............................................................................................................................................................................................................................307
			Brake Manifold, Section 4 of Hydraulic Plate..............................................................................................................................................................................................................................311
				Cooling Circuit.......................................................................................................................................................................................................................................................311
				Service Brake.........................................................................................................................................................................................................................................................311
				Parking Brake.........................................................................................................................................................................................................................................................311
			Flow Amplifier, Section 5 of Hydraulic Plate..............................................................................................................................................................................................................................311
		Manifold, Section 1 of Hydraulic Plate........................................................................................................................................................................................................................................311
			General...................................................................................................................................................................................................................................................................311
			Valves and Pressure Switches..............................................................................................................................................................................................................................................312
		Main Control Valve, Section 2 of Hydraulic Plate..............................................................................................................................................................................................................................315
			Remove....................................................................................................................................................................................................................................................................315
			Disassemble...............................................................................................................................................................................................................................................................315
				Auxiliary Section.....................................................................................................................................................................................................................................................315
				Lift Section..........................................................................................................................................................................................................................................................316
				Lift/Tilt Section.....................................................................................................................................................................................................................................................318
			Clean and Inspect.........................................................................................................................................................................................................................................................319
			Assemble..................................................................................................................................................................................................................................................................319
				Auxiliary Section.....................................................................................................................................................................................................................................................319
				Lift Section..........................................................................................................................................................................................................................................................319
				Lift/Tilt Section.....................................................................................................................................................................................................................................................320
			Install...................................................................................................................................................................................................................................................................320
		Return Manifold, Section 3 of Hydraulic Plate.................................................................................................................................................................................................................................321
			Remove....................................................................................................................................................................................................................................................................321
			Disassemble...............................................................................................................................................................................................................................................................321
			Clean and Inspect.........................................................................................................................................................................................................................................................322
			Assemble..................................................................................................................................................................................................................................................................322
			Install...................................................................................................................................................................................................................................................................322
		Brake Manifold, Section 4 of Hydraulic Plate..................................................................................................................................................................................................................................323
			Remove....................................................................................................................................................................................................................................................................323
			Clean and Inspect.........................................................................................................................................................................................................................................................323
			Install...................................................................................................................................................................................................................................................................323
		Flow Amplifier, Section 5 of Hydraulic Plate..................................................................................................................................................................................................................................324
		Hydraulic Hose Repair.........................................................................................................................................................................................................................................................324
		Hydraulic Hose Identification.................................................................................................................................................................................................................................................324
		Torque Values.................................................................................................................................................................................................................................................................326
		Measurements and Adjustments..................................................................................................................................................................................................................................................327
			Measurements..............................................................................................................................................................................................................................................................327
			Adjustments...............................................................................................................................................................................................................................................................327
		Troubleshooting...............................................................................................................................................................................................................................................................328
	tables............................................................................................................................................................................................................................................................................301
		Table 1. Pilot Hoses..........................................................................................................................................................................................................................................................325
		Table 2. Brake Hoses..........................................................................................................................................................................................................................................................325
		Table 3. Auxiliary Hoses With Alternating P and T.............................................................................................................................................................................................................................325
		Table 4. Steer Hoses..........................................................................................................................................................................................................................................................325
		Table 5. Pressure Settings at 2100 RPM........................................................................................................................................................................................................................................327
1616439-2200SRM1234-(07-2007)-US-EN...................................................................................................................................................................................................................................................337
	toc...............................................................................................................................................................................................................................................................................337
		Instrument Panel Indicators and Senders.......................................................................................................................................................................................................................................337
		Safety Precautions Maintenance and Repair.....................................................................................................................................................................................................................................338
		General.......................................................................................................................................................................................................................................................................341
		Description...................................................................................................................................................................................................................................................................341
			General...................................................................................................................................................................................................................................................................341
			Instrument Panel Meters, Indicators, and LCD Display......................................................................................................................................................................................................................341
			Connector.................................................................................................................................................................................................................................................................346
				Seat Switch Logic.....................................................................................................................................................................................................................................................347
				Central Warning Light Output..........................................................................................................................................................................................................................................347
				Buzzer Output.........................................................................................................................................................................................................................................................347
		Instrument Panel Component Replacement........................................................................................................................................................................................................................................349
			Instrument Panel..........................................................................................................................................................................................................................................................349
				Remove................................................................................................................................................................................................................................................................349
			Light.....................................................................................................................................................................................................................................................................350
				Replace...............................................................................................................................................................................................................................................................350
		Sender Replacement............................................................................................................................................................................................................................................................350
			Fuel Level Sender.........................................................................................................................................................................................................................................................350
			Pressure Sender...........................................................................................................................................................................................................................................................351
			Temperature Sender........................................................................................................................................................................................................................................................351
			Low Coolant Sender........................................................................................................................................................................................................................................................352
			Vacuum Switch.............................................................................................................................................................................................................................................................352
			Crankshaft Position Sensor................................................................................................................................................................................................................................................352
	tables............................................................................................................................................................................................................................................................................337
		Table 1. Instrument Panel and Indicators......................................................................................................................................................................................................................................342
		Table 2. Pin Description......................................................................................................................................................................................................................................................346
		Table 3. Sender Description...................................................................................................................................................................................................................................................347
1616442-8000SRM1236-(03-2007)-US-EN...................................................................................................................................................................................................................................................355
	toc...............................................................................................................................................................................................................................................................................355
		Diagrams......................................................................................................................................................................................................................................................................355
		Safety Precautions Maintenance and Repair.....................................................................................................................................................................................................................................356
1616443-8000SRM1237-(01-2007)-US-EN...................................................................................................................................................................................................................................................419
	toc...............................................................................................................................................................................................................................................................................419
		Periodic Maintenance..........................................................................................................................................................................................................................................................419
		Safety Precautions Maintenance and Repair.....................................................................................................................................................................................................................................420
		General.......................................................................................................................................................................................................................................................................425
			Serial Number Data........................................................................................................................................................................................................................................................425
			How to Move Disabled Lift Truck...........................................................................................................................................................................................................................................425
				How to Tow Lift Truck.................................................................................................................................................................................................................................................426
			How to Put Lift Truck on Blocks...........................................................................................................................................................................................................................................426
				How to Raise Drive Tires..............................................................................................................................................................................................................................................426
				How to Raise Steering Tires...........................................................................................................................................................................................................................................427
		Maintenance Schedule..........................................................................................................................................................................................................................................................428
			Spreader Maintenance......................................................................................................................................................................................................................................................438
		Maintenance Procedures Every 8 Hours or Daily.................................................................................................................................................................................................................................439
			How to Make Checks With the Engine Stopped................................................................................................................................................................................................................................439
				Safety Labels.........................................................................................................................................................................................................................................................439
