Hyster B214 (H16.00-22.00XM-12EC Europe) Service Manual – PDF DOWNLOAD

Description

Hyster B214 (H16.00-22.00XM-12EC Europe) Service Manual – PDF DOWNLOAD

DESCRIPTION:

Hyster B214 (H16.00-22.00XM-12EC Europe) Service Manual – PDF DOWNLOAD

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

TABLE OF CONTENTS:

Hyster B214 (H16.00-22.00XM-12EC Europe) Service Manual – PDF DOWNLOAD

897986-1600SRM0658-(12-2006)-UK-EN....................................................................................................................................................................................................................................................   1
	toc...............................................................................................................................................................................................................................................................................   1
		Steering Axle.................................................................................................................................................................................................................................................................   1
		Safety Precautions Maintenance and Repair.....................................................................................................................................................................................................................................   2
		General.......................................................................................................................................................................................................................................................................   5
		Description...................................................................................................................................................................................................................................................................   5
		Steering Axle Repair..........................................................................................................................................................................................................................................................   5
			Remove....................................................................................................................................................................................................................................................................   5
			Install...................................................................................................................................................................................................................................................................   6
		Wheels and Hubs Repair........................................................................................................................................................................................................................................................   7
			Remove and Disassemble....................................................................................................................................................................................................................................................   7
			Clean.....................................................................................................................................................................................................................................................................   7
			Assemble and Install......................................................................................................................................................................................................................................................   7
		Spindles and Bearings Repair..................................................................................................................................................................................................................................................   8
			Remove....................................................................................................................................................................................................................................................................   8
			Clean.....................................................................................................................................................................................................................................................................   8
			Assemble and Install......................................................................................................................................................................................................................................................   8
		Steering Cylinder Repair......................................................................................................................................................................................................................................................   9
			Remove and Disassemble....................................................................................................................................................................................................................................................   9
			Clean and Inspect.........................................................................................................................................................................................................................................................   9
			Assemble and Install......................................................................................................................................................................................................................................................  10
		Troubleshooting...............................................................................................................................................................................................................................................................  12
897989-4000SRM0661-(05-2006)-UK-EN....................................................................................................................................................................................................................................................  15
	toc...............................................................................................................................................................................................................................................................................  15
		Mast..........................................................................................................................................................................................................................................................................  15
		Safety Precautions Maintenance and Repair.....................................................................................................................................................................................................................................  16
		Safety Procedures When Working Near Mast......................................................................................................................................................................................................................................  19
		General.......................................................................................................................................................................................................................................................................  20
		Description...................................................................................................................................................................................................................................................................  20
		Operation.....................................................................................................................................................................................................................................................................  21
			Control Valve, Carriage/Attachment........................................................................................................................................................................................................................................  22
		Tilt Cylinders Repair (A214 Only).............................................................................................................................................................................................................................................  22
			Remove....................................................................................................................................................................................................................................................................  22
			Disassemble...............................................................................................................................................................................................................................................................  22
			Clean and Inspect.........................................................................................................................................................................................................................................................  22
			Assemble..................................................................................................................................................................................................................................................................  23
			Install...................................................................................................................................................................................................................................................................  23
		Mast Repair...................................................................................................................................................................................................................................................................  24
			Remove....................................................................................................................................................................................................................................................................  24
			Disassemble...............................................................................................................................................................................................................................................................  25
			Clean and Inspect.........................................................................................................................................................................................................................................................  26
			Assemble..................................................................................................................................................................................................................................................................  26
			Install...................................................................................................................................................................................................................................................................  29
		Lift Cylinders Repair.........................................................................................................................................................................................................................................................  31
			Description...............................................................................................................................................................................................................................................................  31
			Remove....................................................................................................................................................................................................................................................................  32
			Disassemble...............................................................................................................................................................................................................................................................  32
			Clean and Inspect.........................................................................................................................................................................................................................................................  32
			Assemble..................................................................................................................................................................................................................................................................  32
			Install...................................................................................................................................................................................................................................................................  32
		Mast Operation Check..........................................................................................................................................................................................................................................................  34
		Lift and Tilt System Leaks Check..............................................................................................................................................................................................................................................  34
			Lift System...............................................................................................................................................................................................................................................................  34
			Tilt System...............................................................................................................................................................................................................................................................  34
		Tilt Cylinder Stroke and Backward Tilt Angle Adjustment.......................................................................................................................................................................................................................  35
		Lift Chain Adjustments........................................................................................................................................................................................................................................................  36
		Mast Adjustments..............................................................................................................................................................................................................................................................  37
			Bearing Blocks............................................................................................................................................................................................................................................................  37
			Wear Plates...............................................................................................................................................................................................................................................................  37
		Carriage Adjustment...........................................................................................................................................................................................................................................................  39
		Troubleshooting...............................................................................................................................................................................................................................................................  39
	tables............................................................................................................................................................................................................................................................................  15
		Table 1. Mast Weights.........................................................................................................................................................................................................................................................  24
		Table 2. Allowable Mast Movement from Internal Leakage (Hydrauli..............................................................................................................................................................................................................  35
910072-1400SRM0046-(07-2007)-UK-EN....................................................................................................................................................................................................................................................  43
	toc...............................................................................................................................................................................................................................................................................  43
		Differential..................................................................................................................................................................................................................................................................  43
		Safety Precautions Maintenance and Repair.....................................................................................................................................................................................................................................  44
		General.......................................................................................................................................................................................................................................................................  47
		Description...................................................................................................................................................................................................................................................................  47
		Differential Repair...........................................................................................................................................................................................................................................................  48
			Remove....................................................................................................................................................................................................................................................................  48
				Differential Carrier From Axle Housing, Remove........................................................................................................................................................................................................................  48
				Differential and Ring Gear From Differential Carrier, Remove..........................................................................................................................................................................................................  50
				Drive Pinion and Pinion Carrier From Differential Carrier, Remov......................................................................................................................................................................................................  52
			Disassemble...............................................................................................................................................................................................................................................................  53
				Differential and Ring Gear Assembly, Disassemble......................................................................................................................................................................................................................  53
				Drive Pinion and Pinion Carrier, Disassemble..........................................................................................................................................................................................................................  55
			Clean and Inspect.........................................................................................................................................................................................................................................................  58
			Assemble..................................................................................................................................................................................................................................................................  59
				Pinion, Bearings, and Pinion Carrier, Assemble........................................................................................................................................................................................................................  59
				Pinion Bearings, Adjust Preload.......................................................................................................................................................................................................................................  59
					Press Method......................................................................................................................................................................................................................................................  59
					Yoke or Flange Method.............................................................................................................................................................................................................................................  60
				Triple-Lip Seal, Install..............................................................................................................................................................................................................................................  61
				Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion)...........................................................................................................................................................................................................  62
				Differential and Ring Gear, Assemble..................................................................................................................................................................................................................................  64
				Differential Gears Rotating Torque, Check.............................................................................................................................................................................................................................  66
				Differential and Ring Gear Assembly, Install..........................................................................................................................................................................................................................  67
				Differential Bearings, Preload Adjust.................................................................................................................................................................................................................................  69
				Ring Gear, Runout Check...............................................................................................................................................................................................................................................  70
				Ring Gear Backlash, Adjust............................................................................................................................................................................................................................................  70
				Gear Set, Tooth Contact Pattern Check.................................................................................................................................................................................................................................  72
				Thrust Screw, Install and Adjust......................................................................................................................................................................................................................................  75
			Install...................................................................................................................................................................................................................................................................  75
				Differential Assembly Into Axle Housing, Install......................................................................................................................................................................................................................  75
		Specifications................................................................................................................................................................................................................................................................  77
		Troubleshooting...............................................................................................................................................................................................................................................................  82
	tables............................................................................................................................................................................................................................................................................  43
		Table 1. Ring Gear Backlash Adjustment Specifications.........................................................................................................................................................................................................................  72
		Table 2. Ring and Pinion Tooth Contact Adjustment.............................................................................................................................................................................................................................  73
		Table 3. General Specifications...............................................................................................................................................................................................................................................  77
		Table 4. Rivet Installation Pressure..........................................................................................................................................................................................................................................  77
		Table 5. Pinion Adjustment....................................................................................................................................................................................................................................................  78
		Table 6. Pinion Preload Pressure..............................................................................................................................................................................................................................................  78
		Table 7. Torque Specifications................................................................................................................................................................................................................................................  79
		Table 8. Torque Specifications for Metric Hardware............................................................................................................................................................................................................................  80
		Table 9. Torque Specifications for Metric (Fine) Hardware.....................................................................................................................................................................................................................  81
910119-4000SRM0135-(10-2003)-UK-EN....................................................................................................................................................................................................................................................  85
	toc...............................................................................................................................................................................................................................................................................  85
		Lift Cylinders................................................................................................................................................................................................................................................................  85
		Safety Precautions Maintenance and Repair.....................................................................................................................................................................................................................................  86
		Safety Procedures When Working Near Mast......................................................................................................................................................................................................................................  89
		General.......................................................................................................................................................................................................................................................................  93
		Description...................................................................................................................................................................................................................................................................  93
			Lowering Control Valve....................................................................................................................................................................................................................................................  93
			Cylinders (General).......................................................................................................................................................................................................................................................  96
			Cylinders (H520-620B, H700-800A)..........................................................................................................................................................................................................................................  96
				Retainer, Install.....................................................................................................................................................................................................................................................  96
			Cylinders (H360-460B).....................................................................................................................................................................................................................................................  98
			Cylinders (Two-Speed)..................................................................................................................................................................................................................................................... 100
		Lift Cylinder Repair.......................................................................................................................................................................................................................................................... 102
			Lift Cylinder Removal Without Removing Mast............................................................................................................................................................................................................................... 102
				Standard Masts With Main Lift Cylinder Fastened to Crossmember o...................................................................................................................................................................................................... 102
				Standard and Full Free-Lift Masts With Lift Cylinder Fastened to...................................................................................................................................................................................................... 102
				Masts That Have Two Cylinders, Main Lift Cylinder and Free-Lift ...................................................................................................................................................................................................... 102
			Disassemble............................................................................................................................................................................................................................................................... 104
			Assemble.................................................................................................................................................................................................................................................................. 104
			Lift Cylinder Installation in Mast........................................................................................................................................................................................................................................ 106
				Standard Masts With Main Lift Cylinder Fastened to Crossmember o...................................................................................................................................................................................................... 106
				Standard and Full Free-Lift Masts With Lift Cylinder Fastened to...................................................................................................................................................................................................... 106
			Chevron-Style Packing..................................................................................................................................................................................................................................................... 106
				Chevron-Style Packing Installation on Piston.......................................................................................................................................................................................................................... 107
				Chevron-Style Packing Installation in Packing Gland................................................................................................................................................................................................................... 109
		Lift Cylinders for VISTA® Masts............................................................................................................................................................................................................................................... 110
			Description............................................................................................................................................................................................................................................................... 110
				Lowering Control Valve................................................................................................................................................................................................................................................ 110
			Remove.................................................................................................................................................................................................................................................................... 112
			Disassemble............................................................................................................................................................................................................................................................... 113
			Assemble.................................................................................................................................................................................................................................................................. 114
			Install................................................................................................................................................................................................................................................................... 115
				Main Lift Cylinders................................................................................................................................................................................................................................................... 115
				Free-Lift Cylinder.................................................................................................................................................................................................................................................... 115
		Lift System Leak Check........................................................................................................................................................................................................................................................ 116
		Specifications................................................................................................................................................................................................................................................................ 117
		Troubleshooting............................................................................................................................................................................................................................................................... 118
	tables............................................................................................................................................................................................................................................................................  85
		Table 1. Lift Trucks with Two-Speed Lift Cylinders............................................................................................................................................................................................................................ 101
		Table 2. Cylinder Retainer Torque Specifications and Weight Guid.............................................................................................................................................................................................................. 117
910442-8000SRM0231-(12-2004)-UK-EN.................................................................................................................................................................................................................................................... 121
	toc............................................................................................................................................................................................................................................................................... 121
		Metric and Inch (SAE) Fasteners............................................................................................................................................................................................................................................... 121
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 122
