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Hyster E117 (H1050HD-CH, H1150HD-CH) Service Manual – PDF DOWNLOAD
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Description
Hyster E117 (H1050HD-CH, H1150HD-CH) Service Manual – PDF DOWNLOAD
DESCRIPTION:
Hyster E117 (H1050HD-CH, H1150HD-CH) 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 E117 (H1050HD-CH, H1150HD-CH) Service Manual – PDF DOWNLOAD
897948-1300SRM0634-(03-2005)-US-EN.................................................................................................................................................................................................................................................... 1 toc............................................................................................................................................................................................................................................................................... 1 Four-Speed Powershift Transmission............................................................................................................................................................................................................................................ 1 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 2 General....................................................................................................................................................................................................................................................................... 5 Automatic Powershift Control.................................................................................................................................................................................................................................................. 6 Transmission Control System............................................................................................................................................................................................................................................... 6 Transmission Control Lever................................................................................................................................................................................................................................................ 6 Mechanical Description and Operation.......................................................................................................................................................................................................................................... 8 General................................................................................................................................................................................................................................................................... 8 Torque Converter.......................................................................................................................................................................................................................................................... 8 Description........................................................................................................................................................................................................................................................... 8 Operation............................................................................................................................................................................................................................................................. 8 Clutch Assemblies......................................................................................................................................................................................................................................................... 9 Description........................................................................................................................................................................................................................................................... 9 Operation............................................................................................................................................................................................................................................................. 9 Transmission Operation in Neutral......................................................................................................................................................................................................................................... 11 Input Shaft, Forward Shaft, and Clutch Assembly........................................................................................................................................................................................................................... 13 Description........................................................................................................................................................................................................................................................... 13 Operation............................................................................................................................................................................................................................................................. 13 Reverse, Second-Speed, and First-Speed Shaft and Clutch Assembli.......................................................................................................................................................................................................... 17 Description........................................................................................................................................................................................................................................................... 17 Operation............................................................................................................................................................................................................................................................. 17 Third-Speed Shaft, Gear, and Clutch Assembly.............................................................................................................................................................................................................................. 17 Description........................................................................................................................................................................................................................................................... 17 Operation............................................................................................................................................................................................................................................................. 17 Fourth-Speed Shaft and Clutch............................................................................................................................................................................................................................................. 18 Description........................................................................................................................................................................................................................................................... 18 Operation............................................................................................................................................................................................................................................................. 18 Output Shaft.............................................................................................................................................................................................................................................................. 18 Description........................................................................................................................................................................................................................................................... 18 Operation............................................................................................................................................................................................................................................................. 18 Hydraulic Description and Operation........................................................................................................................................................................................................................................... 18 Sump, Filter, and Pump.................................................................................................................................................................................................................................................... 18 Transmission Charge Pump.................................................................................................................................................................................................................................................. 20 Pressure Regulator Valve.............................................................................................................................................................................................................................................. 20 Relief Valve.......................................................................................................................................................................................................................................................... 20 Transmission Control Valve................................................................................................................................................................................................................................................ 20 Solenoid Valves....................................................................................................................................................................................................................................................... 20 Direction Spools...................................................................................................................................................................................................................................................... 21 Range Spools.......................................................................................................................................................................................................................................................... 21 Modulator Valves...................................................................................................................................................................................................................................................... 21 tables............................................................................................................................................................................................................................................................................ 1 Table 1. Solenoid Controls.................................................................................................................................................................................................................................................... 11 897949-1300SRM0635-(06-2007)-US-EN.................................................................................................................................................................................................................................................... 27 toc............................................................................................................................................................................................................................................................................... 27 Four-Speed Powershift Transmission............................................................................................................................................................................................................................................ 27 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 28 General....................................................................................................................................................................................................................................................................... 31 Torque Converter Repair....................................................................................................................................................................................................................................................... 32 Torque Converter, Remove.................................................................................................................................................................................................................................................. 32 Torque Converter, Disassemble............................................................................................................................................................................................................................................. 32 Clean and Inspect......................................................................................................................................................................................................................................................... 34 Torque Converter, Assemble................................................................................................................................................................................................................................................ 34 Torque Converter (Turbine) Housing, Disassemble........................................................................................................................................................................................................................... 35 Relief Valve for Lube Pressure, Disassemble and Assemble.................................................................................................................................................................................................................. 35 Oil Sealing Rings Sleeve, Replace......................................................................................................................................................................................................................................... 35 Torque Converter Housing, Assemble........................................................................................................................................................................................................................................ 35 Torque Converter, Install................................................................................................................................................................................................................................................. 36 Transmission Repair........................................................................................................................................................................................................................................................... 36 Remove, Transmission Only................................................................................................................................................................................................................................................. 36 Transmission and Engine Assembly, Remove.................................................................................................................................................................................................................................. 37 Transmission, Disassemble................................................................................................................................................................................................................................................. 38 Output Shaft, Disassemble and Assemble................................................................................................................................................................................................................................ 39 Fourth-Speed Shaft, Disassemble and Assemble.......................................................................................................................................................................................................................... 41 Third-Speed Shaft, Disassemble and Assemble........................................................................................................................................................................................................................... 42 Forward Shaft and Clutch, Disassemble and Assemble.................................................................................................................................................................................................................... 45 Reverse and Second-Speed Shaft and Clutch, Disassemble and Assem...................................................................................................................................................................................................... 47 First-Speed Shaft and Clutch, Disassemble and Assemble................................................................................................................................................................................................................ 49 Input Shaft, Disassemble and Assemble................................................................................................................................................................................................................................. 51 Speed Sensor, Install..................................................................................................................................................................................................................................................... 52 Transmission, Clean and Inspect........................................................................................................................................................................................................................................... 53 Transmission, Assemble.................................................................................................................................................................................................................................................... 53 Control Valve............................................................................................................................................................................................................................................................. 55 Clean and Inspect..................................................................................................................................................................................................................................................... 55 Assemble and Install.................................................................................................................................................................................................................................................. 55 Install, Transmission..................................................................................................................................................................................................................................................... 56 Install, Transmission and Engine Assembly................................................................................................................................................................................................................................. 56 Clean Oil System of Transmission After Major Repair....................................................................................................................................................................................................................... 57 Automatic Powershift Control (APC 100)........................................................................................................................................................................................................................................ 57 Functional Description.................................................................................................................................................................................................................................................... 57 Fuses..................................................................................................................................................................................................................................................................... 60 Transmission Control Lever................................................................................................................................................................................................................................................ 60 First-Speed Shaft Bearings Adjustment......................................................................................................................................................................................................................................... 63 Torque Converter Stall Speed Check............................................................................................................................................................................................................................................ 66 Transmission Oil Pressures Check.............................................................................................................................................................................................................................................. 66 Clutch Pressures Check.................................................................................................................................................................................................................................................... 66 Torque Converter (Torque Converter Regulator) Oil Pressure Check.......................................................................................................................................................................................................... 66 Troubleshooting............................................................................................................................................................................................................................................................... 68 Transmission Controller (APC 100)......................................................................................................................................................................................................................................... 70 tables............................................................................................................................................................................................................................................................................ 27 Table 1. Flange Nut Torque.................................................................................................................................................................................................................................................... 53 Table 2. APC 100 Control Module (Pin Connections)............................................................................................................................................................................................................................. 59 Table 3. Hobbs Gear Selector Connections...................................................................................................................................................................................................................................... 62 Table 4. Example Torque Values at Dimensions Shown............................................................................................................................................................................................................................ 63 Table 5. Transmission Pressures............................................................................................................................................................................................................................................... 67 910072-1400SRM0046-(07-2007)-US-EN.................................................................................................................................................................................................................................................... 77 toc............................................................................................................................................................................................................................................................................... 77 Differential.................................................................................................................................................................................................................................................................. 77 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 78 General....................................................................................................................................................................................................................................................................... 81 Description................................................................................................................................................................................................................................................................... 81 Differential Repair........................................................................................................................................................................................................................................................... 82 Remove.................................................................................................................................................................................................................................................................... 82 Differential Carrier From Axle Housing, Remove........................................................................................................................................................................................................................ 82 Differential and Ring Gear From Differential Carrier, Remove.......................................................................................................................................................................................................... 84 Drive Pinion and Pinion Carrier From Differential Carrier, Remov...................................................................................................................................................................................................... 86 Disassemble............................................................................................................................................................................................................................................................... 87 Differential and Ring Gear Assembly, Disassemble...................................................................................................................................................................................................................... 87 Drive Pinion and Pinion Carrier, Disassemble.......................................................................................................................................................................................................................... 89 Clean and Inspect......................................................................................................................................................................................................................................................... 92 Assemble.................................................................................................................................................................................................................................................................. 93 Pinion, Bearings, and Pinion Carrier, Assemble........................................................................................................................................................................................................................ 93 Pinion Bearings, Adjust Preload....................................................................................................................................................................................................................................... 93 Press Method...................................................................................................................................................................................................................................................... 93 Yoke or Flange Method............................................................................................................................................................................................................................................. 94 Triple-Lip Seal, Install.............................................................................................................................................................................................................................................. 95 Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion)........................................................................................................................................................................................................... 96 Differential and Ring Gear, Assemble.................................................................................................................................................................................................................................. 98 Differential Gears Rotating Torque, Check............................................................................................................................................................................................................................. 100 Differential and Ring Gear Assembly, Install.......................................................................................................................................................................................................................... 101 Differential Bearings, Preload Adjust................................................................................................................................................................................................................................. 103 Ring Gear, Runout Check............................................................................................................................................................................................................................................... 104 Ring Gear Backlash, Adjust............................................................................................................................................................................................................................................ 104 Gear Set, Tooth Contact Pattern Check................................................................................................................................................................................................................................. 106 Thrust Screw, Install and Adjust...................................................................................................................................................................................................................................... 109 Install................................................................................................................................................................................................................................................................... 109 Differential Assembly Into Axle Housing, Install...................................................................................................................................................................................................................... 109 Specifications................................................................................................................................................................................................................................................................ 111 Troubleshooting............................................................................................................................................................................................................................................................... 116 tables............................................................................................................................................................................................................................................................................ 77 Table 1. Ring Gear Backlash Adjustment Specifications......................................................................................................................................................................................................................... 106 Table 2. Ring and Pinion Tooth Contact Adjustment............................................................................................................................................................................................................................. 107 Table 3. General Specifications............................................................................................................................................................................................................................................... 111 Table 4. Rivet Installation Pressure.......................................................................................................................................................................................................................................... 111 Table 5. Pinion Adjustment.................................................................................................................................................................................................................................................... 112 Table 6. Pinion Preload Pressure.............................................................................................................................................................................................................................................. 112 Table 7. Torque Specifications................................................................................................................................................................................................................................................ 113 Table 8. Torque Specifications for Metric Hardware............................................................................................................................................................................................................................ 114 Table 9. Torque Specifications for Metric (Fine) Hardware..................................................................................................................................................................................................................... 115 910091-1900SRM0097-(07-2006)-US-EN.................................................................................................................................................................................................................................................... 119 toc............................................................................................................................................................................................................................................................................... 119 Hydraulic Gear Pumps.......................................................................................................................................................................................................................................................... 119 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 120 Description................................................................................................................................................................................................................................................................... 123 Operation..................................................................................................................................................................................................................................................................... 124 Flow Control Valve........................................................................................................................................................................................................................................................ 124 Relief Valve.............................................................................................................................................................................................................................................................. 125 Hydraulic Gear Pump Repair.................................................................................................................................................................................................................................................... 125 Remove.................................................................................................................................................................................................................................................................... 125 Disassemble............................................................................................................................................................................................................................................................... 126 Clean..................................................................................................................................................................................................................................................................... 126 Inspect................................................................................................................................................................................................................................................................... 127 Assemble.................................................................................................................................................................................................................................................................. 130 Install................................................................................................................................................................................................................................................................... 132 Pump Output Check............................................................................................................................................................................................................................................................. 132 Method No. 1.............................................................................................................................................................................................................................................................. 132 Method No. 2.............................................................................................................................................................................................................................................................. 133 Hydraulic System Air Check.................................................................................................................................................................................................................................................... 134 Troubleshooting............................................................................................................................................................................................................................................................... 135 910442-8000SRM0231-(12-2004)-US-EN.................................................................................................................................................................................................................................................... 141 toc............................................................................................................................................................................................................................................................................... 141 Metric and Inch (SAE) Fasteners............................................................................................................................................................................................................................................... 