				Operator Restraint System.............................................................................................................................................................................................................................................440
					Safety Belt and Seat Rails........................................................................................................................................................................................................................................440
					Steering Column Latch.............................................................................................................................................................................................................................................440
				Tires and Wheels......................................................................................................................................................................................................................................................440
				Forks.................................................................................................................................................................................................................................................................441
					Adjust............................................................................................................................................................................................................................................................441
					Remove............................................................................................................................................................................................................................................................441
					Low Mount Forks, Install..........................................................................................................................................................................................................................................441
				Forks, Mast, and Lift Chains, Inspect.................................................................................................................................................................................................................................442
				Drive Belt............................................................................................................................................................................................................................................................443
				Crankcase Breather Tube...............................................................................................................................................................................................................................................443
				Air Intake Piping and Charge Air Piping...............................................................................................................................................................................................................................443
				Cooling Fan...........................................................................................................................................................................................................................................................444
				Pre-Cleaner for Air Filter............................................................................................................................................................................................................................................444
				Fuel, Oil, or Coolant Leaks...........................................................................................................................................................................................................................................445
				Hydraulic Tank Breather...............................................................................................................................................................................................................................................445
				Engine Oil............................................................................................................................................................................................................................................................445
				Hydraulic System Oil..................................................................................................................................................................................................................................................446
				Hydraulic High Pressure Oil Filter....................................................................................................................................................................................................................................446
				Battery...............................................................................................................................................................................................................................................................447
				Fuel Filter/Water Separator...........................................................................................................................................................................................................................................447
				Cooling System........................................................................................................................................................................................................................................................448
			How to Add Fuel to Lift Truck.............................................................................................................................................................................................................................................449
			How to Make Checks With Engine Running....................................................................................................................................................................................................................................449
				Gauges, Lights, Horn, Fuses, and Relays...............................................................................................................................................................................................................................449
					Sealed Fuses......................................................................................................................................................................................................................................................452
				Transmission Oil......................................................................................................................................................................................................................................................452
				Engine Air Filter.....................................................................................................................................................................................................................................................452
				Engine Oil Pressure...................................................................................................................................................................................................................................................453
				Electrical System.....................................................................................................................................................................................................................................................453
				Steering System.......................................................................................................................................................................................................................................................453
				Service Brakes........................................................................................................................................................................................................................................................453
				Parking Brake.........................................................................................................................................................................................................................................................453
				Control Levers and Pedals.............................................................................................................................................................................................................................................453
				Lift System Operation.................................................................................................................................................................................................................................................453
				Attachments...........................................................................................................................................................................................................................................................454
		First Inspection After First 100 Hours of Operation...........................................................................................................................................................................................................................454
			Engine Oil Filter.........................................................................................................................................................................................................................................................454
			Drive Axle and Differential...............................................................................................................................................................................................................................................454
			Lift Chains...............................................................................................................................................................................................................................................................454
			Transmission Oil Filter...................................................................................................................................................................................................................................................454
			Air Conditioning..........................................................................................................................................................................................................................................................454
			Steer Wheel Hubs..........................................................................................................................................................................................................................................................454
		Maintenance Procedures Every 250 Hours Or Monthly.............................................................................................................................................................................................................................455
			Transmission Oil Filter...................................................................................................................................................................................................................................................455
			Twist Locks (F117 Only)...................................................................................................................................................................................................................................................455
			Gantry Carriage and Container Attachments (F117 Only).....................................................................................................................................................................................................................455
		Maintenance Procedures Every 500 Hours or 3 Months............................................................................................................................................................................................................................455
			Drive Belt................................................................................................................................................................................................................................................................455
			Lift Chains...............................................................................................................................................................................................................................................................455
			Hydraulic Return Line Oil Filter..........................................................................................................................................................................................................................................456
			Air Conditioning..........................................................................................................................................................................................................................................................456
			Wheel Nuts................................................................................................................................................................................................................................................................456
			Heater Air Filter.........................................................................................................................................................................................................................................................456
			Steering Axle Kingpins....................................................................................................................................................................................................................................................456
			Steering Axle Tie Rods....................................................................................................................................................................................................................................................457
			Drive Shaft...............................................................................................................................................................................................................................................................457
			Steering Axle Pivots......................................................................................................................................................................................................................................................457
			Mast and Carriage Load Rollers............................................................................................................................................................................................................................................457
			Mast Pivots, Sliding Surfaces.............................................................................................................................................................................................................................................457
			Sideshift Carriage........................................................................................................................................................................................................................................................457
		Maintenance Procedures Every 500 Hours or 6 Months............................................................................................................................................................................................................................458
			Fuel Filter...............................................................................................................................................................................................................................................................458
			Engine Oil and Filter.....................................................................................................................................................................................................................................................458
			Oil Filter for Oil-Cooled Brakes (Brake Filter)...........................................................................................................................................................................................................................458
			Transmission Oil..........................................................................................................................................................................................................................................................458
				Change................................................................................................................................................................................................................................................................458
		Maintenance Procedures Every 1000 Hours or 6 Months...........................................................................................................................................................................................................................459
			Drive Axle and Differential Oil...........................................................................................................................................................................................................................................459
			Service Brake System......................................................................................................................................................................................................................................................459
			Brake System Accumulator..................................................................................................................................................................................................................................................459
			Hub Bearings, Steer Wheel s...............................................................................................................................................................................................................................................459
			General Lubrication.......................................................................................................................................................................................................................................................459
		Maintenance Procedures Every 1500 Hours or 1 Year.............................................................................................................................................................................................................................459
			Engine....................................................................................................................................................................................................................................................................459
			Water Pump................................................................................................................................................................................................................................................................459
			Turbocharger..............................................................................................................................................................................................................................................................460
			Engine Mounting Bolts.....................................................................................................................................................................................................................................................460
			Air Leaks, Air Intake and Exhaust.........................................................................................................................................................................................................................................461
			Valve and Injector Adjustments............................................................................................................................................................................................................................................462
				General...............................................................................................................................................................................................................................................................462
				Adjust................................................................................................................................................................................................................................................................463
					Injector Adjustment...............................................................................................................................................................................................................................................463
					Valve Adjustment..................................................................................................................................................................................................................................................464
		Maintenance Procedures Every 2000 Hours or 1 Year.............................................................................................................................................................................................................................466
			Parking Brake Assembly....................................................................................................................................................................................................................................................466
				Clean.................................................................................................................................................................................................................................................................466
				Inspect...............................................................................................................................................................................................................................................................466
		Maintenance Procedures Every 3000 Hours or 18 Months..........................................................................................................................................................................................................................468
			Hydraulic Suction Oil Filters.............................................................................................................................................................................................................................................468
		Maintenance Procedures Every 5000 Hours.......................................................................................................................................................................................................................................468
			Container Attachment (F117)...............................................................................................................................................................................................................................................468
		Maintenance Procedures Every 6000 Hours or 2 Years............................................................................................................................................................................................................................468
			Vibration Damper..........................................................................................................................................................................................................................................................468