		General....................................................................................................................................................................................................................................................................... 125
			Threaded Fasteners........................................................................................................................................................................................................................................................ 125
			Nomenclature, Threads..................................................................................................................................................................................................................................................... 125
			Strength Identification................................................................................................................................................................................................................................................... 126
			Cotter (Split) Pins....................................................................................................................................................................................................................................................... 126
			Fastener Torque Tables.................................................................................................................................................................................................................................................... 131
			Conversion Table.......................................................................................................................................................................................................................................................... 133
	tables............................................................................................................................................................................................................................................................................ 121
		Table 1. Bolts and Screws..................................................................................................................................................................................................................................................... 127
		Table 2. Studs and Nuts....................................................................................................................................................................................................................................................... 128
		Table 3. Torque Nuts.......................................................................................................................................................................................................................................................... 129
		Table 4. Torque Nuts With Nylon Insert........................................................................................................................................................................................................................................ 130
		Table 5. Torque Values for Metric Fasteners*.................................................................................................................................................................................................................................. 131
		Table 6. Torque Values for Inch Fasteners*.................................................................................................................................................................................................................................... 132
		Table 7. Conversion Table for Metric and English Units........................................................................................................................................................................................................................ 133
		Table 8. Cotter Pin Dimensional Data.......................................................................................................................................................................................................................................... 134
		Table 9. Cotter Pin Dimensional Data.......................................................................................................................................................................................................................................... 135
		Table 10. Cotter Pin Dimensional Data......................................................................................................................................................................................................................................... 136
		Table 11. Cotter Pin Dimensional Data......................................................................................................................................................................................................................................... 138
1498450-1800SRM0951-(03-2007)-UK-EN................................................................................................................................................................................................................................................... 143
	toc............................................................................................................................................................................................................................................................................... 143
		Wet Brake System.............................................................................................................................................................................................................................................................. 143
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 144
		General....................................................................................................................................................................................................................................................................... 147
		Description and Operation..................................................................................................................................................................................................................................................... 147
			Service Brakes............................................................................................................................................................................................................................................................ 147
			Parking Brake............................................................................................................................................................................................................................................................. 147
			Oil Cooler Circuit........................................................................................................................................................................................................................................................ 147
		Pressure Switch Replacement................................................................................................................................................................................................................................................... 151
		Accumulators Replacement...................................................................................................................................................................................................................................................... 151
		Brake Treadle Valve Repair.................................................................................................................................................................................................................................................... 151
			Remove and Disassemble.................................................................................................................................................................................................................................................... 151
			Clean and Inspect......................................................................................................................................................................................................................................................... 152
			Assemble and Install...................................................................................................................................................................................................................................................... 152
		Parking Brake Valve Repair.................................................................................................................................................................................................................................................... 152
			Remove.................................................................................................................................................................................................................................................................... 152
			Clean and Inspect......................................................................................................................................................................................................................................................... 152
			Repair.................................................................................................................................................................................................................................................................... 152
			Install................................................................................................................................................................................................................................................................... 152
		Parking Brake Caliper Repair.................................................................................................................................................................................................................................................. 153
			Remove.................................................................................................................................................................................................................................................................... 153
			Disassemble............................................................................................................................................................................................................................................................... 155
			Inspect................................................................................................................................................................................................................................................................... 155
			Install................................................................................................................................................................................................................................................................... 155
			Adjust.................................................................................................................................................................................................................................................................... 155
		Brake Pad Repair.............................................................................................................................................................................................................................................................. 156
			Inspect................................................................................................................................................................................................................................................................... 156
			Remove.................................................................................................................................................................................................................................................................... 156
			Install................................................................................................................................................................................................................................................................... 156
		Seals Repair.................................................................................................................................................................................................................................................................. 156
			Remove.................................................................................................................................................................................................................................................................... 156
			Install................................................................................................................................................................................................................................................................... 157
		Service Brake Repair.......................................................................................................................................................................................................................................................... 157
			Remove and Disassemble.................................................................................................................................................................................................................................................... 157
				Drain Lubricating Oil................................................................................................................................................................................................................................................. 157
				Drain Coolant Oil..................................................................................................................................................................................................................................................... 164
				Disconnect Brake Lines................................................................................................................................................................................................................................................ 164
				Wheel End With Outer Bearing on Ring Gear Hub Journal H13.00-14....................................................................................................................................................................................................... 164
				Wheel End With Outer Bearing on Spindle Journal H8.00-12.00XM (H...................................................................................................................................................................................................... 165
				Brake Disc Housing Assembly Wheel End................................................................................................................................................................................................................................. 166
				Brake Piston Housing.................................................................................................................................................................................................................................................. 167
				Brake Piston Housing and Wheel Spindle................................................................................................................................................................................................................................ 168
			Inspect................................................................................................................................................................................................................................................................... 168
			Clean..................................................................................................................................................................................................................................................................... 170
			Assemble.................................................................................................................................................................................................................................................................. 171
				Wheel Spindle......................................................................................................................................................................................................................................................... 171
				Brake Piston Housing.................................................................................................................................................................................................................................................. 171
				Piston Assembly....................................................................................................................................................................................................................................................... 173
				Brake Disc Housing.................................................................................................................................................................................................................................................... 173
				Duo-Cone Face Seal Into Brake Disc Housing and Into Hub............................................................................................................................................................................................................... 175
				Check for Correct Installation of Duo-Cone Seal....................................................................................................................................................................................................................... 176
				Wheel Hub to Brake Disc Housing....................................................................................................................................................................................................................................... 177
			Adjust.................................................................................................................................................................................................................................................................... 178
				Fill Brake System With Coolant Oil.................................................................................................................................................................................................................................... 178
				System Air Removal.................................................................................................................................................................................................................................................... 179
				Adjust Brake With New Disc Pack....................................................................................................................................................................................................................................... 179
				Coolant Change Intervals.............................................................................................................................................................................................................................................. 180
				Coolant Draining and Filling.......................................................................................................................................................................................................................................... 180
		Specifications................................................................................................................................................................................................................................................................ 182
			Minimum Brake Disc Thickness.............................................................................................................................................................................................................................................. 185
			Hydraulic Fluid for Brake Actuation....................................................................................................................................................................................................................................... 185
			Brake Coolant Specifications.............................................................................................................................................................................................................................................. 185
			Coolant Change Intervals.................................................................................................................................................................................................................................................. 185
			Hydraulic Fluid Specifications............................................................................................................................................................................................................................................ 185
		Troubleshooting............................................................................................................................................................................................................................................................... 185
			Brake Does Not Apply...................................................................................................................................................................................................................................................... 185
			Brake Does Not Release.................................................................................................................................................................................................................................................... 186
			Brake Performance......................................................................................................................................................................................................................................................... 186
			Brake Leaks Actuation Fluid............................................................................................................................................................................................................................................... 187
			Brake Cooling Fluid Leakage............................................................................................................................................................................................................................................... 188
			Brake Noise and Vibration................................................................................................................................................................................................................................................. 188
			Brake Overheats........................................................................................................................................................................................................................................................... 188
	tables............................................................................................................................................................................................................................................................................ 143
		Table 1. Brake Pad Adjustment................................................................................................................................................................................................................................................. 155
		Table 2. Minimum Brake Disc Thickness......................................................................................................................................................................................................................................... 169
		Table 3. Formed Seal Wear Chart............................................................................................................................................................................................................................................... 169
1509204-5000SRM0990-(05-2006)-UK-EN................................................................................................................................................................................................................................................... 193
	toc............................................................................................................................................................................................................................................................................... 193
		Empty Container Handling Attachment........................................................................................................................................................................................................................................... 193
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 194
		General....................................................................................................................................................................................................................................................................... 197
		Description................................................................................................................................................................................................................................................................... 197
		Operation..................................................................................................................................................................................................................................................................... 207
			General................................................................................................................................................................................................................................................................... 207
			Selector Valves........................................................................................................................................................................................................................................................... 207
			Sideshift Circuit......................................................................................................................................................................................................................................................... 207
			Extend and Retract Circuit................................................................................................................................................................................................................................................ 207
			Twist Lock Circuit and Control............................................................................................................................................................................................................................................ 207
				Model 572 - Double Horizontally Mounted............................................................................................................................................................................................................................... 207
				Model 573 - Horizontally Mounted...................................................................................................................................................................................................................................... 208
				Model 578 - Vertically Mounted........................................................................................................................................................................................................................................ 208
			Lifting Hooks............................................................................................................................................................................................................................................................. 208
				Model 575............................................................................................................................................................................................................................................................. 208
			Indicator Lights and LEDs................................................................................................................................................................................................................................................. 208
			Lift Interrupt and Override............................................................................................................................................................................................................................................... 209
			Overlowering Interrupt and Override....................................................................................................................................................................................................................................... 209
			Second Container Detection Sensor (Model 572 Only)........................................................................................................................................................................................................................ 210
		Carriage and Attachment Repair................................................................................................................................................................................................................................................ 210
			Remove.................................................................................................................................................................................................................................................................... 210
		Attachment Without Carriage Repair............................................................................................................................................................................................................................................ 211
			Remove.................................................................................................................................................................................................................................................................... 211
		Sideshift Cylinders Repair.................................................................................................................................................................................................................................................... 211
			Remove.................................................................................................................................................................................................................................................................... 211
			Disassemble............................................................................................................................................................................................................................................................... 211
			Assemble.................................................................................................................................................................................................................................................................. 212
		Extension Cylinders Repair.................................................................................................................................................................................................................................................... 212
			Remove.................................................................................................................................................................................................................................................................... 212
			Disassemble............................................................................................................................................................................................................................................................... 212
			Clean and Inspect......................................................................................................................................................................................................................................................... 213
			Assemble.................................................................................................................................................................................................................................................................. 213
			Install................................................................................................................................................................................................................................................................... 213
		Floating End Beams Repair..................................................................................................................................................................................................................................................... 214
			Remove.................................................................................................................................................................................................................................................................... 214
			Install................................................................................................................................................................................................................................................................... 214
			Hose Replacement In End Beams............................................................................................................................................................................................................................................. 214
		Twist Locks Repair for Model 572 and 573...................................................................................................................................................................................................................................... 214
			Remove.................................................................................................................................................................................................................................................................... 214
				Model 573............................................................................................................................................................................................................................................................. 214
				Model 572............................................................................................................................................................................................................................................................. 214
			Disassemble............................................................................................................................................................................................................................................................... 215
			Clean and Inspect......................................................................................................................................................................................................................................................... 215
			Assemble.................................................................................................................................................................................................................................................................. 215
		Hook Replacement for Model 575................................................................................................................................................................................................................................................ 216
			Inspect................................................................................................................................................................................................................................................................... 216
			Remove.................................................................................................................................................................................................................................................................... 216
			Install................................................................................................................................................................................................................................................................... 216
		Twist Locks Repair for Model 578.............................................................................................................................................................................................................................................. 217
			Disassemble............................................................................................................................................................................................................................................................... 217
			Clean and Inspect......................................................................................................................................................................................................................................................... 217
			Assemble.................................................................................................................................................................................................................................................................. 217
		Extension Beams Repair........................................................................................................................................................................................................................................................ 218
			LH and RH Extension Beam, Remove.......................................................................................................................................................................................................................................... 218
			Slave Beam, Remove........................................................................................................................................................................................................................................................ 218
			Clean and Inspect......................................................................................................................................................................................................................................................... 219
			Assemble.................................................................................................................................................................................................................................................................. 219
		Bleed the System.............................................................................................................................................................................................................................................................. 220