141 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 142 General....................................................................................................................................................................................................................................................................... 145 Threaded Fasteners........................................................................................................................................................................................................................................................ 145 Nomenclature, Threads..................................................................................................................................................................................................................................................... 145 Strength Identification................................................................................................................................................................................................................................................... 146 Cotter (Split) Pins....................................................................................................................................................................................................................................................... 146 Fastener Torque Tables.................................................................................................................................................................................................................................................... 151 Conversion Table.......................................................................................................................................................................................................................................................... 153 tables............................................................................................................................................................................................................................................................................ 141 Table 1. Bolts and Screws..................................................................................................................................................................................................................................................... 147 Table 2. Studs and Nuts....................................................................................................................................................................................................................................................... 148 Table 3. Torque Nuts.......................................................................................................................................................................................................................................................... 149 Table 4. Torque Nuts With Nylon Insert........................................................................................................................................................................................................................................ 150 Table 5. Torque Values for Metric Fasteners*.................................................................................................................................................................................................................................. 151 Table 6. Torque Values for Inch Fasteners*.................................................................................................................................................................................................................................... 152 Table 7. Conversion Table for Metric and English Units........................................................................................................................................................................................................................ 153 Table 8. Cotter Pin Dimensional Data.......................................................................................................................................................................................................................................... 154 Table 9. Cotter Pin Dimensional Data.......................................................................................................................................................................................................................................... 155 Table 10. Cotter Pin Dimensional Data......................................................................................................................................................................................................................................... 156 Table 11. Cotter Pin Dimensional Data......................................................................................................................................................................................................................................... 158 1462736-5000SRM0723-(08-2005)-US-EN................................................................................................................................................................................................................................................... 163 toc............................................................................................................................................................................................................................................................................... 163 Extendable Container Attachment (Elme)........................................................................................................................................................................................................................................ 163 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 164 General....................................................................................................................................................................................................................................................................... 169 Description................................................................................................................................................................................................................................................................... 169 Operation..................................................................................................................................................................................................................................................................... 169 Extend and Retract Circuit................................................................................................................................................................................................................................................ 171 Twist Lock Circuit........................................................................................................................................................................................................................................................ 171 Seated Signal............................................................................................................................................................................................................................................................. 171 Slew Circuit.............................................................................................................................................................................................................................................................. 172 Rotation Circuit.......................................................................................................................................................................................................................................................... 172 Stop Cylinder............................................................................................................................................................................................................................................................. 172 Electrical System......................................................................................................................................................................................................................................................... 172 Fault Finding......................................................................................................................................................................................................................................................... 173 Additional Functions...................................................................................................................................................................................................................................................... 173 Automatic Locking..................................................................................................................................................................................................................................................... 173 Over Lowering Interrupt .............................................................................................................................................................................................................................................. 173 Lift Interrupt........................................................................................................................................................................................................................................................ 174 Container Attachment Repair................................................................................................................................................................................................................................................... 174 Remove.................................................................................................................................................................................................................................................................... 174 Install................................................................................................................................................................................................................................................................... 174 Models 812/813........................................................................................................................................................................................................................................................ 174 Model 815............................................................................................................................................................................................................................................................. 175 Model 818............................................................................................................................................................................................................................................................. 175 Slew Cylinder Repair.......................................................................................................................................................................................................................................................... 175 Remove.................................................................................................................................................................................................................................................................... 175 Disassemble............................................................................................................................................................................................................................................................... 176 Clean..................................................................................................................................................................................................................................................................... 176 Inspect................................................................................................................................................................................................................................................................... 176 Assemble.................................................................................................................................................................................................................................................................. 177 Install................................................................................................................................................................................................................................................................... 177 Extension Cylinders Repair.................................................................................................................................................................................................................................................... 177 Remove.................................................................................................................................................................................................................................................................... 177 Disassemble............................................................................................................................................................................................................................................................... 179 Clean..................................................................................................................................................................................................................................................................... 179 Inspect................................................................................................................................................................................................................................................................... 179 Assemble.................................................................................................................................................................................................................................................................. 179 Install................................................................................................................................................................................................................................................................... 180 Sideshift Cylinder Repair..................................................................................................................................................................................................................................................... 180 Remove.................................................................................................................................................................................................................................................................... 180 Disassemble............................................................................................................................................................................................................................................................... 181 Clean..................................................................................................................................................................................................................................................................... 181 Inspect................................................................................................................................................................................................................................................................... 181 Assemble.................................................................................................................................................................................................................................................................. 182 Install................................................................................................................................................................................................................................................................... 182 Pendular Twist Locks Repair................................................................................................................................................................................................................................................... 182 Disassemble............................................................................................................................................................................................................................................................... 182 Clean..................................................................................................................................................................................................................................................................... 183 Inspect................................................................................................................................................................................................................................................................... 183 Assemble.................................................................................................................................................................................................................................................................. 184 Fixed Twist lock Repair....................................................................................................................................................................................................................................................... 185 Remove.................................................................................................................................................................................................................................................................... 185 Install................................................................................................................................................................................................................................................................... 185 Adjustments................................................................................................................................................................................................................................................................... 186 Twist Lock Angle Adjustments.............................................................................................................................................................................................................................................. 186 LOCKED/NOT LOCKED Proximity Switches Adjustment........................................................................................................................................................................................................................... 186 SEATED Signal Adjustment.................................................................................................................................................................................................................................................. 187 Maintenance................................................................................................................................................................................................................................................................... 187 General Maintenance....................................................................................................................................................................................................................................................... 187 Additional Spreader Maintenance........................................................................................................................................................................................................................................... 188 Maintenance Schedule.......................................................................................................................................................................................................................................................... 188 Container Attachment...................................................................................................................................................................................................................................................... 188 Torque Specifications......................................................................................................................................................................................................................................................... 191 Troubleshooting............................................................................................................................................................................................................................................................... 191 tables............................................................................................................................................................................................................................................................................ 163 Table 1. Maintenance Schedule................................................................................................................................................................................................................................................. 189 Table 2. ELME Schematic Overview.............................................................................................................................................................................................................................................. 194 1529749-1800SRM1036-(07-2007)-US-EN................................................................................................................................................................................................................................................... 287 toc............................................................................................................................................................................................................................................................................... 287 Brake Accumulator............................................................................................................................................................................................................................................................. 287 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 288 General....................................................................................................................................................................................................................................................................... 291 Description and Operation..................................................................................................................................................................................................................................................... 291 Accumulator Maintenance....................................................................................................................................................................................................................................................... 291 Precharge Check........................................................................................................................................................................................................................................................... 291 Precharge Filling......................................................................................................................................................................................................................................................... 292 Remove.................................................................................................................................................................................................................................................................... 293 Disassemble............................................................................................................................................................................................................................................................... 293 Clean..................................................................................................................................................................................................................................................................... 295 Inspect................................................................................................................................................................................................................................................................... 295 Repair.................................................................................................................................................................................................................................................................... 295 Assemble.................................................................................................................................................................................................................................................................. 295 Replace................................................................................................................................................................................................................................................................... 295 tables............................................................................................................................................................................................................................................................................ 287 Table 1. Accumulator Pressures................................................................................................................................................................................................................................................ 292 1531822-1800SRM1038-(07-2007)-US-EN................................................................................................................................................................................................................................................... 299 toc............................................................................................................................................................................................................................................................................... 299 Service Brake................................................................................................................................................................................................................................................................. 299 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 300 General....................................................................................................................................................................................................................................................................... 303 Description and Operation..................................................................................................................................................................................................................................................... 303 A917, E117, and F117 Only................................................................................................................................................................................................................................................. 303 B222 Only................................................................................................................................................................................................................................................................. 303 Repair........................................................................................................................................................................................................................................................................ 305 General................................................................................................................................................................................................................................................................... 305 Remove.................................................................................................................................................................................................................................................................... 305 Drive Wheels and Tires................................................................................................................................................................................................................................................ 305 Brake Housing......................................................................................................................................................................................................................................................... 306 Spindle and Brake Cover............................................................................................................................................................................................................................................... 308 Disassemble............................................................................................................................................................................................................................................................... 309 Clean..................................................................................................................................................................................................................................................................... 311 Ground and Polished Parts............................................................................................................................................................................................................................................. 311 Parts With Rough Finish............................................................................................................................................................................................................................................... 311 Wet Disc Brake and Axle Assembly...................................................................................................................................................................................................................................... 311 Inspect................................................................................................................................................................................................................................................................... 311 Face Seals............................................................................................................................................................................................................................................................ 311 Disc.................................................................................................................................................................................................................................................................. 312 Wear Limits....................................................................................................................................................................................................................................................... 312 Replace................................................................................................................................................................................................................................................................... 312 Parts................................................................................................................................................................................................................................................................. 312 Assemble.................................................................................................................................................................................................................................................................. 313 Brake Housings........................................................................................................................................................................................................................................................ 313 Install................................................................................................................................................................................................................................................................... 315 Hub Oil Seals......................................................................................................................................................................................................................................................... 315 Double Seals...................................................................................................................................................................................................................................................... 315 Single Seal....................................................................................................................................................................................................................................................... 316 Spindle and Brake Cover............................................................................................................................................................................................................................................... 317 Brake Housing......................................................................................................................................................................................................................................................... 318 Drive Wheels and Tires................................................................................................................................................................................................................................................ 321 Pressure Switch........................................................................................................................................................................................................................................................... 325 Replace............................................................................................................................................................................................................................................................... 325 Accumulator............................................................................................................................................................................................................................................................... 325 Brake Pedal Valves (Treadle Valves) Repair.................................................................................................................................................................................................................................... 325 All Models Except A917, B222, E117, and F117.............................................................................................................................................................................................................................. 325 Remove................................................................................................................................................................................................................................................................ 325 Clean and Inspect..................................................................................................................................................................................................................................................... 325 Install............................................................................................................................................................................................................................................................... 326 A917, B222, E117, and F117................................................................................................................................................................................................................................................ 329 Remove................................................................................................................................................................................................................................................................ 329 Clean and Inspect..................................................................................................................................................................................................................................................... 329 Install............................................................................................................................................................................................................................................................... 329 Brake System Air Removal...................................................................................................................................................................................................................................................... 329 Specifications................................................................................................................................................................................................................................................................ 330 Brake Coolant............................................................................................................................................................................................................................................................. 333 Coolant Change Intervals.............................................................................................................................................................................................................................................. 333 Normal Maintenance................................................................................................................................................................................................................................................ 333 Hydraulic Fluid........................................................................................................................................................................................................................................................... 333 Troubleshooting............................................................................................................................................................................................................................................................... 334 tables............................................................................................................................................................................................................................................................................ 299 Table 1. Friction Disc........................................................................................................................................................................................................................................................ 312 Table 2. Stationary Disc...................................................................................................................................................................................................................................................... 312 Table 3. Wheel Hub and Brake Housing Torque Chart............................................................................................................................................................................................................................. 331 Table 4. Brake Housing Cover Torque Chart..................................................................................................................................................................................................................................... 