			Fan Drive Idler Pulley....................................................................................................................................................................................................................................................469
			Fan Hub...................................................................................................................................................................................................................................................................470
			Turbocharger..............................................................................................................................................................................................................................................................470
			Cooling System Fluid......................................................................................................................................................................................................................................................470
		Maintenance Procedures Every 10,000 Hours or 5 Years..........................................................................................................................................................................................................................471
			High Pressure Hydraulic Oil Filter........................................................................................................................................................................................................................................471
		Safety Procedures When Working Near Mast......................................................................................................................................................................................................................................472
		Lift and Tilt System Leaks Check..............................................................................................................................................................................................................................................473
			Lift System...............................................................................................................................................................................................................................................................473
			Tilt System...............................................................................................................................................................................................................................................................473
		Pneumatic Tires and Wheels....................................................................................................................................................................................................................................................474
			Remove Wheels From Lift Truck.............................................................................................................................................................................................................................................474
			Remove Tire From Wheel....................................................................................................................................................................................................................................................474
				Remove Tire From Five-Piece Wheel.....................................................................................................................................................................................................................................475
			Install Tire on Wheel.....................................................................................................................................................................................................................................................476
				Install Tire on Five-Piece Wheel......................................................................................................................................................................................................................................477
			Add Air Pressure to Tires.................................................................................................................................................................................................................................................478
			Install Wheels on Lift Truck..............................................................................................................................................................................................................................................479
	tables............................................................................................................................................................................................................................................................................419
		Table 1. Condition Check......................................................................................................................................................................................................................................................430
		Table 2. Daily Inspections − Fluid Level Check................................................................................................................................................................................................................................431
		Table 3. Daily Inspections − Checks With the Engine Running...................................................................................................................................................................................................................432
		Table 4. First Inspection After First 100 Hours of Operation..................................................................................................................................................................................................................433
		Table 5. Periodic Maintenance Schedule − Inspect and Adjust...................................................................................................................................................................................................................434
		Table 6. Periodic Maintenance Schedule − Lubricate............................................................................................................................................................................................................................436
		Table 7. Periodic Maintenance Schedule − Change...............................................................................................................................................................................................................................437
		Table 8. Container Attachment Maintenance - Lubricate.........................................................................................................................................................................................................................439
		Table 9. Container Attachment Maintenance − Replace...........................................................................................................................................................................................................................439
		Table 10. Valve and Injector Adjustment Specifications........................................................................................................................................................................................................................462
		Table 11. Injector and Valve Measurement Sequence.............................................................................................................................................................................................................................463
1616703-1300SRM1220-(07-2007)-US-EN...................................................................................................................................................................................................................................................483
	toc...............................................................................................................................................................................................................................................................................483
		Transmission..................................................................................................................................................................................................................................................................483
		Safety Precautions Maintenance and Repair.....................................................................................................................................................................................................................................484
		Description of Operation......................................................................................................................................................................................................................................................489
			General...................................................................................................................................................................................................................................................................489
			Torque Convertor, Pump Drive, and Pressure Regulating Valve...............................................................................................................................................................................................................490
			Input Shaft and Directional Clutches......................................................................................................................................................................................................................................490
			Range Clutches............................................................................................................................................................................................................................................................491
			Output Section............................................................................................................................................................................................................................................................491
			Transmission Controls.....................................................................................................................................................................................................................................................492
				Valve Operation.......................................................................................................................................................................................................................................................492
				Directional Selection.................................................................................................................................................................................................................................................492
				Range Selection.......................................................................................................................................................................................................................................................493
				Neutral Selection.....................................................................................................................................................................................................................................................493
				Total Neutral Selection...............................................................................................................................................................................................................................................493
				Pressure Switch.......................................................................................................................................................................................................................................................494
			Electric Solenoid Controls................................................................................................................................................................................................................................................494
			Transmission Specifications...............................................................................................................................................................................................................................................523
				Transmission Identification...........................................................................................................................................................................................................................................523
				Weight, Dimensions, and Oil Capacity..................................................................................................................................................................................................................................523
		Transmission Repair...........................................................................................................................................................................................................................................................524
			Remove....................................................................................................................................................................................................................................................................524
			Disassemble...............................................................................................................................................................................................................................................................526
				Transmission Case, Disassemble........................................................................................................................................................................................................................................526
				Converter Housing, Disassemble........................................................................................................................................................................................................................................550
				Reverse and Second-Speed Clutch.......................................................................................................................................................................................................................................552
					Reverse, Disassemble..............................................................................................................................................................................................................................................552
					Second-Speed Clutch, Disassemble..................................................................................................................................................................................................................................556
				Forward Clutch, Disassemble...........................................................................................................................................................................................................................................558
				Third-Speed Clutch, Disassemble.......................................................................................................................................................................................................................................564
				Fourth-Speed Clutch, Disassemble......................................................................................................................................................................................................................................568
				First-Speed Clutch, Disassemble.......................................................................................................................................................................................................................................571
				Output Shaft, Disassemble.............................................................................................................................................................................................................................................577
				Turbine Shaft, Disassemble............................................................................................................................................................................................................................................578
				Impeller and Baffle, Disassemble......................................................................................................................................................................................................................................580
				Impeller Cover and Turbine Assembly, Disassemble......................................................................................................................................................................................................................583
				Pump Drive Gear, Disassemble..........................................................................................................................................................................................................................................584
			Clean and Inspect.........................................................................................................................................................................................................................................................585
				Housings..............................................................................................................................................................................................................................................................585
				Oil Seals and Gaskets.................................................................................................................................................................................................................................................585
				Bearings..............................................................................................................................................................................................................................................................586
				Gears and Shafts......................................................................................................................................................................................................................................................586
			Assemble..................................................................................................................................................................................................................................................................586
				Pump Drive Gear, Assemble.............................................................................................................................................................................................................................................586
				Impeller Cover and Turbine, Assemble..................................................................................................................................................................................................................................587
				Impeller and Baffle, Assemble.........................................................................................................................................................................................................................................589
				Turbine Shaft, Assemble...............................................................................................................................................................................................................................................592
				Output Shaft, Assemble................................................................................................................................................................................................................................................593
				First-Speed Clutch, Assemble..........................................................................................................................................................................................................................................595
				Fourth-Speed Clutch, Assemble.........................................................................................................................................................................................................................................602
				Third-Speed Clutch, Assemble..........................................................................................................................................................................................................................................606
				Forward Clutch, Assemble..............................................................................................................................................................................................................................................612
				Reverse and Second-Speed Clutch.......................................................................................................................................................................................................................................618
					Second-Speed Clutch, Assemble.....................................................................................................................................................................................................................................618
					Reverse Clutch, Assemble..........................................................................................................................................................................................................................................622
				Converter Housing, Assemble...........................................................................................................................................................................................................................................628
				Transmission Case, Assemble...........................................................................................................................................................................................................................................631
			Install...................................................................................................................................................................................................................................................................652
		Speed Sensors.................................................................................................................................................................................................................................................................655
			Type of Sensors...........................................................................................................................................................................................................................................................655
				Speed Sensor With 2-Pin Connector.....................................................................................................................................................................................................................................655
				Speed Sensor With 3-Pin Connector.....................................................................................................................................................................................................................................655
			Speed Sensor, Install.....................................................................................................................................................................................................................................................656