		Valve Assembly................................................................................................................................................................................................................................................................ 220
		Slide Pad Replacement......................................................................................................................................................................................................................................................... 221
		Adjustments................................................................................................................................................................................................................................................................... 221
			Twist Lock Angle Adjustment............................................................................................................................................................................................................................................... 221
				Model 578 Only........................................................................................................................................................................................................................................................ 221
			LOCKED/NOT LOCKED Sensors Adjustment...................................................................................................................................................................................................................................... 222
				Model 573............................................................................................................................................................................................................................................................. 222
				Model 578............................................................................................................................................................................................................................................................. 222
			Seated Sensor Adjustment.................................................................................................................................................................................................................................................. 222
				Model 572 and 573..................................................................................................................................................................................................................................................... 222
				Model 578............................................................................................................................................................................................................................................................. 223
			Overlowering Protection Sensor Adjustment (Models 572, 573, and .......................................................................................................................................................................................................... 223
			Torque Chart.............................................................................................................................................................................................................................................................. 224
		Maintenance................................................................................................................................................................................................................................................................... 224
			Additional Attachment Maintenance......................................................................................................................................................................................................................................... 227
			Interface Boxes With LED Indicators....................................................................................................................................................................................................................................... 228
				Models 572, 573, 575, and 578: Interface Box With LED Indicators...................................................................................................................................................................................................... 228
				Models 573 and 578: Two Additional Interface Boxes With LED Indi...................................................................................................................................................................................................... 228
				Model 572............................................................................................................................................................................................................................................................. 229
		Troubleshooting............................................................................................................................................................................................................................................................... 229
	tables............................................................................................................................................................................................................................................................................ 193
		Table 1. Torque Chart......................................................................................................................................................................................................................................................... 224
		Table 2. Maintenance Schedule................................................................................................................................................................................................................................................. 225
1529749-1800SRM1036-(07-2007)-UK-EN................................................................................................................................................................................................................................................... 259
	toc............................................................................................................................................................................................................................................................................... 259
		Brake Accumulator............................................................................................................................................................................................................................................................. 259
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 260
		General....................................................................................................................................................................................................................................................................... 263
		Description and Operation..................................................................................................................................................................................................................................................... 263
		Accumulator Maintenance....................................................................................................................................................................................................................................................... 263
			Precharge Check........................................................................................................................................................................................................................................................... 263
			Precharge Filling......................................................................................................................................................................................................................................................... 264
			Remove.................................................................................................................................................................................................................................................................... 265
			Disassemble............................................................................................................................................................................................................................................................... 265
			Clean..................................................................................................................................................................................................................................................................... 267
			Inspect................................................................................................................................................................................................................................................................... 267
			Repair.................................................................................................................................................................................................................................................................... 267
			Assemble.................................................................................................................................................................................................................................................................. 267
			Replace................................................................................................................................................................................................................................................................... 267
	tables............................................................................................................................................................................................................................................................................ 259
		Table 1. Accumulator Pressures................................................................................................................................................................................................................................................ 264
1564053-0600SRM1101-(11-2007)-UK-EN................................................................................................................................................................................................................................................... 271
	toc............................................................................................................................................................................................................................................................................... 271
		Cummins Diesel/LPG Engine Fault Code Guide.................................................................................................................................................................................................................................... 271
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 272
		General....................................................................................................................................................................................................................................................................... 275
		Fault Codes................................................................................................................................................................................................................................................................... 275
			Normal Mode............................................................................................................................................................................................................................................................... 275
			Fault Log Mode............................................................................................................................................................................................................................................................ 275
				Access................................................................................................................................................................................................................................................................ 275
				Exit.................................................................................................................................................................................................................................................................. 276
				Clear................................................................................................................................................................................................................................................................. 276
			Electronic Throttle Calibration........................................................................................................................................................................................................................................... 276
				Electronic Throttle Calibration Procedure............................................................................................................................................................................................................................. 276
	tables............................................................................................................................................................................................................................................................................ 271
		Table 1. Error Code Descriptions.............................................................................................................................................................................................................................................. 277
1565789-1800SRM1117-(07-2007)-UK-EN................................................................................................................................................................................................................................................... 293
	toc............................................................................................................................................................................................................................................................................... 293
		Parking Brake................................................................................................................................................................................................................................................................. 293
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 294
		General....................................................................................................................................................................................................................................................................... 297
		Description and Operation..................................................................................................................................................................................................................................................... 297
		Parking Brake Valve Replacement............................................................................................................................................................................................................................................... 297
			Remove.................................................................................................................................................................................................................................................................... 297
			Clean and Inspect......................................................................................................................................................................................................................................................... 298
			Install................................................................................................................................................................................................................................................................... 298
		Parking Brake Caliper Repair.................................................................................................................................................................................................................................................. 298
			Remove.................................................................................................................................................................................................................................................................... 298
			Disassemble............................................................................................................................................................................................................................................................... 298
			Inspect................................................................................................................................................................................................................................................................... 298
			Install................................................................................................................................................................................................................................................................... 299
			Bleed Brakes.............................................................................................................................................................................................................................................................. 301
			Adjust.................................................................................................................................................................................................................................................................... 301
		Brake Pad Repair.............................................................................................................................................................................................................................................................. 302
			Inspect................................................................................................................................................................................................................................................................... 302
			Remove.................................................................................................................................................................................................................................................................... 302
			Install................................................................................................................................................................................................................................................................... 303
		Seals Repair.................................................................................................................................................................................................................................................................. 303
			Remove.................................................................................................................................................................................................................................................................... 303
			Install................................................................................................................................................................................................................................................................... 303
		Specifications................................................................................................................................................................................................................................................................ 304
			Torque Requirements....................................................................................................................................................................................................................................................... 304
			Wear Limits............................................................................................................................................................................................................................................................... 304
			Lining to Disc Clearance.................................................................................................................................................................................................................................................. 304
		Troubleshooting............................................................................................................................................................................................................................................................... 305
	tables............................................................................................................................................................................................................................................................................ 293
		Table 1. Brake Pad Adjustment................................................................................................................................................................................................................................................. 302
		Table 2. Torque Requirements.................................................................................................................................................................................................................................................. 304
		Table 3. Wear Limits.......................................................................................................................................................................................................................................................... 304
		Table 4. Lining to Disc Clearance............................................................................................................................................................................................................................................. 304
1612615-5000SRM1221-(11-2006)-UK-EN................................................................................................................................................................................................................................................... 309
	toc............................................................................................................................................................................................................................................................................... 309
		Extendable Container Attachment (Elme)........................................................................................................................................................................................................................................ 309
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 310
		General....................................................................................................................................................................................................................................................................... 315
		Description................................................................................................................................................................................................................................................................... 315
		Operation..................................................................................................................................................................................................................................................................... 319
			General................................................................................................................................................................................................................................................................... 319
			Optional Powered Pile Slope............................................................................................................................................................................................................................................... 319
			Sideshift................................................................................................................................................................................................................................................................. 320
			Extend and Retract Circuit................................................................................................................................................................................................................................................ 321
			Container locking Model 582............................................................................................................................................................................................................................................... 323
				Sequence Valve........................................................................................................................................................................................................................................................ 323
				Pilot Check Valve..................................................................................................................................................................................................................................................... 324
			Container Locking Model 583............................................................................................................................................................................................................................................... 325
			Container Locking Model 584............................................................................................................................................................................................................................................... 325
			Container Locking Model 585............................................................................................................................................................................................................................................... 326
			Container Locking Models 586, 588, and 589................................................................................................................................................................................................................................ 326
			Electrical System......................................................................................................................................................................................................................................................... 328
			Indicator Lights.......................................................................................................................................................................................................................................................... 328
			Flashing Indicator Lights................................................................................................................................................................................................................................................. 329
			Automatic Locking......................................................................................................................................................................................................................................................... 329
			Lift Interrupt and Override............................................................................................................................................................................................................................................... 329
			Overlowering Interrupt and Override....................................................................................................................................................................................................................................... 329
			Second Container Detection Sensor (Model 582 Only)........................................................................................................................................................................................................................ 330
		Carriage and Attachment Removal............................................................................................................................................................................................................................................... 330
			Carriage.................................................................................................................................................................................................................................................................. 330
			Spreader.................................................................................................................................................................................................................................................................. 331
		Sideshift Cylinder Removal and Installation................................................................................................................................................................................................................................... 331
			Remove.................................................................................................................................................................................................................................................................... 331
			Install................................................................................................................................................................................................................................................................... 331
		Extension Cylinder Removal and Installation................................................................................................................................................................................................................................... 332
			Remove.................................................................................................................................................................................................................................................................... 332
				Upper, Right-Hand..................................................................................................................................................................................................................................................... 332
				Lower, Left-Hand...................................................................................................................................................................................................................................................... 332
			Install................................................................................................................................................................................................................................................................... 332
		Floating End Beams Repair..................................................................................................................................................................................................................................................... 333
			Remove.................................................................................................................................................................................................................................................................... 333
			Install................................................................................................................................................................................................................................................................... 333
			Hose, Replace............................................................................................................................................................................................................................................................. 334
		Twist Lock Repair for Model 582............................................................................................................................................................................................................................................... 335
			Remove.................................................................................................................................................................................................................................................................... 335
				Upper Twist Lock...................................................................................................................................................................................................................................................... 335
				Lower Twist Lock...................................................................................................................................................................................................................................................... 335
			Disassemble............................................................................................................................................................................................................................................................... 336
			Clean and Inspect......................................................................................................................................................................................................................................................... 336
			Assemble.................................................................................................................................................................................................................................................................. 337
			Install................................................................................................................................................................................................................................................................... 337
		Hook Repair for Model 584 and 585............................................................................................................................................................................................................................................. 337
			Remove.................................................................................................................................................................................................................................................................... 337
			Inspect................................................................................................................................................................................................................................................................... 337
			Install................................................................................................................................................................................................................................................................... 337
		Side Clamp Replacement for Model 584.......................................................................................................................................................................................................................................... 338
			Remove.................................................................................................................................................................................................................................................................... 338
			Install................................................................................................................................................................................................................................................................... 339
		Twist Lock Repair for Models 586, 588, and 589................................................................................................................................................................................................................................ 339
			Disassemble............................................................................................................................................................................................................................................................... 339
			Clean and Inspect......................................................................................................................................................................................................................................................... 339
			Assemble.................................................................................................................................................................................................................................................................. 340
		Extension Beam Repair......................................................................................................................................................................................................................................................... 341
			Remove.................................................................................................................................................................................................................................................................... 341
			Inspect................................................................................................................................................................................................................................................................... 341
			Assemble.................................................................................................................................................................................................................................................................. 342
		Cylinder Repair............................................................................................................................................................................................................................................................... 343
			Extension Cylinder........................................................................................................................................................................................................................................................ 343
				Disassemble........................................................................................................................................................................................................................................................... 343