333 1565180-1900SRM1102-(08-2004)-US-EN................................................................................................................................................................................................................................................... 339 toc............................................................................................................................................................................................................................................................................... 339 Hydraulic System.............................................................................................................................................................................................................................................................. 339 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 340 General....................................................................................................................................................................................................................................................................... 345 Description and Operation..................................................................................................................................................................................................................................................... 345 Hydraulic Plate........................................................................................................................................................................................................................................................... 345 Hydraulic Pumps........................................................................................................................................................................................................................................................... 346 Cab Manifold.............................................................................................................................................................................................................................................................. 346 Oil Cooled Brakes (Service Brakes).................................................................................................................................................................................................................................... 346 Lift/Tilt Functions................................................................................................................................................................................................................................................... 346 Over Lower Interrupt.................................................................................................................................................................................................................................................. 347 Lift Interrupt........................................................................................................................................................................................................................................................ 347 Heat Exchanger System..................................................................................................................................................................................................................................................... 347 Steering Control System................................................................................................................................................................................................................................................... 347 Brake System.............................................................................................................................................................................................................................................................. 347 Hydraulic Pump Repair......................................................................................................................................................................................................................................................... 348 Remove.................................................................................................................................................................................................................................................................... 348 Disassemble............................................................................................................................................................................................................................................................... 348 Tandem Gear Pump...................................................................................................................................................................................................................................................... 348 Tri-Section Gear Pump................................................................................................................................................................................................................................................. 348 Clean and Inspect......................................................................................................................................................................................................................................................... 349 Assemble.................................................................................................................................................................................................................................................................. 350 Tandem Gear Pump...................................................................................................................................................................................................................................................... 350 Tri-Section Gear Pump................................................................................................................................................................................................................................................. 351 Install................................................................................................................................................................................................................................................................... 351 Pump Output Check......................................................................................................................................................................................................................................................... 351 First Method.......................................................................................................................................................................................................................................................... 351 Second Method......................................................................................................................................................................................................................................................... 352 Cab Manifold.................................................................................................................................................................................................................................................................. 353 Remove.................................................................................................................................................................................................................................................................... 353 Disassemble Valves and Pressure Switches.................................................................................................................................................................................................................................. 354 Clean and Inspect......................................................................................................................................................................................................................................................... 354 Assemble Valves and Pressure Switches..................................................................................................................................................................................................................................... 354 Install................................................................................................................................................................................................................................................................... 354 Lift and Lower Circuit........................................................................................................................................................................................................................................................ 356 Description............................................................................................................................................................................................................................................................... 356 Operation................................................................................................................................................................................................................................................................. 356 Lift Circuit.......................................................................................................................................................................................................................................................... 357 Lowering.............................................................................................................................................................................................................................................................. 357 Lowering Control Valves............................................................................................................................................................................................................................................... 357 Repairs................................................................................................................................................................................................................................................................... 357 General............................................................................................................................................................................................................................................................... 357 Remote Control Valve.................................................................................................................................................................................................................................................. 358 Description and Operation......................................................................................................................................................................................................................................... 358 Remove............................................................................................................................................................................................................................................................ 358 Disassemble....................................................................................................................................................................................................................................................... 358 Clean and Inspect................................................................................................................................................................................................................................................. 359 Assemble.......................................................................................................................................................................................................................................................... 359 Install........................................................................................................................................................................................................................................................... 360 Adjust............................................................................................................................................................................................................................................................ 360 Lift Manifold......................................................................................................................................................................................................................................................... 360 Description and Operation......................................................................................................................................................................................................................................... 360 Remove............................................................................................................................................................................................................................................................ 360 Clean and Inspect................................................................................................................................................................................................................................................. 360 Assemble and Install.............................................................................................................................................................................................................................................. 360 Checks and Adjustments.................................................................................................................................................................................................................................................... 362 Tilt Control Circuit.......................................................................................................................................................................................................................................................... 363 Description............................................................................................................................................................................................................................................................... 363 Operation................................................................................................................................................................................................................................................................. 363 Tilt/Lift Spool....................................................................................................................................................................................................................................................... 364 Relief Valves in Main Control Valve................................................................................................................................................................................................................................... 364 Relief Valves, Tilt Lock.............................................................................................................................................................................................................................................. 364 Repairs................................................................................................................................................................................................................................................................... 364 General............................................................................................................................................................................................................................................................... 364 Relief Valves, Tilt Lock, Disassemble................................................................................................................................................................................................................................. 364 Clean and Inspect..................................................................................................................................................................................................................................................... 365 Checks and Adjustments................................................................................................................................................................................................................................................ 365 Attachment Circuit Valves..................................................................................................................................................................................................................................................... 365 General................................................................................................................................................................................................................................................................... 365 Selector Valves Auxiliary Functions................................................................................................................................................................................................................................... 365 Carriage Solenoid Valve............................................................................................................................................................................................................................................... 365 Repairs................................................................................................................................................................................................................................................................... 365 Carriage Solenoid Valve............................................................................................................................................................................................................................................... 365 Remove............................................................................................................................................................................................................................................................ 365 Disassemble....................................................................................................................................................................................................................................................... 367 Clean and Inspect................................................................................................................................................................................................................................................. 367 Assemble.......................................................................................................................................................................................................................................................... 367 Install........................................................................................................................................................................................................................................................... 367 Checks and Adjustments.................................................................................................................................................................................................................................................... 367 Other Hydraulic Components.................................................................................................................................................................................................................................................... 368 Description and Operation................................................................................................................................................................................................................................................. 368 Relief Valves in Steering and Lift Circuits........................................................................................................................................................................................................................... 368 Reducer Valve......................................................................................................................................................................................................................................................... 368 Hydraulic Filters..................................................................................................................................................................................................................................................... 368 Hydraulic Filters......................................................................................................................................................................................................................................................... 368 Suction Filters....................................................................................................................................................................................................................................................... 368 High Pressure Filter.................................................................................................................................................................................................................................................. 369 Brake Filter.......................................................................................................................................................................................................................................................... 369 Return Line Filters................................................................................................................................................................................................................................................... 370 Hydraulic Hose Repair..................................................................................................................................................................................................................................................... 371 Checks and Adjustments.................................................................................................................................................................................................................................................... 371 Pilot Setting, Check.................................................................................................................................................................................................................................................. 371 Return Pressure, Check................................................................................................................................................................................................................................................ 371 Main Function Relief Valve Pressure, Check............................................................................................................................................................................................................................ 371 Hydraulic Tank Breathers.............................................................................................................................................................................................................................................. 372 Specifications................................................................................................................................................................................................................................................................ 373 Hydraulic Pumps Output at 2100 rpm (Governed Speed)....................................................................................................................................................................................................................... 373 Cummins 290 Hp (216 kW) Engine........................................................................................................................................................................................................................................ 373 Cummins 330 Hp (246 kW) Engine........................................................................................................................................................................................................................................ 373 Relief Valves (Approximate Operating Pressures)........................................................................................................................................................................................................................... 373 Check Port Pressures...................................................................................................................................................................................................................................................... 374 Main Hydraulic Filters.................................................................................................................................................................................................................................................... 374 Tank Capacity............................................................................................................................................................................................................................................................. 374 Torque Specifications......................................................................................................................................................................................................................................................... 374 Remote Control Valves..................................................................................................................................................................................................................................................... 374 Attachment Control Valve.................................................................................................................................................................................................................................................. 374 Carriage Solenoid Valve................................................................................................................................................................................................................................................... 375 Troubleshooting............................................................................................................................................................................................................................................................... 375 Lift and Lower Circuit.................................................................................................................................................................................................................................................... 375 Tilt Circuit.............................................................................................................................................................................................................................................................. 378 Attachment Circuit Valves................................................................................................................................................................................................................................................. 380 Attachment Control Valve.................................................................................................................................................................................................................................................. 381 Carriage Solenoid Valve................................................................................................................................................................................................................................................... 381 Other Hydraulic Components................................................................................................................................................................................................................................................ 382 Accumulator Circuit....................................................................................................................................................................................................................................................... 382 5 MPa ( 725 psi) Pilot Circuit............................................................................................................................................................................................................................................ 382 Park Brake Circuit........................................................................................................................................................................................................................................................ 383 tables............................................................................................................................................................................................................................................................................ 339 Table 1. Brake Treadle Settings............................................................................................................................................................................................................................................... 347 Table 2. Gauge Ranges......................................................................................................................................................................................................................................................... 371 Table 3. Pressure Settings.................................................................................................................................................................................................................................................... 372 1565181-2000SRM1108-(08-2004)-US-EN................................................................................................................................................................................................................................................... 391 toc............................................................................................................................................................................................................................................................................... 391 Hydraulic Plate............................................................................................................................................................................................................................................................... 391 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 392 General....................................................................................................................................................................................................................................................................... 395 Description and Operation..................................................................................................................................................................................................................................................... 396 Hydraulic Oil Supply...................................................................................................................................................................................................................................................... 396 Manifold, Section 1 of Hydraulic Plate.................................................................................................................................................................................................................................... 396 Main Control Valve, Section 2 of Hydraulic Plate.......................................................................................................................................................................................................................... 396 Description........................................................................................................................................................................................................................................................... 396 Operation............................................................................................................................................................................................................................................................. 397 Auxiliary Section................................................................................................................................................................................................................................................. 397 Tilt Section...................................................................................................................................................................................................................................................... 397 Lift Section...................................................................................................................................................................................................................................................... 397 Return Manifold, Section 3 of Hydraulic Plate............................................................................................................................................................................................................................. 397 Brake Manifold, Section 4 of Hydraulic Plate.............................................................................................................................................................................................................................. 401 Cooling Circuit....................................................................................................................................................................................................................................................... 401 Service Brake......................................................................................................................................................................................................................................................... 401 Parking Brake......................................................................................................................................................................................................................................................... 401 Flow Amplifier, Section 5 of Hydraulic Plate.............................................................................................................................................................................................................................. 401 Manifold, Section 1 of Hydraulic Plate........................................................................................................................................................................................................................................ 402 General................................................................................................................................................................................................................................................................... 402 Valves and Pressure Switches.............................................................................................................................................................................................................................................. 402 Main Control Valve, Section 2 of Hydraulic Plate.............................................................................................................................................................................................................................. 405 Remove.................................................................................................................................................................................................................................................................... 405 Disassemble............................................................................................................................................................................................................................................................... 405 Auxiliary Section..................................................................................................................................................................................................................................................... 405 Lift Section.......................................................................................................................................................................................................................................................... 407 Lift/Tilt Section..................................................................................................................................................................................................................................................... 408 Clean and Inspect......................................................................................................................................................................................................................................................... 409 Assemble.................................................................................................................................................................................................................................................................. 409 Auxiliary Section..................................................................................................................................................................................................................................................... 409 Lift Section.......................................................................................................................................................................................................................................................... 409 Lift/Tilt Section..................................................................................................................................................................................................................................................... 410 Install................................................................................................................................................................................................................................................................... 410 Return Manifold, Section 3 of Hydraulic Plate................................................................................................................................................................................................................................. 411 Remove.................................................................................................................................................................................................................................................................... 411 Disassemble............................................................................................................................................................................................................................................................... 411 Clean and Inspect......................................................................................................................................................................................................................................................... 412 Assemble.................................................................................................................................................................................................................................................................. 412 Install................................................................................................................................................................................................................................................................... 412 Brake Manifold, Section 4 of Hydraulic Plate.................................................................................................................................................................................................................................. 