		Control Valve Repair..........................................................................................................................................................................................................................................................657
			Remove....................................................................................................................................................................................................................................................................657
			Disassemble and Assemble..................................................................................................................................................................................................................................................657
			Clean and Inspect.........................................................................................................................................................................................................................................................657
				Housings..............................................................................................................................................................................................................................................................659
				Oil Seals and Gaskets.................................................................................................................................................................................................................................................659
			Install...................................................................................................................................................................................................................................................................659
		Stall Test....................................................................................................................................................................................................................................................................661
		Transmission Calibration and Electrical Troubleshooting.......................................................................................................................................................................................................................662
			Userlink®.................................................................................................................................................................................................................................................................662
			Connection................................................................................................................................................................................................................................................................662
			Clutch Filling Calibration................................................................................................................................................................................................................................................662
				Purpose...............................................................................................................................................................................................................................................................662
				Clutch Filling Calibration Procedure..................................................................................................................................................................................................................................662
				Alternative Clutch Filling Calibration Procedure......................................................................................................................................................................................................................663
				Heat-up Mode..........................................................................................................................................................................................................................................................664
				Heat-up Mode Stall Test...............................................................................................................................................................................................................................................664
			Inching Pedal Calibration.................................................................................................................................................................................................................................................665
				Purpose...............................................................................................................................................................................................................................................................665
				Brake Pedal Adjustment................................................................................................................................................................................................................................................665
				Inching Pedal Adjustment (Except for C227)............................................................................................................................................................................................................................665
				Inching Pedal Sensor Adjustment (Except for C227).....................................................................................................................................................................................................................666
				Inching Pedal Calibration Procedure (Except for C227).................................................................................................................................................................................................................666
				Verification/Adjustment of Inching Pedal Sensor When Pedal is Fu......................................................................................................................................................................................................667
				Manual Inching Pedal Sensor Calibration Procedure (Except for C2......................................................................................................................................................................................................667
			Troubleshooting...........................................................................................................................................................................................................................................................667
			Transmission Display Warning Codes........................................................................................................................................................................................................................................668
				Access................................................................................................................................................................................................................................................................668
				Clear.................................................................................................................................................................................................................................................................668
				Exit..................................................................................................................................................................................................................................................................668
				Limp Home Mode........................................................................................................................................................................................................................................................704
				Shutdown Mode.........................................................................................................................................................................................................................................................705
				Pressure Feedback Sensor..............................................................................................................................................................................................................................................705
		Transmission Oil Pressure Check...............................................................................................................................................................................................................................................705
			Pressure and Temperature Specifications...................................................................................................................................................................................................................................705
		Clutch Discs..................................................................................................................................................................................................................................................................709
		Electrical Specifications.....................................................................................................................................................................................................................................................711
		Hydraulic Cooler Lines Specifications.........................................................................................................................................................................................................................................711
		Torque Specifications.........................................................................................................................................................................................................................................................712
			Torque Specifications for Lubricated or Plated Screw Threads..............................................................................................................................................................................................................712
		Troubleshooting...............................................................................................................................................................................................................................................................714
	tables............................................................................................................................................................................................................................................................................483
		Table 1. Electric Solenoid Controls...........................................................................................................................................................................................................................................495
		Table 2. 2-Pin Connector Wiring...............................................................................................................................................................................................................................................655
		Table 3. 3-Pin Connector Wiring...............................................................................................................................................................................................................................................655
		Table 4. Controller Connector J2 Wire to Pin Number Cross Refere..............................................................................................................................................................................................................669
		Table 5. Controller Connector J1 Wire to Pin Number Cross Refere..............................................................................................................................................................................................................670
		Table 6. Common Calibration Condition Messages................................................................................................................................................................................................................................672
		Table 7. Calibration Codes During Calibration.................................................................................................................................................................................................................................673
		Table 8. Error Codes During Calibration.......................................................................................................................................................................................................................................673
		Table 9. Display Warning Codes................................................................................................................................................................................................................................................674
		Table 10. Display Warning Exceed Codes........................................................................................................................................................................................................................................703
		Table 11. Type of Warning Codes...............................................................................................................................................................................................................................................704
		Table 12. Forward/Reverse Clutch..............................................................................................................................................................................................................................................709
		Table 13. First-Speed Clutch..................................................................................................................................................................................................................................................709
		Table 14. Second-Speed Clutch.................................................................................................................................................................................................................................................710
		Table 15. Third-Speed Clutch..................................................................................................................................................................................................................................................710
		Table 16. Fourth-Speed Clutch.................................................................................................................................................................................................................................................711
		Table 17. Grade 5.............................................................................................................................................................................................................................................................712
		Table 18. Grade 8.............................................................................................................................................................................................................................................................712
		Table 19. Grades 8.8, 10.9, and 12.9..........................................................................................................................................................................................................................................713
		Table 20. Elastic Stop Nut Torque.............................................................................................................................................................................................................................................714
		Table 21. O-ring Port Plug Torque Chart.......................................................................................................................................................................................................................................714
		Table 22. Pipe Plug Torque Chart..............................................................................................................................................................................................................................................714
		Table 23. Pipe Plug Torque Chart..............................................................................................................................................................................................................................................714
1616924-1900SRM1239-(01-2007)-US-EN...................................................................................................................................................................................................................................................719
	toc...............................................................................................................................................................................................................................................................................719
		Hydraulic System..............................................................................................................................................................................................................................................................719
		Safety Precautions Maintenance and Repair.....................................................................................................................................................................................................................................720
		General.......................................................................................................................................................................................................................................................................725
		Description and Operation.....................................................................................................................................................................................................................................................725
			Hydraulic Plate...........................................................................................................................................................................................................................................................725
			Hydraulic Pumps...........................................................................................................................................................................................................................................................726
			Cab Manifold..............................................................................................................................................................................................................................................................726
				Oil Cooled Brakes (Service Brakes)....................................................................................................................................................................................................................................726
				Lift/Tilt Functions...................................................................................................................................................................................................................................................726
				Over Lower Interrupt..................................................................................................................................................................................................................................................727
				Lift Interrupt........................................................................................................................................................................................................................................................727
			Accumulator Charge Disabling Solenoid (ACDS)..............................................................................................................................................................................................................................727
			Heat Exchanger System.....................................................................................................................................................................................................................................................727
			Steering Control System...................................................................................................................................................................................................................................................727
			Brake System..............................................................................................................................................................................................................................................................727
		Hydraulic Pump Repair.........................................................................................................................................................................................................................................................728
			Remove....................................................................................................................................................................................................................................................................728
			Disassemble...............................................................................................................................................................................................................................................................728
				Tandem Gear Pump......................................................................................................................................................................................................................................................728
				Tri-Section Gear Pump.................................................................................................................................................................................................................................................729
			Clean and Inspect.........................................................................................................................................................................................................................................................730
			Assemble..................................................................................................................................................................................................................................................................730
				Tandem Gear Pump......................................................................................................................................................................................................................................................730
				Tri-Section Gear Pump.................................................................................................................................................................................................................................................731
			Install...................................................................................................................................................................................................................................................................731
			Pump Output Check.........................................................................................................................................................................................................................................................731
				First Method..........................................................................................................................................................................................................................................................731