				Clean and Inspect..................................................................................................................................................................................................................................................... 343
				Assemble.............................................................................................................................................................................................................................................................. 343
			Guide for Extension Cylinder.............................................................................................................................................................................................................................................. 344
				Remove................................................................................................................................................................................................................................................................ 344
				Install............................................................................................................................................................................................................................................................... 344
			Sideshift Cylinder, Powered Pile Slope Cylinder, Retract Cylinde.......................................................................................................................................................................................................... 344
				Disassemble........................................................................................................................................................................................................................................................... 344
				Assemble.............................................................................................................................................................................................................................................................. 344
		Wear Pad Replacement.......................................................................................................................................................................................................................................................... 345
			General................................................................................................................................................................................................................................................................... 345
			Floating End Beam Wear Pads............................................................................................................................................................................................................................................... 345
				Upper Wear Pads....................................................................................................................................................................................................................................................... 345
				Lower Wear Pads....................................................................................................................................................................................................................................................... 345
			Main Frame Wear Pads at Large (Right-Hand) Extension Beam................................................................................................................................................................................................................. 345
			Main Frame Wear Pads at Small (Left-Hand) Extension Beam.................................................................................................................................................................................................................. 345
			Guide for Extension Cylinder.............................................................................................................................................................................................................................................. 346
			Large Extension Beam Internal Wear Pads................................................................................................................................................................................................................................... 347
			Spreader Frame............................................................................................................................................................................................................................................................ 347
				Upper Wear Pads....................................................................................................................................................................................................................................................... 347
				Lower Wear Pads....................................................................................................................................................................................................................................................... 347
			Powered Pile Slope Carriage............................................................................................................................................................................................................................................... 347
				Upper Wear Pads....................................................................................................................................................................................................................................................... 347
				Lower Wear Pads....................................................................................................................................................................................................................................................... 347
		Adjustments................................................................................................................................................................................................................................................................... 347
			Twist Lock Angle Adjustment............................................................................................................................................................................................................................................... 347
				Model 586, 588 and 589................................................................................................................................................................................................................................................ 347
			LOCKED/NOT LOCKED Sensors Adjustment...................................................................................................................................................................................................................................... 348
				Model 582............................................................................................................................................................................................................................................................. 348
				Model 586, 588 and 589................................................................................................................................................................................................................................................ 348
			Side Clamp Open/Closed Sensor Adjustment (Model 584)...................................................................................................................................................................................................................... 348
			Hook in Sensor Adjustment (Model 584)..................................................................................................................................................................................................................................... 348
			Seated Sensor Adjustment.................................................................................................................................................................................................................................................. 349
				Model 582............................................................................................................................................................................................................................................................. 349
				Model 586, 588 and 589................................................................................................................................................................................................................................................ 349
			Overlowering Protection Sensor Adjustment (All 580 Models)................................................................................................................................................................................................................ 349
		Schematics.................................................................................................................................................................................................................................................................... 350
	tables............................................................................................................................................................................................................................................................................ 309
		Table 1. Elme Schematic Overview.............................................................................................................................................................................................................................................. 350
1638471-0100SRM1267-(10-2006)-UK-EN................................................................................................................................................................................................................................................... 437
	toc............................................................................................................................................................................................................................................................................... 437
		Frame......................................................................................................................................................................................................................................................................... 437
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 438
		General....................................................................................................................................................................................................................................................................... 441
		Description................................................................................................................................................................................................................................................................... 441
		Counterweight Repair.......................................................................................................................................................................................................................................................... 442
			General................................................................................................................................................................................................................................................................... 442
			Remove.................................................................................................................................................................................................................................................................... 442
			Install................................................................................................................................................................................................................................................................... 442
		Air Cleaner Repair............................................................................................................................................................................................................................................................ 444
			Remove.................................................................................................................................................................................................................................................................... 444
			Install................................................................................................................................................................................................................................................................... 444
		Hoods and Covers.............................................................................................................................................................................................................................................................. 444
			Remove.................................................................................................................................................................................................................................................................... 444
			Install................................................................................................................................................................................................................................................................... 444
		Floor Plates, Handrails, and Steps............................................................................................................................................................................................................................................ 446
		Hydraulic Tank Repair......................................................................................................................................................................................................................................................... 447
			Remove.................................................................................................................................................................................................................................................................... 447
			Repair.................................................................................................................................................................................................................................................................... 449
				Small Leaks........................................................................................................................................................................................................................................................... 449
				Large Leaks........................................................................................................................................................................................................................................................... 449
			Clean..................................................................................................................................................................................................................................................................... 449
				Steam Method.......................................................................................................................................................................................................................................................... 449
				Chemical Solution Method.............................................................................................................................................................................................................................................. 450
			Other Methods of Preparation for Repair................................................................................................................................................................................................................................... 450
			Install................................................................................................................................................................................................................................................................... 450
		Fuel Tank Repair.............................................................................................................................................................................................................................................................. 451
			Remove.................................................................................................................................................................................................................................................................... 451
			Repair.................................................................................................................................................................................................................................................................... 451
			Install................................................................................................................................................................................................................................................................... 452
		Exhaust System Repair......................................................................................................................................................................................................................................................... 453
			Remove.................................................................................................................................................................................................................................................................... 453
			Install................................................................................................................................................................................................................................................................... 453
		Engine Repair................................................................................................................................................................................................................................................................. 455
			Remove.................................................................................................................................................................................................................................................................... 455
			Install................................................................................................................................................................................................................................................................... 456
		Label Replacement............................................................................................................................................................................................................................................................. 458
	tables............................................................................................................................................................................................................................................................................ 437
		Table 1. Counterweight Weights................................................................................................................................................................................................................................................ 442
1638472-0100SRM1268-(12-2006)-UK-EN................................................................................................................................................................................................................................................... 461
	toc............................................................................................................................................................................................................................................................................... 461
		Operator's Cab................................................................................................................................................................................................................................................................ 461
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 462
		General....................................................................................................................................................................................................................................................................... 465
		Cab Repair.................................................................................................................................................................................................................................................................... 466
			Rear Cab Assembly......................................................................................................................................................................................................................................................... 466
			Bottom Cab Assembly....................................................................................................................................................................................................................................................... 467
			Raising and Lowering Cab.................................................................................................................................................................................................................................................. 468
				Raise Cab............................................................................................................................................................................................................................................................. 468
				Lower Cab............................................................................................................................................................................................................................................................. 468
			Cab Repair................................................................................................................................................................................................................................................................ 468
				Remove................................................................................................................................................................................................................................................................ 468
				Install............................................................................................................................................................................................................................................................... 469
		Oil Filling for Tilt System................................................................................................................................................................................................................................................... 472
		Inching and Brake Pedals...................................................................................................................................................................................................................................................... 472
			Brake Pedal, Adjust....................................................................................................................................................................................................................................................... 472
			Inching Pedal, Adjust..................................................................................................................................................................................................................................................... 473
			Inching Pedal Sensor, Adjust.............................................................................................................................................................................................................................................. 473
		Throttle Pedal Sensor......................................................................................................................................................................................................................................................... 473
			Check..................................................................................................................................................................................................................................................................... 473
			Adjust.................................................................................................................................................................................................................................................................... 473
		Seat Assembly Removal......................................................................................................................................................................................................................................................... 474
		Power Assist Armrest.......................................................................................................................................................................................................................................................... 475
			Adjust.................................................................................................................................................................................................................................................................... 475
		Steering Column Repair........................................................................................................................................................................................................................................................ 476
			Remove.................................................................................................................................................................................................................................................................... 476
			Install................................................................................................................................................................................................................................................................... 476
		Window Washer Motors and Pumps................................................................................................................................................................................................................................................ 477
			Window Wiper and Washer Operating Switches................................................................................................................................................................................................................................ 477
		Window Replacement............................................................................................................................................................................................................................................................ 478
			Front Window, Replace..................................................................................................................................................................................................................................................... 479
			Rear Window, Replace...................................................................................................................................................................................................................................................... 479
			Top Window, Replace....................................................................................................................................................................................................................................................... 479
			Door Window, Replace...................................................................................................................................................................................................................................................... 480
		Heater and Air Conditioning Assembly.......................................................................................................................................................................................................................................... 481
			Heater Parts, Replace..................................................................................................................................................................................................................................................... 482
			Heat Control Knob/Switches................................................................................................................................................................................................................................................ 482
			Heat Control Knob/Cable................................................................................................................................................................................................................................................... 482
				Adjust................................................................................................................................................................................................................................................................ 482
			Air Control Knob/Cable.................................................................................................................................................................................................................................................... 483
				Adjust................................................................................................................................................................................................................................................................ 483
			Air Filter, Replace....................................................................................................................................................................................................................................................... 483
			Air Conditioning Condenser Fan(s)......................................................................................................................................................................................................................................... 484
				Remove................................................................................................................................................................................................................................................................ 484
				Install............................................................................................................................................................................................................................................................... 484
		Instruments, Switches, and Controls........................................................................................................................................................................................................................................... 484
			Switches.................................................................................................................................................................................................................................................................. 484
			Controls.................................................................................................................................................................................................................................................................. 485
		Fuses and Relays.............................................................................................................................................................................................................................................................. 488
			Fuse Panel................................................................................................................................................................................................................................................................ 488
			Fuses..................................................................................................................................................................................................................................................................... 489
			Relays.................................................................................................................................................................................................................................................................... 490
		Label Replacement............................................................................................................................................................................................................................................................. 490
		Electrical Schematics......................................................................................................................................................................................................................................................... 490
1638474-0700SRM1270-(12-2006)-UK-EN................................................................................................................................................................................................................................................... 493
	toc............................................................................................................................................................................................................................................................................... 493
		Multiple Aligned Cooling System............................................................................................................................................................................................................................................... 493
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 494
		General....................................................................................................................................................................................................................................................................... 497
		Description................................................................................................................................................................................................................................................................... 498
			Radiator.................................................................................................................................................................................................................................................................. 498
			Radiator Cap.............................................................................................................................................................................................................................................................. 498
			Thermostat................................................................................................................................................................................................................................................................ 498
			Water Pump................................................................................................................................................................................................................................................................ 499
			Fan and Fan Shroud........................................................................................................................................................................................................................................................ 499
		Cooling System Checks......................................................................................................................................................................................................................................................... 499
			Radiator.................................................................................................................................................................................................................................................................. 499
			Thermostat................................................................................................................................................................................................................................................................ 499
			Water Pump................................................................................................................................................................................................................................................................ 500
			Exhaust Leaks............................................................................................................................................................................................................................................................. 500
			Fan and Fan Shroud........................................................................................................................................................................................................................................................ 500
		Cooling System Repair......................................................................................................................................................................................................................................................... 500
			Remove.................................................................................................................................................................................................................................................................... 500
			Install................................................................................................................................................................................................................................................................... 501
		Core Repair................................................................................................................................................................................................................................................................... 501
			Remove.................................................................................................................................................................................................................................................................... 501
			Install................................................................................................................................................................................................................................................................... 501
		Radiator Cleaning............................................................................................................................................................................................................................................................. 502