413 Remove.................................................................................................................................................................................................................................................................... 413 Clean and Inspect......................................................................................................................................................................................................................................................... 413 Install................................................................................................................................................................................................................................................................... 413 Flow Amplifier, Section 5 of Hydraulic Plate.................................................................................................................................................................................................................................. 414 Hydraulic Hose Repair......................................................................................................................................................................................................................................................... 414 Hydraulic Hose Identification................................................................................................................................................................................................................................................. 414 Torque Values................................................................................................................................................................................................................................................................. 415 Measurements and Adjustments.................................................................................................................................................................................................................................................. 417 Measurements.............................................................................................................................................................................................................................................................. 417 Adjustments............................................................................................................................................................................................................................................................... 417 Troubleshooting............................................................................................................................................................................................................................................................... 417 tables............................................................................................................................................................................................................................................................................ 391 Table 1. Pilot Hoses.......................................................................................................................................................................................................................................................... 415 Table 2. Brake Hoses.......................................................................................................................................................................................................................................................... 415 Table 3. Auxiliary Hoses With Alternating P and T............................................................................................................................................................................................................................. 415 Table 4. Steer Hoses.......................................................................................................................................................................................................................................................... 415 Table 5. Pressure Settings at 2100 RPM........................................................................................................................................................................................................................................ 417 1565182-1600SRM1109-(07-2007)-US-EN................................................................................................................................................................................................................................................... 425 toc............................................................................................................................................................................................................................................................................... 425 Steering System............................................................................................................................................................................................................................................................... 425 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 426 General....................................................................................................................................................................................................................................................................... 429 Description................................................................................................................................................................................................................................................................... 429 Steering Wheel and Column Assembly Repair..................................................................................................................................................................................................................................... 431 General................................................................................................................................................................................................................................................................... 431 Steering Wheel and Horn................................................................................................................................................................................................................................................... 431 Remove................................................................................................................................................................................................................................................................ 431 Install............................................................................................................................................................................................................................................................... 431 Steering Column............................................................................................................................................................................................................................................................... 433 Remove.................................................................................................................................................................................................................................................................... 433 Install................................................................................................................................................................................................................................................................... 433 Steering Control Unit Repair.................................................................................................................................................................................................................................................. 434 General................................................................................................................................................................................................................................................................... 434 Description............................................................................................................................................................................................................................................................... 434 Operation................................................................................................................................................................................................................................................................. 434 Remove.................................................................................................................................................................................................................................................................... 434 Disassemble............................................................................................................................................................................................................................................................... 436 Clean..................................................................................................................................................................................................................................................................... 439 Assemble.................................................................................................................................................................................................................................................................. 439 Install................................................................................................................................................................................................................................................................... 445 Steering System Air Removal................................................................................................................................................................................................................................................... 445 Steering Relief Pressure Check and Adjustments................................................................................................................................................................................................................................ 445 Flow Amplifier Repair......................................................................................................................................................................................................................................................... 447 General................................................................................................................................................................................................................................................................... 447 Description............................................................................................................................................................................................................................................................... 447 Operation................................................................................................................................................................................................................................................................. 447 Neutral Position...................................................................................................................................................................................................................................................... 447 During Steering Function.............................................................................................................................................................................................................................................. 447 Manual Steering Function.............................................................................................................................................................................................................................................. 449 Disassemble............................................................................................................................................................................................................................................................... 449 Pressure Relief Valve................................................................................................................................................................................................................................................. 449 End Cover at PP Port.................................................................................................................................................................................................................................................. 449 End Cover at LS Port.................................................................................................................................................................................................................................................. 449 Spools................................................................................................................................................................................................................................................................ 450 Directional Valve Spool............................................................................................................................................................................................................................................... 450 Priority Valve Spool.................................................................................................................................................................................................................................................. 450 Pressure Control/Amplifier Valve Spool................................................................................................................................................................................................................................ 450 Check Valve........................................................................................................................................................................................................................................................... 451 Cushion/Suction Valves................................................................................................................................................................................................................................................ 451 Clean..................................................................................................................................................................................................................................................................... 452 Assemble.................................................................................................................................................................................................................................................................. 452 Troubleshooting............................................................................................................................................................................................................................................................... 453 1565183-2200SRM1110-(08-2004)-US-EN................................................................................................................................................................................................................................................... 457 toc............................................................................................................................................................................................................................................................................... 457 Instrument Panel Indicators and Senders....................................................................................................................................................................................................................................... 457 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 458 General....................................................................................................................................................................................................................................................................... 461 Description................................................................................................................................................................................................................................................................... 461 General................................................................................................................................................................................................................................................................... 461 Instrument Panel Meters, Indicators, and LCD Display...................................................................................................................................................................................................................... 461 Error Code Display........................................................................................................................................................................................................................................................ 466 Connector................................................................................................................................................................................................................................................................. 468 Seat Switch Logic..................................................................................................................................................................................................................................................... 468 Central Warning Light Output.......................................................................................................................................................................................................................................... 470 Buzzer Output......................................................................................................................................................................................................................................................... 470 Instrument Panel Component Replacement........................................................................................................................................................................................................................................ 472 Instrument Panel.......................................................................................................................................................................................................................................................... 473 Remove................................................................................................................................................................................................................................................................ 473 Light..................................................................................................................................................................................................................................................................... 473 Replace............................................................................................................................................................................................................................................................... 473 Sender Replacement............................................................................................................................................................................................................................................................ 474 Fuel Level Sender......................................................................................................................................................................................................................................................... 474 Pressure Sender........................................................................................................................................................................................................................................................... 474 Temperature Sender........................................................................................................................................................................................................................................................ 474 Low Coolant Sender........................................................................................................................................................................................................................................................ 475 Vacuum Switch............................................................................................................................................................................................................................................................. 475 Crankshaft Position Sensor................................................................................................................................................................................................................................................ 476 tables............................................................................................................................................................................................................................................................................ 457 Table 1. Instrument Panel and Indicators...................................................................................................................................................................................................................................... 462 Table 2. Switches Description................................................................................................................................................................................................................................................. 467 Table 3. Pin Description...................................................................................................................................................................................................................................................... 469 Table 4. Sender Description................................................................................................................................................................................................................................................... 470 1565184-0100SRM1111-(09-2006)-US-EN................................................................................................................................................................................................................................................... 479 toc............................................................................................................................................................................................................................................................................... 479 Operator's Cab................................................................................................................................................................................................................................................................ 479 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 480 General....................................................................................................................................................................................................................................................................... 483 Cab Repair.................................................................................................................................................................................................................................................................... 484 Rear Cab Assembly......................................................................................................................................................................................................................................................... 484 Bottom Cab Assembly....................................................................................................................................................................................................................................................... 485 Cab Repair................................................................................................................................................................................................................................................................ 485 Remove................................................................................................................................................................................................................................................................ 485 Install............................................................................................................................................................................................................................................................... 486 Declutch (E117), Inching (F117), and Brake Pedals............................................................................................................................................................................................................................. 487 Brake Pedal, Adjust....................................................................................................................................................................................................................................................... 487 Declutch Pedal, Adjust (E117 Only)........................................................................................................................................................................................................................................ 487 Inching Pedal, Adjust (F117 Only)......................................................................................................................................................................................................................................... 487 Inching Pedal Sensor, Adjust (F117 Only).................................................................................................................................................................................................................................. 487 Throttle Pedal Sensor Adjustment.............................................................................................................................................................................................................................................. 488 Cable Alignment........................................................................................................................................................................................................................................................... 488 Engine Side........................................................................................................................................................................................................................................................... 488 Pedal Housing Side.................................................................................................................................................................................................................................................... 488 Check..................................................................................................................................................................................................................................................................... 489 Adjust.................................................................................................................................................................................................................................................................... 489 Seat Assembly Removal......................................................................................................................................................................................................................................................... 489 Power Assist Armrest.......................................................................................................................................................................................................................................................... 490 Adjust.................................................................................................................................................................................................................................................................... 490 Steering Column Repair........................................................................................................................................................................................................................................................ 491 Remove.................................................................................................................................................................................................................................................................... 491 Install................................................................................................................................................................................................................................................................... 491 Window Wipers Replacement..................................................................................................................................................................................................................................................... 492 Window Wiper Assembly, Replace............................................................................................................................................................................................................................................ 492 Front Window Wiper Motor Assembly, Replace................................................................................................................................................................................................................................ 492 Rear Window Wiper Motor Assembly, Replace................................................................................................................................................................................................................................. 492 Top Window Wiper Motor Assembly, Replace.................................................................................................................................................................................................................................. 493 Window Washer Motors and Pumps................................................................................................................................................................................................................................................ 493 Window Wiper and Washer Operating Switches................................................................................................................................................................................................................................ 494 Window Replacement............................................................................................................................................................................................................................................................ 494 Front Window, Replace..................................................................................................................................................................................................................................................... 496 Rear Window, Replace...................................................................................................................................................................................................................................................... 496 Top Window, Replace....................................................................................................................................................................................................................................................... 496 Door Window, Replace...................................................................................................................................................................................................................................................... 496 Heater and Air Conditioning Assembly.......................................................................................................................................................................................................................................... 497 Heater Parts, Replace..................................................................................................................................................................................................................................................... 499 Heat Control Knob/Switches................................................................................................................................................................................................................................................ 500 Heat Control Knob/Cable................................................................................................................................................................................................................................................... 500 Adjust................................................................................................................................................................................................................................................................ 500 Air Control Knob/Cable.................................................................................................................................................................................................................................................... 501 Adjust................................................................................................................................................................................................................................................................ 501 Air Filter, Replace....................................................................................................................................................................................................................................................... 501 Air Conditioning Condenser Fan(s)......................................................................................................................................................................................................................................... 502 Remove................................................................................................................................................................................................................................................................ 502 Install............................................................................................................................................................................................................................................................... 502 Instruments, Switches, and Controls........................................................................................................................................................................................................................................... 502 Switches.................................................................................................................................................................................................................................................................. 502 Controls.................................................................................................................................................................................................................................................................. 503 Fuses, Relays, And Power Sources.............................................................................................................................................................................................................................................. 505 Fuse Panel................................................................................................................................................................................................................................................................ 505 Fuses..................................................................................................................................................................................................................................................................... 506 Relays.................................................................................................................................................................................................................................................................... 507 Power Sources............................................................................................................................................................................................................................................................. 508 Label Replacement............................................................................................................................................................................................................................................................. 508 1565582-1600SRM1114-(07-2007)-US-EN................................................................................................................................................................................................................................................... 511 toc............................................................................................................................................................................................................................................................................... 511 Steering Axle................................................................................................................................................................................................................................................................. 511 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 512 General....................................................................................................................................................................................................................................................................... 515 Description................................................................................................................................................................................................................................................................... 515 How To Put Lift Truck On Blocks............................................................................................................................................................................................................................................... 516 How to Lift Steer Tires................................................................................................................................................................................................................................................... 516 Steering Axle Assembly........................................................................................................................................................................................................................................................ 518 Remove.................................................................................................................................................................................................................................................................... 518 Install................................................................................................................................................................................................................................................................... 