				Second Method.........................................................................................................................................................................................................................................................732
		Cab Manifold..................................................................................................................................................................................................................................................................734
			Remove....................................................................................................................................................................................................................................................................734
			Disassemble Valves and Pressure Switches..................................................................................................................................................................................................................................734
			Clean and Inspect.........................................................................................................................................................................................................................................................736
			Assemble Valves and Pressure Switches.....................................................................................................................................................................................................................................736
			Install...................................................................................................................................................................................................................................................................736
		Lift and Lower Circuit........................................................................................................................................................................................................................................................737
			Description...............................................................................................................................................................................................................................................................737
			Operation.................................................................................................................................................................................................................................................................737
				Lift Circuit..........................................................................................................................................................................................................................................................738
				Lowering..............................................................................................................................................................................................................................................................738
				Lowering Control Valves...............................................................................................................................................................................................................................................738
			Repairs...................................................................................................................................................................................................................................................................738
				General...............................................................................................................................................................................................................................................................738
				Remote Control Valve..................................................................................................................................................................................................................................................738
					Description and Operation.........................................................................................................................................................................................................................................738
					Remove............................................................................................................................................................................................................................................................738
					Disassemble.......................................................................................................................................................................................................................................................739
					Clean and Inspect.................................................................................................................................................................................................................................................740
					Assemble..........................................................................................................................................................................................................................................................740
					Install...........................................................................................................................................................................................................................................................740
					Adjust............................................................................................................................................................................................................................................................741
				Lift Manifold.........................................................................................................................................................................................................................................................741
					Description and Operation.........................................................................................................................................................................................................................................741
					Remove............................................................................................................................................................................................................................................................741
					Clean and Inspect.................................................................................................................................................................................................................................................741
					Assemble and Install..............................................................................................................................................................................................................................................741
			Checks and Adjustments....................................................................................................................................................................................................................................................743
		Tilt Control Circuit..........................................................................................................................................................................................................................................................744
			Description...............................................................................................................................................................................................................................................................744
			Operation.................................................................................................................................................................................................................................................................744
				Tilt /Lift Spool......................................................................................................................................................................................................................................................744
				Relief Valves in Main Control Valve...................................................................................................................................................................................................................................745
				Relief Valves, Tilt Lock..............................................................................................................................................................................................................................................745
			Repairs...................................................................................................................................................................................................................................................................745
				General...............................................................................................................................................................................................................................................................745
				Relief Valves, Tilt Lock, Disassemble.................................................................................................................................................................................................................................745
				Clean and Inspect.....................................................................................................................................................................................................................................................745
				Checks and Adjustments................................................................................................................................................................................................................................................746
		Attachment Circuit Valves.....................................................................................................................................................................................................................................................746
			General...................................................................................................................................................................................................................................................................746
				Selector Valves Auxiliary Functions...................................................................................................................................................................................................................................746
				Carriage Solenoid Valve...............................................................................................................................................................................................................................................746
			Repairs...................................................................................................................................................................................................................................................................746
				Carriage Solenoid Valve...............................................................................................................................................................................................................................................746
					Remove............................................................................................................................................................................................................................................................746
					Disassemble.......................................................................................................................................................................................................................................................746
					Clean and Inspect.................................................................................................................................................................................................................................................748
					Assemble..........................................................................................................................................................................................................................................................748
					Install...........................................................................................................................................................................................................................................................748
			Checks and Adjustments....................................................................................................................................................................................................................................................748
		Other Hydraulic Components....................................................................................................................................................................................................................................................748
			Description and Operation.................................................................................................................................................................................................................................................748
				Relief Valves in Steering and Lift Circuits...........................................................................................................................................................................................................................748
				Reducer Valve.........................................................................................................................................................................................................................................................748
				Hydraulic Filters.....................................................................................................................................................................................................................................................748
			Hydraulic Filters.........................................................................................................................................................................................................................................................749
				Suction Filters.......................................................................................................................................................................................................................................................749
				High Pressure Filter..................................................................................................................................................................................................................................................750
				Brake Filter..........................................................................................................................................................................................................................................................750
				Return Line Filters...................................................................................................................................................................................................................................................751
			Hydraulic Hose Repair.....................................................................................................................................................................................................................................................752
			Checks and Adjustments....................................................................................................................................................................................................................................................752
				Pilot Setting, Check..................................................................................................................................................................................................................................................752
				Return Pressure, Check................................................................................................................................................................................................................................................752
				Main Function Relief Valve Pressure, Check............................................................................................................................................................................................................................752
				Hydraulic Tank Breathers..............................................................................................................................................................................................................................................754
		Specifications................................................................................................................................................................................................................................................................754
			Hydraulic Pumps Output at 2100 rpm (Governed Speed).......................................................................................................................................................................................................................754
				Cummins 300 Hp (224 kW)/335 Hp (250 kW) Engine........................................................................................................................................................................................................................754
			Relief Valves (Approximate Operating Pressures)...........................................................................................................................................................................................................................755
			Check Port Pressures......................................................................................................................................................................................................................................................755
			Main Hydraulic Filters....................................................................................................................................................................................................................................................755
			Tank Capacity.............................................................................................................................................................................................................................................................755
		Torque Specifications.........................................................................................................................................................................................................................................................756
			Remote Control Valves.....................................................................................................................................................................................................................................................756
			Attachment Control Valve..................................................................................................................................................................................................................................................756
			Carriage Solenoid Valve...................................................................................................................................................................................................................................................756
		Troubleshooting...............................................................................................................................................................................................................................................................757
			Lift and Lower Circuit....................................................................................................................................................................................................................................................757
			Tilt Circuit..............................................................................................................................................................................................................................................................760
			Attachment Circuit Valves.................................................................................................................................................................................................................................................762
			Attachment Control Valve..................................................................................................................................................................................................................................................763
			Carriage Solenoid Valve...................................................................................................................................................................................................................................................763
			Other Hydraulic Components................................................................................................................................................................................................................................................764
			Accumulator Circuit.......................................................................................................................................................................................................................................................764
			5 MPa ( 725 psi) Pilot Circuit............................................................................................................................................................................................................................................764
			Park Brake Circuit........................................................................................................................................................................................................................................................765
	tables............................................................................................................................................................................................................................................................................719
		Table 1. Brake Treadle Settings...............................................................................................................................................................................................................................................728
		Table 2. Gauge Ranges.........................................................................................................................................................................................................................................................753
		Table 3. Pressure Settings....................................................................................................................................................................................................................................................753
1648455-0100SRM1301-(01-2007)-US-EN...................................................................................................................................................................................................................................................775