			Drain..................................................................................................................................................................................................................................................................... 502
			Clean..................................................................................................................................................................................................................................................................... 502
			Fill...................................................................................................................................................................................................................................................................... 502
		Troubleshooting............................................................................................................................................................................................................................................................... 503
1638475-1300SRM1271-(01-2007)-UK-EN................................................................................................................................................................................................................................................... 507
	toc............................................................................................................................................................................................................................................................................... 507
		Transmission.................................................................................................................................................................................................................................................................. 507
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 508
		Description of Operation...................................................................................................................................................................................................................................................... 511
			General................................................................................................................................................................................................................................................................... 511
			Torque Convertor, Pump Drive, and Pressure Regulating Valve............................................................................................................................................................................................................... 511
			Input Shaft and Range Clutches............................................................................................................................................................................................................................................ 513
			Directional Clutches...................................................................................................................................................................................................................................................... 514
			Output Section............................................................................................................................................................................................................................................................ 514
			Transmission Controls..................................................................................................................................................................................................................................................... 514
				General............................................................................................................................................................................................................................................................... 514
				Operation of the Valve................................................................................................................................................................................................................................................ 514
				Directional Selection................................................................................................................................................................................................................................................. 515
				Range Selection....................................................................................................................................................................................................................................................... 515
				Neutral Selection..................................................................................................................................................................................................................................................... 520
				Total Neutral Selection............................................................................................................................................................................................................................................... 520
				Pressure Switch....................................................................................................................................................................................................................................................... 520
			Electric Solenoid Controls................................................................................................................................................................................................................................................ 520
			Transmission Specifications............................................................................................................................................................................................................................................... 531
				Transmission Identification........................................................................................................................................................................................................................................... 531
				Weight, Dimensions, and Oil Capacity.................................................................................................................................................................................................................................. 531
		Transmission Repair........................................................................................................................................................................................................................................................... 532
			Remove.................................................................................................................................................................................................................................................................... 532
			Disassemble............................................................................................................................................................................................................................................................... 533
				Transmission Case..................................................................................................................................................................................................................................................... 533
				1st Clutch Drum and Turbine Shaft..................................................................................................................................................................................................................................... 554
				Reverse Clutch Drum................................................................................................................................................................................................................................................... 560
				2nd Clutch Drum....................................................................................................................................................................................................................................................... 564
				3rd Clutch Drum....................................................................................................................................................................................................................................................... 567
				FWD Clutch Drum....................................................................................................................................................................................................................................................... 572
				Output Shaft.......................................................................................................................................................................................................................................................... 575
			Clean and Inspect......................................................................................................................................................................................................................................................... 577
				Housings.............................................................................................................................................................................................................................................................. 577
				Oil Seals and Gaskets................................................................................................................................................................................................................................................. 577
				Bearings.............................................................................................................................................................................................................................................................. 577
				Gears and Shafts...................................................................................................................................................................................................................................................... 578
			Assemble.................................................................................................................................................................................................................................................................. 578
				Output Shaft.......................................................................................................................................................................................................................................................... 578
				FWD Clutch Drum....................................................................................................................................................................................................................................................... 580
				3rd Clutch Drum....................................................................................................................................................................................................................................................... 585
				2nd Clutch Drum....................................................................................................................................................................................................................................................... 591
				REV Clutch Drum....................................................................................................................................................................................................................................................... 596
				1st Clutch Drum and Turbine Shaft..................................................................................................................................................................................................................................... 601
				Transmission Case..................................................................................................................................................................................................................................................... 607
			Install................................................................................................................................................................................................................................................................... 628
		Stall Test.................................................................................................................................................................................................................................................................... 632
		Transmission Calibration and Electrical Troubleshooting....................................................................................................................................................................................................................... 633
			Userlink®................................................................................................................................................................................................................................................................. 633
			Connection................................................................................................................................................................................................................................................................ 633
			Clutch Filling Calibration................................................................................................................................................................................................................................................ 633
				Purpose............................................................................................................................................................................................................................................................... 633
				Clutch Filling Calibration Procedure.................................................................................................................................................................................................................................. 634
				Alternative Clutch Filling Calibration Procedure...................................................................................................................................................................................................................... 634
				Heat-up Mode.......................................................................................................................................................................................................................................................... 635
				Heat-up Mode Stall Test............................................................................................................................................................................................................................................... 635
			Inching Pedal Calibration................................................................................................................................................................................................................................................. 636
				Purpose............................................................................................................................................................................................................................................................... 636
				Brake Pedal Adjustment................................................................................................................................................................................................................................................ 636
				Inching Pedal Adjustment.............................................................................................................................................................................................................................................. 636
				Inching Pedal Sensor Adjustment....................................................................................................................................................................................................................................... 637
				Inching Pedal Calibration Procedure................................................................................................................................................................................................................................... 637
				Verification/Adjustment of Inching Pedal Sensor When Pedal is Fu...................................................................................................................................................................................................... 637
				Manual Inching Pedal Sensor Calibration Procedure..................................................................................................................................................................................................................... 638
			Troubleshooting........................................................................................................................................................................................................................................................... 638
			Transmission Display Warning Codes........................................................................................................................................................................................................................................ 639
				Access................................................................................................................................................................................................................................................................ 639
				Clear................................................................................................................................................................................................................................................................. 639
				Exit.................................................................................................................................................................................................................................................................. 639
				Limp Home Mode........................................................................................................................................................................................................................................................ 675
				Shutdown Mode......................................................................................................................................................................................................................................................... 675
				Pressure Feedback Sensor.............................................................................................................................................................................................................................................. 675
		Transmission Oil Pressure Check............................................................................................................................................................................................................................................... 675
			Pressure and Temperature Specifications................................................................................................................................................................................................................................... 675
		Electrical Specifications..................................................................................................................................................................................................................................................... 677
		Hydraulic Cooler Lines Specifications......................................................................................................................................................................................................................................... 677
		Torque Specifications......................................................................................................................................................................................................................................................... 677
			Torque Specifications for Lubricated or Plated Screw Threads.............................................................................................................................................................................................................. 677
	tables............................................................................................................................................................................................................................................................................ 507
		Table 1. Controller Connector J2 Wire to Pin Number Cross Refere.............................................................................................................................................................................................................. 640
		Table 2. Controller Connector J1 Wire to Pin Number Cross Refere.............................................................................................................................................................................................................. 640
		Table 3. Common Calibration Condition Messages................................................................................................................................................................................................................................ 642
		Table 4. Calibration Codes During Calibration................................................................................................................................................................................................................................. 643
		Table 5. Error Codes During Calibration....................................................................................................................................................................................................................................... 643
		Table 6. Display Warning Codes................................................................................................................................................................................................................................................ 644
		Table 7. Display Warning Exceed Codes......................................................................................................................................................................................................................................... 673
		Table 8. Type of Warning Codes................................................................................................................................................................................................................................................ 674
		Table 9. Grade 5.............................................................................................................................................................................................................................................................. 677
		Table 10. Grade 8............................................................................................................................................................................................................................................................. 678
		Table 11. Grades 8.8, 10.9, and 12.9.......................................................................................................................................................................................................................................... 678
		Table 12. Grades 8.8, 10.9, and 12.9.......................................................................................................................................................................................................................................... 679
		Table 13. Elastic Stop Nut Torque............................................................................................................................................................................................................................................. 680
		Table 14. O-ring Port Plug Torque Chart....................................................................................................................................................................................................................................... 680
		Table 15. Pipe Plug Torque Chart.............................................................................................................................................................................................................................................. 680
		Table 16. Pipe Plug Torque Chart.............................................................................................................................................................................................................................................. 680
1638476-1600SRM1272-(12-2006)-UK-EN................................................................................................................................................................................................................................................... 687
	toc............................................................................................................................................................................................................................................................................... 687
		Steering System............................................................................................................................................................................................................................................................... 687
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 688
		General....................................................................................................................................................................................................................................................................... 691
		Description................................................................................................................................................................................................................................................................... 691
		Steering Wheel and Column Assembly Repair..................................................................................................................................................................................................................................... 693
			General................................................................................................................................................................................................................................................................... 693
			Steering Wheel and Horn................................................................................................................................................................................................................................................... 693
				Remove................................................................................................................................................................................................................................................................ 693
				Install............................................................................................................................................................................................................................................................... 693
		Steering Column............................................................................................................................................................................................................................................................... 695
			Remove.................................................................................................................................................................................................................................................................... 695
			Install................................................................................................................................................................................................................................................................... 695
		Steering Control Unit Repair.................................................................................................................................................................................................................................................. 696
			General................................................................................................................................................................................................................................................................... 696
			Description............................................................................................................................................................................................................................................................... 696
			Operation................................................................................................................................................................................................................................................................. 696
			Remove.................................................................................................................................................................................................................................................................... 698
			Disassemble............................................................................................................................................................................................................................................................... 699
			Clean..................................................................................................................................................................................................................................................................... 702
			Assemble.................................................................................................................................................................................................................................................................. 702
			Install................................................................................................................................................................................................................................................................... 707
		Steering System Air Removal................................................................................................................................................................................................................................................... 707
		Troubleshooting............................................................................................................................................................................................................................................................... 708
1638479-1900SRM1275-(12-2006)-UK-EN................................................................................................................................................................................................................................................... 713
	toc............................................................................................................................................................................................................................................................................... 713
		Hydraulic System.............................................................................................................................................................................................................................................................. 713
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 714
		General....................................................................................................................................................................................................................................................................... 717
		Description and Operation..................................................................................................................................................................................................................................................... 717
			Hydraulic Plate........................................................................................................................................................................................................................................................... 717
			Hydraulic Pumps........................................................................................................................................................................................................................................................... 718
			Steering Control System................................................................................................................................................................................................................................................... 718
			Brake System.............................................................................................................................................................................................................................................................. 718
			Tilt Control Valve........................................................................................................................................................................................................................................................ 719
		Hydraulic Pump Repair......................................................................................................................................................................................................................................................... 719
			General................................................................................................................................................................................................................................................................... 719
			Remove.................................................................................................................................................................................................................................................................... 719
			Disassemble............................................................................................................................................................................................................................................................... 719
			Clean and Inspect......................................................................................................................................................................................................................................................... 720
			Assemble.................................................................................................................................................................................................................................................................. 722
			Install................................................................................................................................................................................................................................................................... 723
			Pump Output Check......................................................................................................................................................................................................................................................... 723
				First Method.......................................................................................................................................................................................................................................................... 723
				Second Method......................................................................................................................................................................................................................................................... 724
		Lift and Lower Circuit........................................................................................................................................................................................................................................................ 725
			Description............................................................................................................................................................................................................................................................... 725
			Operation................................................................................................................................................................................................................................................................. 726
				Lift Circuit.......................................................................................................................................................................................................................................................... 727
				Lowering.............................................................................................................................................................................................................................................................. 727
				Lowering Control Valves............................................................................................................................................................................................................................................... 727
			Repairs................................................................................................................................................................................................................................................................... 727
				General............................................................................................................................................................................................................................................................... 727
				Remote Control Valve.................................................................................................................................................................................................................................................. 727
					Description and Operation......................................................................................................................................................................................................................................... 727
					Remove............................................................................................................................................................................................................................................................ 727