519 Wheels and Hubs............................................................................................................................................................................................................................................................... 520 Remove and Disassemble.................................................................................................................................................................................................................................................... 520 Clean..................................................................................................................................................................................................................................................................... 520 Assemble and Install...................................................................................................................................................................................................................................................... 521 Spindles, Bearings, and Tie Rods.............................................................................................................................................................................................................................................. 522 Remove.................................................................................................................................................................................................................................................................... 522 Install................................................................................................................................................................................................................................................................... 523 Steering Cylinder............................................................................................................................................................................................................................................................. 525 Remove and Disassemble.................................................................................................................................................................................................................................................... 525 Clean and Inspect......................................................................................................................................................................................................................................................... 526 Assemble and Install...................................................................................................................................................................................................................................................... 526 Torque Specifications......................................................................................................................................................................................................................................................... 527 Troubleshooting............................................................................................................................................................................................................................................................... 527 1565653-2100SRM1116-(01-2007)-US-EN................................................................................................................................................................................................................................................... 531 toc............................................................................................................................................................................................................................................................................... 531 Tilt Cylinders................................................................................................................................................................................................................................................................ 531 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 532 General....................................................................................................................................................................................................................................................................... 535 Description................................................................................................................................................................................................................................................................... 535 Tilt Cylinder Repair.......................................................................................................................................................................................................................................................... 535 Remove.................................................................................................................................................................................................................................................................... 535 Disassemble............................................................................................................................................................................................................................................................... 537 Clean..................................................................................................................................................................................................................................................................... 538 Inspect................................................................................................................................................................................................................................................................... 538 Assemble.................................................................................................................................................................................................................................................................. 538 Install................................................................................................................................................................................................................................................................... 538 Tilt Cylinder Leak Check...................................................................................................................................................................................................................................................... 538 Tilt Cylinder Stroke and Mast Tilt Angle Adjustment........................................................................................................................................................................................................................... 539 Torque Specifications......................................................................................................................................................................................................................................................... 540 Troubleshooting............................................................................................................................................................................................................................................................... 540 tables............................................................................................................................................................................................................................................................................ 531 Table 1. Movement Rate (Maximum) for Tilt Cylinders........................................................................................................................................................................................................................... 539 1565789-1800SRM1117-(07-2007)-US-EN................................................................................................................................................................................................................................................... 543 toc............................................................................................................................................................................................................................................................................... 543 Parking Brake................................................................................................................................................................................................................................................................. 543 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 544 General....................................................................................................................................................................................................................................................................... 547 Description and Operation..................................................................................................................................................................................................................................................... 547 Parking Brake Valve Replacement............................................................................................................................................................................................................................................... 547 Remove.................................................................................................................................................................................................................................................................... 547 Clean and Inspect......................................................................................................................................................................................................................................................... 548 Install................................................................................................................................................................................................................................................................... 548 Parking Brake Caliper Repair.................................................................................................................................................................................................................................................. 548 Remove.................................................................................................................................................................................................................................................................... 548 Disassemble............................................................................................................................................................................................................................................................... 548 Inspect................................................................................................................................................................................................................................................................... 548 Install................................................................................................................................................................................................................................................................... 549 Bleed Brakes.............................................................................................................................................................................................................................................................. 551 Adjust.................................................................................................................................................................................................................................................................... 551 Brake Pad Repair.............................................................................................................................................................................................................................................................. 552 Inspect................................................................................................................................................................................................................................................................... 552 Remove.................................................................................................................................................................................................................................................................... 552 Install................................................................................................................................................................................................................................................................... 553 Seals Repair.................................................................................................................................................................................................................................................................. 553 Remove.................................................................................................................................................................................................................................................................... 553 Install................................................................................................................................................................................................................................................................... 553 Specifications................................................................................................................................................................................................................................................................ 554 Torque Requirements....................................................................................................................................................................................................................................................... 554 Wear Limits............................................................................................................................................................................................................................................................... 554 Lining to Disc Clearance.................................................................................................................................................................................................................................................. 554 Troubleshooting............................................................................................................................................................................................................................................................... 555 tables............................................................................................................................................................................................................................................................................ 543 Table 1. Brake Pad Adjustment................................................................................................................................................................................................................................................. 552 Table 2. Torque Requirements.................................................................................................................................................................................................................................................. 554 Table 3. Wear Limits.......................................................................................................................................................................................................................................................... 554 Table 4. Lining to Disc Clearance............................................................................................................................................................................................................................................. 554 1566270-0100SRM1118-(08-2004)-US-EN................................................................................................................................................................................................................................................... 559 toc............................................................................................................................................................................................................................................................................... 559 Frame......................................................................................................................................................................................................................................................................... 559 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 560 General....................................................................................................................................................................................................................................................................... 563 Description................................................................................................................................................................................................................................................................... 563 Counterweight Repair.......................................................................................................................................................................................................................................................... 564 Main Counterweight (Cast)................................................................................................................................................................................................................................................. 564 Cover................................................................................................................................................................................................................................................................. 564 Remove............................................................................................................................................................................................................................................................ 564 Install........................................................................................................................................................................................................................................................... 564 Counterweight......................................................................................................................................................................................................................................................... 564 Remove............................................................................................................................................................................................................................................................ 564 Install........................................................................................................................................................................................................................................................... 565 Rear Counterweight (Cast)................................................................................................................................................................................................................................................. 566 Remove................................................................................................................................................................................................................................................................ 566 Install............................................................................................................................................................................................................................................................... 566 Main Counterweight (Fabricated)........................................................................................................................................................................................................................................... 566 Remove................................................................................................................................................................................................................................................................ 566 Install............................................................................................................................................................................................................................................................... 566 Covers........................................................................................................................................................................................................................................................................ 567 Remove.................................................................................................................................................................................................................................................................... 567 Install................................................................................................................................................................................................................................................................... 568 Floor Plates, Handrails, and Steps............................................................................................................................................................................................................................................ 569 Hydraulic Tank Repair......................................................................................................................................................................................................................................................... 570 Remove.................................................................................................................................................................................................................................................................... 570 Repair.................................................................................................................................................................................................................................................................... 572 Small Leaks........................................................................................................................................................................................................................................................... 572 Large Leaks........................................................................................................................................................................................................................................................... 572 Clean..................................................................................................................................................................................................................................................................... 572 Steam Method.......................................................................................................................................................................................................................................................... 572 Chemical Solution Method.............................................................................................................................................................................................................................................. 573 Other Methods of Preparation for Repair................................................................................................................................................................................................................................... 573 Install................................................................................................................................................................................................................................................................... 573 Suction Filters and Inspection Cover...................................................................................................................................................................................................................................... 574 Remove................................................................................................................................................................................................................................................................ 574 Clean and Inspect..................................................................................................................................................................................................................................................... 575 Install............................................................................................................................................................................................................................................................... 575 Fuel Tank Repair.............................................................................................................................................................................................................................................................. 575 Remove.................................................................................................................................................................................................................................................................... 575 Repair.................................................................................................................................................................................................................................................................... 577 Install................................................................................................................................................................................................................................................................... 577 Engine Repair................................................................................................................................................................................................................................................................. 577 Remove.................................................................................................................................................................................................................................................................... 577 Install................................................................................................................................................................................................................................................................... 580 Label Replacement............................................................................................................................................................................................................................................................. 581 1566278-8000SRM1154-(08-2005)-US-EN................................................................................................................................................................................................................................................... 587 toc............................................................................................................................................................................................................................................................................... 587 Periodic Maintenance.......................................................................................................................................................................................................................................................... 587 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 588 General....................................................................................................................................................................................................................................................................... 593 Serial Number Data........................................................................................................................................................................................................................................................ 593 How to Move Disabled Lift Truck........................................................................................................................................................................................................................................... 593 How to Tow Lift Truck................................................................................................................................................................................................................................................. 594 How to Put Lift Truck on Blocks........................................................................................................................................................................................................................................... 594 How to Raise Drive Tires.............................................................................................................................................................................................................................................. 594 How to Raise Steering Tires........................................................................................................................................................................................................................................... 595 Maintenance Schedule.......................................................................................................................................................................................................................................................... 596 Spreader Maintenance...................................................................................................................................................................................................................................................... 604 Maintenance Procedures Every 8 Hours or Daily................................................................................................................................................................................................................................. 605 How to Make Checks With Engine Stopped.................................................................................................................................................................................................................................... 605 Safety Labels......................................................................................................................................................................................................................................................... 605 Operator Restraint System............................................................................................................................................................................................................................................. 605 Safety Belt and Seat Rails........................................................................................................................................................................................................................................ 605 Steering Column Latch............................................................................................................................................................................................................................................. 606 Tires and Wheels...................................................................................................................................................................................................................................................... 606 Inspection of Mast and Lift Chains.................................................................................................................................................................................................................................... 607 Drive Belt............................................................................................................................................................................................................................................................ 607 Crankcase Breather Tube............................................................................................................................................................................................................................................... 608 Air Intake Piping and Charge Air Piping............................................................................................................................................................................................................................... 608 Cooling Fan........................................................................................................................................................................................................................................................... 608 Pre-Cleaner for Air Filter............................................................................................................................................................................................................................................ 609 Fuel, Oil, or Coolant Leak Check...................................................................................................................................................................................................................................... 609 Hydraulic Tank Breather............................................................................................................................................................................................................................................... 609 Engine Oil............................................................................................................................................................................................................................................................ 609 Hydraulic System Oil.................................................................................................................................................................................................................................................. 610 Hydraulic High Pressure Oil Filter.................................................................................................................................................................................................................................... 611 Battery............................................................................................................................................................................................................................................................... 611 Fuel Filter/Water Separator........................................................................................................................................................................................................................................... 612 How to Add Fuel to Lift Truck............................................................................................................................................................................................................................................. 612 How to Make Checks With Engine Running.................................................................................................................................................................................................................................... 613 Gauges, Lights, Horn, Fuses, and Relays............................................................................................................................................................................................................................... 613 Sealed Fuses...................................................................................................................................................................................................................................................... 614 Transmission Oil...................................................................................................................................................................................................................................................... 614 Cooling System........................................................................................................................................................................................................................................................ 615 Engine Air Filter..................................................................................................................................................................................................................................................... 615 Engine Oil Pressure................................................................................................................................................................................................................................................... 615 Electrical System..................................................................................................................................................................................................................................................... 616 Steering System....................................................................................................................................................................................................................................................... 616 Service Brakes........................................................................................................................................................................................................................................................ 616 Parking Brake......................................................................................................................................................................................................................................................... 616 Control Levers and Pedals............................................................................................................................................................................................................................................. 616 Lift System Operation................................................................................................................................................................................................................................................. 616 Attachments........................................................................................................................................................................................................................................................... 616 First Inspection After First 100 Hours of Operation........................................................................................................................................................................................................................... 617 Engine Oil Filter......................................................................................................................................................................................................................................................... 617 Drive Axle and Differential............................................................................................................................................................................................................................................... 617 Lift Chains............................................................................................................................................................................................................................................................... 617 Transmission Oil Filter................................................................................................................................................................................................................................................... 