	toc...............................................................................................................................................................................................................................................................................775
		Operator's Cab................................................................................................................................................................................................................................................................775
		Safety Precautions Maintenance and Repair.....................................................................................................................................................................................................................................776
		General.......................................................................................................................................................................................................................................................................779
		Cab Repair....................................................................................................................................................................................................................................................................781
			Rear Cab Assembly.........................................................................................................................................................................................................................................................781
			Bottom Cab Assembly.......................................................................................................................................................................................................................................................782
			Raising and Lowering......................................................................................................................................................................................................................................................782
				Raise Cab.............................................................................................................................................................................................................................................................782
				Lower Cab.............................................................................................................................................................................................................................................................783
			Cab Repair................................................................................................................................................................................................................................................................783
				Remove................................................................................................................................................................................................................................................................783
				Install...............................................................................................................................................................................................................................................................784
			Oil Filling for Tilt System...............................................................................................................................................................................................................................................785
		Inching/Brake and Brake Pedals................................................................................................................................................................................................................................................786
			Brake Pedal, Adjust.......................................................................................................................................................................................................................................................786
			Inching Pedal, Adjust.....................................................................................................................................................................................................................................................786
			Inching Pedal Sensor, Adjust..............................................................................................................................................................................................................................................786
			Inching Cable, Adjust.....................................................................................................................................................................................................................................................787
		Throttle Pedal Sensor Adjustment..............................................................................................................................................................................................................................................787
			Cable Alignment...........................................................................................................................................................................................................................................................787
				Engine Side...........................................................................................................................................................................................................................................................787
				Pedal Housing Side....................................................................................................................................................................................................................................................788
			Check.....................................................................................................................................................................................................................................................................788
			Adjust....................................................................................................................................................................................................................................................................788
		Seat Assembly Removal.........................................................................................................................................................................................................................................................788
		Power-Assist Armrest..........................................................................................................................................................................................................................................................789
			Adjust....................................................................................................................................................................................................................................................................789
		Steering Column Repair........................................................................................................................................................................................................................................................790
			Remove....................................................................................................................................................................................................................................................................790
			Install...................................................................................................................................................................................................................................................................790
		Window Wipers Replacement.....................................................................................................................................................................................................................................................791
			Window Wiper Assembly, Replace............................................................................................................................................................................................................................................791
			Front Window Wiper Motor Assembly, Replace................................................................................................................................................................................................................................791
			Rear Window Wiper Motor Assembly, Replace.................................................................................................................................................................................................................................792
			Top Window Wiper Motor Assembly, Replace..................................................................................................................................................................................................................................792
		Window Washer Motors and Pumps................................................................................................................................................................................................................................................793
			Window Wiper and Washer Operating Switches................................................................................................................................................................................................................................793
		Window Replacement............................................................................................................................................................................................................................................................794
			Front Window, Replace.....................................................................................................................................................................................................................................................795
			Rear Window, Replace......................................................................................................................................................................................................................................................795
			Top Window, Replace.......................................................................................................................................................................................................................................................795
			Door Window, Replace......................................................................................................................................................................................................................................................796
		Heater and Air Conditioning Assembly..........................................................................................................................................................................................................................................796
			Heater Parts, Replace.....................................................................................................................................................................................................................................................798
			Heat Control Knob/Switches................................................................................................................................................................................................................................................799
			Heat Control Knob/Cable...................................................................................................................................................................................................................................................799
				Adjust................................................................................................................................................................................................................................................................799
			Air Control Knob/Cable....................................................................................................................................................................................................................................................800
				Adjust................................................................................................................................................................................................................................................................800
			Air Filter, Replace.......................................................................................................................................................................................................................................................800
			Air Conditioning Condenser Fan(s).........................................................................................................................................................................................................................................800
				Remove................................................................................................................................................................................................................................................................800
				Install...............................................................................................................................................................................................................................................................800
		Instruments, Switches, and Controls...........................................................................................................................................................................................................................................801
			Switches..................................................................................................................................................................................................................................................................801
			Controls..................................................................................................................................................................................................................................................................802
		Fuses, Relays, and Power Sources..............................................................................................................................................................................................................................................804
			Fuse Panel................................................................................................................................................................................................................................................................804
			Fuses.....................................................................................................................................................................................................................................................................804
			Relays....................................................................................................................................................................................................................................................................805
			Power Sources.............................................................................................................................................................................................................................................................806
		Label Replacement.............................................................................................................................................................................................................................................................807
1648456-0100SRM1302-(01-2007)-US-EN...................................................................................................................................................................................................................................................811
	toc...............................................................................................................................................................................................................................................................................811
		Frame.........................................................................................................................................................................................................................................................................811
		Safety Precautions Maintenance and Repair.....................................................................................................................................................................................................................................812
		General.......................................................................................................................................................................................................................................................................815
		Description...................................................................................................................................................................................................................................................................815
		Counterweight Repair..........................................................................................................................................................................................................................................................816
			General...................................................................................................................................................................................................................................................................816
			Remove....................................................................................................................................................................................................................................................................816
			Install...................................................................................................................................................................................................................................................................817
		Covers........................................................................................................................................................................................................................................................................818
			Remove....................................................................................................................................................................................................................................................................818
			Install...................................................................................................................................................................................................................................................................818
		Floor Plates, Handrails, and Steps............................................................................................................................................................................................................................................820
		Hydraulic Tank Repair.........................................................................................................................................................................................................................................................822
			Remove....................................................................................................................................................................................................................................................................822
			Repair....................................................................................................................................................................................................................................................................824
				Small Leaks...........................................................................................................................................................................................................................................................824
				Large Leaks...........................................................................................................................................................................................................................................................824
			Clean.....................................................................................................................................................................................................................................................................824
				Steam Method..........................................................................................................................................................................................................................................................824
				Chemical Solution Method..............................................................................................................................................................................................................................................824
			Other Methods of Preparation for Repair...................................................................................................................................................................................................................................825
			Install...................................................................................................................................................................................................................................................................825
			Suction Screen and Inspection Cover.......................................................................................................................................................................................................................................826
				Remove................................................................................................................................................................................................................................................................826
				Clean and Inspect.....................................................................................................................................................................................................................................................826
				Install...............................................................................................................................................................................................................................................................827
		Fuel Tank Repair..............................................................................................................................................................................................................................................................827
			Remove....................................................................................................................................................................................................................................................................827