					Disassemble....................................................................................................................................................................................................................................................... 728
					Clean and Inspect................................................................................................................................................................................................................................................. 729
					Assemble.......................................................................................................................................................................................................................................................... 729
					Install........................................................................................................................................................................................................................................................... 729
					Adjust............................................................................................................................................................................................................................................................ 730
		Tilt Circuit.................................................................................................................................................................................................................................................................. 730
			Description............................................................................................................................................................................................................................................................... 730
			Operation................................................................................................................................................................................................................................................................. 730
				Tilt Spool............................................................................................................................................................................................................................................................ 731
				Relief Valves in Main Control Valve................................................................................................................................................................................................................................... 731
				Tilt Control Valves................................................................................................................................................................................................................................................... 731
			Repairs................................................................................................................................................................................................................................................................... 732
				General............................................................................................................................................................................................................................................................... 732
				Valves, Tilt Control Valves........................................................................................................................................................................................................................................... 732
					Disassemble....................................................................................................................................................................................................................................................... 732
					Clean and Inspect................................................................................................................................................................................................................................................. 732
					Assemble.......................................................................................................................................................................................................................................................... 732
					Checks and Adjustments............................................................................................................................................................................................................................................ 732
		Attachment Circuit Valves..................................................................................................................................................................................................................................................... 732
			Description and Operation................................................................................................................................................................................................................................................. 732
		Other Hydraulic Components.................................................................................................................................................................................................................................................... 733
			Description and Operation................................................................................................................................................................................................................................................. 733
				Relief Valves in Steering System...................................................................................................................................................................................................................................... 733
				Hydraulic Filters..................................................................................................................................................................................................................................................... 733
			Hydraulic Filters......................................................................................................................................................................................................................................................... 733
				High Pressure Filter.................................................................................................................................................................................................................................................. 733
				Brake Filter.......................................................................................................................................................................................................................................................... 734
				Return Line Filter.................................................................................................................................................................................................................................................... 734
			Hydraulic Tank Breather................................................................................................................................................................................................................................................... 735
			Hydraulic Hose Repair..................................................................................................................................................................................................................................................... 736
			Checks and Adjustments.................................................................................................................................................................................................................................................... 736
				Main Function Relief Valve Pressure, Check............................................................................................................................................................................................................................ 736
				Oil Level, Check...................................................................................................................................................................................................................................................... 737
		Specifications................................................................................................................................................................................................................................................................ 738
			Hydraulic Pumps Output at 2200 rpm (Governed Speed)....................................................................................................................................................................................................................... 738
				Cummins 142Hp (190 kW)/164 Hp (220 kW) Engine......................................................................................................................................................................................................................... 738
			Relief Valves (Approximate Operating Pressures)........................................................................................................................................................................................................................... 738
			Check Port Pressures...................................................................................................................................................................................................................................................... 738
			Main Hydraulic Filters.................................................................................................................................................................................................................................................... 738
			Tank Capacity............................................................................................................................................................................................................................................................. 738
		Torque Specifications......................................................................................................................................................................................................................................................... 739
			Pump...................................................................................................................................................................................................................................................................... 739
			Tilt Control Valve........................................................................................................................................................................................................................................................ 739
			Hydraulic Filters......................................................................................................................................................................................................................................................... 739
			Remote Control Valves..................................................................................................................................................................................................................................................... 739
		Troubleshooting............................................................................................................................................................................................................................................................... 740
			Lift and Lower Circuit.................................................................................................................................................................................................................................................... 740
			Tilt Circuit.............................................................................................................................................................................................................................................................. 742
			Attachment Circuit Valves................................................................................................................................................................................................................................................. 745
			Attachment Control Valve.................................................................................................................................................................................................................................................. 746
			Carriage Solenoid Valve................................................................................................................................................................................................................................................... 746
			Pump...................................................................................................................................................................................................................................................................... 746
			Other Hydraulic Components................................................................................................................................................................................................................................................ 748
			Accumulator Circuit....................................................................................................................................................................................................................................................... 748
			Pilot Circuit............................................................................................................................................................................................................................................................. 748
			Park Brake Circuit........................................................................................................................................................................................................................................................ 749
	tables............................................................................................................................................................................................................................................................................ 713
		Table 1. Brake Treadle Settings............................................................................................................................................................................................................................................... 719
		Table 2. Gauge Ranges......................................................................................................................................................................................................................................................... 737
		Table 3. Pressure Settings.................................................................................................................................................................................................................................................... 737
1638480-2100SRM1276-(05-2006)-UK-EN................................................................................................................................................................................................................................................... 753
	toc............................................................................................................................................................................................................................................................................... 753
		Tilt Cylinders................................................................................................................................................................................................................................................................ 753
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 754
		General....................................................................................................................................................................................................................................................................... 757
		Description................................................................................................................................................................................................................................................................... 757
		Tilt Cylinder Repair.......................................................................................................................................................................................................................................................... 757
			Remove.................................................................................................................................................................................................................................................................... 757
			Disassemble............................................................................................................................................................................................................................................................... 759
			Clean..................................................................................................................................................................................................................................................................... 760
			Inspect................................................................................................................................................................................................................................................................... 760
			Assemble.................................................................................................................................................................................................................................................................. 760
			Install................................................................................................................................................................................................................................................................... 761
		Tilt Cylinder Leak Check...................................................................................................................................................................................................................................................... 761
		Tilt Cylinder Stroke and Mast Tilt Angle Adjustment........................................................................................................................................................................................................................... 762
		Torque Specifications......................................................................................................................................................................................................................................................... 762
		Troubleshooting............................................................................................................................................................................................................................................................... 763
	tables............................................................................................................................................................................................................................................................................ 753
		Table 1. Movement Rate (Maximum) for Tilt Cylinders........................................................................................................................................................................................................................... 762
1638481-2000SRM1277-(12-2006)-UK-EN................................................................................................................................................................................................................................................... 767
	toc............................................................................................................................................................................................................................................................................... 767
		Hydraulic Plate............................................................................................................................................................................................................................................................... 767
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 768
		General....................................................................................................................................................................................................................................................................... 771
		Description and Operation..................................................................................................................................................................................................................................................... 772
			Hydraulic Oil Supply...................................................................................................................................................................................................................................................... 772
			Main Control Valve, Section 1 of Hydraulic Plate.......................................................................................................................................................................................................................... 772
				Description........................................................................................................................................................................................................................................................... 772
				Operation............................................................................................................................................................................................................................................................. 772
					Lift Section...................................................................................................................................................................................................................................................... 773
					Tilt Section...................................................................................................................................................................................................................................................... 773
					Auxiliary Section................................................................................................................................................................................................................................................. 773
			Combination Manifold, Section 2 of Hydraulic Plate........................................................................................................................................................................................................................ 773
		Main Control Valve, Section 1 of Hydraulic Plate.............................................................................................................................................................................................................................. 775
			Remove.................................................................................................................................................................................................................................................................... 775
			Disassemble............................................................................................................................................................................................................................................................... 776
				Lift Section.......................................................................................................................................................................................................................................................... 776
				Tilt Section.......................................................................................................................................................................................................................................................... 777
				Auxiliary Section..................................................................................................................................................................................................................................................... 777
				Spool................................................................................................................................................................................................................................................................. 777
				Relief Valve.......................................................................................................................................................................................................................................................... 777
			Clean and Inspect......................................................................................................................................................................................................................................................... 778
			Assemble.................................................................................................................................................................................................................................................................. 778
				Relief Valve.......................................................................................................................................................................................................................................................... 778
				Spool................................................................................................................................................................................................................................................................. 778
				Auxiliary Section..................................................................................................................................................................................................................................................... 778
				Tilt Section.......................................................................................................................................................................................................................................................... 779
				Lift Section.......................................................................................................................................................................................................................................................... 779
			Install................................................................................................................................................................................................................................................................... 779
		Combination Manifold, Section 2 of Hydraulic Plate............................................................................................................................................................................................................................ 780
			General................................................................................................................................................................................................................................................................... 780
			Valves and Pressure Switches.............................................................................................................................................................................................................................................. 780
		Hydraulic Hose Repair......................................................................................................................................................................................................................................................... 781
		Hydraulic Hose Identification................................................................................................................................................................................................................................................. 781
		Torque Values................................................................................................................................................................................................................................................................. 782
		Measurements and Adjustments.................................................................................................................................................................................................................................................. 783
			Measurements.............................................................................................................................................................................................................................................................. 783
			Adjustments............................................................................................................................................................................................................................................................... 783
		Troubleshooting............................................................................................................................................................................................................................................................... 784
	tables............................................................................................................................................................................................................................................................................ 767
		Table 1. Pilot Hoses.......................................................................................................................................................................................................................................................... 781
		Table 2. Brake Hoses.......................................................................................................................................................................................................................................................... 781
		Table 3. Steer Hoses.......................................................................................................................................................................................................................................................... 781
		Table 4. Pressure Settings at 2100 RPM........................................................................................................................................................................................................................................ 783
1638482-2200SRM1278-(01-2007)-UK-EN................................................................................................................................................................................................................................................... 789
	toc............................................................................................................................................................................................................................................................................... 789
		Instrument Panel Indicators and Senders....................................................................................................................................................................................................................................... 789
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 790
		General....................................................................................................................................................................................................................................................................... 793
		Description................................................................................................................................................................................................................................................................... 793
			General................................................................................................................................................................................................................................................................... 793
			Instrument Panel Meters, Indicators, and LCD Display...................................................................................................................................................................................................................... 793
			Connector................................................................................................................................................................................................................................................................. 799
			Seat Switch Logic......................................................................................................................................................................................................................................................... 800
			Central Warning Light Output.............................................................................................................................................................................................................................................. 800
			Buzzer Output............................................................................................................................................................................................................................................................. 800
		Instrument Panel.............................................................................................................................................................................................................................................................. 801
			Remove.................................................................................................................................................................................................................................................................... 802
		Sender Replacement............................................................................................................................................................................................................................................................ 803
			Fuel Level Sender......................................................................................................................................................................................................................................................... 803
			Pressure Sender........................................................................................................................................................................................................................................................... 803
			Brake Pressure Sender..................................................................................................................................................................................................................................................... 804
			Low Coolant Sender........................................................................................................................................................................................................................................................ 804
			Vacuum Switch............................................................................................................................................................................................................................................................. 804
		Specifications................................................................................................................................................................................................................................................................ 805
		Troubleshooting............................................................................................................................................................................................................................................................... 806
	tables............................................................................................................................................................................................................................................................................ 789
		Table 1. Instrument Panel and Indicators...................................................................................................................................................................................................................................... 794
		Table 2. Pin Description...................................................................................................................................................................................................................................................... 799
		Table 3. Sender Description................................................................................................................................................................................................................................................... 800
1638483-2200SRM1279-(05-2006)-UK-EN................................................................................................................................................................................................................................................... 809
	toc............................................................................................................................................................................................................................................................................... 809
		Electrical System............................................................................................................................................................................................................................................................. 809
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 810
		Description................................................................................................................................................................................................................................................................... 813
		Warning Devices............................................................................................................................................................................................................................................................... 816
			General................................................................................................................................................................................................................................................................... 816
			Description............................................................................................................................................................................................................................................................... 816