617 Air Conditioning.......................................................................................................................................................................................................................................................... 617 Steer Wheel Hubs.......................................................................................................................................................................................................................................................... 617 Maintenance Procedures Every 250 Hours Or Monthly............................................................................................................................................................................................................................. 617 Twist Locks............................................................................................................................................................................................................................................................... 617 Gantry Carriage and Container Attachments................................................................................................................................................................................................................................. 618 Maintenance Procedures Every 500 Hours or 3 Months............................................................................................................................................................................................................................ 618 Drive Belt................................................................................................................................................................................................................................................................ 618 Lift Chains............................................................................................................................................................................................................................................................... 618 Hydraulic Return Line Oil Filter.......................................................................................................................................................................................................................................... 618 Air Conditioning.......................................................................................................................................................................................................................................................... 618 Wheel Nuts................................................................................................................................................................................................................................................................ 619 Heater Air Filter......................................................................................................................................................................................................................................................... 619 Steering Axle Kingpins.................................................................................................................................................................................................................................................... 619 Steering Axle Tie Rods.................................................................................................................................................................................................................................................... 619 Drive Shaft............................................................................................................................................................................................................................................................... 619 Steering Axle Pivots...................................................................................................................................................................................................................................................... 619 Mast and Carriage Load Rollers............................................................................................................................................................................................................................................ 619 Mast Pivots, Sliding Surfaces............................................................................................................................................................................................................................................. 620 Sideshift Carriage........................................................................................................................................................................................................................................................ 620 Maintenance Procedures Every 500 Hours or 6 Months............................................................................................................................................................................................................................ 620 Fuel Filter............................................................................................................................................................................................................................................................... 620 Engine Oil and Filter..................................................................................................................................................................................................................................................... 620 Oil Filter for Oil Cooled Brakes (Brake Filter)........................................................................................................................................................................................................................... 620 Change Transmission Oil................................................................................................................................................................................................................................................... 620 Maintenance Procedures Every 1000 Hours or 6 Months........................................................................................................................................................................................................................... 621 Drive Axle and Differential Oil........................................................................................................................................................................................................................................... 621 Service Brake System...................................................................................................................................................................................................................................................... 621 Brake System Accumulator.................................................................................................................................................................................................................................................. 621 Hub Bearings, Steer Wheels................................................................................................................................................................................................................................................ 621 General Lubrication....................................................................................................................................................................................................................................................... 621 Maintenance Procedures Every 1500 Hours or 1 Year............................................................................................................................................................................................................................. 621 Engine.................................................................................................................................................................................................................................................................... 621 Water Pump................................................................................................................................................................................................................................................................ 621 Turbocharger.............................................................................................................................................................................................................................................................. 621 Engine Mounting Bolts..................................................................................................................................................................................................................................................... 622 Air Leaks, Air Intake and Exhaust......................................................................................................................................................................................................................................... 622 Valve and Injector Adjustments............................................................................................................................................................................................................................................ 624 General............................................................................................................................................................................................................................................................... 624 Adjust................................................................................................................................................................................................................................................................ 625 Injector Adjustment............................................................................................................................................................................................................................................... 625 Valve Adjustment.................................................................................................................................................................................................................................................. 626 Maintenance Procedures Every 2000 Hours or 1 Year............................................................................................................................................................................................................................. 628 Hydraulic High Pressure Oil Filter........................................................................................................................................................................................................................................ 628 Parking Brake Assembly.................................................................................................................................................................................................................................................... 628 Clean................................................................................................................................................................................................................................................................. 629 Inspect............................................................................................................................................................................................................................................................... 629 Maintenance Procedures Every 4000 Hours or 2 Years............................................................................................................................................................................................................................ 630 Hydraulic Suction Oil Filters............................................................................................................................................................................................................................................. 630 Maintenance Procedures Every 5000 Hours....................................................................................................................................................................................................................................... 631 Container Attachment...................................................................................................................................................................................................................................................... 631 Maintenance Procedures Every 6000 Hours or 2 Years............................................................................................................................................................................................................................ 631 Vibration Damper.......................................................................................................................................................................................................................................................... 631 Fan Drive Idler Pulley.................................................................................................................................................................................................................................................... 631 Fan Hub................................................................................................................................................................................................................................................................... 632 Turbocharger.............................................................................................................................................................................................................................................................. 633 Cooling System Fluid...................................................................................................................................................................................................................................................... 633 Safety Procedures When Working Near Mast...................................................................................................................................................................................................................................... 633 Lift and Tilt System Leaks Check.............................................................................................................................................................................................................................................. 635 Lift System............................................................................................................................................................................................................................................................... 635 Tilt System............................................................................................................................................................................................................................................................... 635 Pneumatic Tires and Wheels.................................................................................................................................................................................................................................................... 636 Remove Wheels From Lift Truck............................................................................................................................................................................................................................................. 636 Remove Tire From Wheel.................................................................................................................................................................................................................................................... 636 Remove Tire From Five-Piece Wheel..................................................................................................................................................................................................................................... 637 Install Tire on Wheel..................................................................................................................................................................................................................................................... 638 Install Tire on Five-Piece Wheel...................................................................................................................................................................................................................................... 639 Add Air Pressure to Tires................................................................................................................................................................................................................................................. 640 Install Wheels on Lift Truck.............................................................................................................................................................................................................................................. 641 tables............................................................................................................................................................................................................................................................................ 587 Table 1. Daily Inspections − Condition Check.................................................................................................................................................................................................................................. 597 Table 2. Daily Inspections − Fluid Level Check................................................................................................................................................................................................................................ 597 Table 3. Daily Inspections − Checks With the Engine Running................................................................................................................................................................................................................... 598 Table 4. First Inspection After First 100 Hours of Operation.................................................................................................................................................................................................................. 599 Table 5. Periodic Maintenance Schedule − Inspect and Adjust................................................................................................................................................................................................................... 600 Table 6. Periodic Maintenance Schedule − Lubricate............................................................................................................................................................................................................................ 602 Table 7. Periodic Maintenance Schedule − Change............................................................................................................................................................................................................................... 603 Table 8. Container Attachment Maintenance - Lubricate......................................................................................................................................................................................................................... 604 Table 9. Container Attachment Maintenance − Replace........................................................................................................................................................................................................................... 605 Table 10. Valve and Injector Adjustment Specifications........................................................................................................................................................................................................................ 624 Table 11. Injector and Valve Measurement Sequence............................................................................................................................................................................................................................. 625 1566279-8000SRM1155-(02-2005)-US-EN................................................................................................................................................................................................................................................... 645 toc............................................................................................................................................................................................................................................................................... 645 Capacities and Specifications................................................................................................................................................................................................................................................. 645 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 646 Counterweight Weights......................................................................................................................................................................................................................................................... 649 Container Attachment Weights.................................................................................................................................................................................................................................................. 649 Carriage Weights.............................................................................................................................................................................................................................................................. 649 Vehicle Weights............................................................................................................................................................................................................................................................... 650 Capacities.................................................................................................................................................................................................................................................................... 650 Electrical System............................................................................................................................................................................................................................................................. 650 Engine Specifications (Cummins QSM 11)........................................................................................................................................................................................................................................ 651 Mast Weights.................................................................................................................................................................................................................................................................. 651 Lifting and Lowering Speeds................................................................................................................................................................................................................................................... 652 Tires......................................................................................................................................................................................................................................................................... 652 Hydraulic System Specifications............................................................................................................................................................................................................................................... 653 Torque Specifications......................................................................................................................................................................................................................................................... 654 Control Valves............................................................................................................................................................................................................................................................ 654 Electrical System......................................................................................................................................................................................................................................................... 654 Counterweight (Cast)...................................................................................................................................................................................................................................................... 654 Counterweight (Fabricated)................................................................................................................................................................................................................................................ 654 Counterweight (Slab)...................................................................................................................................................................................................................................................... 654 Drive Axle................................................................................................................................................................................................................................................................ 654 Wheel Bearing Adjusting Nut............................................................................................................................................................................................................................................... 654 Differential.............................................................................................................................................................................................................................................................. 655 Transmission.............................................................................................................................................................................................................................................................. 655 Torque Converter.......................................................................................................................................................................................................................................................... 655 Steering.................................................................................................................................................................................................................................................................. 655 Wheel Nuts................................................................................................................................................................................................................................................................ 655 Carriages (All)........................................................................................................................................................................................................................................................... 655 Attachment - 20- to 40-Foot............................................................................................................................................................................................................................................... 655 tables............................................................................................................................................................................................................................................................................ 645 Table 1. Fabricated Type...................................................................................................................................................................................................................................................... 649 Table 2. Cast Type............................................................................................................................................................................................................................................................ 649 1566449-1300SRM1156-(08-2004)-US-EN................................................................................................................................................................................................................................................... 659 toc............................................................................................................................................................................................................................................................................... 659 Four-Speed Powershift Transmission............................................................................................................................................................................................................................................ 659 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 660 Description of Operation...................................................................................................................................................................................................................................................... 663 General................................................................................................................................................................................................................................................................... 663 Torque Convertor, Pump Drive, and Pressure Regulating Valve............................................................................................................................................................................................................... 663 Input Shaft and Directional Clutches...................................................................................................................................................................................................................................... 663 Range Clutches............................................................................................................................................................................................................................................................ 664 Output Section............................................................................................................................................................................................................................................................ 666 Transmission Controls..................................................................................................................................................................................................................................................... 666 Valve Operation....................................................................................................................................................................................................................................................... 666 Range Selection....................................................................................................................................................................................................................................................... 666 Electric Solenoid Controls................................................................................................................................................................................................................................................ 667 Transmission Specifications............................................................................................................................................................................................................................................... 691 Transmission Identification........................................................................................................................................................................................................................................... 691 Weight, Dimensions, and Oil Capacity.................................................................................................................................................................................................................................. 691 Automatic Powershift Control (APC 100)........................................................................................................................................................................................................................................ 692 Transmission Control System............................................................................................................................................................................................................................................... 692 Functional Description................................................................................................................................................................................................................................................ 693 Fuses................................................................................................................................................................................................................................................................. 695 Transmission Control Lever................................................................................................................................................................................................................................................ 695 Transmission Repair........................................................................................................................................................................................................................................................... 696 Remove.................................................................................................................................................................................................................................................................... 696 Disassemble............................................................................................................................................................................................................................................................... 698 Transmission Case, Disassemble........................................................................................................................................................................................................................................ 698 Torque Convertor Housing, Disassemble................................................................................................................................................................................................................................. 718 Reverse and Second-Speed Clutch....................................................................................................................................................................................................................................... 719 Reverse Clutch, Disassemble....................................................................................................................................................................................................................................... 719 Second-Speed Clutch, Disassemble.................................................................................................................................................................................................................................. 724 Forward Clutch, Disassemble........................................................................................................................................................................................................................................... 727 Low (First-Speed) Clutch, Disassemble................................................................................................................................................................................................................................. 732 Third-Speed Clutch, Disassemble....................................................................................................................................................................................................................................... 737 Fourth-Speed Clutch, Disassemble...................................................................................................................................................................................................................................... 742 Output Shaft, Disassemble............................................................................................................................................................................................................................................. 746 Turbine Shaft, Disassemble............................................................................................................................................................................................................................................ 747 Impeller and Oil Baffle, Disassemble.................................................................................................................................................................................................................................. 749 Impeller Cover and Turbine, Disassemble............................................................................................................................................................................................................................... 752 Pump Drive Gear, Disassemble.......................................................................................................................................................................................................................................... 753 Clean and Inspect......................................................................................................................................................................................................................................................... 754 Housings.............................................................................................................................................................................................................................................................. 754 Oil Seals and Gaskets................................................................................................................................................................................................................................................. 754 Bearings.............................................................................................................................................................................................................................................................. 754 Gears and Shafts...................................................................................................................................................................................................................................................... 755 Assemble.................................................................................................................................................................................................................................................................. 755 Pump Drive Gear, Assemble............................................................................................................................................................................................................................................. 755 Impeller Cover and Turbine, Assemble.................................................................................................................................................................................................................................. 756 Impeller and Oil Baffle, Assemble..................................................................................................................................................................................................................................... 757 Turbine Shaft, Assemble............................................................................................................................................................................................................................................... 760 Output Shaft, Assemble................................................................................................................................................................................................................................................ 