			Repair....................................................................................................................................................................................................................................................................827
			Install...................................................................................................................................................................................................................................................................827
		Exhaust System Repair.........................................................................................................................................................................................................................................................830
			Remove....................................................................................................................................................................................................................................................................830
			Install...................................................................................................................................................................................................................................................................831
		Engine Repair.................................................................................................................................................................................................................................................................831
			Remove....................................................................................................................................................................................................................................................................831
			Install...................................................................................................................................................................................................................................................................832
		Label Replacement.............................................................................................................................................................................................................................................................834
	tables............................................................................................................................................................................................................................................................................811
		Table 1. Counterweight Weights (Up to February 2007)..........................................................................................................................................................................................................................816
		Table 2. Counterweight Weights (February 2007 and Up).........................................................................................................................................................................................................................816
		Table 3. Counterweight Weights................................................................................................................................................................................................................................................816
1648457-0700SRM1303-(01-2007)-US-EN...................................................................................................................................................................................................................................................837
	toc...............................................................................................................................................................................................................................................................................837
		Multiple Aligned Cooling System...............................................................................................................................................................................................................................................837
		Safety Precautions Maintenance and Repair.....................................................................................................................................................................................................................................838
		General.......................................................................................................................................................................................................................................................................841
		Description...................................................................................................................................................................................................................................................................842
			Radiator..................................................................................................................................................................................................................................................................842
			Radiator Cap..............................................................................................................................................................................................................................................................842
			Thermostat................................................................................................................................................................................................................................................................842
			Water Pump................................................................................................................................................................................................................................................................843
			Fan and Fan Shroud........................................................................................................................................................................................................................................................843
		Cooling System Checks.........................................................................................................................................................................................................................................................843
			Radiator..................................................................................................................................................................................................................................................................843
			Thermostat................................................................................................................................................................................................................................................................843
			Water Pump................................................................................................................................................................................................................................................................844
			Exhaust Leaks.............................................................................................................................................................................................................................................................844
			Fan and Fan Shroud........................................................................................................................................................................................................................................................844
		Cooling System Repair.........................................................................................................................................................................................................................................................844
			Remove....................................................................................................................................................................................................................................................................844
			Install...................................................................................................................................................................................................................................................................846
		Core Repair...................................................................................................................................................................................................................................................................846
			Remove....................................................................................................................................................................................................................................................................846
			Install...................................................................................................................................................................................................................................................................846
		Radiator Cleaning.............................................................................................................................................................................................................................................................847
			Drain.....................................................................................................................................................................................................................................................................847
			Clean.....................................................................................................................................................................................................................................................................847
			Fill......................................................................................................................................................................................................................................................................847
		Troubleshooting...............................................................................................................................................................................................................................................................848
1648458-2200SRM1304-(01-2007)-US-EN...................................................................................................................................................................................................................................................851
	toc...............................................................................................................................................................................................................................................................................851
		Electrical System.............................................................................................................................................................................................................................................................851
		Safety Precautions Maintenance and Repair.....................................................................................................................................................................................................................................852
		Description...................................................................................................................................................................................................................................................................855
		Warning Devices...............................................................................................................................................................................................................................................................859
			General...................................................................................................................................................................................................................................................................859
			Description...............................................................................................................................................................................................................................................................859
				Operator-Controlled Air Horn..........................................................................................................................................................................................................................................859
				Reverse Warning Horns/Lights..........................................................................................................................................................................................................................................860
				Warning Lights........................................................................................................................................................................................................................................................860
					Strobe Lights.....................................................................................................................................................................................................................................................860
					Brake Lights......................................................................................................................................................................................................................................................860
					Hazard Lights.....................................................................................................................................................................................................................................................860
				Replace...............................................................................................................................................................................................................................................................862
					General...........................................................................................................................................................................................................................................................862
					Horns.............................................................................................................................................................................................................................................................862
					Horn Relay........................................................................................................................................................................................................................................................862
					Light Assemblies..................................................................................................................................................................................................................................................862
					Flashing Unit.....................................................................................................................................................................................................................................................862
		Meters, Senders, and Switches.................................................................................................................................................................................................................................................863
			General...................................................................................................................................................................................................................................................................863
1648459-8000SRM1305-(01-2007)-US-EN...................................................................................................................................................................................................................................................871
	toc...............................................................................................................................................................................................................................................................................871
		Capacities and Specifications.................................................................................................................................................................................................................................................871
		Safety Precautions Maintenance and Repair.....................................................................................................................................................................................................................................872
		Counterweight Weights.........................................................................................................................................................................................................................................................875
		Carriage Weights..............................................................................................................................................................................................................................................................876
		Vehicle Weight................................................................................................................................................................................................................................................................876
		Capacities....................................................................................................................................................................................................................................................................876
		Electrical System.............................................................................................................................................................................................................................................................876
		Engine Specifications (Cummins QSM11).........................................................................................................................................................................................................................................877
		Mast Weights..................................................................................................................................................................................................................................................................877
		Lifting and Lowering Speeds...................................................................................................................................................................................................................................................878
		Tires.........................................................................................................................................................................................................................................................................878
		Forks.........................................................................................................................................................................................................................................................................878
		Hydraulic System Specifications...............................................................................................................................................................................................................................................879
		Torque Specifications.........................................................................................................................................................................................................................................................880
			Control Valves............................................................................................................................................................................................................................................................880
			Electrical System.........................................................................................................................................................................................................................................................880
			Counterweight (Fabricated)................................................................................................................................................................................................................................................880
			Counterweight (Secondary).................................................................................................................................................................................................................................................880
			Counterweight (Slab)......................................................................................................................................................................................................................................................880
			Drive Axle................................................................................................................................................................................................................................................................880
			Wheel Bearing Adjusting Nut...............................................................................................................................................................................................................................................880
			Differential..............................................................................................................................................................................................................................................................880
			Transmission..............................................................................................................................................................................................................................................................880
			Torque Converter..........................................................................................................................................................................................................................................................880
			Steering..................................................................................................................................................................................................................................................................880
			Wheel Nuts................................................................................................................................................................................................................................................................881
			Carriages (All)...........................................................................................................................................................................................................................................................881
	tables............................................................................................................................................................................................................................................................................871