				Operator-Controlled Horn.............................................................................................................................................................................................................................................. 816
				Reverse Warning Horns/Lights.......................................................................................................................................................................................................................................... 816
				Warning Lights........................................................................................................................................................................................................................................................ 817
					Strobe Light...................................................................................................................................................................................................................................................... 817
					Brake Lights...................................................................................................................................................................................................................................................... 817
					Hazard Lights..................................................................................................................................................................................................................................................... 817
				Replace............................................................................................................................................................................................................................................................... 817
					General........................................................................................................................................................................................................................................................... 817
					Horns............................................................................................................................................................................................................................................................. 817
					Horn Relay........................................................................................................................................................................................................................................................ 817
					Light Assemblies.................................................................................................................................................................................................................................................. 819
					Flashing Unit..................................................................................................................................................................................................................................................... 819
		Meters, Senders, and Switches................................................................................................................................................................................................................................................. 819
			General................................................................................................................................................................................................................................................................... 819
1638484-8000SRM1280-(10-2006)-UK-EN................................................................................................................................................................................................................................................... 827
	toc............................................................................................................................................................................................................................................................................... 827
		Periodic Maintenance.......................................................................................................................................................................................................................................................... 827
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 828
		General....................................................................................................................................................................................................................................................................... 833
			Serial Number Data........................................................................................................................................................................................................................................................ 833
			How to Move a Disabled Lift Truck......................................................................................................................................................................................................................................... 833
				How to Tow the Lift Truck............................................................................................................................................................................................................................................. 834
			How to Put Lift Truck on Blocks........................................................................................................................................................................................................................................... 834
				How to Raise the Drive Tires.......................................................................................................................................................................................................................................... 835
				How to Raise the Steer Tires.......................................................................................................................................................................................................................................... 835
		Maintenance Schedule.......................................................................................................................................................................................................................................................... 836
			Empty Container Attachment Maintenance.................................................................................................................................................................................................................................... 844
		Maintenance Procedures Every 8 Hours or Daily................................................................................................................................................................................................................................. 846
			How to Make Checks With the Engine Stopped................................................................................................................................................................................................................................ 846
				Safety Labels......................................................................................................................................................................................................................................................... 846
				Operator Restraint System............................................................................................................................................................................................................................................. 846
					Seat Belt and Seat Rails.......................................................................................................................................................................................................................................... 846
					Steering Column Latch............................................................................................................................................................................................................................................. 847
				Tires and Wheels...................................................................................................................................................................................................................................................... 847
				Inspection of Mast and Lift Chains.................................................................................................................................................................................................................................... 847
				Drive Belt............................................................................................................................................................................................................................................................ 848
				Crankcase Breather Tube............................................................................................................................................................................................................................................... 848
				Air Intake Piping and Charge Air Piping............................................................................................................................................................................................................................... 848
				Cooling Fan........................................................................................................................................................................................................................................................... 849
				Pre-Cleaner for Air Filter............................................................................................................................................................................................................................................ 849
				Fuel, Oil, or Coolant Leaks........................................................................................................................................................................................................................................... 849
				Hydraulic Tank Breather............................................................................................................................................................................................................................................... 849
				Engine Oil............................................................................................................................................................................................................................................................ 850
				Hydraulic System Oil.................................................................................................................................................................................................................................................. 850
				Brake Filter.......................................................................................................................................................................................................................................................... 851
				Battery............................................................................................................................................................................................................................................................... 851
				Fuel Filter/Water Separator........................................................................................................................................................................................................................................... 852
				Cooling System........................................................................................................................................................................................................................................................ 852
			How to Add Fuel to Lift Truck............................................................................................................................................................................................................................................. 853
			How to Make Checks With Engine Running.................................................................................................................................................................................................................................... 853
				Gauges, Lights, Horn, Fuses, and Relays............................................................................................................................................................................................................................... 853
					Sealed Fuses...................................................................................................................................................................................................................................................... 854
				Transmission Oil...................................................................................................................................................................................................................................................... 855
				Engine Air Filter..................................................................................................................................................................................................................................................... 856
				Engine Oil Pressure................................................................................................................................................................................................................................................... 856
				Electrical System..................................................................................................................................................................................................................................................... 856
				Steering System....................................................................................................................................................................................................................................................... 856
				Service Brakes........................................................................................................................................................................................................................................................ 856
				Parking Brake......................................................................................................................................................................................................................................................... 856
				Control Levers and Pedals............................................................................................................................................................................................................................................. 856
				Lift System Operation................................................................................................................................................................................................................................................. 857
				Attachments........................................................................................................................................................................................................................................................... 857
		First Inspection After First 100 Hours of Operation........................................................................................................................................................................................................................... 857
			Engine Oil Filter......................................................................................................................................................................................................................................................... 857
			Drive Axle and Differential............................................................................................................................................................................................................................................... 857
			Lift Chains............................................................................................................................................................................................................................................................... 857
			Transmission Oil Filter................................................................................................................................................................................................................................................... 858
			Air Conditioning.......................................................................................................................................................................................................................................................... 858
			Steer Wheel Hubs.......................................................................................................................................................................................................................................................... 858
		Maintenance Procedures Every 250 Hours Or Monthly............................................................................................................................................................................................................................. 858
			Twist Locks............................................................................................................................................................................................................................................................... 858
			Drive Belt................................................................................................................................................................................................................................................................ 858
			Lift Chains............................................................................................................................................................................................................................................................... 858
			Wheel Nuts................................................................................................................................................................................................................................................................ 860
			Drive Axle and Differential Oil........................................................................................................................................................................................................................................... 860
			Steering Axle Tie Rods.................................................................................................................................................................................................................................................... 860
			Drive Shaft............................................................................................................................................................................................................................................................... 860
			Mast Pivots, Sliding Surfaces............................................................................................................................................................................................................................................. 860
			Sideshift Carriage........................................................................................................................................................................................................................................................ 860
		Maintenance Procedures Every 500 Hours or 3 Months............................................................................................................................................................................................................................ 860
			Air Conditioning.......................................................................................................................................................................................................................................................... 860
		Maintenance Procedures Every 500 Hours or 6 Months............................................................................................................................................................................................................................ 861
			Fuel Filter............................................................................................................................................................................................................................................................... 861
			Engine Oil and Filter..................................................................................................................................................................................................................................................... 861
		Maintenance Procedures Every 1000 Hours or 6 Months........................................................................................................................................................................................................................... 861
			Brake System Accumulator.................................................................................................................................................................................................................................................. 861
			Steering Axle Kingpins.................................................................................................................................................................................................................................................... 861
			Mast and Carriage Load Rollers............................................................................................................................................................................................................................................ 861
			Brake Filter.............................................................................................................................................................................................................................................................. 862
			Change Transmission Oil and Filter........................................................................................................................................................................................................................................ 862
			Fan Drive Idler Pulley.................................................................................................................................................................................................................................................... 862
			Fan Hub................................................................................................................................................................................................................................................................... 863
		Maintenance Procedures Every 1500 Hours or 1 Year............................................................................................................................................................................................................................. 864
			Engine.................................................................................................................................................................................................................................................................... 864
			Water Pump................................................................................................................................................................................................................................................................ 864
			Turbocharger.............................................................................................................................................................................................................................................................. 865
			Engine Mounting Bolts..................................................................................................................................................................................................................................................... 865
			Air Leaks, Air Intake and Exhaust......................................................................................................................................................................................................................................... 865
			Valve and Injector Adjustments............................................................................................................................................................................................................................................ 866
				General............................................................................................................................................................................................................................................................... 866
				Adjust................................................................................................................................................................................................................................................................ 867
		Maintenance Procedures Every 2000 Hours or 1 Year............................................................................................................................................................................................................................. 869
			Drive Axle and Differential Oil........................................................................................................................................................................................................................................... 869
			Hub Bearings, Steer Wheels................................................................................................................................................................................................................................................ 869
			Parking Brake Assembly.................................................................................................................................................................................................................................................... 869
				Clean................................................................................................................................................................................................................................................................. 869
				Inspect............................................................................................................................................................................................................................................................... 870
			Vibration Damper.......................................................................................................................................................................................................................................................... 871
			Cooling System Fluid...................................................................................................................................................................................................................................................... 872
		Maintenance Procedures Every 3000 Hours or 18 Months.......................................................................................................................................................................................................................... 872
			Hydraulic System Oil...................................................................................................................................................................................................................................................... 872
			Hydraulic Return Line Oil Filter.......................................................................................................................................................................................................................................... 873
		Maintenance Procedures Every 6000 Hours or 2 Years............................................................................................................................................................................................................................ 873
			Turbocharger.............................................................................................................................................................................................................................................................. 873
		Safety Procedures When Working Near Mast...................................................................................................................................................................................................................................... 874
		Lift and Tilt System Leaks Check.............................................................................................................................................................................................................................................. 875
			Lift System............................................................................................................................................................................................................................................................... 875
			Tilt System............................................................................................................................................................................................................................................................... 875
		Pneumatic Tires and Wheels.................................................................................................................................................................................................................................................... 876
			Remove Wheels From Lift Truck............................................................................................................................................................................................................................................. 876
			Remove Tire From Wheel.................................................................................................................................................................................................................................................... 876
				Remove Tire From Five-Piece Wheel..................................................................................................................................................................................................................................... 877
			Install Tire on Wheel..................................................................................................................................................................................................................................................... 878
				Install Tire on Five-Piece Wheel...................................................................................................................................................................................................................................... 879
			Add Air Pressure to Tires................................................................................................................................................................................................................................................. 880
			Install Wheels on Lift Truck.............................................................................................................................................................................................................................................. 881
	tables............................................................................................................................................................................................................................................................................ 827
		Table 1. Condition Check...................................................................................................................................................................................................................................................... 837
		Table 2. Fluid Level Check.................................................................................................................................................................................................................................................... 838
		Table 3. Daily Inspections − Checks With the Engine Running................................................................................................................................................................................................................... 839
		Table 4. First Inspection − Initial 100 - Hour Check or Change................................................................................................................................................................................................................ 840
		Table 5. Periodic Maintenance Schedule − Inspect and Adjust................................................................................................................................................................................................................... 840
		Table 6. Periodic Maintenance Schedule − Lubricate............................................................................................................................................................................................................................ 841
		Table 7. Periodic Maintenance Schedule − Change............................................................................................................................................................................................................................... 842
		Table 8. Inspect and Adjust................................................................................................................................................................................................................................................... 844
		Table 9. Lubricate............................................................................................................................................................................................................................................................ 845
		Table 10. Replace............................................................................................................................................................................................................................................................. 845
		Table 11. Valve and Injector Adjustment Specifications........................................................................................................................................................................................................................ 867
1638485-8000SRM1281-(01-2007)-UK-EN................................................................................................................................................................................................................................................... 885
	toc............................................................................................................................................................................................................................................................................... 885
		Diagrams...................................................................................................................................................................................................................................................................... 885
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 886
1638486-8000SRM1282-(06-2006)-UK-EN................................................................................................................................................................................................................................................... 925
	toc............................................................................................................................................................................................................................................................................... 925
		Assembly Guide................................................................................................................................................................................................................................................................ 925
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 926
		List of All Special Tools and Equipment Needed for the Assembly............................................................................................................................................................................................................... 929
		General Considerations Before Starting the Job................................................................................................................................................................................................................................ 930
		Preparation of the Components Before Assembly................................................................................................................................................................................................................................. 931
		Checking of the Wheels........................................................................................................................................................................................................................................................ 931
			Air Pressure.............................................................................................................................................................................................................................................................. 931
			Drive Wheels.............................................................................................................................................................................................................................................................. 932
			Steer Wheels.............................................................................................................................................................................................................................................................. 936
			Wheel Nut Torque.......................................................................................................................................................................................................................................................... 939
		Label Placement............................................................................................................................................................................................................................................................... 940
			Mast Labels............................................................................................................................................................................................................................................................... 940