762 Fourth Speed Clutch, Assemble......................................................................................................................................................................................................................................... 764 Third-Speed Clutch, Assemble.......................................................................................................................................................................................................................................... 768 Low (First-Speed) Clutch, Assemble.................................................................................................................................................................................................................................... 773 Forward Clutch, Assemble.............................................................................................................................................................................................................................................. 780 Reverse and Second-Speed Clutch....................................................................................................................................................................................................................................... 787 Second-Speed Clutch, Assemble..................................................................................................................................................................................................................................... 787 Reverse Clutch, Assemble.......................................................................................................................................................................................................................................... 790 Torque Convertor Housing, Assemble.................................................................................................................................................................................................................................... 795 Transmission Case, Assemble........................................................................................................................................................................................................................................... 798 Speed Sensor Installation................................................................................................................................................................................................................................................. 816 Install................................................................................................................................................................................................................................................................... 816 Low (1st) Speed Shaft Bearing Adjustment...................................................................................................................................................................................................................................... 819 Control Valve Repair.......................................................................................................................................................................................................................................................... 822 Remove.................................................................................................................................................................................................................................................................... 822 Disassemble and Assemble.................................................................................................................................................................................................................................................. 822 Clean and Inspect......................................................................................................................................................................................................................................................... 822 Housings.............................................................................................................................................................................................................................................................. 822 Oil Seals and Gaskets................................................................................................................................................................................................................................................. 824 Install................................................................................................................................................................................................................................................................... 824 Limp Home Function........................................................................................................................................................................................................................................................ 824 Stall Test.................................................................................................................................................................................................................................................................... 825 Transmission Oil Pressure Check............................................................................................................................................................................................................................................... 826 Pressure and Temperature Specifications................................................................................................................................................................................................................................... 826 Electrical Wiring and Specifications.......................................................................................................................................................................................................................................... 828 Electrical Wiring......................................................................................................................................................................................................................................................... 828 Electrical Specifications................................................................................................................................................................................................................................................. 828 Hydraulic Cooler and Filter Lines Specifications.............................................................................................................................................................................................................................. 829 Torque Specifications......................................................................................................................................................................................................................................................... 829 Torque Specifications for Lubricated or Plated Screw Threads.............................................................................................................................................................................................................. 829 Troubleshooting............................................................................................................................................................................................................................................................... 831 tables............................................................................................................................................................................................................................................................................ 659 Table 1. Solenoid Controls.................................................................................................................................................................................................................................................... 667 Table 2. APC 100 Control Module (Pin Connections)............................................................................................................................................................................................................................. 694 Table 3. Example Torque Values at Dimensions Shown............................................................................................................................................................................................................................ 820 Table 4. Speed and Energized Wires............................................................................................................................................................................................................................................ 829 Table 5. Wire Numbers and Color Codes......................................................................................................................................................................................................................................... 829 Table 6. Grade 5.............................................................................................................................................................................................................................................................. 829 Table 7. Grade 8.............................................................................................................................................................................................................................................................. 830 Table 8. Grades 8.8, 10.9, and 12.9........................................................................................................................................................................................................................................... 830 Table 9. Elastic Stop Nut Torque.............................................................................................................................................................................................................................................. 831 Table 10. O-ring Port Plug Torque Chart....................................................................................................................................................................................................................................... 831 Table 11. Pipe Plug Torque Chart.............................................................................................................................................................................................................................................. 831 1567897-8000SRM1153-(09-2005)-US-EN................................................................................................................................................................................................................................................... 835 toc............................................................................................................................................................................................................................................................................... 835 Diagrams...................................................................................................................................................................................................................................................................... 835 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 836 1568204-0700SRM1159-(07-2007)-US-EN................................................................................................................................................................................................................................................... 871 toc............................................................................................................................................................................................................................................................................... 871 Multiple Aligned Cooling System............................................................................................................................................................................................................................................... 871 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 872 General....................................................................................................................................................................................................................................................................... 875 Description................................................................................................................................................................................................................................................................... 877 Radiator.................................................................................................................................................................................................................................................................. 877 Radiator Cap.............................................................................................................................................................................................................................................................. 877 Thermostat................................................................................................................................................................................................................................................................ 877 Water Pump................................................................................................................................................................................................................................................................ 878 Fan and Fan Shroud........................................................................................................................................................................................................................................................ 878 Cooling System Checks......................................................................................................................................................................................................................................................... 878 Radiator.................................................................................................................................................................................................................................................................. 878 Thermostat................................................................................................................................................................................................................................................................ 878 Water Pump................................................................................................................................................................................................................................................................ 879 Exhaust Leaks............................................................................................................................................................................................................................................................. 879 Fan and Fan Shroud........................................................................................................................................................................................................................................................ 879 Cooling System Repair......................................................................................................................................................................................................................................................... 879 Remove.................................................................................................................................................................................................................................................................... 879 Install................................................................................................................................................................................................................................................................... 880 Core Repair................................................................................................................................................................................................................................................................... 881 Remove.................................................................................................................................................................................................................................................................... 881 Install................................................................................................................................................................................................................................................................... 881 Radiator Cleaning............................................................................................................................................................................................................................................................. 882 Drain..................................................................................................................................................................................................................................................................... 882 Clean..................................................................................................................................................................................................................................................................... 882 Fill...................................................................................................................................................................................................................................................................... 882 Troubleshooting............................................................................................................................................................................................................................................................... 883 1569718-4000SRM1160-(01-2007)-US-EN................................................................................................................................................................................................................................................... 887 toc............................................................................................................................................................................................................................................................................... 887 Mast.......................................................................................................................................................................................................................................................................... 887 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 888 General....................................................................................................................................................................................................................................................................... 891 Description and Operation..................................................................................................................................................................................................................................................... 891 General................................................................................................................................................................................................................................................................... 891 Lifting................................................................................................................................................................................................................................................................... 892 Lowering.................................................................................................................................................................................................................................................................. 892 Safety Procedures When Working Near Mast...................................................................................................................................................................................................................................... 892 Forks Repair.................................................................................................................................................................................................................................................................. 893 Adjust.................................................................................................................................................................................................................................................................... 893 Remove.................................................................................................................................................................................................................................................................... 893 Install................................................................................................................................................................................................................................................................... 893 Low-Mount Fork........................................................................................................................................................................................................................................................ 893 Carriage Repair............................................................................................................................................................................................................................................................... 894 General................................................................................................................................................................................................................................................................... 894 Remove.................................................................................................................................................................................................................................................................... 894 Disassemble............................................................................................................................................................................................................................................................... 897 Clean and Inspect......................................................................................................................................................................................................................................................... 899 Assemble.................................................................................................................................................................................................................................................................. 899 Install................................................................................................................................................................................................................................................................... 901 Carriage Side Blocks...................................................................................................................................................................................................................................................... 901 Adjust................................................................................................................................................................................................................................................................ 901 Mast Repair................................................................................................................................................................................................................................................................... 902 Remove.................................................................................................................................................................................................................................................................... 902 Disassemble............................................................................................................................................................................................................................................................... 903 Clean and Inspect......................................................................................................................................................................................................................................................... 905 Assemble.................................................................................................................................................................................................................................................................. 906 Install................................................................................................................................................................................................................................................................... 908 Lift Cylinders Repair......................................................................................................................................................................................................................................................... 908 Remove.................................................................................................................................................................................................................................................................... 908 Disassemble............................................................................................................................................................................................................................................................... 908 Clean and Inspect......................................................................................................................................................................................................................................................... 909 Assemble.................................................................................................................................................................................................................................................................. 909 Install................................................................................................................................................................................................................................................................... 909 Fork Positioner Cylinders Repair.............................................................................................................................................................................................................................................. 910 Remove.................................................................................................................................................................................................................................................................... 910 Disassemble............................................................................................................................................................................................................................................................... 910 Clean and Inspect......................................................................................................................................................................................................................................................... 910 Assemble.................................................................................................................................................................................................................................................................. 910 Install................................................................................................................................................................................................................................................................... 910 Sideshift Cylinder Repair..................................................................................................................................................................................................................................................... 911 Remove.................................................................................................................................................................................................................................................................... 911 Disassemble............................................................................................................................................................................................................................................................... 911 Clean and Inspect......................................................................................................................................................................................................................................................... 911 Assemble.................................................................................................................................................................................................................................................................. 911 Install................................................................................................................................................................................................................................................................... 911 Header Hoses Replacement...................................................................................................................................................................................................................................................... 911 Carriage Side Blocks Adjustment............................................................................................................................................................................................................................................... 913 Mast Side Blocks Adjustment................................................................................................................................................................................................................................................... 913 Mast Load Rollers Adjustment.................................................................................................................................................................................................................................................. 913 Lift Chains Adjustment........................................................................................................................................................................................................................................................ 914 Lift and Tilt Cylinders Leak Check............................................................................................................................................................................................................................................ 914 Troubleshooting............................................................................................................................................................................................................................................................... 915 1572882-8000SRM1173-(12-2005)-US-EN................................................................................................................................................................................................................................................... 919 toc............................................................................................................................................................................................................................................................................... 919 Assembly Guide................................................................................................................................................................................................................................................................ 919 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 920 List of All Special Tools and Equipment Needed for the Assembly............................................................................................................................................................................................................... 923 General Considerations Before Starting the Job................................................................................................................................................................................................................................ 923 Preparation of the Components Before Assembly................................................................................................................................................................................................................................. 924 Checking of the Wheels........................................................................................................................................................................................................................................................ 924 Air Pressure.............................................................................................................................................................................................................................................................. 924 Drive Wheels.......................................................................................................................................................................................................................................................... 925 Steer Wheels.......................................................................................................................................................................................................................................................... 930 Wheel Nut Torque.......................................................................................................................................................................................................................................................... 934 Installation of the Cab....................................................................................................................................................................................................................................................... 936 Preparation Of The Mast....................................................................................................................................................................................................................................................... 939 Mast...................................................................................................................................................................................................................................................................... 939 Mast Label Placement...................................................................................................................................................................................................................................................... 940 Safety Procedures When Working Near Mast...................................................................................................................................................................................................................................... 941 Mast Installation............................................................................................................................................................................................................................................................. 942 Mast...................................................................................................................................................................................................................................................................... 942 Tilt Cylinder Pin Installation............................................................................................................................................................................................................................................ 944 Truck Header Hoses and Electrical Cable Connections....................................................................................................................................................................................................................... 946 Installation of the Dedicated Carriage/Gantry................................................................................................................................................................................................................................. 948 Install................................................................................................................................................................................................................................................................... 948 Carriage Side Blocks...................................................................................................................................................................................................................................................... 948 Adjust................................................................................................................................................................................................................................................................ 948 Connection of the Hoses and Cables to the Carriages........................................................................................................................................................................................................................... 949 Installation of the Container Attachment on the Dedicated Carria.............................................................................................................................................................................................................. 954 Installation of the Container Attachment on the Gantry........................................................................................................................................................................................................................ 956 Lights Installation - Operator Compartment.................................................................................................................................................................................................................................... 958 General Procedures After Assembly............................................................................................................................................................................................................................................. 959 Hydraulic Oil Check........................................................................................................................................................................................................................................................... 959 Lubrication Points............................................................................................................................................................................................................................................................ 960 Check Points.................................................................................................................................................................................................................................................................. 960 Checkpoint 1.............................................................................................................................................................................................................................................................. 960 Checkpoint 2.............................................................................................................................................................................................................................................................. 