		Table 1. Up to February 2007..................................................................................................................................................................................................................................................875
		Table 2. February 2007 and Up.................................................................................................................................................................................................................................................875
		Table 3. March 2007 and Up....................................................................................................................................................................................................................................................875
		Table 4. Slab Counterweight (Up to February 2007).............................................................................................................................................................................................................................875
1648460-8000SRM1306-(01-2007)-US-EN...................................................................................................................................................................................................................................................885
	toc...............................................................................................................................................................................................................................................................................885
		Assembly Guide................................................................................................................................................................................................................................................................885
		Safety Precautions Maintenance and Repair.....................................................................................................................................................................................................................................886
		List of All Special Tools and Equipment Needed for the Assembly...............................................................................................................................................................................................................889
		General Considerations Before Starting the Job................................................................................................................................................................................................................................889
		Preparation of the Components Before Assembly.................................................................................................................................................................................................................................890
		Wheels Check..................................................................................................................................................................................................................................................................890
			Air Pressure..............................................................................................................................................................................................................................................................890
				Drive Wheels..........................................................................................................................................................................................................................................................891
				Steer Wheels..........................................................................................................................................................................................................................................................896
			Wheel Nut Torque..........................................................................................................................................................................................................................................................899
		Installation of the Exhaust Extension Pipe....................................................................................................................................................................................................................................901
		Preparation of the Mast.......................................................................................................................................................................................................................................................902
			Mast......................................................................................................................................................................................................................................................................902
			Mast Label Placement......................................................................................................................................................................................................................................................904
		Safety Procedures When Working Near Mast......................................................................................................................................................................................................................................905
		Mast Installation.............................................................................................................................................................................................................................................................905
			Mast......................................................................................................................................................................................................................................................................905
			Tilt Cylinder Pin Installation............................................................................................................................................................................................................................................907
			Truck Header Hoses and Electrical Cable Connections.......................................................................................................................................................................................................................908
		Lights Installation - Operator Compartment....................................................................................................................................................................................................................................911
		General Procedures After Assembly.............................................................................................................................................................................................................................................912
		Hydraulic Oil Check...........................................................................................................................................................................................................................................................912
		Lubrication Points............................................................................................................................................................................................................................................................913
		Check Points..................................................................................................................................................................................................................................................................913
			Checkpoint 1..............................................................................................................................................................................................................................................................913
			Checkpoint 2..............................................................................................................................................................................................................................................................913
			Checkpoint 3..............................................................................................................................................................................................................................................................913
			Checkpoint 4..............................................................................................................................................................................................................................................................913
			Checkpoint 5..............................................................................................................................................................................................................................................................913
		General Truck Install Procedures..............................................................................................................................................................................................................................................913
Aurora_AC.............................................................................................................................................................................................................................................................................919
	912-100-0148_engl_1.pdf...........................................................................................................................................................................................................................................................920
		Compressors - Applications, Conditions of Use and Liability...................................................................................................................................................................................................................920
			..........................................................................................................................................................................................................................................................................926
				Filling procedure for refrigerants....................................................................................................................................................................................................................................926
					Do not exceed the maximum operating pressure of the compressor. (see type label)..................................................................................................................................................................................926
					Compressors are machines under pressure and as such require special care in handling..............................................................................................................................................................................926
					Only qualified personnel are allowed to perform any work on refrigeration compressors.............................................................................................................................................................................926
					The national safety regulations, accident prevention regulations, technical rules and specific regulations must be taken into account abolutely...................................................................................................................926
					Never put the safety switch out of action.........................................................................................................................................................................................................................926
					Prior to commissioning, check wether all teh components installed by the user have been fastened expertly and connected pressure-tight with the compressor........................................................................................................926
					Prior to starting the compressor open discharge shut-off valve and suction shut-off valve.........................................................................................................................................................................926
					Do not start the cmpressor in vacuum. Operate the compressor only when the system is charged......................................................................................................................................................................926
					Caution! Danger of burning because of high surface temperatures...................................................................................................................................................................................................926
					Never grab rotating parts during operation. Danger of injury!.....................................................................................................................................................................................................926
					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....926
					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....926
					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...................926
					Full bottles of refrigerant must not be thrown or.................................................................................................................................................................................................................926
					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.....................................................926
		4. Troubleshooting............................................................................................................................................................................................................................................................927
			..........................................................................................................................................................................................................................................................................927
				......................................................................................................................................................................................................................................................................927
					Check refrigerant level and pressure as instructed in the Technical Information sheet for the unit................................................................................................................................................................927
					By wrong refrigerant level there is a danger of compressor malfunction............................................................................................................................................................................................927
					The outcome of too much refrigerant is a oil attenuation and reflux of the refrigerant can cause damages on the valve plate.......................................................................................................................................927
					With undercharged refrigerant the compressor will become hotwhich caused a failure. The sealing will be damaged...................................................................................................................................................927
					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....927
					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.....927
					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....927
	912-100-0007_e.pdf................................................................................................................................................................................................................................................................928
		Technical modifications reserved..............................................................................................................................................................................................................................................928
	912-100-0258_e.pdf................................................................................................................................................................................................................................................................939
		Condenser unit, 24V...........................................................................................................................................................................................................................................................939
			..........................................................................................................................................................................................................................................................................939
				......................................................................................................................................................................................................................................................................939
					..................................................................................................................................................................................................................................................................939
						..............................................................................................................................................................................................................................................................939
							part no.:175-FR2-0002.....................................................................................................................................................................................................................................939
						Safety advices................................................................................................................................................................................................................................................939
			- we reserve the right to make technical modifications -..................................................................................................................................................................................................................939
		1Safety advices...............................................................................................................................................................................................................................................................940
			Maintenance work on the refrigeration circuit:............................................................................................................................................................................................................................940
				......................................................................................................................................................................................................................................................................941
					2.2Condenser blowers..............................................................................................................................................................................................................................................941
					5Electrical connection............................................................................................................................................................................................................................................942
			every six months – authorised workshop:...................................................................................................................................................................................................................................943
				......................................................................................................................................................................................................................................................................943
					..................................................................................................................................................................................................................................................................943
						..............................................................................................................................................................................................................................................................943
							State of the refrigerant hoses............................................................................................................................................................................................................................943
				State of the condenser................................................................................................................................................................................................................................................943
			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).................................................................................................................943
			every month sight checks - Operator.......................................................................................................................................................................................................................................944
				......................................................................................................................................................................................................................................................................944
					..................................................................................................................................................................................................................................................................944
						..............................................................................................................................................................................................................................................................944
							State of the refrigerant hoses............................................................................................................................................................................................................................944
				State of the condenser................................................................................................................................................................................................................................................944
			Check condenser of contamination by dust, insects or parts of plants......................................................................................................................................................................................................944
			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).................................................................................................................944
				Installation of replacement parts.....................................................................................................................................................................................................................................944
					8Technical data...................................................................................................................................................................................................................................................944
					9Fault diagnosis..................................................................................................................................................................................................................................................945

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