			Attachment Labels......................................................................................................................................................................................................................................................... 940
		Safety Procedures When Working Near Mast...................................................................................................................................................................................................................................... 941
		Installation of the Mast...................................................................................................................................................................................................................................................... 942
			Mast...................................................................................................................................................................................................................................................................... 942
			Truck Header Hoses-Part 1................................................................................................................................................................................................................................................. 943
			Mast Pin Installation..................................................................................................................................................................................................................................................... 944
			Tilt Cylinder Pin Installation............................................................................................................................................................................................................................................ 946
			Truck Header Hoses-Part 2................................................................................................................................................................................................................................................. 948
			Attachment Connection..................................................................................................................................................................................................................................................... 949
		Exhaust Installation.......................................................................................................................................................................................................................................................... 951
		Lights Installation........................................................................................................................................................................................................................................................... 951
			Flood..................................................................................................................................................................................................................................................................... 951
			Beacon.................................................................................................................................................................................................................................................................... 951
		Hydraulic Oil Check........................................................................................................................................................................................................................................................... 953
		Lubrication Points............................................................................................................................................................................................................................................................ 954
		Check Points.................................................................................................................................................................................................................................................................. 955
			Checkpoint 1.............................................................................................................................................................................................................................................................. 955
			Checkpoint 2.............................................................................................................................................................................................................................................................. 955
			Checkpoint 3.............................................................................................................................................................................................................................................................. 955
			Checkpoint 4.............................................................................................................................................................................................................................................................. 955
			Checkpoint 5.............................................................................................................................................................................................................................................................. 955
		General Truck Install Procedures.............................................................................................................................................................................................................................................. 955
1643888-1400SRM1296-(12-2006)-UK-EN................................................................................................................................................................................................................................................... 959
	toc............................................................................................................................................................................................................................................................................... 959
		Planetary Gear Axle........................................................................................................................................................................................................................................................... 959
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 960
		General....................................................................................................................................................................................................................................................................... 963
		Description................................................................................................................................................................................................................................................................... 963
		Operation..................................................................................................................................................................................................................................................................... 963
		Planetary Gear Axle Repair.................................................................................................................................................................................................................................................... 966
			Remove.................................................................................................................................................................................................................................................................... 966
				Drive Wheels and Tires................................................................................................................................................................................................................................................ 966
			Disassemble............................................................................................................................................................................................................................................................... 967
				Drive Axle............................................................................................................................................................................................................................................................ 967
				Planetary Gear Carrier................................................................................................................................................................................................................................................ 968
				Ring Gear, Ring Gear Hub, and Wheel Hub............................................................................................................................................................................................................................... 969
				Hub Oil Seal and Bearings............................................................................................................................................................................................................................................. 971
				Axle Shaft............................................................................................................................................................................................................................................................ 971
				Spindle............................................................................................................................................................................................................................................................... 971
			Repair.................................................................................................................................................................................................................................................................... 972
				Repairing or Replacing Parts.......................................................................................................................................................................................................................................... 972
				Welding............................................................................................................................................................................................................................................................... 972
			Clean..................................................................................................................................................................................................................................................................... 973
				Ground or Polished Parts.............................................................................................................................................................................................................................................. 973
				Parts With Rough Finishes............................................................................................................................................................................................................................................. 973
				Axle Assemblies....................................................................................................................................................................................................................................................... 973
				Drying Cleaned Parts.................................................................................................................................................................................................................................................. 973
			Preventing Corrosion...................................................................................................................................................................................................................................................... 973
			Parts Inspection.......................................................................................................................................................................................................................................................... 974
			Assemble.................................................................................................................................................................................................................................................................. 974
				Spindle............................................................................................................................................................................................................................................................... 974
				Axle Shaft............................................................................................................................................................................................................................................................ 974
				Hub Oil Seal and Bearings............................................................................................................................................................................................................................................. 974
				Ring Gear, Ring Gear Hub, and Wheel Hub............................................................................................................................................................................................................................... 975
				Wheel Bearing Preload................................................................................................................................................................................................................................................. 975
					Adjust............................................................................................................................................................................................................................................................ 975
				Planetary Gear Carrier................................................................................................................................................................................................................................................ 976
				Drive Axle............................................................................................................................................................................................................................................................ 977
				Wheel Ends............................................................................................................................................................................................................................................................ 978
					Fill.............................................................................................................................................................................................................................................................. 978
			Install................................................................................................................................................................................................................................................................... 978
				Drive Wheels and Tires................................................................................................................................................................................................................................................ 978
		Torque Specifications......................................................................................................................................................................................................................................................... 980
		Troubleshooting............................................................................................................................................................................................................................................................... 981
	tables............................................................................................................................................................................................................................................................................ 959
		Table 1. Wheel Bearing Adjustment Torque...................................................................................................................................................................................................................................... 975
		Table 2. Planetary Gear Carrier Capscrew and Stud Torque Specifi.............................................................................................................................................................................................................. 977
		Table 3. Standard Torque Values for Axle Fasteners............................................................................................................................................................................................................................ 980
1643889-8000SRM1297-(10-2006)-UK-EN................................................................................................................................................................................................................................................... 985
	toc............................................................................................................................................................................................................................................................................... 985
		Capacities and Specifications................................................................................................................................................................................................................................................. 985
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 986
		Counterweight Weights......................................................................................................................................................................................................................................................... 989
		Vehicle Weights............................................................................................................................................................................................................................................................... 989
		Container Attachment Weights.................................................................................................................................................................................................................................................. 989
		Capacities.................................................................................................................................................................................................................................................................... 990
		Electrical System............................................................................................................................................................................................................................................................. 990
		Engine Specifications......................................................................................................................................................................................................................................................... 990
		Function Speeds............................................................................................................................................................................................................................................................... 991
		Steering...................................................................................................................................................................................................................................................................... 991
		Tire Sizes.................................................................................................................................................................................................................................................................... 992
		Hydraulic System Specifications............................................................................................................................................................................................................................................... 992
		Torque Specifications......................................................................................................................................................................................................................................................... 993
			Main Control Valve........................................................................................................................................................................................................................................................ 993
			Engine.................................................................................................................................................................................................................................................................... 993
			Electrical System......................................................................................................................................................................................................................................................... 993
				Alternator............................................................................................................................................................................................................................................................ 993
			Counterweight............................................................................................................................................................................................................................................................. 993
			Drive Axle................................................................................................................................................................................................................................................................ 994
			Planetary Gear Axle....................................................................................................................................................................................................................................................... 994
			Steering Axle............................................................................................................................................................................................................................................................. 994
			Wheel Bearing Adjusting Nut (PRC1756-W3H)................................................................................................................................................................................................................................. 994
			Differential.............................................................................................................................................................................................................................................................. 994
			Transmission.............................................................................................................................................................................................................................................................. 994
			Torque Converter.......................................................................................................................................................................................................................................................... 994
			Steering.................................................................................................................................................................................................................................................................. 994
			Wheel Nuts................................................................................................................................................................................................................................................................ 994
			Attachment................................................................................................................................................................................................................................................................ 994
Aurora_AC............................................................................................................................................................................................................................................................................. 997
	912-100-0148_engl_1.pdf........................................................................................................................................................................................................................................................... 998
		Compressors - Applications, Conditions of Use and Liability................................................................................................................................................................................................................... 998
			..........................................................................................................................................................................................................................................................................1004
				Filling procedure for refrigerants....................................................................................................................................................................................................................................1004
					Do not exceed the maximum operating pressure of the compressor. (see type label)..................................................................................................................................................................................1004
					Compressors are machines under pressure and as such require special care in handling..............................................................................................................................................................................1004
					Only qualified personnel are allowed to perform any work on refrigeration compressors.............................................................................................................................................................................1004
					The national safety regulations, accident prevention regulations, technical rules and specific regulations must be taken into account abolutely...................................................................................................................1004
					Never put the safety switch out of action.........................................................................................................................................................................................................................1004
					Prior to commissioning, check wether all teh components installed by the user have been fastened expertly and connected pressure-tight with the compressor........................................................................................................1004
					Prior to starting the compressor open discharge shut-off valve and suction shut-off valve.........................................................................................................................................................................1004
					Do not start the cmpressor in vacuum. Operate the compressor only when the system is charged......................................................................................................................................................................1004
					Caution! Danger of burning because of high surface temperatures...................................................................................................................................................................................................1004
					Never grab rotating parts during operation. Danger of injury!.....................................................................................................................................................................................................1004
					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....1004
					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....1004
					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...................1004
					Full bottles of refrigerant must not be thrown or.................................................................................................................................................................................................................1004
					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.....................................................1004
		4. Troubleshooting............................................................................................................................................................................................................................................................1005
			..........................................................................................................................................................................................................................................................................1005
				......................................................................................................................................................................................................................................................................1005
					Check refrigerant level and pressure as instructed in the Technical Information sheet for the unit................................................................................................................................................................1005
					By wrong refrigerant level there is a danger of compressor malfunction............................................................................................................................................................................................1005
					The outcome of too much refrigerant is a oil attenuation and reflux of the refrigerant can cause damages on the valve plate.......................................................................................................................................1005
					With undercharged refrigerant the compressor will become hotwhich caused a failure. The sealing will be damaged...................................................................................................................................................1005
					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....1005
					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.....1005
					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....1005
	912-100-0007_e.pdf................................................................................................................................................................................................................................................................1006
		Technical modifications reserved..............................................................................................................................................................................................................................................1006
	912-100-0258_e.pdf................................................................................................................................................................................................................................................................1017
		Condenser unit, 24V...........................................................................................................................................................................................................................................................1017
			..........................................................................................................................................................................................................................................................................1017
				......................................................................................................................................................................................................................................................................1017
					..................................................................................................................................................................................................................................................................1017
						..............................................................................................................................................................................................................................................................1017
							part no.:175-FR2-0002.....................................................................................................................................................................................................................................1017
						Safety advices................................................................................................................................................................................................................................................1017
			- we reserve the right to make technical modifications -..................................................................................................................................................................................................................1017
		1Safety advices...............................................................................................................................................................................................................................................................1018
			Maintenance work on the refrigeration circuit:............................................................................................................................................................................................................................1018
				......................................................................................................................................................................................................................................................................1019
					2.2Condenser blowers..............................................................................................................................................................................................................................................1019
					5Electrical connection............................................................................................................................................................................................................................................1020
			every six months – authorised workshop:...................................................................................................................................................................................................................................1021
				......................................................................................................................................................................................................................................................................1021
					..................................................................................................................................................................................................................................................................1021
						..............................................................................................................................................................................................................................................................1021
							State of the refrigerant hoses............................................................................................................................................................................................................................1021
				State of the condenser................................................................................................................................................................................................................................................1021
			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).................................................................................................................1021
			every month sight checks - Operator.......................................................................................................................................................................................................................................1022
				......................................................................................................................................................................................................................................................................1022
					..................................................................................................................................................................................................................................................................1022
						..............................................................................................................................................................................................................................................................1022
							State of the refrigerant hoses............................................................................................................................................................................................................................1022
				State of the condenser................................................................................................................................................................................................................................................1022
			Check condenser of contamination by dust, insects or parts of plants......................................................................................................................................................................................................1022
			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).................................................................................................................1022
				Installation of replacement parts.....................................................................................................................................................................................................................................1022
					8Technical data...................................................................................................................................................................................................................................................1022
					9Fault diagnosis..................................................................................................................................................................................................................................................1023

HYSTER B214 (H16.00-22.00XM-12EC EUROPE) SERVICE MANUAL – PDF DOWNLOAD:

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