960 Checkpoint 3.............................................................................................................................................................................................................................................................. 960 Checkpoint 4.............................................................................................................................................................................................................................................................. 960 Checkpoint 5.............................................................................................................................................................................................................................................................. 960 General Truck Install Procedures.............................................................................................................................................................................................................................................. 960 tables............................................................................................................................................................................................................................................................................ 919 Table 1. Wire Connections..................................................................................................................................................................................................................................................... 954 1573930-0600SRM1172-(03-2005)-US-EN................................................................................................................................................................................................................................................... 965 toc............................................................................................................................................................................................................................................................................... 965 Cummins Diesel Engine Fault Code Guide........................................................................................................................................................................................................................................ 965 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 966 General....................................................................................................................................................................................................................................................................... 969 Description................................................................................................................................................................................................................................................................... 969 Base Control System....................................................................................................................................................................................................................................................... 969 Fault Code Snapshot Data.................................................................................................................................................................................................................................................. 969 Maintenance Monitor (A222 Only)............................................................................................................................................................................................................................................... 970 General................................................................................................................................................................................................................................................................... 970 Electronic Throttle Calibration............................................................................................................................................................................................................................................... 970 Electronic Throttle Calibration Procedure................................................................................................................................................................................................................................. 970 Fault Codes................................................................................................................................................................................................................................................................... 970 General................................................................................................................................................................................................................................................................... 970 E117...................................................................................................................................................................................................................................................................... 971 Access................................................................................................................................................................................................................................................................ 971 Exit.................................................................................................................................................................................................................................................................. 972 A222...................................................................................................................................................................................................................................................................... 972 Access................................................................................................................................................................................................................................................................ 972 Exit.................................................................................................................................................................................................................................................................. 972 tables............................................................................................................................................................................................................................................................................ 965 Table 1. Error Code Descriptions.............................................................................................................................................................................................................................................. 973 1574068-1400SRM1171-(02-2008)-US-EN................................................................................................................................................................................................................................................... 987 toc............................................................................................................................................................................................................................................................................... 987 Planetary Gear Axle........................................................................................................................................................................................................................................................... 987 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 988 General....................................................................................................................................................................................................................................................................... 991 Description................................................................................................................................................................................................................................................................... 991 Operation..................................................................................................................................................................................................................................................................... 991 Planetary Gear Axle Repair.................................................................................................................................................................................................................................................... 995 Remove.................................................................................................................................................................................................................................................................... 995 Drive Wheels and Tires................................................................................................................................................................................................................................................ 995 Disassemble............................................................................................................................................................................................................................................................... 996 Drive Axle............................................................................................................................................................................................................................................................ 996 Planetary Gear Carrier................................................................................................................................................................................................................................................ 997 Ring Gear, Ring Gear Hub, and Wheel Hub............................................................................................................................................................................................................................... 998 Hub Oil Seal and Bearings.............................................................................................................................................................................................................................................1000 Axle Shaft............................................................................................................................................................................................................................................................1000 Spindle...............................................................................................................................................................................................................................................................1000 Repair....................................................................................................................................................................................................................................................................1001 Repairing or Replacing Parts..........................................................................................................................................................................................................................................1001 Welding...............................................................................................................................................................................................................................................................1001 Clean.....................................................................................................................................................................................................................................................................1002 Ground or Polished Parts..............................................................................................................................................................................................................................................1002 Parts With Rough Finishes.............................................................................................................................................................................................................................................1002 Axle Assemblies.......................................................................................................................................................................................................................................................1002 Drying Cleaned Parts..................................................................................................................................................................................................................................................1002 Preventing Corrosion......................................................................................................................................................................................................................................................1002 Parts Inspection..........................................................................................................................................................................................................................................................1002 Assemble..................................................................................................................................................................................................................................................................1003 Spindle...............................................................................................................................................................................................................................................................1003 Axle Shaft............................................................................................................................................................................................................................................................1003 Hub Oil Seal and Bearings.............................................................................................................................................................................................................................................1003 Ring Gear, Ring Gear Hub, and Wheel Hub...............................................................................................................................................................................................................................1004 Wheel Bearing Preload.................................................................................................................................................................................................................................................1004 Adjust............................................................................................................................................................................................................................................................1004 Planetary Gear Carrier................................................................................................................................................................................................................................................1005 Drive Axle............................................................................................................................................................................................................................................................1006 Wheel Ends............................................................................................................................................................................................................................................................1007 Fill..............................................................................................................................................................................................................................................................1007 Install...................................................................................................................................................................................................................................................................1007 Drive Wheels and Tires................................................................................................................................................................................................................................................1007 Torque Specifications.........................................................................................................................................................................................................................................................1011 Troubleshooting...............................................................................................................................................................................................................................................................1012 tables............................................................................................................................................................................................................................................................................ 987 Table 1. Wheel Bearing Adjustment Torque......................................................................................................................................................................................................................................1004 Table 2. Planetary Gear Carrier Capscrew and Stud Torque Specifi..............................................................................................................................................................................................................1006 Table 3. Standard Torque Values for Axle Fasteners............................................................................................................................................................................................................................1011 1578950-2200SRM1119-(08-2004)-US-EN...................................................................................................................................................................................................................................................1015 toc...............................................................................................................................................................................................................................................................................1015 Electrical System.............................................................................................................................................................................................................................................................1015 Safety Precautions Maintenance and Repair.....................................................................................................................................................................................................................................1016 General.......................................................................................................................................................................................................................................................................1019 Description...................................................................................................................................................................................................................................................................1019 Warning Devices...............................................................................................................................................................................................................................................................1021 General...................................................................................................................................................................................................................................................................1021 Description...............................................................................................................................................................................................................................................................1021 Operator-Controlled Horns.............................................................................................................................................................................................................................................1021 Reverse Warning Horns/Lights..........................................................................................................................................................................................................................................1022 Warning Lights........................................................................................................................................................................................................................................................1022 Beacon Lights.....................................................................................................................................................................................................................................................1022 Brake Lights......................................................................................................................................................................................................................................................1024 Hazard Lights.....................................................................................................................................................................................................................................................1024 Replace...............................................................................................................................................................................................................................................................1024 General...........................................................................................................................................................................................................................................................1024 Horns.............................................................................................................................................................................................................................................................1024 Horn Relay........................................................................................................................................................................................................................................................1024 Warning Lights/Bulbs..............................................................................................................................................................................................................................................1024 Light Assemblies..................................................................................................................................................................................................................................................1025 Flashing Unit.....................................................................................................................................................................................................................................................1025 Meters, Senders, System Warning Lights, and Switches..........................................................................................................................................................................................................................1025 General...................................................................................................................................................................................................................................................................1025 Alternator....................................................................................................................................................................................................................................................................1026 General...................................................................................................................................................................................................................................................................1026 Description...............................................................................................................................................................................................................................................................1026 Charging System Indicator and Accessory Power Supply..................................................................................................................................................................................................................1026 Remove....................................................................................................................................................................................................................................................................1027 Install...................................................................................................................................................................................................................................................................1027 Troubleshooting...............................................................................................................................................................................................................................................................1028 Aurora_AC.............................................................................................................................................................................................................................................................................1035 912-100-0148_engl_1.pdf...........................................................................................................................................................................................................................................................1036 Compressors - Applications, Conditions of Use and Liability...................................................................................................................................................................................................................1036 ..........................................................................................................................................................................................................................................................................1042 Filling procedure for refrigerants....................................................................................................................................................................................................................................1042 Do not exceed the maximum operating pressure of the compressor. (see type label)..................................................................................................................................................................................1042 Compressors are machines under pressure and as such require special care in handling..............................................................................................................................................................................1042 Only qualified personnel are allowed to perform any work on refrigeration compressors.............................................................................................................................................................................1042 The national safety regulations, accident prevention regulations, technical rules and specific regulations must be taken into account abolutely...................................................................................................................1042 Never put the safety switch out of action.........................................................................................................................................................................................................................1042 Prior to commissioning, check wether all teh components installed by the user have been fastened expertly and connected pressure-tight with the compressor........................................................................................................1042 Prior to starting the compressor open discharge shut-off valve and suction shut-off valve.........................................................................................................................................................................1042 Do not start the cmpressor in vacuum. Operate the compressor only when the system is charged......................................................................................................................................................................1042 Caution! Danger of burning because of high surface temperatures...................................................................................................................................................................................................1042 Never grab rotating parts during operation. Danger of injury!.....................................................................................................................................................................................................1042 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....1042 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....1042 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...................1042 Full bottles of refrigerant must not be thrown or.................................................................................................................................................................................................................1042 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.....................................................1042 4. Troubleshooting............................................................................................................................................................................................................................................................1043 ..........................................................................................................................................................................................................................................................................1043 ......................................................................................................................................................................................................................................................................1043 Check refrigerant level and pressure as instructed in the Technical Information sheet for the unit................................................................................................................................................................1043 By wrong refrigerant level there is a danger of compressor malfunction............................................................................................................................................................................................1043 The outcome of too much refrigerant is a oil attenuation and reflux of the refrigerant can cause damages on the valve plate.......................................................................................................................................1043 With undercharged refrigerant the compressor will become hotwhich caused a failure. The sealing will be damaged...................................................................................................................................................1043 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....1043 Noises Mechanical 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.....1043 Electrical faults A 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....1043 912-100-0007_e.pdf................................................................................................................................................................................................................................................................1044 Technical modifications reserved..............................................................................................................................................................................................................................................1044 912-100-0258_e.pdf................................................................................................................................................................................................................................................................1055 Condenser unit, 24V...........................................................................................................................................................................................................................................................1055 ..........................................................................................................................................................................................................................................................................1055 ......................................................................................................................................................................................................................................................................1055 ..................................................................................................................................................................................................................................................................1055 ..............................................................................................................................................................................................................................................................1055 part no.:175-FR2-0002.....................................................................................................................................................................................................................................1055 Safety advices................................................................................................................................................................................................................................................1055 - we reserve the right to make technical modifications -..................................................................................................................................................................................................................1055 1Safety advices...............................................................................................................................................................................................................................................................1056 Maintenance work on the refrigeration circuit:............................................................................................................................................................................................................................1056 ......................................................................................................................................................................................................................................................................1057 2.2Condenser blowers..............................................................................................................................................................................................................................................1057 5Electrical connection............................................................................................................................................................................................................................................1058 every six months – authorised workshop:...................................................................................................................................................................................................................................1059 ......................................................................................................................................................................................................................................................................1059 ..................................................................................................................................................................................................................................................................1059 ..............................................................................................................................................................................................................................................................1059 State of the refrigerant hoses............................................................................................................................................................................................................................1059 State of the condenser................................................................................................................................................................................................................................................1059 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).................................................................................................................1059 every month sight checks - Operator.......................................................................................................................................................................................................................................1060 ......................................................................................................................................................................................................................................................................1060 ..................................................................................................................................................................................................................................................................1060 ..............................................................................................................................................................................................................................................................1060 State of the refrigerant hoses............................................................................................................................................................................................................................1060 State of the condenser................................................................................................................................................................................................................................................1060 Check condenser of contamination by dust, insects or parts of plants......................................................................................................................................................................................................1060 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).................................................................................................................1060 Installation of replacement parts.....................................................................................................................................................................................................................................1060 8Technical data...................................................................................................................................................................................................................................................1060 9Fault diagnosis..................................................................................................................................................................................................................................................1061
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